Rear chain Guide Replacement

[GlennK]

I'm working on a 1981 GS750 EX. I have the head and cylinders off. The rear cam chain guide has chunks out of it and needs to be replaced. From the look of the repair manuals and what I've seen in the forums I have to split the cases to replace it. Anybody know if there is any other way to change the rear cam chain guide.

[BassCliff]

Greetings and Salutations!!

Hi Mr. GlennK,

I have no first hand experience with replacing the cam chain guide but I'm sure others will be along shortly who have. In the meantime you can probably find the procedure in the manual. You will find that and a lot more in the links below. It's the "mega-welcome".

If you are here you probably have a 30 year old motorcycle that needs about 20 years worth of maintenance. You'll find all kinds of helpful tips, procedures, manuals, diagrams, "how-to" guides, etc, in the links below. Let's get started.

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[GlennK]

Thanks for the welcome. I've been lurking here for a couple years. I have taken advantage of the wealth of knowledge found on the GS forum to do maintenance and upgrades to my GS.

[chef1366]

You have to pull the head and cylinders. Splitting the cases is not necessary.

http://www.mrcycles.com/fiche_section_detail.asp?section=94825&category=Motorcycles&make=SUZUKI&year=1980&fveh=2136

[TeamDar]

You have to pull the head and cylinders. Splitting the cases is not necessary.
http://www.mrcycles.com/fiche_sectio...1980&fveh=2136

This is incorrect. The 1980-82 GS750 engine has to have the cases split to remove the rear chain guide. There is no bolt to hold it in place. it is retained between the case halves.

[chef1366]

This is incorrect. The 1980-82 GS750 engine has to have the cases split to remove the rear chain guide. There is no bolt to hold it in place. it is retained between the case halves.

To replace a part that wears.
WOW
Sorry for the misinformation

[GlennK]

Thanks for the input. I was pretty sure the cases had to be split. UGH!
OK. All the cover plates are off and the engine is on the bench. What is the minimum amount of disassembly necessary to split the cases. I'm not asking for a "how To", just a list of what has to come off. This info would be a great help. Thanks.

[chef1366]

Thanks for the input. I was pretty sure the cases had to be split. UGH!
OK. All the cover plates are off and the engine is on the bench. What is the minimum amount of disassembly necessary to split the cases. I'm not asking for a "how To", just a list of what has to come off. This info would be a great help. Thanks.

The shifter has to come out. Be careful of the springs and small parts on the shifter drum.
Remove the clutch and you'll see all the brackets that need to come off.
There are case bolts everywhere! If you have a manual it will tell you where they all are.
Oil filter cover has to come off too.

[Carter Turk]

Find some pieces of cardboard for the case half bolts.

Draw a rough picture of the top and bottom halfs with bolt locations, poke holes where the various length/size bolts go.

Zip lock bags for the plates behind clutch. Might be worth taking a picture of the shift shaft orientation behind the clutch or drawing it.

Maybe this is already on Bass's site, but just in case.

I can't remember if the 81 has 2 allen bolts inside the oil filter housing. My friends 83 750ES had them, which made it rather difficult to split the case with them still attached.

[GlennK]

Thanks guys. I do have manuals. Last year I changed out the clutch plates and put on a new chain and sprockets (630 to 530 conversion). So I've had all the side covers off except the one over the generator cover. It looks like everything on both side of the motor has to come off to get at all the bolts. I've enough info now to get started.
I really appreciate the help and advice. I'm sure I'll need more of it!

[GlennK]

rear cam chain guide replacement-Update

This weekend, I finished getting the cases split and the damaged rear cam chain guide out. There are two allen head bolts in the oil filter housing. I have a factory and a Clymers manual. The Clymers was actually more helpful. It explained what needed to be removed to split the cases. The other manual has better illustrations but shows complete disassembly. Luckily, none of the bolts wrung off and I didn't damage any surfaces. Time to order parts and try to clean off 32 years of gunk.

Glenn