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Cam chain tensioner middle bolt - removal?

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louis_sutton
Mothra the Radioactive
Mothra the Radioactive

Posts : 216
Location : north london

Cam chain tensioner middle bolt - removal?

Post by louis_sutton on Sun 27 Aug 2017, 1:50 pm

hi all, quick question.  Just pulled the CCT as my shims need replacing.  Rounded bolts, but managed to get it off.  The cover bolt for the tensioner (the middle one, which lets you remove tension whilst getting it off or installing it) is rounded off.  After a week on the train for work, I'm half tempted to sort the clearances and reinstall it without fighting this bolt off and leave it for another day.  Kind of goes against the grain as I like replacing everything needed when doing a job on the  bike, but I want to get riding again.

Anyone have any thoughts?
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ANDYC
the 900
the 900

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Posts : 785
Location : Windsor

Re: Cam chain tensioner middle bolt - removal?

Post by ANDYC on Sun 27 Aug 2017, 2:32 pm

Unfortunately you won't get it back in without rewinding the tensioner.
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louis_sutton
Mothra the Radioactive
Mothra the Radioactive

Posts : 216
Location : north london

Re: Cam chain tensioner middle bolt - removal?

Post by louis_sutton on Sun 27 Aug 2017, 3:18 pm

Dammit.  I was hoping you wouldn't say that.  Hmmm.  Thanks Andy, I'll have to crack on with the usual delights in trying to shift it then!
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Jameshambleton
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Posts : 1912
Location : Bedale, North Yorkshire

Re: Cam chain tensioner middle bolt - removal?

Post by Jameshambleton on Sun 27 Aug 2017, 9:51 pm

try using an E-Torx socket, they're great for removing bolts with rounded heads
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louis_sutton
Mothra the Radioactive
Mothra the Radioactive

Posts : 216
Location : north london

Re: Cam chain tensioner middle bolt - removal?

Post by louis_sutton on Mon 28 Aug 2017, 3:30 pm

Oh cool, they're worth a try are they? I'll grab some. Really appreciate it
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Jameshambleton
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Posts : 1912
Location : Bedale, North Yorkshire

Re: Cam chain tensioner middle bolt - removal?

Post by Jameshambleton on Mon 28 Aug 2017, 4:37 pm

When the pinch bolt for the front axle bolt on the leg rounded itself off I tried imperial and metric tools to undo it with no luck, tried an e-torx socket and it came undone straight away
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louis_sutton
Mothra the Radioactive
Mothra the Radioactive

Posts : 216
Location : north london

Re: Cam chain tensioner middle bolt - removal?

Post by louis_sutton on Mon 28 Aug 2017, 9:53 pm

ah well, worth a try, but sadly no joy.  Nor was dremeling a slot for a screwdriver.  It's stuck fast.  I'll have to drill it.
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wornsprokets
the 900
the 900

Posts : 1257
Location : dublin

Re: Cam chain tensioner middle bolt - removal?

Post by wornsprokets on Mon 28 Aug 2017, 10:30 pm

Davidsiverspares sell them for 60ish pounds....not a part i take chance with....
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Beresford
the 900
the 900

Posts : 1451
Location : not that far from Kirkistown

Re: Cam chain tensioner middle bolt - removal?

Post by Beresford on Tue 29 Aug 2017, 12:32 am

The bolt is merely a blanking plug. If you have the CCT off the bike grip the bolt in a vice and rotate the body.
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louis_sutton
Mothra the Radioactive
Mothra the Radioactive

Posts : 216
Location : north london

Re: Cam chain tensioner middle bolt - removal?

Post by louis_sutton on Tue 29 Aug 2017, 12:52 am

Thanks all - the vice idea was a great one, but no joy.  The bolt is now (after a variety of methods) pretty banjaxed.  But it is seventeen years old, so I don't begrudge buying a new one!
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louis_sutton
Mothra the Radioactive
Mothra the Radioactive

Posts : 216
Location : north london

Re: Cam chain tensioner middle bolt - removal?

Post by louis_sutton on Thu 31 Aug 2017, 11:00 pm

Finally (finally!) managed to get the shims out.  I'm rather happy.  New tensioner arriving tomorrow too.

I measured the shims with a micrometer - is it usual to find they measure up as 0.01 larger than the stamped size on the face?  I'm presuming that since it's relatively constant across all eight shims it's just the micrometer (which I have calibrated), and that I should just order replacements based on calculations from the stamped size?

Sound about right?  Let me guess, I'm overthinking it...
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Jameshambleton
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Posts : 1912
Location : Bedale, North Yorkshire

Re: Cam chain tensioner middle bolt - removal?

Post by Jameshambleton on Thu 31 Aug 2017, 11:19 pm

Sully has a spreadsheet somewhere for the calculations, I think I lost my copy when 2 of my hdd's died
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louis_sutton
Mothra the Radioactive
Mothra the Radioactive

Posts : 216
Location : north london

Re: Cam chain tensioner middle bolt - removal?

Post by louis_sutton on Thu 31 Aug 2017, 11:22 pm

I'd be enjoying myself a lot if I weren't already sick of the train and tube

sullivj
the 900
the 900

Posts : 2121
Location : Gatwick

Re: Cam chain tensioner middle bolt - removal?

Post by sullivj on Fri 01 Sep 2017, 10:48 pm

I do have a shim spreadsheet for you to calculate which ones you need.

I also have a few shims in the exchange, so might have what you need.

PM me your email address, and I'll send you the spreadsheet.
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louis_sutton
Mothra the Radioactive
Mothra the Radioactive

Posts : 216
Location : north london

Re: Cam chain tensioner middle bolt - removal?

Post by louis_sutton on Sat 02 Sep 2017, 1:48 pm

Thanks mate - that's really kind of you.  But I've already done the calculations (felt like getting ready to help my lads with their homework when they're old enough).  And ordered the shims from Lings.

I do however need some help with my stupidity (not sure whether to start a new thread).  Ended up taking the cams off without having the crank properly aligned (with the "O" mark visible through the inspection port).  All fine on the removal.

I can line the O mark back up in the inspection port and reinstall the camshafts no problem, aligning them correctly.  But there are two engine positions where the O mark is visible in the inspection port.  In one position the camshaft sprockets are aligned (sprocket marks at 9 and 3 o clock respectively).  Turning the engine 360 degrees (so again with the O mark visible in the inspection port) puts the sprocket marks in the wrong place.

I'm trying to find a way to confirm from the Haynes that it won't matter - as long as the right mark is lined up in the inspection port, and the cam shafts go back on properly aligned, it will make no difference to the engine.  But I'm struggling with it (running around bellowing at the kids every now and then doesn't help with checking it out).  So I thought I'd ask - any thoughts from anyone who's pulled an engine apart?

Cheers
Louis
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ANDYC
the 900
the 900

Mechanic
Posts : 785
Location : Windsor

Re: Cam chain tensioner middle bolt - removal?

Post by ANDYC on Sat 02 Sep 2017, 2:20 pm

It won't matter as the rest of the engine is timed by the crankshaft. 
It's only because the camshafts are geared to turn at half the speed of the crankshaft that you need to turn the crankshaft over twice to re align the camshafts.
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louis_sutton
Mothra the Radioactive
Mothra the Radioactive

Posts : 216
Location : north london

Re: Cam chain tensioner middle bolt - removal?

Post by louis_sutton on Mon 04 Sep 2017, 9:12 pm

Andy you're a legend
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louis_sutton
Mothra the Radioactive
Mothra the Radioactive

Posts : 216
Location : north london

Re: Cam chain tensioner middle bolt - removal?

Post by louis_sutton on Mon 09 Oct 2017, 9:51 am

Thanks to all who commented - runs like a dream (and one of the camshafts was a tooth out, so nice to have been able to correct it!)
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Beresford
the 900
the 900

Posts : 1451
Location : not that far from Kirkistown

Re: Cam chain tensioner middle bolt - removal?

Post by Beresford on Thu 12 Oct 2017, 6:42 pm

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louis_sutton
Mothra the Radioactive
Mothra the Radioactive

Posts : 216
Location : north london

Re: Cam chain tensioner middle bolt - removal?

Post by louis_sutton on Thu 12 Oct 2017, 10:40 pm

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