Cam lobe positions

[-Monty-]

Hi all,

I have just tried checking the valve clearances on the DRZ. Got the piston to TDC using the T notch below:

https://i.imgur.com/s5BfQeE.png

With the notch in this position, the cam lobes should be pointing away from each other in roughly the 10 to 2 position; however, this is the position they are in:

https://i.imgur.com/tl2JMNW.png

When I check the clearances like this, the exhaust is in spec; however, the intake shows zero clearance.

To me, this would seem as though the the timing is somehow out, but the engine still runs (albeit requiring a lot of cranking to start when cold). If the timing was out, surely the engine would have eaten itself by now?

I was a little confused by this, so had a look at the timing chain sprokets. This is what I found:

https://i.imgur.com/ZAvWrSC.png

Something is definitely not right here; those arrows on the sprockets should point towards each other with the engine at TDC.

Does anyone have any ideas on what is going on here?
____________________
Present: [Kawasaki ZX7r][Suzuki DRZ 400s]
Past: [Honda PCX 125] [Yamaha RXS 100] [Honda CB 500] [Triumph Speed Four] [Honda ST1100 Pan European - Po-Po Edition]

[Howling Terror]

Definitely TDC on the compression stroke?
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[-Monty-]

[Pete.]

Firstly make sure you're at TDC by removing the plug and dropping a pencil down the hole. Rock the engine back and forth over TDC with a spanner holding the pencil and watching the mark to see that they correspond.

If that's OK pull the cams and re-time them, always starting with the exhaust cam. Make sure you don't have them in the wrong side - I once built an engine with the cams swapped over it was very embarrassing.

A quick look around the forums says that the 1 and 3 arrows on the exhaust cam should be flat with the gasket face on the head. You cam looks one or two teeth retarded.

https://thumpertalk.com/uploads/monthly_01_2012/post-18851-13264038639465.jpg

Once the exhaust is timed right set the pin count on the chain to time the inlet. In the pic they have pin 1 at the 2 arrow on the exhauhst and pin 15 on the 3 arrow of the unlet.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[-Monty-]

Thanks for the reply.

I have done as you suggested; however, I think the mistake I made was not taking up the slack in the cam chain to ensure the timing was right. Ran out of time yesterday so will have to attempt it when I'm back home in about a week now.
____________________
Present: [Kawasaki ZX7r][Suzuki DRZ 400s]
Past: [Honda PCX 125] [Yamaha RXS 100] [Honda CB 500] [Triumph Speed Four] [Honda ST1100 Pan European - Po-Po Edition]

[Pigeon]

Wedge something down the CCT hole (like a toothbrush handle) to keep some tension on chain.
Can also wedge something suitable between chain and case.

That should keep chain tight enough.

If the ladder is removed, then Cable ties to lock chain to sprocket while tightening up cam ladder.

[Pete.]

[MCN]

I don't know exact spec for that engine but make sure you are not 360° out.
Turn the engine 1 revolution and recheck.

I have not even given that too much thought but it is common if No 1 at TDC is not set properly.
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Disclaimer: The comments above may be predicted text and not necessarily the opinion of MCN.

[Pete.]

[MCN]

[P.]

Shouldn't make much difference, but has someone put the 400E cams in there?

[-Monty-]

Sorry for the delay in getting back to you all on this, I was away last week but have had a fiddle around in the garage tonight.

I've re-done the timing and managed to get the sprockets/lobes in exactly the correct positions while the chain was tensioned. I thought while I was at it I may as well install a Manual Cam Chain tensioner, as it is a recommended mod for the DRZ. So much easier to fit than the old automatic one

I was having some pretty severe cold start issues before I sorted the timing out, to the point that last time I tried it just kept cranking until the battery went flat. After adjusting the timing, it starts immediately from cold, idles better and feels as though it is putting out significantly "moar powah" than before. Pretty good result I think, so thank you very much for the replies.

Also Paddy, I have no idea whether the 400 E cams have been put in here as I wouldn't know the difference between to two to be fair. Someones obviously been here before though for the timing to be out. The old automatic tensioner had the chain so tight, theres no way it could have skipped two teeth on its own.
____________________
Present: [Kawasaki ZX7r][Suzuki DRZ 400s]
Past: [Honda PCX 125] [Yamaha RXS 100] [Honda CB 500] [Triumph Speed Four] [Honda ST1100 Pan European - Po-Po Edition]

[Pete.]

Good result!
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good