cam / timing chain replacement

[ulikedat]

It's time to replace the cam chain on my bike.
According to the manual, the cam chain is supposed to be replaced every 4 years.

I've been watching videos on YouTube on how this is done as well as reading and re-reading the service manual to figure out the best way to go about it.


Option 1
Remove the valve cover,
drop the cam chain,
remove the magneto cover,
remove the flywheel and stator,
remove the old cam chain,
put the new cam chain in through the magneto end,
fish the chain up through the top end of the motor with a wire clothes hanger and set the chain on both gears on tdc of course.

Option 2
Remove the valve cover,
Break the old cam chain,
Break the new cam chain,
Link one end of the old chain to one end of the new chain together with a piece of wire,
Attach a piece of wire or a wire hanger to the opposite end of the new cam chain (to prevent the new chain from falling in to the bottom end)
Use the old chain to run the new chain through the motor,
Remove the wire holding the old chain and new chain together,
Rivet the new chain together


What do you guys think is the best way to replace the cam chain?

Has anyone here changed the cam chain before? If so, how did you do it?


Does anyone know where to get a flywheel puller for the xf200?

[ulikedat]

Nice cam chain tension adjustment video.

http://www.youtube.com/watch?v=QUvPp96hpXc

[ulikedat]

Here's a link to a video of Option 2 above.

If I go this route, I'll use a chain break to break the chain and a chain riveter to put the chain back together.

http://www.youtube.com/watch?v=IkSl0ZUDnZc

[humanbeing]

Option 1

That bike is similar to dr125 which uses 12mm spark plug.

[ulikedat]

thanks humanbeing.ab
my biggest concern with option 1 is aquiring the correct flywheel puller. does anyone know where to find one or how to go about figuring out which puller i need?

[ulikedat]

Option 1

That bike is similar to dr125 which uses 12mm spark plug.

WOW! can the flywheel on the xf200 be removed the same way as the guy in the video above removed his? is a flywheel puller even needed?

[MJH]

Seems to me that a moving part would be scheduled to be replaced based on mileage, not on years. Most cars have cam belts these days and they typically get replaced around 100K.


There is a Q-link shop manual online, on this site, a PDF I believe, I never downloaded it since I have a hard copy. I cannot find the recommendation you stated in the maintenance schedule.


The manual recommend inspecting the tensioner every 3000 miles, that’s it, that’s on page 13 and also on that same page is the recommendation to replace the fuel line every four years.


If you are hearing excessive chain noise then check the tension device, it could be failing? But just replacing a cam chain that is not making noise is not required or recommended by the manufacturer.

[ulikedat]

The manual recommend inspecting the tensioner every 3000 miles, that’s it, that’s on page 13 and also on that same page is the recommendation to replace the fuel line every four years.


If you are hearing excessive chain noise then check the tension device, it could be failing? But just replacing a cam chain that is not making noise is not required or recommended by the manufacturer.

*foot in mouth*

You are absolutely right MJH, I was mistaken. The manual mentioned replacing the fuel lines every 4 years which just so happened to be right below the cam chain adjustment topic.

I hear no noise at all other than the valves chattering a bit (while accelerating [i set the valves within the limits of the manual not long ago]). I will end up adjusting the cam chain tensioner anyway for good measure.

The manual mentions using a rotor detatcher slider to remove the flywheel (I'm going to have to replace my starter clutch. the starter motor spins but doesn't start the bike. luckily, this bike also has a kick starter :D)

Has anyone here ever removed the flywheel on a xf200 before? If so, how did you do it? what tool or tools did you use and where did you get the tools?

[ulikedat]

Here are some pictures from the xf200 manual of the tools needed to pull the flywheel.

flywheel tools.jpg

[humanbeing]

"Trade grade" tools are are affordable inside China
http://item.taobao.com/item.htm?&id=1004596173 | http://item.taobao.com/item.htm?id=1020537949