| Author | Message | ||
     Mark_massey |
I had a small oil leak coming from the cam gear cover on my '03 9R. Easy fix, just replace the gasket. I have all the tools and the service manual. Really, how hard could it be, right? So here I am, four days later, and I just finished putting the engine back in the bike. It should be noted by all you do-it-yourselfers that when removing the cam cover gasket, great care should be taken to not pull out any of the cam gears. When the cover came off it pulled out the rear cylinder exhaust cam gear and the lifter dropped. It should also be noted that the only fix for this is the complete removal of the engine so the rocker box can be removed to release valve spring tension. On the plus side, having the engine out allowed me to completely clean it and then heat wrap the headers. Let's hope she runs when I get it all back together. | ||
| Reepicheep |
True, that. If you pull the cam cover, expect to remove a rocker box or two. Except you didn't need to pull the motor, you can just rotate it forward. Here is hoping it runs! How did your oil pump drive gear look? | ||
| Mark_massey |
The oil pump drive gear appears to be in good shape. No nicks or burrs, and no abnormal wear. So I got it all back together and it fired right up. Sounded awesome. Took it out for a short test ride and it ran great...for about 12 miles. then it stalled and wouldn't re-start. Got it home and spent a couple hours checking voltage on the fuel injectors and TPS. Everything was in specs, so on a hunch I checked the timing. That's when I had my "DUH" moment. I realized I forgot to put some thread lock on the bolt that holds the cam position sensor plate to the end of the gear shaft. It vibrated loose and wasn't spinning with the gear shaft. I tightened it down (with Loc-tite this time) and everything seems to be 5x5. | ||
| Mark_massey |
Just an update: After several days of fairly extensive riding, there are no problems, no leaks, no abnormal noises. Although, I do seem to be getting a little bit more decel pop from the straight pipes than I did with the Pro Series exhaust. Might bother the neighbors, but seems fine to me.   Sorry about the pic quality. Garage lighting and cell phones aren't always the best things to use. LOL. | ||
| Rho_138 |
Hey man I'm about to do this to my bike, any thing you would suggest? And any ways not to have the exhaust cam gear not fall out? Lol |
