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HELP!! I hope this isnt serious......

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I recently bought an XR6oo for cheap as chips......... and i took all the plastics, seat, tank off, carb off, put a bag over the carb inlet and decided to power wash it........... it is after a dirtbike, but it doesnt have to be a DIRTY dirt bike.... anyway, after i finished i noticed the part in the picture below, the lower arrowed part, was sticking out of the engine a good inch......

BUGGER.jpg

so i pulled it out, looked at it, thought oh:foul::banghead::foul::cheers::foul: and put it back again.

Ok now i know im gonna have to take the rocker cover off........but it occurs to me one of two things has happened....

1. someone with the IQ of a bag of popcorn has messed about in the engine and not put the holding bolt back in place (likeley as there are signs of sealant around rocker cover)

or

2. it fell out, and buggered something up, so 1. decided to have a look, couldnt find anything and put it back together...:)

now, where should i look for the part if it fell out? if it did, what damage will it do?, or should i forget it and just put a new bolt in to hold the tensioner?....

Ive never owned an XR before so all the help i can get would be awesome.

sorry im a n00b asking a shitload of stoopid questions.:lol:

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I recently bought an XR6oo for cheap as chips......... and i took all the plastics, seat, tank off, carb off, put a bag over the carb inlet and decided to power wash it........... it is after a dirtbike, but it doesnt have to be a DIRTY dirt bike.... anyway, after i finished i noticed the part in the picture below, the lower arrowed part, was sticking out of the engine a good inch......

BUGGER.jpg

so i pulled it out, looked at it, thought oh:foul::cheers::foul::smirk::foul: and put it back again.

Ok now i know im gonna have to take the rocker cover off........but it occurs to me one of two things has happened....

1. someone with the IQ of a bag of popcorn has messed about in the engine and not put the holding bolt back in place (likeley as there are signs of sealant around rocker cover)

or

2. it fell out, and buggered something up, so 1. decided to have a look, couldnt find anything and put it back together...:banghead:

now, where should i look for the part if it fell out? if it did, what damage will it do?, or should i forget it and just put a new bolt in to hold the tensioner?....

Ive never owned an XR before so all the help i can get would be awesome.

sorry im a n00b asking a shitload of stoopid questions.:lol:

I would pull the clutch cover off and look in that area of the bottom end, if it fell out it would drop down that side of the motor. you were lucky it did not catch up in the lower timing chain gear, if you dont see it right there take a telescoping magnet and fish around in all the openings... good luck:thumbsup::)

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Getting that piece back in properly can be a challenge. There may be no damage. Pull off the rocker cover and see what you have.

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Getting that piece back in properly can be a challenge. There may be no damage. Pull off the rocker cover and see what you have.

do you mean retensioning the cam adjuster is a challenge? or getting the chrome plug/shaft back in? the shaft just pushed back in, but rotated both ways............good or bad?

Funny innit, i will pull a car apart in my sleep, but this is uncharted territory for me so kinda freaks me out a lil...... i SO wanted to get this on the road for a Xmas Day blast.

so far it has needed rear wheel bearings, which i ordered, a carb air valve rubber diaphragm thing, which i also ordered, air n oil filter which i have, now i hope it don't have to be pulled apart too far..... I know i bought it as a non runner, caveat emptor n all that.... but it had goodish compression as i kicked it over, a spark which was good, and it had been stood, so i figured carb, which when i stripped it was full of shit, jets blocked etc, diaphragm busted, well, rotten actually! now im just prayin' it aint worse....

But i gotta say a HUGE :lol::) to all you guys on here for helpin a n00b out n not treating me like a twat (yet....:banghead:)

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The Cam chain tensioner is not supposed to rotate both ways. , If that top arrowed bolt (later models system) or pin on the earlier models isn't there that's what's going to happen..Head cover needs to come off and you need to replace the bolt or pin if it's missing,.How you get the Tappet (head cover) off is down to you., Some say it can be done with the engine in the bike,,I'll let them explain how you do that as I find it easier to simply remove the motor.,Or if removing the motors too much stress just remove all the engine frame holding bolts,,disconnect the exhaust , carb, and chain then lift the motor up a bit at the rear so it's out of that particular frame mount and roll it over so you can get at the bolts on the head cover,,Estimated time,,1 hour.,,

Edit::Carb shouldn't need removing ,,just pull the aircleaner attachment off the back of the carb and pull the plastic nozzle bit back towards the rear of the bike and rest it behind the part of the frame downtube close behind it while you do the job.,Don't leave the nozzle in that position for a long time or it becomes hard to put back on the rear of the carb due to a bit of deformation..,Ie,,an hour or so's ok,,not days,,

Personally since you've pulled that pin out I'd be going through the whole scenario of pulling the tensioner completely out and redoing the installation with the zip tie on the tensioner spring to make sure things are still set correctly in that department ,May as well replace the tensioner spring while you're there,,

Edit"",,Theres a video around somewhere on Youtube on using the zip tie to install the spring,,Follow it's instructions,,though I find a red hot fine tipped blade (coping saw blades ideal) the easiest thing to use to cut the zip tie,,It's a bit tricky getting the used tie out after you cut it with the blade so follow the vid closely or you'll have the leftover tie jamming in there..Ties got to be orientated correctly for ease of removal

Edited by Horri

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The Cam chain tensioner is not supposed to rotate both ways. , If that top arrowed bolt (later models system) or pin on the earlier models isn't there that's what's going to happen..Head cover needs to come off and you need to replace the bolt or pin if it's missing,.How you get the Tappet (head cover) off is down to you., Some say it can be done with the engine in the bike,,I'll let them explain how you do that as I find it easier to simply remove the motor.,Or if removing the motors too much stress just remove all the engine frame holding bolts,,disconnect the exhaust , carb, and chain then pull the motor over so you can get at the bolts on the head cover,,

Personally since you've pulled that pin out I'd be going through the whole scenario of pulling the tensioner completely out and redoing the installation with the zip tie on the tensioner spring to make sure things are still set correctly in that department ,May as well replace the tensioner spring while you're there,,

OK, thanks for the clarification...:lol:...but :banghead:::):banghead:

oh well, it will give me chance to look over the engine a little better. peace of mind when im 30 miles into the back of godknowswhere is worth it suppose.......

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redoing the installation with the zip tie on the tensioner spring to make sure things are still set correctly in that department ,May as well replace the tensioner spring while you're there,,

Edit"",,Theres a video around somewhere on Youtube on using the zip tie to install the spring,,l

Thanks Horri, I have spent 2 hours using every search work i can from zip tie, to camchain to XR600 zip tie trick to midget porn,( no wait that was last night......:lol:)

If ANYONE knows where to find the Vid of the zip tie trick, PLEASE let me know......and if you want midget porn, IM me..........lol:thumbsup:

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650L,,same deal,,same method,,30secs to find that..Courtesy of a joker who used to hang out at 4strokes..

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650L,,same deal,,same method,,30secs to find that..Courtesy of a joker who used to hang out at 4strokes..

i took the valve cover off, well moved it far enough to see in engine, the tensioner has not displaced! turned the shaft till the holes lined up and now it only turns one way!....:lol:

i had a good look with a flashlight, twice, and see there is a thread for a bolt....so going to find one that fits if i can.

next job, after a coffee is to pull the casing and see if the bolt is down there.....if not......then.........

cheers for all your help so far guys.....:).. im sure there will be many more questions in future.

GG

EDIT.. well i took the clutch cover casing off and found the pictured metallic debris, after raking about with a magnetized long screwdriver.... looks like a gear tooth and some mashed up softer metal......maybe a bolt?? Bike.jpg

Bike1.jpg

the Cam sensor which is magnetic had a good coating of filings which i wiped off, and i checked the filter screen which was pristine.

Is it worth pulling the stator cover off, as i figure the stator being magnetic may also have a shedload of chunks adhering to it.

also after doing that would it be a better idea to reassemble, get running and testride or just say sod it and tear the engine down? cash being tight and all.....

Edited by GreaseGorilla

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if you were able to get the pin back in with out collapsing the tensioner the cam chain sounds pretty stretched out and might need replacing along with the guides, you might check the cam chain gear on the crank for the missing tooth, if the bolt fell down that side it might be the first gear for it to go through. you can try running it but my chain was stretched out when i first picked up my 93 a few years ago and while idleing it jumped a few teeth which made valves hit the piston bending them a little bit which lead to a top end rebuild.

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