cam chain tensioner, how many clicks left?

geez mark, when did you join my "slow old guy" club? i didn't see your application. :lol:
best way to ck it is to put the engine at tdc compression (good time to adjust the valves) and remove the center bolt and spring from the tensioner. then remove the two other tensioner bolts and pull it out. note the position of the plunger and pull it all the way out. the number of clicks you have left before full extension is how much more time you have before chain replacement. putting in a new chain in my experience will have the tensioner sitting at about 30-40% extension (after a short bedding-in time).
to replace the tensioner, push in on the ratchet on the side and push the plunger back in. then reinstall the unit and gently push the plunger back out with a small screwdriver or whatever fits (a pencil is too big :wink: ). reinstall spring and cap (do it in a clean area so you can find the spring when it goes flying).

velosapiens said:

Typical ******** velo-question: I know that eventually, even a pansy slow old guy like me will need to replace my cam chain. I keep checking for shavings in the oil (none yet at 190 hrs or so). Can I just check the cam chain tensioner somehow to get an idea of whether or not it's running out of tensioning ability (which would indicate that the cam chain is getting pretty worn)?

Please use small words. This is for an 05 fe550.

Click to expand...

Hi Velo,

Ned hit on the head for the checking. I checked mine (04 550) at 170 something hours and had 4 clicks left. When I replaced my cam followers at 188 it only had two left.

When I put in the new DID with the 05 chain slider which is bit thicker in the tensioner plunger area I think it only went out about 3 clicks from the sound of it. After replacing the chain I noticed that the bike sounded a bit different, but didn't notice any performance changes.

If you do change your chain, and you use the rivet type link, buy, borrow or steal the stock Husaberg/KTM riveting tool. Your life will probably be a lot easier. I did not use the Husaberg tool, but, rather used the motion pro tool lent to me most graciously by JoeUSA. The peening pin on the motion pro tool is made for a larger chain and makes a different type of peen on the pin than does the stock tool. I went through a few master links before I got it right, over peened the first few and the end of the pin spalled. Apparently the stock tool doesn't let you push the side plate on too far, or over peen the pins, at least that is what Rick Bozarth told me.

Don't be surprised if you need a chain.

Hope this helps,

Dale