GPZ500s cam chain tensioner, or clutch...

[dextersaurus]

Since i've never done this kind of maintenance before, i'm wondering if there is anything i should be watching out for...

The bike has only done 33k miles in 16 years, so the camchain should hopefully be good for another wee while...

The main problem is that when it's running at really low revs (-2k revs) it taps quite loudly... And the tapping gets a lot quieter if the bike is leaned over to the right.

Now after doing some research, i've come to the conclusion that it's either the clutch or the cam chain tensioner.

I noted that once when i started the bike cold, i went to stick it into first gear, with the clutch held in, and it jerked forward and stalled... So the clutch didn't seem to be working. (this was before the oil change)... But starting it back up and grabbing the lever a few times, it worked fine afterwards.

I'm thinking if it's the cam chain being too loose (i've heard the tensioner sticks sometimes), i'll take off the tensioner and clean it up to the best of my ability, then slap it back in and see if that solves anything....

But if that doesn't help, i'm taking it that it's the clutch...

Any ideas?

If it IS the cam chain, what's the best way to clean up the tensioner?

Cheers

Dunc

[Acemastr]

I noticed the exact same thing today, on tickover or coming down from very very low revs i can hear it tapping, bike shop said cam chain tensioner, although my clutch makes funky noises when it's not pulled in.
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2017 KTM 350 XC-F - 2014 Yamaha R6 - 2005 Yamaha YZ125
2016 Toyota Tacoma Limited

[Kickstart]

Hi

Cam chain itself on the GPZ500 is sometimes not the longest lived item. However the other thing that can slap around is the primary drive chain.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Dazbo666]

Did some minor maintenance of the CCT on my old GPZ some time ago...
I seem to remember removing it, using Gunk/degreaser to clean it up, then using a Dremel to clean off some surface corrosion, then some Hammerite spray paint to prevent future corrosion.

From memory you just need to be careful about maintaining pressure on the spring when re-installing it - the spring inside the tensioner needs to remain compressed until after you've tightened the fitting bolts. Sorry I don't have the bike or the Haynes manual to be able to quote the exact fitting instructions.
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1st bike (Sept'06 - May'10) : 1991 GPZ500S / Current bike (since Nov 2009) : 2003 Suzuki Bandit 600N
Word of the day : DILLIGAF

[Acemastr]

anyone know how dangerous the tapping is? mines been doing it slightly for a couple months (not really noticed as i wear earplugs) changed oil on sat and noticed it far more lately. It's quite noisy at low revs/tick over

sorry to steal your thread dunk
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2017 KTM 350 XC-F - 2014 Yamaha R6 - 2005 Yamaha YZ125
2016 Toyota Tacoma Limited

[Pickledswede]

Those of you with Hondas... are you sure it's not just the clutch rattling? If you're idling it and it's rattling then you pull the clutch in and it stops then that's what it is. I believe this is quite normal on Hondas and nothing to worry about!

[c-m]

Remember that the GPZ (i fact most kawasaki) do sound like a bag of spanners rattling around.. its normal.

My GPZ used to sound like a diesel hackney carriage.

[dextersaurus]

Well, now that an incident while it was running involving bouncing it off the limiter happened, it now only runs on one cylinder...

Thought this might have something to do with it, unless it's just that buggered the carbs.

Again.

Dunc

[robocog]

AFAIK there is no "rev limiter" function from the CDI (based on what I have read)...apart from physical mechanical limits of components

I would be doing a compression check and whipping the cam cover off to have a nosey if its only running on one cyl since its been bouncing off a non exhistant limiter

cam chain is easily accessible when the cam cover is off (just done my clearences)

Only bit that caused any drama was the rubber O-rings for the water take offs on the head
Took me a few minutes of swearing at one of them and much lube till I got one of the swines in place without it pinching/twisting up, the other popped straight back in place without drama

I have my fingers crossed for you that valves have not been intimate with the piston on the non running side (and its nothing more serious than a bit of crap in the carb!...get a filter fitted if it hasn't already)

Regards
Rob
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Needs a bigger garage...