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Old 12-21-2005, 01:57 PM   #1
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Quick question for all of you out there widhing it would snow....

I have a '01 ZR600 EFI. Last year I tore the drive out of it (don't ask). Needless to say, I replaced the drive, bearings, seals, etc. i rode the rest of the year without issue. However, on my last ride, the chain case began to make a lot of noise. As you depressed the throttle, it sounded as if the chain was slapping against the side of the chain case. I stopped, and found there was no oil in the case. I remedied this problem, and headed home......needless to say there was no oil when I got home. At this point, I have replaced the drop case, cover, and bearing seals. My question is this.....when everything is re-installed, it appears that the chain is VERY loose on the sprockets. I have to screw the tensioner bolt in all the way to get it to become remotely tight. Can anyone tell me why this is so, or how loose the shain ought to be? Before screwing in the tensioner, the chain was actually sitting off the bottom of the driven sprocket.

Any help would be appreciated!
Thanks!
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Old 12-21-2005, 03:17 PM   #2
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Check your sprockets and see whats in there. Stock gears should be 22 top 41 bottom. As far as tension on the chain you should have the tensioner bolt as tight as you can get it by hand. There should not be alot of flex in the chain. make sure you still hav the rollers on eithe side of the chain and the sping that connects the two rollers together to keep the chain pulled in towards the center. Browns leisure world has an online microfiche that shows a goos diagram of what goes in there. If you are still loosing oil check the drain plug thats on the inside of the tunnel. If the o-ring is not on that drain plug that may be your problem. If its loosing oil as fast as you say it is clean all the areas around the chain case and look for where its leakin from. It sounds to me like something might be missing in your chain case or the sprockets were changed and they used the wrong length chain with them. If you get a chance to look it over let me know what you find and I can help you further. I have spent alot of time playing with gears on the 2001-2002 ZR 600 EFI. I should be able to help you. You can PM me or e-mail me.
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Old 12-22-2005, 02:14 AM   #3
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Sled: 1999 zr 600 efi
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if you ran it out of oil, you more than likely streched your chain. if your tensioner is already maxed its time anyway. id replace it now before it gets more expesive and breaks taking out your case.
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Old 12-22-2005, 03:05 PM   #4
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Thanks for the thoughts guys. I did pick up a new chain today, and will probably try and throw it on on Saturday. I'll let you know of the out come. Also, I already checked both sprockets, and they are correct for the stock setup.
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Old 12-27-2005, 08:10 AM   #5
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Gentlemen......Again, thank you for the input. As I stated before, I completed the repair on Saturday......and it was the chain. The original chain had approx. 3/4" of stretch in it. After installing the new chain, and re0installing tensioners/case cover, I took it for a spin, and all was well. I thank you for all your help, and hope you have a great holiday season!
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Old 12-28-2005, 03:34 AM   #6
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2010 Mileage: 1260
2009 Mileage: 1300
2008 Mileage: 1200
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congrats and happy trails!
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