Background: Today I did a top end tear down, cleaned up the pistons, and replaced some gaskets.
Problems:
1. When I removed the right intake cam cap, I noticed that it was split in two in a way that is impossible to see when the two halves are together.
2. I can't get the stock cam chain tensioner back in. It is an automatic tensioner. When I place the thing back on the engine with the cam chain over the cams, I can barely get one of the tensioner bolts to start threading. The tensioner doesn't seem to want to relax.
Questions:
1. Can I ride the bike with the cam tensioner cap cracked in a way that is unnoticeable, or will I need a new one?
2. What is going on with my cam chain tensioner? How can I get the thing to relax so I can put it back on the bike?
In relation to the cam chain tensioner, did you compress it before you removed it? This means you need to remove the cap to access a slot head screw, then you turn it to pull the tensioner back into the tensioner housing. There is some information on the wiki section.
The automatic tensioner is best, but you can order a manual tensioner and install it, it will require more maintenance etc
In terms of the cap, I would not recommend riding with it broken. Once you loosened the bolts you disturbed the way the cam was sitting. With out proper torque teh cam will wobble and damage things, expensive things.
Order the part you need.
+1 on tensioner.
The cam shaft cap bores are machined in assembly with the head and caps are not considered replaceable. You can't order a new cap without the head as an assembly.
Not an uncommon problem with bikes including the GSs. Some have used them as is, some have tried welding, a few have been successful in getting a used cap from a salvage yard and fitting it, and some have replaced the head with with a used one. It's a problem.
Quote from: gsJack on July 02, 2012, 06:13:20 AM
+1 on tensioner.
The cam shaft cap bores are machined in assembly with the head and caps are not considered replaceable. You can't order a new cap without the head as an assembly.
Not an uncommon problem with bikes including the GSs. Some have used them as is, some have tried welding, a few have been successful in getting a used cap from a salvage yard and fitting it, and some have replaced the head with with a used one. It's a problem.
Bad Bingo from Jack :(
Mixing and matching cams and the caps Never worked for me.
Heck sometimes even the cam shafts wont work right in a different head but with the right cam shaft mounts!
They did work ONE time for me tho, my original 94 cams and mounts in a 95 head worked, but I ran into other problems with the engine.
and yes even ONE out of 4 cam shaft mounts that are wrong will cause problems.
I dont know the "damage" it will cause.
but it will either refuse to start because its too hard to crank from being WAY too tight on the cam.
or it could have enough clearance to start but run like crap because there isnt enough clearance to run smoothly.
which is the reason I couldnt use my 89 head in my 01 engine recently......
I accidentally mixed up my 94s and 89s cam shafts and mounts.
Tried sorting it out.
Few tries it wouldnt kick over and hard to turn.
When it did kick over after a few swaps, it ran like an utter piece of garbage because I Knew I had one mismatched mount because the one that belonged there needed helicoiling.
I tried for awhile and had Zero luck.
Simply gave up and replaced the head.
Which, honestly.....
If you have the money (around $80 to $120)
I would just replace the head and avoid the headache of trying mix and match like I did.
If you plan to replace the head, ask on here in the for sale section, someone might be able to hook you up.
They did for me recently when I was off of 2 wheels.
But if you replace the head, you have to make 100%%%% sure the cams and mounts are original to the head.
I would be able to help if it wasnt for my bad luck with these dang engines (simple mistakes that cause Alot of damage)
aka unnoticed header leak ruined my 01 head.
As I just fixed up my 01 engine with a replacement head and just won an ebay auction on another complete head but I need that for the extra 89 motor I have to keep as backup to keep me on 2 wheels.
As I honestly still dont trust everything to stay 100% smoothly for me.
If you plan to replace the head, I'll keep an eye out for a deal for ya.
Dag nabbit! I guess I'm in the market for a new head.
Hang on did I miss something? You broke the cap that holds the cam in it's proper position? That is a part with two bolts and is lettered with an A, B,C or D. If that is the part that snapped, you can buy a replacement cap.
I understood that that is the part that was cracked or split? Did I misunderstand?
In any event good luck.
Merlinq21,
You understand. Apparently the part is matched to the cam, and per Tombstones81, one can run into trouble if the cam cap doesn't perfectly match the cam and engine. If you know where i can get just the part I need and it will match, let me know where to order it.
Tombs and Jack are correct. You can't order those parts, because they are matched to the head. Take a look at the fiche here (http://www.ronayers.com/Fiche/TypeID/26/Type/Motorcycle/MakeID/2/Make/Suzuki/YearID/34/Year/1993/ModelID/7106/Model/GS500E/GroupID/307503/Group/CYLINDER_HEAD). You will notice that there is no part number for the cam shaft journal caps.
#5011
There is no part number for the caps. You could only get some used ones from someone. Were they machined to match? -Highly unlikely. Hence one reason for the A, B, C and D -- so you get them back in the right place. Would they work? With great luck - maybe for a while. Since they would not be an exact machined fit, they will probably wear out fast or destroy something. It could buy you enough time to get a new, complete head with the original cams and caps. I wouldn't do it. I'd shop for a replacement head. (That's a reason to have more than one bike: you have a spare when one goes down.)
As they have said, the caps are machined with the head. They do not have a part number and can not be purchased as replacements.
The cams are a separate item and could be replaced.
Cam shafts do have a part number. Newer cam shafts (with all the associated washers & stuff) can replace older ones to eliminate the cam shaft clatter. Older ones are not to replace newer ones. (That's info I gleaned from some service manuals though I do not remember which one at the moment.)
Learned something new. Surprised really, a low cost motor like the GS would have anything but mass produced parts and generic milling and machining. Good to know. Tough break I guess