Argh. Tappet screws escaped and broke cam chain. Double Argh.

[chef1366]

Sorry it happened so far from home. Good luck with the cam chain link. I would split the cases and put the right cam chain on. No worries.

[Big Jay]

You will want totake a good look at the drive sprocket on the crankshaft. That screw got between the chain and something else.

Jay

[rapidray]

What Jay said PLUS.... the only way to fix this CORRECTLY, no matter what anyone else tells you, is to split the cases & replace the cam chain with a ONE piece, continuous, NON master link chain! Yes you can get master link cam chains but in my book they are JUNK! There is a reason Suzuki used all NON master link cam chains! Ray.

[Nessism]

The only real issue as I see it is whether or not one can get the head of the pin properly peened over. Should be possible with either a proper tool or maybe even a punch of some sort as long as the pin is supported from the backside. I'd go for it vs. spliting the cases but it would be a good idea to pratice first to make sure the pin is secure.

[t3rmin]

I bought the tool and an extra link, so there will be no master link involved, but I don't intend to split the cases.

[mark]

I bought the tool and an extra link, so there will be no master link involved, but I don't intend to split the cases.

I've been practicing on my practice 850 motor to roll on a new cam chain without splitting the cases. As far as the new cam chain goes, once that link is back on there, its REALLY on there........so much so, I feel very comfortable with the process. Watch that you don't press the link too far so that it binds of course.

Still I have talked with a few guys who while comfortable with splitting and re-linking the chain still say that if it was their bike they would split the cases. Gotta be honest about my "data".

[Kris V]

WOW thats a brave move to master link it:shock:. Split the cases and be done with it and NEVER worry about it again.

[t3rmin]

Z1 = Quick

Dang, the chain just arrived. That's amazingly fast! Kudos to Z1 as usual!

[mark]

I'm interested at least in how it goes for you. I'm all set to do the job myself but right now I've just got zero time to work on it............

[t3rmin]

Too bad I still have to wait for MikesXS (chain tool) before I can do anything... Then I have to wait for Bikebandit before I can finish (new tappet screws).

[chef1366]

Do you need any rocker arms? I've got alot of extras. Also tappet screws and locknuts. I've got a box of cylinder head goodies.

[marz]

thanx

you might of just saved me and my engine ..(what a headache).
this might be...heres why

i found a tiny peice of metal attached to the mag.last time i changed the oil.
i threw it away.(v.v.stupid)but it could be part of my chain!
im considering opening it up to check it.aaahhggrrrrhhh
but on the other hand.well might of saved me a trip in the ambulance.

i really dont wanna do this .but i have to im gonna look thgough my boxes and see if i can find somwhere else it could of come from.ive got cam chains,in there i think 3.so ill see.
arrrghhh.(should of changed the engine..)
one way or another.im gonnna get it running .proper!

[t3rmin]

i found a tiny peice of metal attached to the mag.last time i changed the oil.

Could be a bit of a gear -- or anything. Camchain is easy to check at least...

[t3rmin]

Do you need any rocker arms? I've got alot of extras. Also tappet screws and locknuts. I've got a box of cylinder head goodies.

Thanks, Chef. I'll have to get back to you once the cams are off. But I think everything is OK (fingers crossed!). I ordered two new screws to replace the ones that came off (both were slightly chewed), and the old locknuts are fine.

I have a backup plan in case the crank sprocket is hosed -- put on the bits to make it a 750! What kind of compression ratio do you get if you stick with the domed 700 pistons?

[t3rmin]

Finally got all parts/tools today. Pulled off the tensioner and cams. Then the chain breaker tool broke the instant I tried to use it. Got the pins on the new chain out with a punch, though, and broke the old chain with a dremel. Hooked the new chain to the old chain with a teensy zip-tie.

Had my father-in-law play tensioner while I turned the crank to roll on the new chain and HE DROPPED IT! I was super lucky and fished it out with a magnet tool and it was still on the crank sprocket.

After that, all went well. Crank sprocket looks to be unharmed. Chain rivet tool worked fine. Put in the cams and timed them according to the manual. Tomorrow I just have to bolt them down, re-adjust the valves, and put everything together. Fingers crossed!