Timing chain tensioner ktm solved (i think)

[ChrisMember]

as some of you know I have been struck down with a noisy timing chain, resulting from the tensioner not releasing to the next notch, as I couldn’t get a dirt tricks one and am riding sunday I decided to give it another go fixing it.. I followed the below instructions.

INSTALLING THE TIMING CHAIN TENSIONER! Note: IF YOU DO NOT FOLLOW THESE INSTRUCTIONS THE CHAIN WILL NOT BE TENSIONED CORRECTLY AND WILL SKIP, RESULTING IN ENGINE DAMAGE!!
The timing chain tensioner operated with spring force and with oil pressure. A stop system is used to ensure the right amount of chain tension in the starting phase, even if the oil pressure is insufficient. The stop system prevents the piston on the timing chain tensioner from being retracted. In a dismounted state, the piston on the timing chain tensioner extends completely.
Fully depress the spring tensioner. This will require some effort since the oil must be squeezed out. If the timing chain tensioner is released it will extend completely again; it may not be mounted in this state, since the locking mechanism will not function.
Press down on the timing chain tensioner to ensure smooth operation.
To prepare the timing chain tensioner for installation, place 2 washers or similar spacers with a thickness 2 to 2.5mm (two nickels, one each side of the tensioner in between is perfect) next to the piston of the timing chain tensioner. This will ensure that the piston can not be completely retracted when the piston is pressed down. If you release the piston, the stop system will lock, the piston will protrude approx 3mm and stay in this position – this position is mandatory for refitting!

If you press the timing chain tensioner again and it extends no more than half way (preventing it from extending completely), the stop system will “lock” and the timing chain tensioner can go no longer be pressed together – this position is necessary to ensure that the timing chain is adequately tensioned, even if the oil pressure is low.
Slip the hydraulic tensioner into its hole the telescoping end first, install the plug with its sealing ting and tighten to 25NM.
Then with a substantial screwdriver enter it into the RF corner of the head, straight down just forward of the cam chain, get the tip of the screwdriver on the front side of the black tensioner bar and force it back against the chain to “relieve” the previously “locked” tensioner so it can hold the chain tension firm until oil pressure takes over!
Caution
If the chain tensioner is not “relieved” after assembly as described above, the timing chain will skip when the engine is started resulting in valve damage.

So after doing this, and everything going well I started the bike up and damn noise still there, I then followed the below which is a trick that Dicky (RIP) told me when I first had this happen,

my 450exc-r and two others that i service started making the clicking/ticking noise on the left side of motor after approx 600klms, talked to KTM australia tech dept and they informed me that some times the cam chain tensioner doesnt quite jump up to the next adjustment tooth by its self(it should do it aotumatically). all you do is loosen the tensioner(THE BIG NUT NOT THE LITTLE ONE) while the engine is off and wind it out a few turns until you here click, (listen carefully) then do it back up and noise will be gone, if not there must be another issue but i have now done this procedure on 4 bikes and all were cured,

NOTE: I had to do this twice, run the bike after each adjustment, on the 3rd try there was no click so I assume it is in as far as it should be, and there is absolutely no noise, I will take it for a test ride in the morning to confirm. Just info incase it happens to anyone else.

Cheers
Chris.

[AlexMember]

Ah memories. When i had my excf i wondered every ride if it was going to fail and lunch itself. There are some things like this that make you wonder why KTM why.

[alanMember]

it will still stuff up get another tensioner as soon as posible .i put a cafe racer one in mine .it worked made the moter run better down low due to correct cam timing and made the decompresser work better roll started heaps better (when you stall it going down hills coming into corners etc)looked a bit basic but worked

[Justin WilliamsMember]

I have a cafe racer type stored somewhere if you want it?

[ChrisMember]

where about are u justo.

[Justin WilliamsMember]

Northern beaches. But probably can’t pick it up for a week or so as its on the central coast !!!!!?

[Scott HanleyMember]

Hi guys
I know this is a old thread but was wondering how is the cafe racer tensioner going? Have bought a new genuine tensioner but after reading a few article this is probably not the best way to go. Let me know your thoughts.

Cheers
Scotto

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