cam chain tensioner

[Kopfjaeger]

G'day
the ol 86 fj1200 has a cam chain rattle, only had it three months had 98 000 k's on clock when bought has done 4 runs from newcastle to brisbane now has 8000 k's on clock, change oil every 4000k's air filter clean , oil filter every change,tappett clearance at the most is .025 on the exhaust side,( going by the measurement system in the manual of subtracting measured clearance from the mid point of the specified clearance) runs great dont ride it above 4-5 grand, bit buzzy over 5 grand,but the cam chain is rattling and im blown if i can understand why you would remove the cams and chain just to adjust the tensioner (its the original automatic one) as per the manual states. im curious if any one has done one or knows of how to do this? it should be simple as it was on my GPz ( remove reset and rebolt) just curious and hesitant as broken bikes are expensive and this is my daily ride, usually clock up about 50 -60 thousand k's a year 

[Arnie]

Kopfjaeger,

Usually you won't hear the cam chain, but the starter chain.  These make some noise, especially if your idle speed is too low, but don't seem to break.  I'd check the cam chain inside the cover visually to see if there's any excessive slop if you're worried, but the auto adjuster seems to work pretty well on my bike.  I've got about 127K kms now.

Cheers,
Arnie

[racerman_27410]

+1 on the starter chain being the culprit.

what is your idle set at?


welcome to the group!


Frank

[mz_rider]

Neil,

As other have said the cam chain & tensioner never seem to give problems.  The older of my two FJs has done 130,000 miles (200k+ km) with no cam chain rattles (lots of other rattles of course!) If you find the bike buzzy try upping the gearing – the FJ can pull it no problem. I run 18t front/ 39t rear.

Stuart (Glasgow, Scotland)

[Kopfjaeger]

Thanks for the info, the idle is at 1 grand once warmed up, but on start up full choke i still have to blip the throttle for it too run, once the chokes off have to hold it at 1- 1500 for about the first 4-5 mins or so of the ride before it sits at 1 grand comfortably, ( didnt once and the engine died when i pulled the clutch in going down the street, nice and quiet then beleive me!!!) all sounds wierd but im stepping off the gpz series of bikes so its all kinda new to me this air cooled thing.i will try upping the idle a bit to see if it makes a difference and will have a squiz at the starter chain, i imagine as its a non tensioned item that it will be a replace job if its worn. apart from that it seems to run ok, just goes and goes and goes, occasionally the starter will( after pushing the go button) turn over then whirrrrrrrrrrr whiirrrrrrrrrr, just spins so maybe its not engaging properly, will have a look and get back too you all. thanks again for your input, will post pics of the beast when i have more

[Harvy]

i imagine as its a non tensioned item that it will be a replace job if its worn.

Its also a split the crankcases job mate...     ....so if you do need to replace it, look at other work you may want to do to the engine while you have it apart.

Harvy

[andyb]

Sounds like you could well use some mild work to fix these things.  A little carb tuning will probably get you a rather easier to live with machine..

Thanks for the info, the idle is at 1 grand once warmed up, but on start up full choke i still have to blip the throttle for it too run, once the chokes off have to hold it at 1- 1500 for about the first 4-5 mins or so of the ride before it sits at 1 grand comfortably, ( didnt once and the engine died when i pulled the clutch in going down the street, nice and quiet then beleive me!!!) all sounds wierd but im stepping off the gpz series of bikes so its all kinda new to me this air cooled thing.i will try upping the idle a bit to see if it makes a difference and will have a squiz at the starter chain, i imagine as its a non tensioned item that it will be a replace job if its worn. apart from that it seems to run ok, just goes and goes and goes, occasionally the starter will( after pushing the go button) turn over then whirrrrrrrrrrr whiirrrrrrrrrr, just spins so maybe its not engaging properly, will have a look and get back too you all. thanks again for your input, will post pics of the beast when i have more

[Pat Conlon]

".... runs great, dont ride it above 4-5 grand....."

uuuh, then, how do you know it "runs great"?    +3 for starter chain

[Kopfjaeger]

ok. full run down.i have taken it out to 200k's once or twice and once with a pillion. it pulls cleanly through every gear, doesnt stutter or refuse to do anything i ask of it, the engine just ( to me) feels a bit soft in the top end of the rev range from about 5 grand onwards, so i just dont take it there ( bearing in mind its a 23 yo m'cycle). the carbs i have checked with a vacuum gauge and they are all pulling the same amount of mm/haig( i did all this just after i purchased it and then again about 3 weeks ago.) It probably needs new rings they may be a bit sad i havnt done a compression test.if it didnt run great i wouldnt be sitting here id be stuck somwhere between qld and nsw.it doesnt blow smoke that i can see, have had one instance of smoke when someone was following me and in 5th gear wound it out from 100- 160. once warmed up it idles at 1 grand nicely its on start up that its a bit rough full choke it stays at 1500 and then dies down after 1-2 mins thats wehen i have to crack the throttle abit, usually then i drop the choke and hold it open on throttle at about 1500 till im ready to ride, then after about 3 -4 mins of riding the engine will idle at 1 grand. the steering stem bearings need replacing as they have a "notch" in the centre. the only thing as far as ican work out is i already suspected may need new rings and the starter chain rattle has come on a bit since purchase... not super bad but im over cautious( broken motorcycles suck) have measured shim/tappet clearance and they are ok ( but im a perfectionist) and possibly in the future could be replaced. the cush drive in the clutch is giving a bit of a rattle ( thought it was clutch bearing) and im sure all fork fluids need to be replaced (it also gives a bit of a head shake through corners at speed) apart from these few things it does run great. starts every time when warm, doesnt have (other) abnormal rattles and bangs the sump plug weeped a bit but have fixed that and the rocker cover bolts weeped a bit too. no oil leaks and i get about 340 k's to a tank without hitting reserve ( fuel light comes on going up hills when close to reserve.)

[racerman_27410]

if your FJ feels soft above 5 grand then either your clutch is slipping or you arent opening the throttle.

thats what the Kookaloo! is all about brother   8K RPM in 3rd gear is pure KOOKALOO!

hmmmmm.... you wouldnt happen to have one of those restricted FJ's?  where is your FJ from originally?


it would totally suck to have a FJ and no Kookaloo!....... let us help you find the lost kookaloo!


Frank

[Harvy]

ok. full run down.i have taken it out to 200k's once or twice and once with a pillion. it pulls cleanly through every gear, doesnt stutter or refuse to do anything i ask of it, the engine just ( to me) feels a bit soft in the top end of the rev range from about 5 grand onwards, so i just dont take it there ( bearing in mind its a 23 yo m'cycle). the carbs i have checked with a vacuum gauge and they are all pulling the same amount of mm/haig( i did all this just after i purchased it and then again about 3 weeks ago.) It probably needs new rings they may be a bit sad i havnt done a compression test.if it didnt run great i wouldnt be sitting here id be stuck somwhere between qld and nsw.it doesnt blow smoke that i can see, have had one instance of smoke when someone was following me and in 5th gear wound it out from 100- 160. once warmed up it idles at 1 grand nicely its on start up that its a bit rough full choke it stays at 1500 and then dies down after 1-2 mins thats wehen i have to crack the throttle abit, usually then i drop the choke and hold it open on throttle at about 1500 till im ready to ride, then after about 3 -4 mins of riding the engine will idle at 1 grand. the steering stem bearings need replacing as they have a "notch" in the centre. the only thing as far as ican work out is i already suspected may need new rings and the starter chain rattle has come on a bit since purchase... not super bad but im over cautious( broken motorcycles suck) have measured shim/tappet clearance and they are ok ( but im a perfectionist) and possibly in the future could be replaced. the cush drive in the clutch is giving a bit of a rattle ( thought it was clutch bearing) and im sure all fork fluids need to be replaced (it also gives a bit of a head shake through corners at speed) apart from these few things it does run great. starts every time when warm, doesnt have (other) abnormal rattles and bangs the sump plug weeped a bit but have fixed that and the rocker cover bolts weeped a bit too. no oil leaks and i get about 340 k's to a tank without hitting reserve ( fuel light comes on going up hills when close to reserve.)

Neil, your start/warm up sounds just like mine. Its been that way since I've owned it.....from stock to 4-1, stage3 and UNI pod filters......that's the way she has always started.

Does it use oil between changes?

Probably the crush washer on the sump plug needs replacing.

Replace the rubber grommets on the 8 cover bolts......maybe do the cover gasket at the same time........all do'able with the motor in the frame.

You have good economy.........I'm at around 300km b4 the reserve light comes on.......that being said, I need to replace the jets and the emulsion tubes......I going for Factory pro replacements.
The low fuel sensor is at the front of the tank.......make the fuel slosh forward as you go uphill will keep you running for a little longer b4 switching to reserve to defeat the sensor and allow the pump to "keep pumpin till it can't pump no more" . OH....forgot to look.....is yours a fuel pump model?

Harvy

[Harvy]

Answering my own question......no, its not fuel pumped........so ignore that last bit.

Cheers
Harvy