Motorcycle Repair: 03 kfx 400, kfx 400, pushing the chain


Question
My cam chain is making a lot of noise to the point that an interested buyer is sure going to think there is a serious problem.  I really want an expert opinion on what I must do.  How big of a job is it to changeout the chain and is it possible that the tensioner is causing the problem and what does it entail to deal with it?

Answer
Ron,  The tensioner may be fully extended and not keeping the chain tight. The chain may need to be replaced. To replace it is extensive. Remove fuel tank,remove valve cover,remove chain tensioner. Its spring loaded so as its pulled out of the cylinder casting it will fully extend out and is locked in place by a ratchet pawl. Remove the side cover now remove the flywheel bolt and flywheel. Before pulling the flywheel remove the spark plug and turn the crank to set piston at TDC. Verify this with the timing maks on flywheel and timing marks on cam sprocket. Now remove the cam hold down bolts and carefully lift the cam hold down casting and remove it. Now lift the cam tilting the sproket down and remove the chain. Drop it down by the crank and pull it out. When going back in with new one the tensioner will need to be reset. The 10mm head bolt on the casting can be removed and let the spring come out. Lift the ratchet pawl and push the plunger back in all the way.Leave it apart for now untill the casting is bolted in place then place spring back in and replace bolt which will retention the spring pushing the chain guide against the chain. Once all back togethor turn the crank over with a socket and recheck the timing if its binds up the timing may be off a little. If it turns over smoothly then finish the covers and plug and so on. A simole reason if the timing is off you'll bend a valve trying to kick it over.