GS 450 Cam Chain tensioner reinstall

[Guest]

After reinstalling and timing the cams and setting the preinstall tensioner per the manual, the tensioner will not seat because the "socket" that
the plunger sets into is not lined up with tensioner bore. Any ideas how to correct this?

1980 GS 450S

Thanks, Paul

[Nessism]

I'm not following you.

In general, you need to wind up the tensioner spring and push in the tensioner plunger, then set the lock screw, which should keep the plunger from springing out. Next, install the tensioner into the cylinder, then release the lock screw and allow the plunger to spring out and tension the chain.

[TheNativeSon]

I'm not following you.

In general, you need to wind up the tensioner spring and push in the tensioner plunger, then set the lock screw, which should keep the plunger from springing out. Next, install the tensioner into the cylinder, then release the lock screw and allow the plunger to spring out and tension the chain.

Thanks for the reply, I did do all the above as far as setting up the tensioner before install. The problem is the "socket" that is on the tensioner rubbing block inside the engine that the plunger seats on is not lined up with bore that the tensioner assembly slides into. I have a borescope and have confirmed this. As a consequence, the plunger hits the edge of the "socket", preventing the assembly from sliding into place.

[Nessism]

I don't know what a "socket" is.

[tkent02]

It just pushes on a flat surface.

[TheNativeSon]

I don't know what a "socket" is.

Darn cataracts! I thought I could see a shallow "socket", something with slight ring around the edge. At any rate, I think I am looking at the place where the tensioner plunger
contacts the tensioner and it is not centered with bore. I can move the chain slider around a little and cause the landing point to move around a bit. I will look again.
Thanks for your help.

[TheNativeSon]

It just pushes on a flat surface.

Oh, OK. I'm just not looking at correctly.
Thanks for your help.
Paul

[TheNativeSon]

Darn cataracts! I thought I could see a shallow "socket", something with slight ring around the edge. At any rate, I think I am looking at the place where the tensioner plunger
contacts the tensioner and it is not centered with bore. I can move the chain slider around a little and cause the landing point to move around a bit. I will look again.
Thanks for your help.

I will also verify that all the chain slack is on the intake side.

[sam000lee]

I think you are referring to the cam chain tensioner guide - #8 in this:

http://www.bikebandit.com/oem-parts/1981-suzuki-gs450l/o/m21417#sch256928

or even better : this ebay item

The plunger should hit that little round bit in the second picture on the ebay listing. Make sure that before you install, you wind the 'knurled knob' as far back as it goes while depressing the plunger and then tighten the lockscrew.

If it isn't lined up right, the guide could have gotten knocked loose at some point and just needs to be reseated.

[TheNativeSon]

I think you are referring to the cam chain tensioner guide - #8 in this:

http://www.bikebandit.com/oem-parts/1981-suzuki-gs450l/o/m21417#sch256928

or even better : this ebay item

The plunger should hit that little round bit in the second picture on the ebay listing. Make sure that before you install, you wind the 'knurled knob' as far back as it goes while depressing the plunger and then tighten the lockscrew.

If it isn't lined up right, the guide could have gotten knocked loose at some point and just needs to be reseated.

Thank you, that's an excellent picture of what I'm talking about! I see two pivot pins on the lower end. Do they ride in saddles? With that info, I have a better idea of what I'm dealing with.
I have already set the tensioner plunger.

[sam000lee]

In the manual on BassCliff's site - they refer to that piece as the `rear cam chain tensioner'. I've never messed with it in mine, but after looking at pg 114 in that same manual, it looks like the only way to get it in/out is in the crankcase (as far as I could tell but I could be wrong).
If it's somehow come out of it's pivot I'm not entirely sure how one would realign it;it did come out on somehow so maybe it can wiggle back in, or something.... Good luck!

[TheNativeSon]

Thank you, that's an excellent picture of what I'm talking about! I see two pivot pins on the lower end. Do they ride in saddles? With that info, I have a better idea of what I'm dealing with.
I have already set the tensioner plunger.

I am in business! After making sure that the cams were timed properly and the tensioner was set, I was able to reseat the tensioner guide (it was off to one side slightly). After ensuring that all the chain slack was toward the intake side, the tensioner assembly slid into place perfectly! Thanks to all