Pictures of the parts and tools.


Two tools for holding tensioners for installation and removal. Homemade and ebay. Old parts. List of gaskets.

Oil pump alignment pins. Plastic block to hold gears from turning while tightening bolts. 1" socket to turn tensioners and pin in place. Plugs for oil draining back into the cavity.

C-clips you will need.

Gasket list.

 

Here is a list of the procedures that I put together after doing the job. It was from memory and should just be used for reference.
Hope it will help you or anyone in the future doing this job. Notes on Cam Chain Tensioner replacement.
Items already removed and completed. -Oil drained, seat, tank, exhaust, spark plugs, cam cover, valve covers, rockers, rods, cam plate with cams. Oil pump left in place on crank and removed after cam plate removal.



1. Under cam cover plate are three o-rings to replace. Two on the left side about ½ dia. The third is on the oil pump large nipple that goes into the engine case. It is about ¾ in dia. and thick.
2. Oil pump assy may come off with the cam plate or with the 4 bolts removed –stay on the engines crank shaft.
3. Install the oil pump, align the flats on crank hold oil pump assy together and slide onto crank, matching the flats. O-ring on oil tube, O-ring on outward face that mates to inside of cam plate. 2 in dia.
4. On the cam plate with cams installed – align the index marks or dots together facing each other. 0- -0. Mark lines with marker.
5. When installing cam plate. Inner and outer tensioners are “pinned” and being held off of the cam chain. Slide plate on to crank and cams ends into engine case bearings. Watch oil pump tube with large greased O-ring.
6. Install thick washer / spacer onto rear cam shaft. Lettering facing out. Install 6 bolts, snug to hold. Use blue 242 Loctite on bolts. 110 in lb.
7. Oil pump has 4 bolts. Leave top right and lower left loose. Install alignment bolts / pins in the other two holes. Hand tighten. While rocking or rotating the rear wheel go slowing back and forth to 45 in lb torque. Tighten other two bolts to 45 in lb. Remove top alignment bolt and install regular bolt and tighten to 45 in lb. Same with the lower pin, remove & install regular bolt, tighten 45 in lb. Slowly in criss-cross pattern tighten all 4 bolts to 110 in lb.
8. Install side plastic chain guide. Push until it snaps into place.
9. Rear cylinder is at TDC, Comp stroke. Install sprockets and chain as an assy. Dots on gears facing each other. Mark the gear tip on lower sprocket where the dot is. Washer will cover dot on gear when installed.
10. With gears and chain assy installed and dots aligned facing each other while cam marks are also facing each other. Use the two bolts to hold in place. Install gear lock tool with dots aimed at end other on gears.
11. Tighten two gear bolts with Loctite 242 blue on threads to 180 in lb [15 ft lb] Loosen one 360° rotation, CCW. Retighten to 408 in lb [34 ft lb] for the top bolt. Same procedure for the lower bolt. Tighten to 180 in lb torque and then 360° rotation, CCW. Tighten to 288 in lb [ 24 ft lb] torque.
12. Release tensioners & pull pins.
13. Install lifters. Holes in lifters face outward. Grease on lift ends. Oil on body.
14. Install lift blocks. Each has an o-ring and 4 bolts and a securing pin laying on side. Blue 242 Loctite. 110 in lb torq.
15. Install rod covers with o-rings and greased. Do not use top securing pieces to lock in yet. There are 3 O-rings on each rod cover assy. Top, middle, lower.
16. Lower push rods from the top into place. Grease on ends.
17. Rotate engine to confirm rods for rear cylinder are at lowest point and TDC comp stroke.
18. Rocker assy. – confirm the one O-ring under assy is replaced. Approx ¾ dia. Grease O-ring to hold in place.
19. Lower rocker assy into place and confirm rod ends in proper position. Install the 4 bolts for rocker assy. Slow 1/8 turn at a time,
criss-cross pattern, tighten bolts until seated. Allow 45 minutes for lifters to relax. Rods should be able to be rotated by hand from rod covers pulled up. Final tightening is 250 in lb
[ 20 ft lb]. Criss-cross slowly getting to the final torque.
20. Install breather assy. torque to 110 in lb.
Rotate engine to find TDC, comp stroke for front cylinder. Marks on gears should be approx. in the opposed position of rear cylinders orientation. -Across the gears from each other. Follow same assy. as rear cylinder assy. for install.
21. Valve covers – install gasket dry. Criss-cross pattern 180-216 in lb [ 18 ft lb.]
22. Install cam cover, dry gasket. Tighten to 140 in lb. Criss-cross pattern. Loctite 242 blue.
23. Final install of push rod covers and locking pieces.
24. Exhaust gaskets new installed. Anti-seize the 4 header studs.
25. Install exhaust.
26. When completed all installation. Refill oil tank. Use dash panel loosely installed to see oil pressure light while cranking engine to confirm oil pressure by light going out while cranking. Plugs still removed.
27. Install spark plugs. .040 gap. Torque to 216 in lb [ 18 ft lb.]
28. Install fuel tank, fuel line QD and cross-over 5/16” 6”-7” fuel line.

 

my cup runneth over man.