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March 23rd, 2015, 12:19 PM   #1
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04-08 Mounting The Timing Chain

What is the best way to mount the timing chain on 04-08 models?

The workshop manual has a procedure but it is with the clutch basket removed.

I would like to leave clutch in.

The head has been removed and reinstalled.

I can get everything to line up O.K., TDC, balancer to primary, cam etc.
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March 23rd, 2015, 12:26 PM   #2
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Not to hijack, but I have a replacement chain (OEM) and no tool to rivet it with. Taking a hammer to it isn't an option since the only thing supporting the chain would be the timing/cam gear. Suggestions?

To answer the above, attach one link to the old chain and feed it through that way. Coat hanger style too!

Reading it again, which would the clutch basket need to be removed?
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March 23rd, 2015, 12:31 PM   #3
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Originally Posted by jmscrttndn View Post
To answer the above, attach one link to the old chain and feed it through that way. Coat hanger style too!

Reading it again, which would the clutch basket need to be removed?
The chain has already been removed completely. The clutch basket would need to be removed for access. Per the workshop manual you would attach the chain together right underneath the clutch.
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March 23rd, 2015, 01:00 PM   #4
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Originally Posted by husabutt View Post
The chain has already been removed completely. The clutch basket would need to be removed for access. Per the workshop manual you would attach the chain together right underneath the clutch.
Sorry, I am lookign at photos of my left side and cannot see why the clutch basket would need to be removed. I will study the manual a bit when I get home. A coat hanger can be fed from the top (head) down the rear cam guide/path... hook the chain on there and attach the master link at the cam gear after you make sure everything lines up gearing-wise.
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March 23rd, 2015, 01:15 PM   #5
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Originally Posted by jmscrttndn View Post
A coat hanger can be fed from the top (head) down the rear cam guide/path... hook the chain on there and attach the master link at the cam gear after you make sure everything lines up gearing-wise.

That's exactly the kind of input I am looking for. "Using a coat hanger down the rear guide path to pull the chain up".

The workshop manual is based upon completely reassembling the engine after teardown.

I just started to play with the timing chain last night and it was getting late. When I first put the chain down the front guide path I was not able to get it to go around the rear balancer gear at all. It would just bunch up and then drop down.
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March 23rd, 2015, 01:32 PM   #6
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Here is what I was looking at:
Attached Files
File Type: pdf 05 Timing Chain Install.pdf (698.1 KB, 58 views)
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March 23rd, 2015, 04:10 PM   #7
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I just went and had a look at mine ... It is lying on its side with the side cover off. I don't thing you can slip a chain by the sprocket to feed it in. Things just look too tight. If I recall correctly, I had to pull the clutch basket, install the chain and re time the engine.
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March 23rd, 2015, 04:21 PM   #8
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Originally Posted by Kayeffess View Post
I just went and had a look at mine ... It is lying on its side with the side cover off. I don't thing you can slip a chain by the sprocket to feed it in. Things just look too tight. If I recall correctly, I had to pull the clutch basket, install the chain and re time the engine.
Darn... I guess the method I thought of somehow involved using the old chain. Sorry mate. If you are pulling the clutch basket, look for the two half moon parts to see if they are worn as per here:



Also, see here:

Last edited by jmscrttndn; March 23rd, 2015 at 04:27 PM.
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March 23rd, 2015, 05:09 PM   #9
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Yeah, with the old chain in place , it is easy. You just break it, attach the new one to the old one and pull it through.
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March 23rd, 2015, 05:40 PM   #10
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only other way is to pull the idler / lower cam gear. personally, i think it's easier to pull the clutch. just mark the gears like in the pic then realign after back together.
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04-08 Mounting The Timing Chain-berg650-lh-1-tdc.jpg  
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