Refitting the timing chain...

[Jules-C]

It is tricky since the lobes try to push the can put of position.  It looks like the intake cam needs to be rotated one tooth to the left. It will be out of alignment when the chain slack but everything should line up again when the tension taken up

[anutz]

that's another thing I was thinking - when I torqued it down it was ALWAYS off, so as you say, line it up OFF and then when torqued it should line up - might take a few goes!

[anutz]

Progress - bang on with correct tension now   


Has been cranked through many revolutions with a socket and no movement of the timing marks


Onward with the rest of the rebuild...measuring clearances....this is going to be fun 

[red98]

Good work anutz......got to take your time with timing  :rolleyes.......check and double check and check again, making good progress well done.....clearences and shims and things are a bit easier...........but , if you need to change any shims its a cams out jobbie....but you are foc-u's timing expert now so no problems there  .........I did mine last year at 40,000 miles and they were within tolerances, on the limit , but just inside , I did change 5 shims to get them spot on but did'nt really need too......let us watchers know how you get on, iam sure you will, with pics as well 

[unfazed]

Now exhaust is right, 

The slack in the centre will not disappear until the tensioner is fully installed and you rotate the crank and allow the tensioner takes up the slack.
Then check the marks again.

[anutz]

thanks red98 - measuring clearances now....

Unfazed - yep, its good now, until that penny dropped I was fighting a losing battle - but I got there!

Before I start taking anything apart again I am going to Tipex the sprocket and chain for future reference...

Unless anyone has any alternatives...

[Jules-C]

Have to check the number of teeth on the sprocket and links on the chain there's no guarantee a chain link will match up to the same tooth every time it comes round

[anutz]

Ok so have done the clearances.....


And managed to get the chain and cams spot on again..


Here is what i did


Found TDC


Held Exhaust Side of Timing chain taught ( not silly but firmly )


Located Exhaust Cam and varied the sprocket mating position to chain until there was as good alignment as possible with the caps ( was not 100% )


Located Intake Cam and aligned as best as possible


Secured Caps with Bolts, ensuring to be aware of tightening on to Opened Valves before Closed and following a criss cross pattern


Used a Socket on the Flywheel to turn it clockwise a little whilst making sure chain does not jump off the Exhaust Sprocket, this took up any slack in between the sprockets


Installed the tensioner taking up slack in the intake side of the chain


Installed the top side chain guide/guard ( required 4 center bolts losening but no issues there )

Took opportunity to check the Cylinder Head Bolt torque before i put cams in as well as i have put the head back on


I have done this twice now and its worked fine each time - past week i have been using all sorts of methods and too focused on lining them up perfect not taking into account the effect of the slack and the effect of cranking clockwise slightly to take it up and move it to the Intake side for the tensioner to deal with...


Any observations fine, but it worked for me!


Thanks for previous posters input as well it all alluded to the fact it was not as simply as line them up and tighten down

[Paulfzs]

so is it back together and rideable yet

[anutz]

not yet  :b


But i think i will be there by this time next week!


Fair bit still to do but not nearly 1/2 a tricky or time consuming


last tricky thing is the sprocket nut change i plan to do tommorow then the rest is just putting it all back where it belongs...

[Paulfzs]

drink lots of orange juice wash it down with milk, trick i used at school to get the day off, then phone in work say youre sick then you can finish it off!

[anutz]

what if I throw up all over the bike?!

:rollin

[Paulfzs]

what if I throw up all over the bike?!

:rollin

Excuse to take it for a ride to wash it when youre done

[anutz]

Well engines back together anyway and just battling like crazy with the carbs - saw your article on engine change and finding something to lever them in with!

[red98]

Take it the clearences were all OK........yep, carbs can be a bit of a pain, I've tried it always and still dont know whats best  :\.....last time I fitted carbs to air box first, securing with the clips as they do slip out easy, then offer the carbs and air box upto the inlet rubbers.....oh, dont forget to connect the throttle cables first 

[anutz]

Hi red98...

Clearances were appalling....

Some were 0.06 an others were 0.35...

Reason being that the whole cylinder head was turned upside down by someone who shall remain nameless!!!

So it was a random put back together and then measure and adjust as needed

Ended up changing 9 shims, had a box of about 30 so was fine...and could re-use some that I took out

One or 2 were on the limit i.e 29 and 19 etc... but I am ok with that for now - once it turns over and runs I can always go back to it and adjust

Throttle cables are in and going to try fitting the carbs again now...

[red98]

Wow,9 replaced , thats a lot ......going to be one well sorted fazer when your finished  :thumbup......just to keep you busy, you going to balance the carbs when its all back together again and running ?

[anutz]

yep - I have a carb sync tool - it was one of the first things I did a few weeks after getting it....at least now I have no question in my mind where the correct screws are....and im not scared of the bike and un-doing things any more lol

Have the carbs on now - used a bar as a lever on the back of the airbox, with some WD40 around the seals - popped in nicely

I did actually leave the jubilee clips in different angles to where they were - easier access to the hex bolts if I need it again in the future....

[red98]

Nice one  :thumbup........just a few bits and bobs and your ready to hit the start button........

[unfazed]

When all is back together, do a quick recheck.
All bolts tightened, throttle adjusted and checked lock to lock, all connection connected, fuel tap turned on, plug caps in the right position.
Turn on the ignition with the kill switch on run, wait until the pump stops ticking, switch of the ignition, switch it on again, wait until the pump stops ticking, keep doing this until the pumps stops, then the float bowls are full. :thumbup
Now hit the starter button. :woot