From Jesse himself
Replacing Cam Chain Tensioner Gasket
- First, set the engine at TDC compression stroke. This takes the valve spring tension off of the cam chain.
- Remove the small bolt from the rear of the cam chain tensioner and insert a small screwdriver into the hole and engage the screw inside. Start turning the screw. A spring tension will be felt but keep turning it until it stops, but give it some pressure and then let the pressure off slightly. The tensioner should stay there. If it should pop out, it will stop when it reaches its limit. Just wind it back again and exert more pressure. When it stops, it should stay retracted.
- Remove the bolts (2) and extract the tensioner. The plunger should be fully retracted. If handled carefully, it should stay retracted.
- Clean the old gasket off and put a new one on dry with no sealant.
- Slip the tensioner back in, making sure the plunger is fully retracted, and tighten the bolts 6 to 7 ft lbs torque.
- Insert the small screw driver into the hole and turn it the opposite direction. You will feel the plunger take off inside and put tension on the cam chain follower. Make sure this happens. If the tensioner goes in the fully out position it will put too much pressure on the cam chain follower.
On a related note
I totally bagged the shaft plug hex (#18) below trying to open it to set to TDC. Anyone no how to get that out now that it is stripped? Damn thing is made of cheese.