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100HR SERVICE???

Joined Dec 2003
111 Posts | 0+
Australia
Hi all,

(I have a 2003 Fe501e, 6 months old, 5000kms/100Hrs on it)

just wondering if sticking to the service manual is the right thing to do. After having my dealer tell me not to worry abou the rocker bearings at 50Hrs like the manual says, and then having them fail at 70Hrs, which also damaged the rocker and cam, plus put shavings all through my motor (it was fixed under 12 months Aussie warranty luckily!), i am a bit nervous about not following the service schedule.

However, the 100Hr service seems pretty expensive.....replacement of

timing chain incl tensioner
connecting rod
crankshaft pin
main bearings
rocker bearings(only 25 hrs old but anyway...!)
counterbalancer bearings
intermediate shaft counter bal. bearing
rod bushing
clutch shaft bushing

bike is used half for trail, and half ridden pretty hard on practice track but not racing.

so what's everyone else do????do you do the service or just wait for it to go bang and possibly cost more?????i wouldn't split the cases myself so labour will be a major expense here by the sounds of things.


thanks for your help....

nervous JJW501
 
i have a '02 400 that is thrashed with neither fear nor favour. they're fairly similar and IMHO you should look to see how much cam chain tensioner teeth you have left, that and the condition of the button on the end should be all i'd worry about.

send me an e-mail address to my PM and i'll send you a 6-page information broshure about the perils etc of ownership.

Taffy
 
JJW501,
I was at Powerhouse last weekend and asked much the same question. They said most guys do tend to wait on the rebuild until they start to hear noises, no surprises there.

Apparently a typical rebuild will cost about $600 in labour. The costs for parts obviously varies but expect the total to be 900-$1000.
 
Brian

Is that $900-$1000 total being parts & labour or just parts..?

LuKe.
 
Hi Luke,
That was parts and labour.

From memory the typical parts mentioned were

Bearings/Bushes
Gaskets
Seals
Usually intake valves
Cam chain
Rings

Hone the bore

If the piston is worn it may need replacement or teflon coating.

Other parts may have been mentioned but I can't remember.
 
ok i checked the cam chain tensioner.

it had 1 or 2 teeth left before it will be fully pushing all the way in.

the end of the tensioner was marked a bit where it touches the cam chain guide but i wouldn't say it appeared to be very worn.

i remember reading on here a while ago about a cam chain tensioner mod. can't find it at present....maybe it was lost when the site when down????or am i just going blind???? :D

bike is making a slight "loose tappets" type of noise when cruising along at certain revs and not under load(yes - valves are adjusted!!!!!!). performance is still good tho. maybe this noise is the camchain slapping around a bit??? i just dropped oil and there were probably a few more metal shavings than normal. could cam chain be hitting/wearing something????also took rocker cover off...everything look ok there.

cheers
 
go to my gallery for a picture of the mod. if you're nearly out of teeth you need a new chain and i would look at the camwheel to see if you have aluminium or steel.

someone had alloy but it was the steel on the half speed shaft (at the bottom) that was knackered.

replace camchain
camchain tensioner mod
check the wheels
while rocker cover is off have you checked the follower bearings?

regards

Taffy
 

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