Author Topic: Is there a plug which fits in the outside of the cylinder under the camchain ?  (Read 202 times)

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Offline cmjp74

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I think mines an xs500 c. I'm losing oil which is running out of a cylindrical hole in the cylinder which is located under the camchain.

The manual doesn't show any hole or plug so I'm thinking there must be a grommet or bung that's missing.

Does that sound right ?

Cheers.

Offline nk140

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From my motor rebuild, I do remember something in that hole.  Let me research.

Offline CrouchyUK

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There's a hole in the front that the camchain tensioner bolt comes out of- cannot think of any others though.  You got a photo of this hole?
1975 Honda CB200T (2) - 1975 Yamaha XS500B (2) - 1976 Yamaha XS500C
1977 Yamaha RD400D - 1977 Yamaha XS500D - 1978 Honda CB550K - 1980 Honda CB400N
1980 Honda CB900FA - 2000 Kawasaki ZX6-RG2 - 2002 Suzuki GSX-R1000K2

Offline cmjp74

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Yep I reckon it's where the cam chain tensioner bolt goes through. I've got a couple of photos but can't seem to upload them from my iPad.
It looks like someone took the cam chain out and put it back minus the adjuster bolt.

I've got a Haynes manual which doesn't mention what the bolt / mechanism looks like or how it's fitted. Can you point me in the right direction please ?

Offline CrouchyUK

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Hopefully if you look or probe into that hole you will see the sheared off end of the tensioner bolt.  It's a common failure- gets over-tightened and the bolt snaps under fatigue.  The dome nut bottoms out before the camchain slider is clamped- solution is to add an extra washer, but peeps just keep tightening until the bolt snaps.

If you cannot see anything in there- then it has dropped into the engine.  Not good.  I wouldn't be running that engine until what has happened is investigated.

« Last Edit: June 23, 2018, 07:56:13 PM by CrouchyUK »
1975 Honda CB200T (2) - 1975 Yamaha XS500B (2) - 1976 Yamaha XS500C
1977 Yamaha RD400D - 1977 Yamaha XS500D - 1978 Honda CB550K - 1980 Honda CB400N
1980 Honda CB900FA - 2000 Kawasaki ZX6-RG2 - 2002 Suzuki GSX-R1000K2

Offline cmjp74

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I've just had a look, no trace of any sheared bolt. Bugger.

I've done about 30 miles on it since noticing the leak / missing bolt. Is it an engine rebuild needed ?

Offline cmjp74

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The part that's missing is what's circled in the photo. Is that the adjusting bolt we've been talking about ?

Offline CrouchyUK

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No- the camchain adjuster bolt/nut is at the front of the engine.  The camchain adjuster is the mechanism located vertically RHS of your image.

Are you sure this bike is a C?  What is the engine number- as this looks like the 2 piece early head and they had a cap head under that hole that was part of the fixings that held the cam box to the head.  The hole then had a rubber cap pressed in.....
« Last Edit: June 24, 2018, 10:53:27 AM by CrouchyUK »
1975 Honda CB200T (2) - 1975 Yamaha XS500B (2) - 1976 Yamaha XS500C
1977 Yamaha RD400D - 1977 Yamaha XS500D - 1978 Honda CB550K - 1980 Honda CB400N
1980 Honda CB900FA - 2000 Kawasaki ZX6-RG2 - 2002 Suzuki GSX-R1000K2

Offline cmjp74

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Engine number 371-208829

It's got disc brakes front and back registered on a w plate 1981. I looked up the vin and pretty sure it said it was a 'C'. I'll check again.

It's obviously been fiddled with as all fixings are stainless, braided hoses, powder coat is mint etc so a good chance it's Heinz 57 varieties.

Offline cmjp74

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Ps- yes there is a cap head under the hole that screws vertically down, it seems that the hole is there to give access to screw / unscrew it as there's not enough room to get an Allen key in the recess between the fins.

Offline CrouchyUK

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That's an interesting bike you have there then?  371-208829 is a 1975 model year XS500B engine- first year we got the TX/XS500 here in the UK?  Most were registered on an "N" plate.  XS500B was the last of the classic styled bikes with the 2 piece head.  UK bikes were unique in that they got the "FS1E" style back light and twin front disks.  Back brake was a drum though...

I'm guessing you have a different frame number- maybe indicating the bike has been re-engined in the past? For our bikes frame and engine number were always the same.

The plug you are missing is part number "90338-16003-00 PLUG, SPEC''L SHAPE" - item 10 on this diagram....

1975 Honda CB200T (2) - 1975 Yamaha XS500B (2) - 1976 Yamaha XS500C
1977 Yamaha RD400D - 1977 Yamaha XS500D - 1978 Honda CB550K - 1980 Honda CB400N
1980 Honda CB900FA - 2000 Kawasaki ZX6-RG2 - 2002 Suzuki GSX-R1000K2

Offline cmjp74

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Great, thank you. Your time is very much appreciated.