Cam Chain Tensioner

I'm sure this subject has been discussed here, but I was unable to find an answer. Took my valve cover off (1982 KZ1000J) and noticed that the cam chain has a lot of slack, probably a half inch or so between the cam sprockets. You could see where it rubbed on the rubber guide in the top of the cover. I have the stock automatic tensioner on the engine, How do I take up that slack, if that is in fact too much? I did perform the 20 pin measure and the chain is at about 127mm (in spec). Also, are manual adjusters made to fit my engine? Thanks.

I'd imagine this website has, or can make you a manual cam chain tensioner:
www.clems-garage.com/CCT/

I'm no expert at all, but your description sounds normal to me. When you first remove the valve cover, the cam chain appears to dip because the upper guide was pressing down on it. Also, the guide will appear to have some minor "wear", but it looks more like rub marks to me.

Having said that, I guess if the chain is too tight, the cam guides could get gouged out?

Photos from my 81 KZ650-CSR.
(1st pic looks the same as the illustration in the manual).

If i remember correctly the j model motors use the valve cover as part of tenisor setup. I think on them your suspose to back off the tenisor before removing the valve cover. But with it removed it should appear to have some slack.

You should back off the tensioner before you remove the cover or the tensioner will take up the slack when the engine is turned over and if you just bolt the cover back on it will cause excessive wear to the chain guides.

etbike3135 is absolutely correct. This is essential info that every J motor mechanic should know and its in the OEM shop manual

Thanks for the input. I think my chain is OK. However, the J model uses an automatic cam chain tensioner and you would not loosen it to remove the valve cover.

grumpy56 wrote: Thanks for the input. I think my chain is OK. However, the J model uses an automatic cam chain tensioner and you would not loosen it to remove the valve cover.

You MUST release the tensioner BEFORE removing the camcover and reinstall it AFTER the cover has been replaced.
It is automatic so will move to it's furthest travel as soon as slack is present in the chain as is the case when the camcover is removed.
Removing and refitting the camcover without releasing the tensioner will cause damage.

Grumpy, take a look at your cam chain tensioner, you should see a large 17 mm nut on one side of the tensioner.

This is the cross wedge cap - prior to installing the valve cover you must remove the wedge cap and the washer, spring and wedge behind it, if you don't the tensioner plunger can't move backwards when you install the cam cover and the top guide tightens the chain.

The wedge, spring, washer and cap should be installed last, after you install the cam cover.

As already mentioned this is essential, you have to do this.

The service manual should have a warning about not installing the cam cover without removing tensioner from the tensioner.

The 550 manuals have the warning, but very few ever read them, so I made a web page with this warning:

home.comcast.net/~loudgpz/GPZweb/CamsKZZ...KZZXZR550500400.html

It was the only way to get people's attention.

Is the warning in the 550 manual clearly indicated as a CAUTION?

The "warning" in the 81 650 manual is rather mundane & it is included in a NOTE about removing the tensioner - it would be easy to miss & there is no mention of it in the valve clearance check section... unless I've overlooked it. This is one thing that seems somewhat lacking in the factory service manual.

As mentioned by martin_csr, I also have not found an "express warning" to do during valve cover removal. However, the section on Chain Tensioner Removal does state to remove the tensioner assembly before starting any disassembly operation that slackens the camshaft chain. So, as indicated by loudhvx, can I remove the 17mm nut and the contents, install the valve cover, and then re-install the wedge and spring without completely removing the auto tensioner unit (two mounting bolts)? Do appreciate the information.