Kawasaki Motorcycle Forums - View Single Post - Timing chain came off, need help putting it together again.

MrGiggles · 06-30-2009

Today I went to go for a ride normally, aired up my tires, checked gas and oil, and took off. I rode for maybe two minutes and I was in 3rd going decently fast my 220 popped and it made a whirring type noise. I tried to restart but it had no compression, but not seized. After a couple pulls with the pull starter it locked up. At this point I towed it back. It had a knock, but it was not cam related.

After removing the timing chain cover, I saw that the timing chain was resting on the nut that holds the cam sprocket on. It had just popped off, I have no idea why. I had just adjusted the tension, and it seemed fine. The reason I couldn't pull it over is because of the slack in the chain, it had jammed up in the bottom end somewhere. I spun the engine backwards and pull the chain tight it spins freely now, it was not broke. The cam also spins fine. I am completely clueless as to why it popped off. I wasn't even riding it hard.

Here are my questions. And there are many.

First off, will the piston hit the valves if they are stuck open and bend them? I don't want to take off the head if I have to, but if it has to be done I will. I am on a very strict budget, so the less money the better.

Second, how would I go about timing it back again? I've been reading up and the procedure I have seen is to set the piston at TDC, then line up the cam with the dot at the 12:00 position. Simple enough?

Finally, I am wondering if I will have to remove the flywheel and what will I need to do so?

Thanks.

06-30-2009	#1 (permalink)
MrGiggles Never quite fixed. BTK Expert Join Date: Aug 2008 Posts: 383	Timing chain came off, need help putting it together again. Today I went to go for a ride normally, aired up my tires, checked gas and oil, and took off. I rode for maybe two minutes and I was in 3rd going decently fast my 220 popped and it made a whirring type noise. I tried to restart but it had no compression, but not seized. After a couple pulls with the pull starter it locked up. At this point I towed it back. It had a knock, but it was not cam related. After removing the timing chain cover, I saw that the timing chain was resting on the nut that holds the cam sprocket on. It had just popped off, I have no idea why. I had just adjusted the tension, and it seemed fine. The reason I couldn't pull it over is because of the slack in the chain, it had jammed up in the bottom end somewhere. I spun the engine backwards and pull the chain tight it spins freely now, it was not broke. The cam also spins fine. I am completely clueless as to why it popped off. I wasn't even riding it hard. Here are my questions. And there are many. First off, will the piston hit the valves if they are stuck open and bend them? I don't want to take off the head if I have to, but if it has to be done I will. I am on a very strict budget, so the less money the better. Second, how would I go about timing it back again? I've been reading up and the procedure I have seen is to set the piston at TDC, then line up the cam with the dot at the 12:00 position. Simple enough? Finally, I am wondering if I will have to remove the flywheel and what will I need to do so? Thanks.