2003 TT600R cam chain change
 

Hi All - I'd like to replace the cam chain on TT600R (kick start), as it's noisy when cold and I know it's been on there a long time.

However it's more in depth than work I've done previously (servicing, changing clutches, kick starts etc), so am worried I could c**k it up on a grand scale.

How hard is it for an amateur mechanic? Should I be sending it to a garage instead?

First i would ask the mileage on this? How do you kow its the cam chain? There is alot of strange noises from these engines so before you start changing anything be sure its necessary.

Mileage is around 10k I think. The odometer hadn't been working for a while and it had been stood outside unused for about six years before I brought it back to life.

10K is a walk in the park for these bikes. Either miles or KM, that is very low.

If it were mine, I would pull the rocker box off and look at the cam and rocker arm faces. If they are not scored and the cam bearing in the rocker box itself is good, put it back together and set the valves.

Next, because this can be a problem if left unattended, drain oil, remove the clutch cover and look at the nut on the end of the crankshaft and the nut inside the clutch. These can and do come loose and can cause major damage. While open, look at the gear faces. While ordering gaskets, order the check valve rubber piece, check valve ball will be ok. Check valve is on clutch side, bottom of engine. Remove old check valve and clean before reinstalling. If everything else looks intact reinstall the cover using a new OEM gasket. Install a new oil filter.

Same for the rotor cover, make sure the flywheel nut is not loose. Reinstall with a new OEM gasket.

As was stated, these engines are a bit noisy when running. They should not be making any knocking sounds but are a bit clattery. Make sure you get a good setting of the valves, too loose can be noisy, too tight can cause low compression and burned valves.

anyone else can jump in here.

That's a very low mileage, and the cam chain is the "morse" type which last a long time, so wouldn't expect much wear.
The first and easiest thing to check would be the tensioner condition.
If you follow Steveloomis recommendation re checking the crankshaft right side nut(and keyway), also check the balance shaft nut next to it(and the keyway) as they have a tendency to work loose with disastrous consequences, and the TT600 are known for it.

I have a 2001 XT600E 4PT DJ02 which had a noisy cam chain only at 3400-3700 RPM. Supposedly only done 19K, but was a 2nd/h import, so the odometer may have been tampered with?
I renewed the camchain, although the new one was the same length as the old one, but since it was apart thought it best to renew it anyway.
The most difficult part was removing the flywheel as they're really tight & easy to damage the end of the crankshaft.

The chain tensioner was in good condition so reused that.

Checked the camshaft bearing surfaces, good.

The front chain guide was worn on the top ears, so I renewed that also.
Then discover the old front chain guide had previously been bowed slightly compared to the new one, which was straight. So someone had previously removed the chain guide & bowed it, then refitted it to hopefully cure the chain noise.

Put it back together and still have the same cam chain noise at 3400-3700 RPM , although not quite as bad as before and not noticeable unless riding constantly in that rev range.
It's not loud, but noticeable if you're listening for it. I guess it's just the nature of the beast.

Maybe you or others can benefit from my experience, which was mostly a waste of time.

Bob

Great advice thanks guys, I'll check the tensioner and other parts you mention instead. Other than that it's been running very well and probably done 500 or so miles with no issues since I've had it going again. :-)

Thank you BOBMECH. A first hand experience is a worthwhile read. Too bad the chain noise did not go away, but will help others with the same noise not to worry about it so much. Good show.

Here is an old post explaining how to check the cam chain wear by inspecting the number of tensioner teeth exposed

Old 4th June 2003
aukeboss aukeboss is offline
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Join Date: Jan 2001
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Yes, it is probably your camchain that is worn. Test by pushing in just a bit more the plunger of the tensioner, as the spring is not strong enough to push it all the way. First remove the large 'coverbolt' on the tensioner L/H side of cilinder. If sound stops it is the camchain.
Another indication: remove coverbolt and spring on tensioner. Remove tensioner. Count number of notches out on the plunger. If more than 60% of total replace chain. Spring to be remoived first, otherwise the spring will push out he plunger all the way and you loose the actual reading of thenumer of notches.

Replacement of chain does not require new sprockets, see post about two months ago.

Auke

cheers
Bob