Cam Chain worn out at 22000 km(14000 mls)???
 

I have a 2001 XT600E DJ02 4PT with 22000 km(14000 mls) on the clock and the cam chain is worn out/noisy.
The auto tensioner has half of the teeth exposed(8 out of 16).
It is only audible between 3200 rpm and 4000 rpm on the highway & that's with a loud straight-through muffler !!
My first thought, being the 4th owner, was that previously the speedo had been disconnected. But the mileage done by each previous owner seems consistent. Also, the cam chain guides, camshaft, valve stem ends & clutch plates, etc all show virtually no wear, & it uses no oil.
The first 7000 km were done in Japan which would typically include a lot of idling in traffic, which may be a factor?
.
Is it normal for the cam chain to be noisy at this mileage ?? :confused1:
.
Bob

mine gave up with 30,000 km so yeah.. change it soon!

Do you feel her as being "sick"? This is how I treat my baby! :innocent:
Mine was feeling "weird" like when you have the flu...
That was just a few 10-15 miles before the cam chain broke!

If I wasn't in a hurry to get back home from the beach and off to the airport it wouldn't have happened that day...

I was riding at 80km/h give or take a few when that happened on my way back home... :oops2:


Vando :cool4:

Hi Vando,
sorry to hear of your loss at only 30000 km.
Mine was running fine, but the noise was telling me it was crying out for help!!
I have it apart & waiting for the new chain to arrive.
I am hoping I don't have to go through this procedure(not an easy job removing the flywheel!!!) again in another 20000 km?? :(
Bob

Hi.
I have always been under the belief that a cam chain gets quieter the more you rev the engine while the tappet/valve clearences get noisier. Is the tensioner working ok? Befor putting in anew cam chain I would be checking valve clearences also if you only get the noise at a specific rev range maybe there is something else wrong. I would have expected the chain tensioner to be at full adjustment befor there was any noise if it is working correctly.
I see Bobmech suggested removing the flywheel when doing his cam chain, I suggest drop the cam and use a joining link riviting the pins, a easy process and doesnt fail. Have done many bikes like and saves time and money. Imagine the cost on say a Kawa z1000 or similar if to replace the cam chain you had to drop the crank because the cam chain runs between the pistons.
Cheers Ernie.

Hi Ernie,
thanks for your feedback.
But the noise is definitely not noisy tappets.
The tensioner is not worn & working fine.
The noise comes in at the mid rev range only, the same as the old 70's Chrysler Valiant 6 cyl Hemi's did when their morse cam chain was worn. Gee that's going back a few years!!
I think if the tensioner was out further then the chain would be noisy also at idle.
I have read other forum members who have manually extended the tensioner by another tooth before refitting it, as a way of reducing cam chain noise, so others have had this problem. Auke has claimed that once 2 thirds of the tensioner teeth are exposed, the chain is worn out. I have half of the teeth exposed.
I chose to not use a joining link (although I have done so many times on car engines without any problems) as the dealer said the chain doesn't come with a joining link & I didn't think removing the side casing & flywheel would be much of a problem. Also I wanted to remove & inspect both chain guides for possible damage which may have been the cause of the noise. The front guide slides out the top once the rocker cover is off, but the rear guide anchor is bolted to the crankcase at the bottom behind the flywheel.
But I take your point with regards to the 4 cyl bikes with the chain in the middle between the cyl's.
I heard that the early Ninja 900's needed a new chain every 20000 km, but expected the XT600 would last 40000 - 50000 km ??? :(
All comments are welcome.
Bob

My 2003 has passed 75.000km. As far as i know, the whole engine is still stock.

Hi Jens
thanks for your feedback.
It seems odd that there is such a large variation in cam chain life.
Is yours getting noisy at all ?
Bob

Norwp nothing. I've been riding the bike for the last 25.000km ish.

I'll try to make a video sometime soon.

Heres a quick crappy video: YouTube - Yamaha xt600e 2003, with 75.000km

Hi Jens,
The problem is that my PC doesn't have a sound card or speakers :crying:.
But I appreciate the trouble you have gone to.
Bob

Heres the sound for ya: *thump* *thump* *thump* *thump* *thump* *thump* :scooter:

That's excellent, Jens.

:funmeteryes:


Who said Scandanavians don't have a sense of humour?