leaky camchain tensioner

[Jeff P]

Got home from a ride yesterday, noticed quite a bit of oil on the engine, to the point that it was dripping off the side pretty quickly.  The oil level was down ~ 1/2 qt. after a 30 mile ride.  I wiped most of it up and quickly saw that it was coming from the cam chain tensioner.  I'd replaced the gasket a couple of years ago, and it was always a little bit greasy back there, but it's a full blown leak now.

I haven't started taking things apart yet.  I'm figuring it's probably best to go ahead and replace both the gasket as well as the tensioner itself.  It's a '96.  Any thoughts?

jeff

[Kerry]

At $44.49 (new from MrCycles) the tensioner seems kinda pricey.  The gasket is only $1.96.

Do you suspect the tensioner to be bad because of other symptoms?

I recently had my first opportunity to remove a camchain tensioner and replace the gasket.  It was on a friend's bike; in fact, it was my old '96 GS500E (the one pictured on my home page!).  In the process, I...

...needed a lot of patience to scrape the old gasket off.

...couldn't get

every tiny scrap of the gasket off with my small knifeblade.

...left a few teeny weeny scratches in the aluminum.[/list]

I wanted the metal surface to be as smooth and nick-free as possible, so I cut a small square from a sheet of 2000-grit sandpaper and used it to get rid of the tiny scraps of gasket and the scratches.  I haven't heard back from my friend about the leak.  I guess I should ask....

PS - My friend was going to order the gasket online, but it was back-ordered for weeks, and the shipping cost was discouraging.  He happened to stop in at the local Suzuki dealer for something else, and asked about the gasket.  They actually had some in stock!  (Probably to support some other bike model  )  A couple bucks later, he was in business without the long wait.

[Jeff P]

Nice to see you posting again Kerry 

Nothing aside from the leak.  It may well just be the gasket, but I figure if I'm gonna be in there taking things apart I may as well replace the whole thing.  I ordered a new gasket, the tensioner, and an extra "plug" (which I found easy to destroy the last time I did this) for $58 delivered from bikebandit.  It held up fine for a couple of years, but either it or the seal within the tensioner completely failed on Wednesday.   

It's possible that I wasn't as careful as you describe the last time I put a new gasket on.  I'll be more careful this time and post back on the results once I get it finished. 

Any thoughts on what sort of gasket sealant would be best?  My standard is the high temp red silcon rtv type stuff.  Thanks,

jeff

[Mandres]

If you're using stock gaskets don't use any sealant.  They come pre-coated with that black paint stuff.  Just make sure the sealing surfaces are totally clean and dry (acetone on a rag does a good job).

-M

[Kerry]

Ditto.

[Chuck]

I haven't heard back from my friend about the leak.  I guess I should ask....

If you haven't heard, I'm sure it's fine.

[NWDave]

If you're using stock gaskets don't use any sealant.  They come pre-coated with that black paint stuff.  Just make sure the sealing surfaces are totally clean and dry (acetone on a rag does a good job).

-M

And if your not using stock gaskets?

[Jeff P]

giddyup, as far as I know these should be stock items so I'll put the RTV away.   

jeff

[scratch]

You should never have to replace the camchain tensioner, the camchain when it wears out/stretches, yes, but the tensioner, unless it gets bent, should just be rewound (very easy to do with a screwdriver) and reinstalled.

[NWDave]

Ok, I rewind mine but it doesn't pop back unless I try to unwind it which causes it to pop out... what is the correct way to test these?

[DerekNC]

Not sure how to test a tensioner. If I was concerned that the tensioner wasn't letting out properly it would definitely be replaced. A tossed camchain can trash a motor. My old one actually leaked through the body so thats definitely something to check out also. If you pull the little rubber plug out and there's a lot of oil in there it's most likely leaking. Mine was leaking so bad it looked like someone dumped fresh oil around the starter cover.   

[Jeff P]

Man this board is busy.  Had to go 11 pages back to find this thread!

Well whether it needed the new tensioner or not, it got one on Friday.  I got the tensioner, a new gasket, and a new plug thingy from Bikebandit.com for ~$55 delivered.  Installation of the new one was pretty easy, bike runs well (after I remembered to open the gas tank petcock ), no leaks. 

jeff

[HPP8140]

Not sure how to test a tensioner. If I was concerned that the tensioner wasn't letting out properly it would definitely be replaced. A tossed camchain can trash a motor. My old one actually leaked through the body so thats definitely something to check out also. If you pull the little rubber plug out and there's a lot of oil in there it's most likely leaking. Mine was leaking so bad it looked like someone dumped fresh oil around the starter cover.   

hmm...replaced end gasket and plug but mine is still leaking. Does that mean it's leaking through the body? Have to replace tensioner?

[FJCharlie]

its leaking on the screw itself, used silicone paste (gasket seal paste) and applied on the screw no more leaking. if you want a pic, just say..