Cam tensioner spring

[shnyroq]

Just another heads up on the cam chain tensioners... I had heard recently that a couple members here had checked the travel remaining on their tensioners and had found that the big spring had broken after reinstalling the tensioner cap. Well on mine, the spring got caught between the bearing and the pushrod. I was able to free them and it doesn't look like any damage was done, but I had only ridden less than 100 miles like that - not sure what would've happened with more mileage.
Take care when checking your tensioners...

[AlabamaNomadRider]

What symptons did your bike have with it like that?

[shnyroq]

I didn't notice anything different. With more mileage, the spring's ability to push on the tensioner might have caused some trouble.
Based on recent events, I personally would suggest removing the entire tensioner when checking the amount of travel left, not just the cap.

[Cajunrider]

Originally Posted by shnyroq

Just another heads up on the cam chain tensioners... I had heard recently that a couple members here had checked the travel remaining on their tensioners and had found that the big spring had broken after reinstalling the tensioner cap. Well on mine, the spring got caught between the bearing and the pushrod. I was able to free them and it doesn't look like any damage was done, but I had only ridden less than 100 miles like that - not sure what would've happened with more mileage.
Take care when checking your tensioners...

That is exactly what happened to mine, only it broke a small piece of the flat end of the spring. You are the third member that I can remember to report this. I agree, I wouldn't check the travel and re-install the cap without removing the assembly and re-setting it according to the shop manual or gadjet's instructions. Even if no damage is done, you can't purchase the spring alone from Kaw, you have to get the entire assembly which is nearly $100.

[macmac]

I am not sure how the spring breaks, But i do know there is no reason to pull or loosen the locking bolt to check. There is 0 point. That was locked at the factory and then the unit was installed and then the bolt was unlocked. Loosening after that is pointless unless you are re setting the bearing holder and bearing.

[MAS Tequila]

And under NO circumstances should you remove the entire assembly to check the travel.

Think about it; it is under pressure from the springs.

What is going to happen as you loosen the bolts?

It WILL extend. Now you have no way of knowing how far it has traveled.

Check e-bay for tensioner assemblies. A few bucks is better than the price of a new one.

MT

[shnyroq]

I don't know if you need to buy a whole new assembly just to check your travel. I just think you should remove the cap and spring and then the entire assembly, following the manual for installation.

[Cajunrider]

Originally Posted by MAS Tequila

And under NO circumstances should you remove the entire assembly to check the travel.

Think about it; it is under pressure from the springs.

What is going to happen as you loosen the bolts?

It WILL extend. Now you have no way of knowing how far it has traveled.

Check e-bay for tensioner assemblies. A few bucks is better than the price of a new one.

MT

You are correct DC. I failed to mention clearly that you should pull the cap and check the travel and then remove the assembly to compress the large spring with the bearing and hold it with the lock screw. This is how the shop manual says to load the spring after checking the travel. If the assembly is pulled before removing the cap and checking travel it will be fully extended when you remove it. My point was I don't think it's a good idea to compress the big spring with the cap because it appears that sometimes the end of the spring gets jammed around the bearing when tightening the cap. That is what happened to mine and there was no way for me to be aware that it happened. If you can find the room to push the bearing and spring below the lock screw with the assembly in place that would work just as well. It would be difficult to see that the bearing is below the lock screw while the assembly is in place though.