Suzuki DR650 Cam Chain Tensioner Replacement

[@andyblack5687]

I’ve already commented on this video a while back, but I had my gasket literally break in half and oil started spraying out like crazy. Just wanted to say thanks for sharing your trick for installing the tensioner with ease. It worked like a charm when I replaced my gasket just now.

[@johnjaschke8171]

Very helpful and liked your “pace of progress” suggestions. I started early and substituted coffee for beer and was done in a half day, including some degreaser cleanup time while the exhaust was off. An impact driver with hex head (6mm) to remove my aftermarket (Staintune) exhaust was an important first step. An intermittent extra set of hands to help twist the exhaust around a bit was useful too. As noted nicely in this vid, you need a very narrow flat blade screwdriver to turn the CCT to lock and then to release. I ground down a cheap old one I had on bench grinder make it slimmer to fit. No need to worry about TDC if you do not move the wheel (and thus the engine piston) while the bike is opened up. I used a small amount of Grey permatex on the engine side and blue thread locker on all the bolts (expect for oil cooler line special bolts as they have reusable copper crush washers). Appreciate the torque setting mention as I did not have the service manual. Bought a $35 torque wrench which will someday get used again. Again, thanks for this making and sharing this vid - gave all the key steps and thus the confidence to do the job right. Keep rolling...

[@michaelpaccione3801]

Thanks for filming this Sam. I have to do this on the street and your video has helped me visualize the steps better and surely save time. Cheers.

[@JumpingWatermelons]

great video, thanks. Of the videos i watched, yours is the only one showing the release of the plunger after it's installed.

[@daugbret]

I think this is the video where you use an air gun to get a bolt or something out from under your starter. Tonight I dropped the pilot jet under there and used that trick. Had to keep puffing until it landed on top of the "shelf" between the cylinder and the starter well. Thanks 😆

[@crjpeg]

Thanks for the video and the advise. I have to tackle this in the next week or so. Very helpful.

[@livierluna1155]

I have that same problem now. I just ordered the gasket. Thanks for sharing.

[@MrMacon5]

Thanks for the tutorial, I am going to attempt tomorrow

[@markymarkfromreefton]

Fantastic video bud .. thanks

[@genomedia44]

Thanks Sam. I see you had the Clymer manual there; it talks about a "tool" one has to make from thin metal; you didn't mention or use that at all?

[@mt1885]

Suzuki must have some secret 'glue' they use on gaskets it is like indestructible and can repel about everything known to man.

[@joeh8486]

Hi, very helpful video. Why did you change yours? Was it an oil leak or a rattling/tapping sound coming from the engine? I just pulled mine off and I was wondering is there a way to see that the tensioner is broken? Mine looks totally fine but I'm guessing it's an internal part that has given up. Thanks.

[@taosbentley]

It was leaking all over the engine case. No odd noises thankfully!

[@adrianpancaldi8646]

Hey man, thanks for making this video! My ‘03 DR650 is now leaking oil worse than my old Triumph! Was suspecting the cam tensioner cover gasket and I reckon your video confirms it. In doing research, as I don’t possess a workshop manual for the bike, I saw a comment that someone put there motor at top dead centre before removing the tensioner. I can’t see any reason as to why this would be necessary? And you didn’t mention it. Does the manual say to?

[@taosbentley]

It was actually fun to make this one. Thanks. I didn't see a reason either, as long as you don't move the bike again until the job is finished.

[@marcogonzalez7829]

Information I'm getting is that it's important to be at TDC and TDC in compression stroke. What's your thoughts?

[@intellectualkshatriya3046]

Do we have to release it ? I thought it will automatically adjust

[@trentfrompunchbowl]

Which side does the cam tension go up?

[@genomedia44]

Would using a Dremel with some tip maybe make the gasket removal easier?

[@genomedia44]

oh! I missed that part, you already said it 👍

[@andyblack5687]

What kind of headlight setup are you running? Is it better than stock? Looks like a cool robot or something.

[@taosbentley]

It's from Brittania Composites. Out of Canada. Called the Lynx I think.

[@simonlanc1]

Hi Have you got a bigger aftermarket oil cooler fitted?

[@taosbentley]

Nope it's stock.

[@ianmangham4570]

Darn that infamous cam chain tensioner

[@Unknownas1337]

Where did you buy the headlight from ? Looks mean

[@taosbentley]

Brittania Composites. Lynx fairing.

[@Flame-Bright-Cheer]

🤘🏻🏍Dr650SE💪🤜🦆💨🤢🤮....THANKS DOOD FOR THE VID

[@MichaelTrivisonno-h3e]

What's up with that suspension? You probably got asked a million times I'm sure.

[@taosbentley]

@@MichaelTrivisonno-h3e rmz 450 front end and cogent rear. Super freaking awesome!

[@MichaelTrivisonno-h3e]

@@taosbentley Thanks for getting back to me. Were those forks and triple clamps a direct bolt on?

[@taosbentley]

@@MichaelTrivisonno-h3e you know, I'm not sure. I didn't do the build.