Gauging the chain tensioners - Kawasaki ATV Forum
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post #1 of 61 Old 06-26-2019, 07:03 AM Thread Starter
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Gauging the chain tensioners

Has anyone ever gauged the front and rear tensioners for useable length? I ran a search but didn't find much. I forget how many teeth are on the extender, but it seems the chains could be loose long before all the teeth are out.
I had 9 teeth showing on the front tensioner in November, and now I have 12. There's still lots of teeth left, but I wonder how many can be used before it's too loose.

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post #2 of 61 Old 06-26-2019, 07:17 AM
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I don't know.. but I do know our shop always replaced chains on every rebuild regardless of miles..well unless it was just done. When the chain stretches and the gears & chain wear, even though the tensioners keeps the slack out of the non load side, the valve timing will retard. Probably notice this when setting it.. that it's off a bit but one link forward or advanced is too much. Kickstart...replace the chains! All of them.. and the cam gears....and the bars. You won't believe how much better it will run with the valve timing spot-on. My Brute was on the 5th notch when I sold it...and I though that was getting there. Can't imagine the 12th. Gota be past it's limits or getting real close.

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post #3 of 61 Old 06-26-2019, 09:07 AM
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The brute 750 only has like 12 notches. Take her out of gear and set in neutral, pick a cylinder and remove the tensioner . Once the tensioner is out, you can extend it to see where full extend is and full compression is. When I installed new chains on my 750 recently, I think I was at 2 - 3 notches showing.

Correction: there is 22 notches on the cam chain tensioners.

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post #4 of 61 Old 06-26-2019, 12:18 PM
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Ignore the tensioners.
Did you replace the chains last rebuild? If not, do it now.

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post #5 of 61 Old 06-26-2019, 12:43 PM
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Quote:
Originally Posted by NovaKaw650 View Post
Ignore the tensioners.
Did you replace the chains last rebuild? If not, do it now.
As I recall, he is still running the original factory chains,bars and sprockets with 15+k miles on them. Yeah...its time

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post #6 of 61 Old 06-26-2019, 01:02 PM Thread Starter
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I had a feeling you all were going to say that!

You are correct NMK, all original chains and guides at 17,666 miles.
They've not been making any noise, and I have been listening for it for awhile. But as I was breaking in the new piston last night, I think I might have heard the front one. Hard to say though because it sounds so different with all the plastic off, and a new exhaust. But, I did notice it was easier to get the chain over the camshaft when I was setting the timing. Last time, it was a bear.

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post #7 of 61 Old 06-26-2019, 01:07 PM Thread Starter
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Quote:
Originally Posted by dman66 View Post
The brute 750 only has like 12 notches. Take her out of gear and set in neutral, pick a cylinder and remove the tensioner . Once the tensioner is out, you can extend it to see where full extend is and full compression is. When I installed new chains on my 750 recently, I think I was at 2 - 3 notches showing.

Correction: there is 22 notches on the cam chain tensioners.
I just had the tensioners off to fix the oil burning issue. I think you're right.....I think I counted 22 teeth too. I know 12 looked about halfway out.

2005 Prairie 732cc Team Green Special Edition
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2015 BF750 camshafts
Warn winch/Amsteel Custom Splice synthetic winch rope
Maxxis VIPR tires/12" DWT Rattlesnake wheels
Twin Air filter/TPI air box vent valve
Powermadd Star series handguards/Symtec Heat Demon grips
Adjustable Progressive front springs
VFJ adjustable clutch weights
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post #8 of 61 Old 06-27-2019, 08:13 AM Thread Starter
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Ok, so here is the front chain tensioner where it is now vs all the way out:


2005 Prairie 732cc Team Green Special Edition
Wiseco pistons
2015 BF750 camshafts
Warn winch/Amsteel Custom Splice synthetic winch rope
Maxxis VIPR tires/12" DWT Rattlesnake wheels
Twin Air filter/TPI air box vent valve
Powermadd Star series handguards/Symtec Heat Demon grips
Adjustable Progressive front springs
VFJ adjustable clutch weights
EPI pink primary/VFJ #1 secondary
QuadBoss 8" sound tube
8" Cree LED bar/LED Underglow kit
Custom RCM shift knob
DYNATEK CDI
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post #9 of 61 Old 06-27-2019, 10:13 AM Thread Starter
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And here is the rear. Only 7 teeth out.


So, it looks like the rear has some time yet. So for now, the question is, can I replace just the front chain? Or do you have to take everything apart on the left side anyway to change the front so I might as well change all the chains? Service manual isn't real clear on that.

2005 Prairie 732cc Team Green Special Edition
Wiseco pistons
2015 BF750 camshafts
Warn winch/Amsteel Custom Splice synthetic winch rope
Maxxis VIPR tires/12" DWT Rattlesnake wheels
Twin Air filter/TPI air box vent valve
Powermadd Star series handguards/Symtec Heat Demon grips
Adjustable Progressive front springs
VFJ adjustable clutch weights
EPI pink primary/VFJ #1 secondary
QuadBoss 8" sound tube
8" Cree LED bar/LED Underglow kit
Custom RCM shift knob
DYNATEK CDI
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post #10 of 61 Old 06-27-2019, 11:20 AM
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Yes you can, the front is the last chain installed. Pull the clutch and the plug behind it. Its a tight fit getting the chain back on the sprocket, couple picks will do the trick to guide it back on. Just line up the marks before you take the chain off.

This is a good video to show the process of it all.

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