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Replacing a broken timing chain

T

tin-tin

Joined Mar 2010
12 Posts | 0+
Klerksdorp, South Africa
Hi,

The inevitable happened :(
My timing chain on my '07 Fe 550e broke and wedged in somewhere ...I will not disclose how it happend :oops:
It has 8000km on and 190 hours.
I'm replacing it but would like to know from someone who did it before, if there is an easy way of doing it.
I will have to replace the clutch cover gasket, the chain guide and obviously the chain. Do i need to remove the head as well?

Also while I'm in there what do you guys (and if there is any girls; girls) think is should replace.

Help fellow bergers....
 
Well, since it broke, you really should pull the head. Hopefully, the cam, and head is ok.

Mine was easy, I just broke a link, and wired the new chain to the old one and jiggled it around the bottom cog after installing the head.

It was a pretty easy job for being an amateur mechanic.

To be safe I would replace the following if you can afford to.

A rough estimate of parts costs. (At the KTM dealer)
Timing chain $30
Valve seals $30
Valve springs $90 I used these KTM full set(4X) ATV DVSK part#83036028044
Cam Follower bearings $40
Labor for ^CFB install ugh! $70
Head Gasket $30

As far as how to get it timed correctly, I don't know as I just put the engine at TDC before touching it and took a few pictures before breaking the chain. Putting it back together I just lined the cam sprocket up the same as the picture.

You'll have to get a repair manual to make sure I think.

c25f418c.jpg



Estimates only, I don't remember exact $
 
Hi,

Thanks for the help. I took the clutch cover off... The chain wedged in some of the gears..
I need to take off the clutch to get it out. It doesn't look like any of the gears got hurt. I'll do further inspection as I progress.
One problem... The chain broke the thread that holds the chain guide retaining bolt. I'll have to look for a solution there.
I managed to download a repair manual in the mean while. Yay
 
It's the head and valves you really need to worry about. They are going to be damaged 95% of the time.
 

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