CAM Chain Tensioner Failure, and other tales of the road

[hootmon]

Which one normally goes?

Terry, the Front goes, I've never had an issue with the rear.
I now travel with a new spare tensioner, a ratcheting 8mm box end wrench, mini telescoping magnet, and a pair of latex gloves to do the job. 
Not recommended to do it while engine is hot... only tiny fingers fit!
Hop Along

what do you use the magnet for?

[TLRam1]

Same question as Hoot and which side on the front, clutch side or stator side?

And is the tensioner the same for both sides on the front? I am looking to do what you do to be prepared.

I thought you bought a different bike to tour with?

[hootmon]

Same question as Hoot and which side on the front, clutch side or stator side?

And is the tensioner the same for both sides on the front? I am looking to do what you do to be prepared.

I thought you bought a different bike to tour with?

Terry - The tensioner is on the rear side of each bank of cylinders, between the cylinders, in the center of the bike (the front one is directly below the carbs. It is a little tower that stands up.
It looks like a very easy replacement when the carbs are out..
I figure I'll replace mine and then my present one will be my spare (I guess I need to buy 2 gaskets, one for if the new one ever fails..

[hop along]

Yep, there is one tensioner for each pair of cylinders; both tensioners located center of bike, behind the cylinders.
They are different, though I've never had issues personally with the rear and have not heard of others having issues with the rear-only the front.
Removing the side covers is also helpful.

The magnet is useful for retrieving the little bolts when dropped.  There are two to mount the tensioner, and one to close off the top after install.  Tiny hands are also helpful haha.  The crush washers I fetch out with a long allen key in the toolkit when I drop those (copper not being magnetic). 

As for other rides-I did get a DR650 but I don't use that for the major mileage tours.  In fact, my first dual sport ride in Vermont on Class IV roads and trails schooled me pretty good.... loose clutch, bent handlebars, lights not working, but at least I found out how tough the bash plate is!!

Hop Along

[TLRam1]

Honda calls this a Lifter Assembly PN14530-MZ5-003, I thought they would be around 25.00 dollars.

[hootmon]

I bought one today, but it is NOT $25!!
Hop provided me with some instructions, so I'm posting it here so I can search for it later

Tensioner install instructions

It's pretty easy.  I always leave bike in gear while doing the work.

NOTE: new tensioner comes with a little key in the top of it... DO NOT REMOVE KEY UNTIL AFTER IT IS INSTALLED (manual has directions on how to reset if needed but it is a pain)

1 Loosen top bolt on old tensioner, do not remove yet.
2 remove two mounting bolts-if there is still tension, back bolts off a little at a time, alternating sides.  Save bolts and crush washers for re-use.  This is where I find the magnet useful... I always drop these bolts.  reclaim the bolts and crush washers if dropped, before pulling the tensioner out of the hole.
--now pull tensioner out of the hole, and remove the top bolt/crush washer.  Save for re-use.
3 replace gasket if needed (not likely).  Do not drop anything in the open hole!
4 put new tensioner in place, tighten both mounting bolts.  There shouldn't be tension yet, you can fully tighten one bolt at a time.  Note: torque is low, no need to crank.  Barely more than finger tight is sufficient.
5 now that new tensioner is in place, and mounting bolts tightened-remove the key from the top to engage the spring (IE the tensioner now has tension).
6 replace the top bolt and crush washer.  Again, low torque needed.  Barely more than finger tight is sufficient.

Ride away with a smile.   

Hop Along

[TLRam1]

Where did you get the tensioner at?

[hootmon]

Where did you get the tensioner at?

I'm in the middle of several projects on the bike, I have the carbs out to up the main jets.
I would like to get it all back together, so I got it at my local Honda dealer.. I have an account with them under my work name, so they give me 10% off.. Not a big deal but better than Retail..
Anyone else (yes I can get it cheaper) like Ron Ayers, Bike Bandit, etc, then they have to order it, receive it and then re ship to me.. So at least a week for parts..

I ordered on Friday, my parts should be in late Tuesday.

[MagnaMan]

On really long trips I ride with a front tensioner, replacement levers, and a replacement kill switch.

But mostly I just trailer to far-away destinations now since I don't have a windshield or touring set up.

[hootmon]

On really long trips I ride with a front tensioner, replacement levers, and a replacement kill switch.

But mostly I just trailer to far-away destinations now since I don't have a windshield or touring set up.

No regulator or Vacuum shut-off rebuild kit???

[MagnaMan]

On really long trips I ride with a front tensioner, replacement levers, and a replacement kill switch.

But mostly I just trailer to far-away destinations now since I don't have a windshield or touring set up.

No regulator or Vacuum shut-off rebuild kit???

Nope. Not yet. I've only had to replace one regulator and haven't had an issue with it since then. Of course I don't have a meter on my Magna I just ride it and go. You can bypass the vacuum fuel cutoff if you have to or I actually used gum to block it up until I got home when it did fail.

[hootmon]

A little long and wondering.. But shows some pretty good views of the tensioners and how to install them...
Youtube

[TLRam1]

Thanks for the video Harry.

We have never tracked the failure rate of these and have no record how often these fail. Should replacing the front one be part of the maintenance every 60,000 miles or what would be reasonable? Easier to replace at home with all your tools and a cold motor than on a trip.

[Jerry G Turner]

The tensioners tend to fail more often if you rev the engine up to high rpms before shifting if you shift at lower rpms they don't seem to fail as often.

[hootmon]

I had 90K on my Yellow Magna
I have 50K on my Red Magna
I have never had a tensioner failure... I've been accused of reving the Magna a little.. (Just a little, between each shift )