TOPIC:

Hi Scotch,

Thanks but it ran this morning when I set the mixture. I'm sure it doesn't now as I have disconnected the Reg/Rec and the coils etc. and the M-Unit prevents starting because it is sensing something wrong with the electrics.

I will take the RH engine cover off and try turning by hand, but I need to put the tensioner in first and drain the oil. The nylon sprocket can be seen from above and looks fine.

Paul

Paul,

I am pretty sure the fault is not the Nylon Gear.

Take your ZX tensioner out and take a photo of it fully extended next to a tape measure for reference.
I will do the same over the next hour and post it too (after me dinner)

Then we can kill or cure the tensioner being the culprit ??

Pete F
UK

5.8cm at full stretch.

Paul,

My tensioner removed for my bike at 7.30pm tonight.........the tensioner is obviously not the problem then !!

Just throwing this out there and no meaning to insult anyone's intelligence, but I recall someone (Stan G maybe) rebuilt an engine and unknowingly routed the cam chain wrong when he installed the tensioner. The rear side of the chain coming off of the secondary shaft runs in the fork of the tensioner making the nylon gear run on the inside of the chain. The Black (or sometimes grey) flat surfaced tensioning wheel runs on the back side of the chain pushing the chain inboard. As I remember it, ( if it was Stan) didn't run the chain in the fork of the tensioner so in effect, the chain was not working against the nylon sprocket and the end result was the tensioner couldn't push the chain in far enough to tension the chain.

Page 71 in the manual - They didn't put it there for nothing. Must be a common mistake !@#@!$#

Kawboy,

You are correct with regards to the route of the chain (thanks), which I mentioned to Paul earlier as I know some owners have fallen foul to this error in past, so thinking outloud, as both you and I are.............this is one of the strongest contenders to the "extra" chain slack and the bike would still run even with the chain incorrectly routed.............but in very much danger of................well we all know that !!!

Problem here is...............I cannot remember if this chain routing can be viewed from the top of the motor looking down the cam chain tunnel.................but I dont think it can be, without the use of some sort of clever camera ????????

Pete F
UK