alt chain tensioner hitting pressure plate

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ARCHIVE_crash

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? about zl600

I have a ?
did the zl600's come with spoke wheels or mags, or was that a choice when you buy the bike new? or was it a year thing? see i just looked at Mark's website and his zl6 has spokes. but few years ago i had a friend that had a zl6 and it had mags. the other thing is the color. black, red, and yellow no wineberry like my bike(1987zl1000). thats it any answers
crash
 
I believe it was a year thing. My wife has a yellow 1996 that came with spoke wheels. The earlier models came with mag wheels.
 
color and wheels

Joe, you are correct. The '86 and '87 models came with mag wheels. The 90's models came with spoke wheels. Also the color in 80's model was red and black for the '86 and yes wineberry is a color for the '87. My '87 is wineberry. Don't know if any other color is or was available for the '87. The 90's models came in yellow and red if I am not mistaken. Furchin
 
when I am cranking the engine over about every third turn the tensioner makes a snapping sound and hits the pressure plate. Why? I have the cover off and I can see the tensioner popping. It seems to do fine for a couple of turns then POW. Now I know where the shavings are coming from and the cause from a previous post.
 
Give me time to think..........first guesses are Wrong tensioner, wrong chain, not mounted properly, but who knows? I haven't heard this mentioned before!!!!

I have a motor in bits on the shed floor. Give me a bit of time and I'll see what clearance there is on that one

Can you get a 'side on' picture of what is fitted to your bike (and put it in the gallery or whatever)

KK
 
I have added pics in my gallery. Pulled the plugs and tried again, it doesn't kick the tensioner out with no compression. How about the rubber couplings under the alt sprocket, anyone ever have a problem there? I have all my goodies back together and am ready to test fire but scared of getting shavings all over the place. I don't want to have to flush the crankcase again, that was a terrible mess. Oil and kitty litter all over the floor and stand.
 
If we don't come up with an answer here try the gpz site and Concours owners group(COG)
 
Right....bear in mind that this is an engine laying on my shed floor so no comment about bits missing and muck everywhere LOL

Also, its a GTR (concours) engine, but they are identical anyway.

As you can see from the first picture, I have the same damage as you on the clutch cover. The only difference I can see with the tensioner is that yours has 'C' stamped on it and mine has 'D'. OK so far.
DSCF0003.jpg


The tensioner is a simple ratchet. As the tensioner goes forward, the smaller spring-loaded arm allows the rod to move towards the chain and is not supposed to allow it to move back again.
Looking at this second picture the point where the adjusting rod goes through the smaller arm (where the screwdriver is pointing) could be worn, allowing the tensioner to slip backwards. Have you tried to push against the chain to see if there is any movement in the wrong direction? When I tried it with this one, there was about 1/8th inch (or maybe a bit less) movement and then it jammed solid and would not move any further. As far as I can see, the only way that the main tensioner arm can touch the clutch cover is if the tensioner is worn around that small hole. Its possible that it may be time to get a new tensioner (and chain etc).
DSCF0005.jpg


Hope this helps.

BTW.......BIG round of applause for managing to post pictures :groupcheers:

PS Use Photobucket and not Photobox (pile of pish)

KK
 
Part 2 ...Just been back out to the shed, wondering why I'd got the same damage on the clutch housing, when in my last post I said that the tensioner only moved backwards about 1/8th inch .......BUT........if you take it by surprise, and by that I mean pushing quickly against the chain using a screwdriver (like a chisel and striking it sharply), to simulate backlash through the chain, the small tensioner arm does not have time to grip and can move back far enough to hit the clutch. This should not happen, I'm sure.

I really think that you would have to replace the tensioner.

KK
 
Don't need specs, Thank you. I think we are on the right track and I need a new tensioner. I can't get it to stay in the lock position so Im guessing there is some ware in the stop lever that wont allow the rod to grab. Now for the real mystery. Looking at the clutch from the left side as in my pic you can see the damage to the pressure plate. The top part of the tensioner is the only part that can contact the plate and the clutch turns anti-clockwise.....but..... the marks on the plate would seem to indicate just the opposite. In other words the plate is rotating into the tensioner This would seem to me that this engine had been turned the wrong way ....or? somebody tell me I am hallucinating.
 
Ahhhh........Penny has just dropped with an almighty CLANG

DOH

Years ago the alternator drive chain snapped and threw itself through the engine casing making a mess of everything in that area. I thought at the time that it was the chain snapping that caused all the damage. BUT NOW I'm beginning to think that the tensioner jammed up against the clutch and broke the chain....not the other way round. Had to replace chain, both sprockets, tensioner, and engine casing.

I think that the tensioner should be on the "relace at so many miles list". I can't remember what mileage was on mine when it went. Whats on yours now?

KK
 
from ZRX61 @ BCF

Easy to diagnose the problem: the chain & tensioner need replacing. It's a known deal with that engine & all the variants of it.

Great now I have an "Eliminator-money pit". Kinda like a woman, can't live with em and you can't live with out them. :banghead:
 
Dang, I have 25K on mine now, guess I better order some parts! I really don't mind, it is a small price to pay for the adrenalin.....
 
wuputt said:
Dang, I have 25K on mine now, guess I better order some parts! I really don't mind, it is a small price to pay for the adrenalin.....
Click to expand...
But surely that's what this site is all about.

It's unfortunate for one member but could save a fourtune for all the rest, and I'm sure that elimafreak will benefit from someone else's misfortune at sometime in the future.

What we need is a locked technical section where, (when we've DEFINATELY solved an issue for a member), the post can be moved and the bits that are not relevant can be edited out, so that we don't end up repeating ourselves. Mark???
KK
 
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