How to obtain and fit sprocket - Motorcycles

There are no timing marks on this engine - the engine has to be "locked" using special engine locking / setting kit which you wil have to obtain to do the job.

I will give you the instructions to do the job for when you have the locking kit to do the job.. as follows:

Removal

1. Raise and support front of vehicle.
2. Remove:
   • • RH front wheel.
     • RH inner wing panel.
     • Air filter assembly.
3. Support engine.
4. Remove:
   • • RH engine mounting and bracket.
     • Timing belt upper cover,
     • AC receiver/drier (if fitted). DO NOT disconnect hoses.
     • Timing belt lower cover.
     • Auxiliary drive belt.
     • Support bracket between gearbox and cylinder block (Palio).
5. Palio: Remove bell housing cover plate. Fit flywheel locking tool. Tool No.1.867.029.000. or equivalent commercially available.
6. Remove:
   • • Crankshaft pulley bolts
     • Crankshaft pulley
     • Spark plug leads.
     • Ignition coil and bracket.
     • Spark plugs.
7. Fit dial gauge and adapter to No.1 cylinder. Tool No.1.860.895.000.
8. Turn crankshaft to TDC on No.1 cylinder. Set dial gauge to zero.
9. Ensure notch in rear of camshaft aligned as shown.
10. Install camshaft aligning tool. Tool No.1.870.823.000
11. 
    NOTE: If camshaft aligning tool cannot be fitted: Turn crankshaft one turn clockwise.

Installation

1. Ensure No.1 cylinder at TDC by turning crankshaft slightly clockwise and anti-clockwise. Use dial gauge .
2. Ensure camshaft aligning tool fitted correctly
3. Hold camshaft sprocket. Use tool No.1.860.831.000/001
4. Slacken camshaft sprocket bolt
5. Fit timing belt in following order:
   • • Crankshaft sprocket.
     • Water pump sprocket.
     • Camshaft sprocket.
     • Tensioner pulley.
   NOTE: Observe direction of rotation marks on belt.
6. Fit tensioning tool locating pegs to tensioner pulley holes -Tool No.1.860.745.100/300. Ensure tensioning tool arm is horizontal.
7. Set weight at 70 mm mark on scale bar.
8. Hold camshaft sprocket
9. Tighten camshaft sprocket bolt - Tightening torque: 70 Nm.
10. Remove aligning tool
11. Turn crankshaft two turns clockwise.
12. Ensure No.1 cylinder at TDC by turning crankshaft slightly clockwise and anti-clockwise. Use dial gauge
13. Ensure camshaft aligning tool can be fitted - If not: Repeat installation procedure.
14. Tighten tensioner nut to 28 Nm
15. Remove:
    • • Tensioning tool
      • Camshaft aligning tool
      • Dial gauge
16. Install components in reverse order of removal.
17. Tighten crankshaft pulley bolts - Tightening torque: 20 Nm + 90°.

Hi Jake if you have the right tools it will be no trouble. Before you remove the rear wheel remove the front sprocket cover and loosen the nut or nuts holding the front sprocket. This will be safer than doing it with the r/wheel off. Next remove the wheel and keep note as to where the spacers go (don't mix them up!) remove the sprocket nuts and the sprocket. Again note which way the sprocket goes some have a thinner center so make sure the new one fits the same way. Refit the wheel leave it loose and loosen the adjusters allowing the wheel all the way forward. Then open the chain and join the new chain to the end of the old one with the link supplied then pull the old chain until the new one is fitted. Next join the new chain together. ( you may need to remove a link or two) it will depend on the length of the new chain. After this fit the new f/sprocket and tighten the nut then adjust the chain leaving 1.5inches of free play up and down. Make sure the adjusters sre even on the marks each side. And finaly After a day or two of use adjust again to around 1 inch up and down. Have fun. Regards Jim...

When you fit new sprockets you also have to fit a new chain if you dont your sprockets will wear out very quickly, as your old chain is stretched to the old sprockets.

Hi there, Yeah this is a bit tricky. First things first. what engine do you have in ? Double cams have unique marks. You will see the left cam sprocket should be aligned with "IN" on the intake side and "Exhaust" on the exhaust side. On the same sprocket is a indent line on the edge of the sprocket on the exhaust side. The sprocket on the right side "Exhaust side", should be aligned exactly as the left one. So you have both sprockets aligned with the "intake" facing the intake side and the exhaust facing the exhaust side. You will now notice that there is a line up indent on the outer ring of both sprockets. These should be exactly facing towards each other. Now caution is advised here, even before you start with this, you must move your crankshaft sprocket to the left just so that all pistons are half way up. This will make sure when you do turn the cam shafts that the valves don't interfere with any piston. Now adjust the cam shafts as described above and use inventful mind to lock both cam sprockets in line together. Make dead sure with use of a ruler, that the lines on both sprockets are definitely lined up. Now move your crankshaft sprocket to the right and line up the two markers on the outer side with the line directly above further away from the TDC marks, "Located to the left". So to the right of those TDC marks is a Forged out line. Line the two dots on the c-shaft up with this line. When done with this you may fit on the belt and make sure that the belt is fitted tightly on the exhaust side meaning pulled to near tension, then follow through to the left cam and then over the water pump. Fit on the tension-er. Here you get two different types of tension-ers. Automatic one is fitted under the intake side cam sprocket, it gets hold down with a bolt. the wire fitted with the tension-er loops over a bolt already fitted on the motor. Using a allen key turn the tension er so that the align plate with v-shaped indent is facing directly to the bottom loop of the wire. Then tighten the bolt hold down to lock the tension er in place. Lastly the ideal method before you fire up the engine is to remove the negative battery terminal and after you have fitted the external belt sprockets, on the crankshaft is to turn the engine clock wise and make sure that no valve is interfering with a piston. Turn until you can see the timing marks you just setup aligns back to normal. On the outer belt sprocket fitted on the c-shaft, there is a mark as well, this should also line up with the line further away to the right from the other marks to the left located on the belt cover. When you have spun the c-shaft clockwise, about eight times and all the marks align back to normal without any valve interfering with any piston, you may finish of the rest and fire up. Here your good to go. Good luck

Sounds like your chain is stretched and not fitting the sprocket properly or is just too loose. Check your front and rear chain sprockets for wear and ensure the teeth are straight. Check to insure the chain fits snuggly on the rear sprocket. As a chain stretches over its life, it won't fit in all of the teeth on the rear sprocket. This will cause the chain to ride up on the teeth at higher RPMs and jump (causing the feeling of a jolt or **** as it grabs again). Typically, the chain should have no more than an inch or so of play when properly adjusted.

Re assemble the brake in the actuated mode, remove the clutch and sprocket from the saw, now fit the brake back to the saw and use the hand guard to load the brake, now re fit the clutch and sprocket

have you made sure that chain pitch and gauge are the same as the sprocket pitch pitches can be 3/8 lo pro 0.50 gauge

.325 x 0.50 gauge , .325 x 0.58 gauge

3/8 std x 0.50 or 3/8 x 0.58 gauge or 3/8 x 0.63 gauge

you could even have the correct drum but wrong rim sprocket on it

worst case is you could have mismatch bar and chain

make sure that bar adjjuster assy is working correctly

recheck chain / sprocket pitches and bar pitch and groove
gauge

be sure that you fitted chain to rim on sprocket correctly when you fitted bar and chain?

is the clutch cover pulling down tight ?

have a look and let me know if and what you find

cheers paul

Smaller sprockets will only give you about 500 less RPM.

Disconnect battery earth lead. Do not turn crankshaft or camshaft when timing belt removed. Remove spark plugs to ease turning engine. Turn engine in normal direction of ratation unless otherwise stated, Support engine. Remove, engine mounting, auxilliaty drive belts. Water pump pulley 1. Crankshaft pulley bolts 21. crankshaft pully 2. timing belt covers 3. Turn crankshaft to TDC on No 1 cyclinder. Ensure crankshaft sprocket, camshaft sprocket, oil pump sprocket and balancer shaft sprocket timing marks aligned. Timing marks on camshaft sprockets should align with cylinder head upper face. Dowel pins on camshaft sprockets should face upwards. Slacken tensioner bolt. Move tensioner away from belt and lightly tighten bolt. Remove, automatic tensioner unit bolts. Automatic tensioner unit. Timing belt, crankshaft centre bolt, crankshaft sprocket. Crankshaft sprocket guide washer. Slacken blancer shaft belt tensioner bolt. Move tensioner away from belt and lightly tighten bolt. Remove balancer shaft belt.

Installation
Ensuring timing marks arligned. Note timing marks on camshaft sprockets should align with cylinder head upper face. Exhaust sprocket mark is on recess, but inlet sprocket mark is on tooth. Note: to check oil pump sprocket positioned correctly, removing blanking plug from cylinder block. Insert 8mm diameter Phillips srcrewdriver in hole. Ensure screwdriver is inserted 60mm from face of cylinder block. if screwdriver can only be inserted 20mm: turn oil pump sprocket 360°. Insert screwdriver again. Fit balancer shaft belt in anti-clockwise direction, starting at crankshaft sprocket. Slacken balancer shaft belt tensioner bolt. Turn tensioner clockwise to tension belt. Tighten bolt to 15-22Nm. Apply thumb pressure to belt. Belt should deflect 5-7 mm. If not repeat tensioning procedure. Install crankshaft sprocket guide washer, crnakshaft sprocket. Tighten crankshaft cente bolt. Tighten torque:110-130 Nm. Note ensure crankshaft sprocket guide washer is fitted correclty. Oil treads and contact face of crankshaft body before fitting. Check tensioner body for leakage or damage replace if necessary. Check pushrod protrusion is 12mm. If not replace automatic tensioner unit. Slowly compress pushrod into tensioner body until holes aligned. Resistance should be felt. Place flat washer under tnesioner body to avoid damage to body end plugs. Retain pushrod with suitable pin through hole in tensioner body. install automatic tensioner unit to cylinder block. Tighten bolts to 22-27Nm. Fit timing belt in anti-clockwise direction, starting at the tensioner pulley. Slacken tensioner pulley bolt. Turn tensioner pully clockwise to temporarily tension belt. Tighten bolts to 43-45Nm. Turn crankshaft slowly 1/4 turn anti-cockwise. Turn crankshaft clockwise until timing marks alligned. Slacken tensioner pully bolt. Fit tool to tensioner pulley. Tool No 09244 28100. Apply clockwise torque of 2,6-2,8 Nm to tensioner pulley. Tighten bolt to 43-45Nm. Insert special tool in timing belt rear casing. Tool no 09244-28000. Screw in tool until pin can be removed from automatic tensioner unit. Remove special tool. Tool nr 09244-28000. turn crankshaft two turns clockwise. Wait 15 minutes. Ensure timing marks aligned. Check extended length of pushrod is 3,8-4,5mm. Install components in reverse order of removal. Tighten crankshaft pulley bolts, Tighten torque 20-30Nm

Dear Friend
Removal: Support engine: remove -engine mounting, auxiliary drive belt, water pump pulley, crankshaft pully bots & crankshaft pully, timing belt covers....turn crankshaft to TDC on No 1 cylinder, ensure crankshaft sprocket, camshaft sprocket, oil pump sprocket & balancer shaft sprocket timing marks lighned. Pls note: Timing marks on camshaft sprockets should align with cylinder head uppter face, dowl pins on camshaft sprockets should face downwards....Slacken tensioner botl. Move tensioner away from belt & tighten bolt.
Remove: automatic tensioner unit bolts, automatic tensioner unit, timing belt, crankshaft bolt, crankshaft sprocket, crankshaft sprocket guide washer...slacken balancer shaft belt rensioner bolt, move tensioner away from belt & lightly tighten bolt...Remove balancer shaft belt.

Installation:
ensure timeing marks aligned.Note: Timing marks on camshaft sprockets ahould align with cylinder head upper face, exhaust sprocket mark is on recess but inlet sprocket mark is on tooth. To check oil pump sprocket positionded sorrectly: remove blanking plug from cylinder block, insert 8mm diameter Phillips screwdriver in hole. ensure screwdriver is inserded 60mm from face of cylinder block. If screwdriveer can only be inserted 20mm-turn oil pump sprocket 360". Inset screwdiver again.
Fit balancer shaft delt in anti-clockwise direction starting at crandkshaft sprocket....Slacken balancer shaft belt tensioner notl, turn tensioner clockwise to tension belt. Tighten bolt to 15-22 Nm... Applu thump pressure to belt at tentioner, belt should deflect 5-7mm. If not: Repeat tensioning procedure.... Install - chankshaft sprocket guide washer & crankshaft sprocket.
Thighten crankshaft centre bolt, tightening torque:110-130Nm. Please note, ensure crankshaft sprocket guide washer is fittet correctly. oil threads & contact face crankshaft botl before fitting.