Replacing Cam Chain

[suzuki33]

take the head cover off, cams out.
take off the right side cover, take the 6? bolts out holding the clutch disks in.
bend the tab holding the big nut on the clutch then use 27mm socket on impact gun and take that off and remove basket.

next remove the big nut on the gear that runs cam chain but it is a Reverse thread (use 27mm and impact gun) then you can pull the gear out enough to remove the chain and pull the chain up.

(I took the left guide out because i thought i hade too but i dont think i hade too, But if you do there is a washer on the back of the guide that will fall and land right one the oil pump gear, i was thinking that it might have caused that gear to strip for some people?

Also there is a little piece of metal holding one of the big bolts on that you have to take out but cant remember which gear.
Hope this helps

Edited with NormalZ's, and hackattack's photo to make more sense

Some information on fitting the 4/5 pitch cam chain.
http://suzuki.theatvchannel.com/invision/i...30&start=30

[jbsilverado]

QUOTE (Suzuki33 @ Sep 8 2008, 05:17 PM)

well i was reading up on some threads before doing it and from what i read, it was said it could be done but no one could do it. But i did it fine, if this has already been found then i wont get into detail but if somone wants to know i will[/b]

I'm gonna need to do it soon lets hear it

[suzuki33]

take the head cover off, cams out.
take off the right side cover, take the 6? bolts out holding the clutch disks in.
bend the tab holding the big nut on the clutch then use 27mm socket on impact gun and take that off and remove basket.
next remove the big nut on the gear that runs cam chain but it is a Reverse thread (use 27mm and impact gun) then you can pull the gear out enough to remove the chain and pull the chain up.
(I took the left guide out because i thought i hade too but i dont think i hade too, But if you do there is a washer on the back of the guide that will fall and land right one the oil pump gear, i was thinking that it might have caused that gear to strip for some people?

Also there is a little piece of metal holding one of the big bolts on that you have to take out but cant remember which gear. I will check this when i get my new gasket and get a picture to explain
Hope this helps

[captain uno]

Still doesn't explain how you get the front guide out. There have been many discussions on how to do this, the problem is the front guide. You can do all of that without removing the clutch, just remove the primary nut.

How did you get the front guide out of the way?

[orangeracer434]

the chain guide on the exhaust side wont come out without removing the head, the guide has a retainer that is sandwich between the the and cylinder jug.

[xxnightraven73x]

i did mine without pulling the head ive explained it many times the front guide does have enough flex to just barely move and clear the way for the old chain to come out and new one to go in

[hackattack]

I'm still confused on the little bar that runs across the top of the head though...right in between the two cams.

Does the cam chain have a Master Link in it that you have to bust OR how does that little bar come out?

Any help would be fantastic. I've inquired about it a couple of times BUT have not been out to work on the quad to answer my own question...so any assistance before I finish the job would be fantastic!

Thanks,
Ben

[xxnightraven73x]

bar on top you mean the bolt that goes through?? unscrew the big hex on the side of the head i think its an 8mm..and no theres no master link in a cam chain

[orangeracer434]

i believe it a 5 mm allen at the cam journal.

[xxnightraven73x]

could be i havent taken that one out in a while but either way ben all it is is a bolt

[suzuki33]

guys if you take the clutch out and basket then you can pull the gear forward and then move the chain around it an pull the chain up threw the cylinder. No trying to get around guides, Im getting my gasket tommorow hopefully then i can get picture to explain better. and orangeracer434 is right its 5mm

[hackattack]

QUOTE (xxnightraven73x @ Sep 9 2008, 09:53 PM)

bar on top you mean the bolt that goes through?? unscrew the big hex on the side of the head i think its an 8mm..and no theres no master link in a cam chain[/b]

I'm such an idiot...!

Guess I'll be finishing mine either tonight or tomorrow night I hope!!!

Thanks Scott! And...everyone else who input on this thread! I think someone SHOULD do a movie on this...it'd make life so much easier...

[xxnightraven73x]

haha no problem ben sometimes we over complicate things when youre sitting there doing it and think about it later and its really just that simple

[hackattack]

QUOTE (xxnightraven73x @ Sep 10 2008, 12:23 PM)

haha no problem ben sometimes we over complicate things when youre sitting there doing it and think about it later and its really just that simple[/b]

Yep, you're totally right on that one...kinda like a carb issue and all that it is is the throttle cable sticking...

[z400kiksazz]

QUOTE (xxnightraven73x @ Sep 9 2008, 07:45 PM)

i did mine without pulling the head ive explained it many times the front guide does have enough flex to just barely move and clear the way for the old chain to come out and new one to go in[/b]

Yup + 1........I've did it.

BUT be carefull and dont break anything.