Balance chain and timing.

Questions regarding the DR800

Balance chain and timing.

Postby GraySWTRF » Mon Feb 05, 2018 7:58 pm

Finally got round to finding time to have another go at getting this 800 going.

Starting by rechecking things again and would like to know before I check the balance chain alignment.
Should it be a tdc to do this or doesn't it matter ?

I recharged the battery and the plugs are sparking nicely when removed, but I wonder if they don't when they are fitted.
Reason I say this as I don't even get a puff out of it even using damp start as well and read about pulse coil issues.

Seems to have plenty of compression though.

Carbs have been apart and ultrasonically cleaned many times, but it still doesn't draw fuel in as plugs are dry.
Tried an aux tank and with and without the fuel pump.
Tried adjusting float levels on numerous occasions so the line on them is parallel with the carb face and also as it shows in the book measuring from face to the high point.

Maybe its something more serious like bent valves e.t.c but that doesn't explain good compression.

Anyway will have yet another stab at it, and any advice is appreciated.
It would be good to get it running again though, and I live in hope.....
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Re: Balance chain and timing.

Postby Mr.Z » Mon Feb 05, 2018 8:16 pm

the balance chain should be tight, doesn't matter it's on DC or not.
and the plugs should be dry or they would get to much fuel.
if they spark they work

Did you do something to the engine? and did you while starting spray some brake cleaner in the airbox to try to get it starting?

And did you check your auto decompression? should do a pull at the first moment when you try to start and then come back out
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Re: Balance chain and timing.

Postby GraySWTRF » Mon Feb 05, 2018 8:22 pm

Ok thank you.
Yes I sprayed damp start directly through carbs while starting.

Its a manual decompressor SR42 800.
I pulled the lever on the bars and then hit the starter button.

I have done nothing to the motor apart from replace the starter gears and rotor as they were worn and damaged.
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Re: Balance chain and timing.

Postby GraySWTRF » Mon Feb 05, 2018 8:25 pm

Are any of you Big experts local to me in Hereford that may be able to help me out by any chance ?
Or I could bring it to you ?
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Re: Balance chain and timing.

Postby Mr.Z » Mon Feb 05, 2018 11:04 pm

Get a spark plug out, put it's head on, grap it and hit the start button, if it hurts it works :o
Did you unhook the timing chain?
And did you check the timing of the cam shaft?
If you did take of the rotor could there be change that the balancer chain and so the cam chain shifted position?
What happened that you had to change the rotor?

To check the timing take of the fuel tank, take of the valve covers and turn the piston on DC, if there play on the rockers your timing should be okay.

You'r welcome to come by but live in Utrecht, Holland so it is a bit far :D
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Re: Balance chain and timing.

Postby GraySWTRF » Tue Feb 06, 2018 2:16 pm

The rotor had tooth damage and the timing chain was not removed.
As far as I am aware the camera chain hasn't moved.
I haven't checked the timing as believed it was fixed and unadjustable unless the chain has moved.
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Re: Balance chain and timing.

Postby Mr.Z » Tue Feb 06, 2018 8:11 pm

The rotor is part number 2 here https://www.motorcyclespareparts.eu/suz ... 68324.aspx and there are no tooth on it so what did you replace?

And what happened with your engine?

Ow and do look at the wires going out of the rotor cover, if you got them between the cover it won't start, feel of you can move them freely.
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Re: Balance chain and timing.

Postby dave#22 » Tue Feb 06, 2018 8:47 pm

I see you replaced the rotor, was it from the same model?
As far as I know the SR 41/42 are the same and the 43 is different. If you've fitted a 43 DR800 rotor, that could be your problem.
I'm up by Ellesmere Port if that's any good to you.
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Re: Balance chain and timing.

Postby GraySWTRF » Sat Mar 03, 2018 5:13 pm

Sorry for the delay in replying.
The starter gear rotor with the sprag type bearing in it was replaced.

I have now rechecked all the balance timing chain settings and cam/timing markings and all as far as following the book is correct,I hope !

I have found that my cable operated decompressor shaft does not come into contact with the exhaust valve rocker at ANY point whilts turning the crank.
I have taken the shaft out and it does not appear to be worn and is not bent.
The top of the rocker has a flat on it which looks as though it was desinged that way ?
Or has it worn down ?
I will try and upload a picture of it.
Is it common for that section of the rocker to wear ?
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Re: Balance chain and timing.

Postby GraySWTRF » Sat Mar 03, 2018 5:27 pm

This is the shaft.

Doesn't matter where how you turn it,it will not come into contact to open the exhaust rocker to decompress it to be able to turn it over.
It struggled before too turn over with any gusto even with another battery jump starting
Whilst the head was off I checked all the valves and none are bent thankfully.
All relapped and new stem seals and gaskets fitted.
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