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July 5th, 2015, 05:53 AM   #1
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Valve cover with hole inside.

Today I saw that "hole" in my valve cover.
Last time it was not there.
It looks like it has been eaten by a chain?
But the cam chain is tight even without tensioner.
Has anyone seen something like that?

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July 5th, 2015, 07:23 AM   #2
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1) it was there last time and you didn't notice it. From the previous owner.
2) you are right, and it wasn't there last time.

Your screen should have most of the aluminum that was removed if (2) is the case.

I had the same thing happen when I used a 550 tensioner blade on a 650. It turns out it's a little shorter.

When I set it up, the CCT came up against the blade, but after running it, it slipped underneath it and started flapping about.
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July 5th, 2015, 09:11 AM   #3
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First photo is from today.
The second photo is also mine but taken a few months ago.
I had a lot aluminum flakes in oil. But I have read that this is normal.

I have a good new slides.
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July 5th, 2015, 04:02 PM   #4
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Sorry to hear this happened. Is there a chance that the cam chain was picking up debris and "throwing" it into that area? Just a thought. Without a cam chain failure (or something else failing), this is quite bizarre. Does the affected area look like a clean break in the metal, or does it look worn away like a sand blaster? This might help determine if it was something large that hit it once, or some smaller pieces that hit it continuously. Also, is there any related damage on the down-side of the cam chain (if the chain threw possible particles downwards into the crankshaft gear)?



Originally Posted by hacker33 View Post
First photo is from today.
The second photo is also mine but taken a few months ago.
I had a lot aluminum flakes in oil. But I have read that this is normal.

I have a good new slides.
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July 5th, 2015, 06:20 PM   #5
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Surely that's a tensioner issue? It's possible that the tensioner ratchet has broken and is releasing and tightening back up. Have a look at the cam chain and see if it's damaged.
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July 5th, 2015, 09:59 PM   #6
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Originally Posted by jmscrttndn View Post
Sorry to hear this happened. Is there a chance that the cam chain was picking up debris and "throwing" it into that area? Just a thought. Without a cam chain failure (or something else failing), this is quite bizarre. Does the affected area look like a clean break in the metal, or does it look worn away like a sand blaster? This might help determine if it was something large that hit it once, or some smaller pieces that hit it continuously. Also, is there any related damage on the down-side of the cam chain (if the chain threw possible particles downwards into the crankshaft gear)?
The edge looks very harshly. I show you in next photo.
With this piece. I lost one tooth in gear on the water pump shaft.
CCT looks good. But I ordered a new one.
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July 6th, 2015, 12:18 AM   #7
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Now I'm wondering if the broken tooth was caused by the aluminium from the valve cover jamming in the gear, or if the tooth broke and was thrown up and broke the valve cover?
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July 6th, 2015, 03:41 AM   #8
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Originally Posted by WArdogG View Post
Now I'm wondering if the broken tooth was caused by the aluminium from the valve cover jamming in the gear, or if the tooth broke and was thrown up and broke the valve cover?
Aluminum would be hard pressed to break a hardened steel tooth (pun intended).

I'm thinking that the tooth broke off and was thrown by the chain up into this piece, breaking off the chunk of aluminum. The F650 Part Out from Saskatchewan, Canada (the snow bike) that appears in the Classifieds section died from the same fat I believe.

Good thing your engine is salvageable from what you tell us.
Thanks from tourist
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July 6th, 2015, 03:55 AM   #9
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Can I ride with this hole?
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July 6th, 2015, 08:08 AM   #10
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Originally Posted by hacker33 View Post
Can I ride with this hole?
Yes, but if you use the stock breather hose on top of the engine (the one that vents to the frame), you may notice more oil going up the hose since this hole (absence of original shelf) won't block the oil spray coming off the cam chain.

In order to mitigate this, you could pinch off the rear breather tube, or reduce its size to slow the flow of oil up and out of the engine. Try to use a coat hanger or some thin steel rod to create a slight pinch like in the below photo. Just a thought. I was going to do this anyway on my engine since the rear breath hose contributes to the majority of the oil out of the engine apparently. Instead I used two stock foam filters in the breather hose (should reduce the amount of blow-by oil into the frame).

Thanks from tourist, hacker33 and fefy
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