Cam chain tensioner plastic plug

[Erika]

I just replaced all of the gaskets and the plastic plug on my cam chain tensioner. But oil is leaking out of that stupid plastic plug. I need to stop that leak so I can take the bike to do a track day, but I'm not sure what to do. It's such a stupid place to have an oil leak. I curse that plastic plug! Has anyone tried something different to plug that up?

[Erika]

Here's a photo of the leaky plastic plug.

[burning1]

I raced ran without a plug. AFAIK, there shouldn't be any oil behind that plug... I strongly suspect there's something wrong with your CCT.

Since you're prepping for a track-day, my advise is to plug the hole with JB Weld or Silicone. Replace the whole unit with a manual CCT when you have time.

[Erika]

I was wondering about that when I pulled it off and saw oil where the spring is. The spring is in good condition and I looked down at the the cam chain when I put the tensioner back on to make sure it had the right amount of tension. I checked for any loose spots and it seemed fine. I rode it around and nothing was wrong... other than oil coming up into where the spring is and then leaking through the plug.

Any recommendations on a manual CCT... brands that you like?

[dinkydonuts]

IF for the sake of making your bike track-day-ready, you can just remove the plug, clean inside there as much as possible, and then put some RTV and pop the plug back in. If I recall, there's a flathead screw inside there for pre-tensioning the spring. Then when you need to work on the CCT, just take a knife and cut out the RTV.

[Blueknyt]

its not that hard to make one, trace the gasket onto a chunk of 1/4 aluminum, drill the mount bolt holes to same as stock, grab a 4" long (I believe) 7/16 bolt with threads all the way up (or tap and die the threads to the bolt head) drill and tap the plate for the bolt, run a nut up the bolt, thread the bolt through the plate useing the nut to lock the bolt in place.  ran mine finger tight then backed it off between 1/8-1/4 turn out then locked the nut. the idea is to leave some slack.

[burning1]

Any recommendations on a manual CCT... brands that you like?

APE is the major player on the market. I have no complaints with their products.

They don't officially list a tensioner for the GS500, but there is a GSX-R part that's cross compatible. You can either call them and ask which part you need, or track through the 4+ revisions of the GS500 CCT to find the part that's used on both the GS and the GSX-R, and then buy the Ape CCT from that compatible year.

[The Buddha]

There is oil flying around everywhere, that plastic plug isn;t even supposed to seal it up, the hole is like a + with a "o" hole in the middle ... nothing wrong with the CCT, in fact that's not even that much oil, I'd ignore it and race it.

Cool.
Buddha.

[gsJack]

Suzuki adjuster assembly 12830-01D12 fits all years GS500/E/F 89-09 and also fits 97-00 GSXR600.  APE makes a manual CCT for the 97-00 GSXR600.  http://gsxrzone.com/tensioners.html

Many brands and prices on ebay if you want to sort thru them.  I may be replacing my CCT but will go with oem auto one from Susuki if I do.

+1 on what Buddha said.

[The Buddha]

+1 to GSJack as well. I'm not a huge fan of the manual tensioners. Its one more thing you can screw up and ruin your day. And the GS tensioner isn't known for failing - unlike the kawasaki crap from the same era.
Cool.
Buddha.

[Erika]

Thanks Jack. I think Buddha's right, though... it seems to be functioning normally, or I would have noticed on the day ride I did Sunday. Good to know in case I end up needing one anyway, though. I would ignore that little drip, if it wasn't pooling all over the engine case and seeping down the left side when I put the kickstand down. I can't believe how much oil is dripping out of that thing. I keep checking to make sure it isn't from anywhere else... but nope. It's all from that plastic plug.

[The Buddha]

Is the crankcase vent blocked ?
I cant see how else it can send so much oil ouuta that one ...
Cool.
Buddha.

[Erika]

Uhhh... where's the crankcase vent? Is it the breather all the way on top that vents to the airbox?