Timing chain tensioner -09

Just did mine tonight and Sabink is right. Loosening the 21mm nut a few turns til you hear a click won't work if the mechanism is stuck. In fact, I took mine all the way out and it was still compressed. However, it's not difficult to squeeze it until it releases and fully extends. Not sure about the procedure to reinstall because THERE STILL ARE NO F**KING WORKSHOP MANUALS, but what I did (i was told by another Berg owner who had been fiddling for hours) was compress it to the last click before full compression, reinstall the tensioner and large nut without the smaller nut, then use the short side of an allen wrench to compress it the rest of the way and let it spring back out. Then put the smaller nut back on. My buddy Paul reckons there is probably a tool that screws in place of the smaller nut that compresses the tensioner until it releases. Anyway it seems to be much quieter now.

piggd said:

Just did mine tonight and Sabink is right. Loosening the 21mm nut a few turns til you hear a click won't work if the mechanism is stuck. In fact, I took mine all the way out and it was still compressed. However, it's not difficult to squeeze it until it releases and fully extends. Not sure about the procedure to reinstall because THERE STILL ARE NO F**KING WORKSHOP MANUALS, but what I did (i was told by another Berg owner who had been fiddling for hours) was compress it to the last click before full compression, reinstall the tensioner and large nut without the smaller nut, then use the short side of an allen wrench to compress it the rest of the way and let it spring back out. Then put the smaller nut back on. My buddy Paul reckons there is probably a tool that screws in place of the smaller nut that compresses the tensioner until it releases. Anyway it seems to be much quieter now.

Click to expand...

Hi Piggd,

I know there isn't any work shop manuals available to you, however, here's a section of my post on page 4 of this thread.

"
On the KTM bikes with this tensioner, when the valves are adjusted, it is necessary to remove the cam. And since the cam is coming out the tensioner has to be removed. There is a very detailed 3 step procedure for resetting the cam chain tensioner of this type before re assembly. Apparently there are a couple of washers inside that perform as a sort of lock to keep the tensioner taught for lack of a better way of putting it, and this set up procedure in the KTM shop manual get's things set up right.

My mechanic friend did have one experience with a tensioner not working correctly after he had pulled it out to adjust valves on a bike. He simply removed the tensioner, did the set procedure again and it worked perfectly. Further, they have not had this problem come into their shop--ever, that includes 250's, 450's, 530's, 950's or 990's.

He also went on to tell me that at the KTM mechanics school, they, the KTM techs, were adamant about checking the oil pressure at the galley plug on the front of the motor, on the left side of the motor. There is a small torx bit oil galley plug there where one is to check the oil pressure.

Also, it is my uderstanding that the tensioner cannot be dis assembled.

I was not able to get a copy of the page out of the KTM shop manual, however, if those of you who are having problems can get a copy yourself and just try resetting the tensioner as mentioned in the book to see if that alleviates your problem."

Hope this helps you fix your problem,


Dale

I played with my tensioner one more time last night. I did some measurement. Before inserting it in the bike, you have to compress it to 40mm length. After screwing the 21mm cap push it with something so that you compress it a little more and it will extend. Fully extended the tensioner is almost 56mm, and then you can compress it by hand to transport position.

I think that the problem with the noise iis that the ratchet system blocks on steps of 2mm which is too big step, and the oil preasure or volume is not enough to hold resistance. I inserted mine using this procedure, but I still did not liked how it worked, as I had noises when reving the bike.

At the end, I created a manual tensioner and set it to just hold the chain guide as it is at TDC and now, I can ride without worrying it the tensioner will fail at some point

Here is a cutoff of the ratchet system

DaleEO said:

On the KTM bikes with this tensioner, when the valves are adjusted, it is necessary to remove the cam. And since the cam is coming out the tensioner has to be removed. Also, it is my uderstanding that the tensioner cannot be dis assembled.

Click to expand...

Nothing to do with the tensioner,but you don´t have to remove the cam when adjusting the valve clearance on the single cam engine.Just pull out the rocker arm shafts and remove the rocker arms instead.

DaleEO said:

I was not able to get a copy of the page out of the KTM shop manual, however, if those of you who are having problems can get a copy yourself and just try resetting the tensioner as mentioned in the book to see if that alleviates your problem."

Click to expand...

Hi Dale
I did read your post, especially the part about "as mentioned in the book". and since I don't have "the book" either, I posted my efforts to solve my problem.

Dalton

Fourstrokeforce said:

DaleEO said:

On the KTM bikes with this tensioner, when the valves are adjusted, it is necessary to remove the cam. And since the cam is coming out the tensioner has to be removed. Also, it is my uderstanding that the tensioner cannot be dis assembled.

Click to expand...

Nothing to do with the tensioner,but you don´t have to remove the cam when adjusting the valve clearance on the single cam engine.Just pull out the rocker arm shafts and remove the rocker arms instead.

Click to expand...

Correct,

That is the procedure for the Husaberg's.

But, as I understand it, removing the cam is the procedure for the KTM's when adjusting the valves, and that is why there is a reset procedure for the cam chain tensioner in their service manual.

piggd said:

DaleEO said:

I was not able to get a copy of the page out of the KTM shop manual, however, if those of you who are having problems can get a copy yourself and just try resetting the tensioner as mentioned in the book to see if that alleviates your problem."

Click to expand...

Hi Dale
I did read your post, especially the part about "as mentioned in the book". and since I don't have "the book" either, I posted my efforts to solve my problem.

Dalton

Click to expand...

Right on,

Just wanted to make sure you saw that, so you'd have that resource, if a KTM shop manual was available to you.

Here's the page in the now available repair manual for the 2009 Husaberg. My apologies for the bad quality but I believe it is readable.

If some one of the gurus can explain me how to upload the manual I will do so. (about 11 Mb PDF)

sorry, second attempt.

dustbite said:

sorry, second attempt.

Click to expand...

Ahhhhhhhhhhh swing and a miss..............When you think of hot dogs, think farmer John.

Dale, please help me out here. This is getting really embarrassing. I try to upload a JPEG image of only 124Kb but it seems 2 b impossible.
Browse, select, "add attachment" is what I do....

No worries, up until just recently I couldn't do it either!!

Dale

dustbite said:

Dale, please help me out here. This is getting really embarrassing. I try to upload a JPEG image of only 124Kb but it seems 2 b impossible.
Browse, select, "add attachment" is what I do....

Click to expand...

addrian

you will have a note saying "allow pop ups temporarily" or "allow pop ups from only this site".

pick option 2 and then you'll be ok.

depending on which word programme you have, open a photo to 'edit' and then it'll give you options of 'web page large' and web page small' etc etc. 2 minute job now. i went three years without putting photos up and in the end none of the geeks could help me and mr computer dunce did it all by himself = incredible!

regards

Taffy

RE: Re: RE: Re: RE: Re: RE: Timing chain tensioner -09

Great site and good to see so many passionate Berg owners. Can't ride my Berg at the moment (waiting for Shock Treatment to send back my suspension) so I've been checking out the forums. Excuse the long-winded reply as this is my first post on this forum. I've read with great interest the hydraulic tensioner issue so I went to my dealer to discuss. He said they (and presumably the factory?) are aware of the problem. For sure my local dealer is aware as they've had similar issues with some of the KTM hydraulic tensioners. He showed me a customer's tensioner and demonstrated what a few MAY be experiencing. The tensioner is not fully extending right away due to lack of oil pressure at initial startup/warmup. Once the motor warms up the ticking (which is caused by the tensioner not making contact with the cam chain guide) the tensioner should fully extend. Their fix is installing a head washer (or similar) against the tensioner between it and the end screw cap. The washer's thickness provides the extra millimeter or so contact needed to eliminate the ticking. It is CRITICAL that the inner circumference surface area of the washer doesn't block the oil channel at the screw cap end. Otherwise the tensioner won't extend and someone could be looking at a very expensive engine repair. Anyway, it's a cheap and simple fix and IMO is bulletproof. My two cents.

Fe450 / 570 cam chain tensioner

Hi Guys,
I have just sold My old XR600 and am picking up a new 570 next week.
I have been doing a bit of research on the new machine and was told by a mate that the 09's have the exact same hydraulic cam chain tensioner as the KTM's, which I believe have been known to fail frequently causing bent valves smashed piston $$$$etc.
A suggested fix is to fit either a manually adjustable tensioner or a spring loaded ratchet
type. This problem has been widely debated in the dirtbike world forums (manual tensioners) http://www.dirtbikeworld.net/forum/arch ... 45397.html
I have been following topics on this site for a while now and found a lot of usefull info from posters. What are your thoughts on this issue.

Can't wait to get my new bike!!!

Thankyou
Steve

Hi Steve,
Like you say, the cam tensioner threads on this forum will give you all the info you need on this subject and any fixes should you have a problem, which is unlikely.
Dont read too much into year old links that relate mainly to one persons DOHC 250. As for "frequently bending valves and smashing pistons", there is not one case of that happening with the new bergs.
If it does happen to yours, dont worry, Taffy will supply the parts, and along with Bushmechanic, they will take you through the rebuild :lol:

Welcome to the 570 club Steve, you will love it!
Give us a report as soon as you give it a blast.

Cheers,
Nick

Hello Tazer,

Welcome to the site.

I merged your timing chain tensioner thread into the existing thread on this topic so we wouldn't have parallel threads on the same topic.

As you can see from your threads new location, there is a lot of info about this subject on the 09's in this pre existing thread that was started sometime ago.

You're going to find that there is quite a difference between your beloved XR600, and the new 570. Kind of like the difference between driving a 1955 Chevrolet Bel Air, and an 08 F-430 Ferrari.

Hi Dale,

I will have a read through when I get a chance.

And I'm hanging out to test drive my new Ferrari.

Thanks Steve