Final Drive leak and cam chain tensioner warranty replacement

[tjhess74]

Well, as the title aptly states, my final drive started leaking on my 08 with 80k miles on the clock.  I took it into the dealer for the repair, as a good customer should.  Of course, this happens in the height of the repair season, so two weeks just to look at it!  I also had them take a gander at the cam chain tensioner.  It can take up to 2 minutes to build pressure sometimes, and lo and behold, it actually did that for them when they started it!  So, all told, the final drive seals are getting replaced as well as the tensioner, under warranty.

I know, I know, "get the APE manual tensioner" they say...I will, I promise...when this new unit bites the dust long after the warranty has expired!    I have a serious issue with buying replacement parts when the warranty covers them.

Now, If only I can get these guys to fix my cold weather, no-pressure clutch issue before the warranty runs out in May...

[gPink]

....but it'll be warm in May...Seriously. I've not heard of cold weather clutch issues. Have you mentioned this before?

[VirginiaJim]

What does the clutch do in cold weather?  That sounds interesting.  That's roughly the mileage I have on mine but I don't have those issues.  I'm thinking either clutch fluid, oil viscosity, clutch plates, or cylinder issues (master/slave)...

[Deziner]

 

[zarticus]

Mine was doing the same this past winter in cold weather. Flushed the fluid & instantly like new 

[angelo]

Way to get your money's worth on the warrantee. 80k and still repairs. Nice

[lather]

I am at 165,000 miles on my 08. The cam chain sometimes takes 30 seconds or so to stop rattling. I have purchased the APE manual tensioner but have not installed yet as not sure  how to set it.

I also am wondering if the cam chain eventually stretches to the point that a new tensioner or a manual tensioner will not work and if I should replace the chain. I don't have a warranty.

[tjhess74]

Well, I finally got the bike back! Rear end doesn't leak and the cam chain tensioner makes no noise...at all, ever! I'm so used to it clattering for a while, that it's strange to hear nothing.

I assume it's the new tensioner, but the bike has a supercharger/cam gear whine sound now under 3k rpms. It's very subtle and kinda sounds bad ass.  I'm glad it's back and I'm glad it was covered under warranty.

[tjhess74]

I apologize to those that asked about my clutch issue, I overlooked those questions.

When the weather gets cold, the clutch will have no pressure.  The longer it sits (overnight, etc), the less pressure it has.  As the engine warms up, the pressure begins to come back.  That rules out the master cylinder and clutch line, but points the finger at the slave cylinder.

There is a leaking seal in there that allows engine oil into the slave cylinder and prevents it from operating properly.  Somehow, bleeding the clutch is a temporary bandaid. It's done it since it was new.  In 2013, the dealer FINALLY listened to me and replaced a seal in the slave cylinder.  It was fine until last winter and started doing it again.

I pulled the slave cylinder myself and was bathed in oil.  A lot came out, plus there was a ton of 'gunk' in there.  Once that pressure was released, it worked fine the rest of the winter.  I took the pictures back to the dealer and they said something is causing that seal to fail, possibly a manufacturers defect.  They won't know until they get in there, but won't do it until it happens again since I'm not paying shop rates...that's what the warranty is for.

[Daytona_Mike]

Well, I finally got the bike back! Rear end doesn't leak and the cam chain tensioner makes no noise...at all, ever! I'm so used to it clattering for a while, that it's strange to hear nothing.

I assume it's the new tensioner, but the bike has a supercharger/cam gear whine sound now under 3k rpms. It's very subtle and kinda sounds bad ass.  I'm glad it's back and I'm glad it was covered under warranty.

That bothers me. I had a brand new tensioner  installed under warranty and it still made noise on startup. With less than 5 miles on the new tension er  I replaced it with a manual APE .
Yours sounds like it maybe way way too tight causing that whine. If that is the case that can be a very bad thing.

[maxtog]

Yours sounds like it maybe way way too tight causing that whine. If that is the case that can be a very bad thing.

That is a good point/idea.  If too tight, it might make exactly that type of sound.

[VirginiaJim]

I've also seen reports of the star spring breaking..  Not sure of the symptoms with that.

[MAN OF BLUES]

TJ
You should have gotten an itemized printout of everything they did during this service, computer printout, with all the service codes, labor hours, and every part used and replaced during this warranty repair.

Please go ov that sheet, and see exactly what part numbers they installed, I'm wondering if they installed the correct tensioner, or if they installed a ZX one, which doesn't have the oil pressure assist.. id be very curious to see the list of parts. I know my dealer supplied me with a complete printout of all the service that was reported to Kaw, you are supposed to get a copy, and sign a copy aknowledging you received it, and the work order was completed.

[tjhess74]

MOB, there were two parts for the cam chain tensioner job listed on the invoice., job code 0320, .8 hours
1. Tensioner-assy, hydrau P/N 12408-0047
2. Gasket, Tensioner P/N 11061-9=0299

I want to clarify, this whine noise is very subtle, but definitely new. If there are incorrect parts, then they will rectify it. If the engine grenades, daddy gets a new engine! I'd start over on my valve adjustments though, and that's no fun...

[Daytona_Mike]

12408-0047 That is the correct tension-er.

[MAN OF BLUES]

MOB, there were two parts for the cam chain tensioner job listed on the invoice., job code 0320, .8 hours
1. Tensioner-assy, hydrau P/N 12408-0047
2. Gasket, Tensioner P/N 11061-9=0299

I want to clarify, this whine noise is very subtle, but definitely new. If there are incorrect parts, then they will rectify it. If the engine grenades, daddy gets a new engine! I'd start over on my valve adjustments though, and that's no fun...

Good deal.

[tjhess74]

Ok, that's good to here, thank you.