New cam chain tensioner, still clatters

[macx]

I did the swap, from what I read I've got the 2nd upgrade version with parts ending in
656 922 and 688 629, and don't have the little short internal dark colored piston or whatever
it was that is pictured in the "original upgrade".

I even took it apart and checked to make sure.

Trouble is, it didn't quiet the clatter down very much.

And, yes, the rockers and valve lash are set to the closer end of the tolerance range,
but I think about .003 above the tight end if I remember right. If that number is wrong,
at least it's closer to the tight end of the range than the loose end, but not at the
minimum clearance.

It clatters all the time at idle and just above, sound is like some very loose lifters.
Clatter goes away about 2k rpm. I'm half deaf and it still sounds alarmingly loud to me.
Haven't checked with my stethescope, but sounds a little louder on the left side than the right.

Warm or cold, doesn't matter. Engine oil weight doesn't matter.

Any ideas? People regularly post that they did the tensioner swap and the engine
is then virtually clatter free. Has me worried. Going to cut my filter apart and see
if I have any flakes. And see if I can pinpoint the clatter with my stethescope.

Got the bike July of 08 with 25k miles, it's an 04 model.

I don't remember it clattering that much before I set the rockers and valves,
other than during startup before I did the tensioner swap.
They were within tolerance but were uneven and more toward the loose end.

Thanks!

[Sunbeemer]

I've got the 2nd upgrade version with parts ending in
656 922 and 688 629

Same part #'s I used to do mine a couple years ago, which quieted the initial start-up rattle completely.

Sounds like your noise is more of a valve train issue...
My valves clatter a bit when cold, but after warmed up they subside to a noticeable but not disconcerting ticking.

My feeling is a little loose is better than too tight.

[macx]

Yes, it actually does sound more like loose lifters, even tho I had very carfully clearanced
the valves not long ago. But, I rechecked them. They're set exactly where they should be,
or at least where I want them. I've got my last oil filter which I'm going to cut apart and
spread out the filter media just to (hopefully!) rule out any bearing or other metal damage inside.

Maybe it's just cuz there's no hood over the valve covers like there of course was on my
old solid lifter hot rods in the 60's. 426 hemi, 375 hp 396 Camaro, both "tinkered" with to
one degree or another, of course!

[spoon]

I understand some folks get noise from the pushrods. The ends come loose from the rod. A new design is suspose to fix this. I too have noise and will do the pushrods next.

[owldaddy]

Did you adjust the valve rocker end play? This is different from valve lash adjustment. After I did mine the engine quieted down a lot.

[Sunbeemer]

They're set exactly where they should be,
or at least where I want them.

I am curious what clearances you used...

BTW, the Clymer's for my bike had an incorrect spec for valve lash clearances and included an errata sheet tucked in the front that said the correct clearances are:
intake = 0.006"
exhaust = 0.012"

Hope you didn't fall prey to that problem

[owldaddy]

I bought my gauges from the dealer, they are 15mm and 30mm. That does indeed work out to about .006" and .012".

[macx]

i'd have to look up what the exact specs say
but they came out of a regular service manual, not
a Clymer etc.

I checked and it's the .006 & .012

And, yes, the same applies to my rockers.

I'll have to check out those pushrods next, I guess.

What other production problems lurk?!

[aborigine]

Hello, macx

My 04 R w/18K miles behaves just like yours ( I also have done the right side: new spring was ~ 1/8 inch longer than old)

Noise persists, and I'm about ready to trade it. Just wondered if you ever got the satisfaction of finding the ROOT CAUSE

of the persistent noise. Hope you're still in the group to receive this.

[Keppelj]

I have an '02 with 20k miles and I've done all the right adjustments including updating the right side tensioner and mine is quieter now when it's cold - the tensioner fix accomplished that - but noisy when it's hot. I've read threads here and there with worried riders who've come to the same conclusion: it's noisy hot. I wear ear plugs and I suppose I could hear the racket at a stoplight in the summer. Basically though, I really like the beast and I've quit hearing the noise. I just quit worrying about it.

[fpgirard]

I did the left side tensioners but not yet the right. Do you need to remove the exhaust to remove this tensioner? It seems that you do.... comments?