Author Topic: Help me remove a stuck cam chain tensioner 1977 CB550 F (Read 6099 times)

Michael Wilson · « **on:** April 11, 2011, 11:23:34 AM »

OK I've come across a problem in my build. I've got a 1977 CB550 F. I need to replace the cam chain tensioner. The top fastener came out with out a problem. The lock nut on the bottom bolt is stuck and the slot in the bolt is stripped so I can't get any tension on it to un lock it. The whole unit spins freely and I just can't get the darn thing off.

Should I just cut the nut off the bolt (its very small and would be a delicate job)?
Or should I just cut through the entire bolt at the base near the washer?
Or should I drill it out?

I have no idea what will get this little sucker out so I can replace the part. I am open to any suggestion short of using a flame thrower.

Michael Wilson · « **Reply #1 on:** April 13, 2011, 06:24:29 AM »

[BUMP]

turkey2143 · « **Reply #2 on:** April 13, 2011, 06:46:01 AM »

try taking a picture of it so one of us can get a better idea on what would be possible

turboguzzi · « **Reply #3 on:** April 13, 2011, 07:21:37 AM »

if the bolt + nut turn freely then the little rack and pinion gear inside is shot,

would cut across the face of the nut and bolt with a dremel disc so that essentially you are splitting the nut into two halves, a bit like you do with a nut splitter.

you will obviously have an easier time if you remove the cyl block.

Oddjob · « **Reply #4 on:** April 15, 2011, 06:10:59 PM »

The nut spinning means the cam inside the tensioner is either shot or it has become disconnected from the rachet bar it connects to. Either way you have 2 choices, you can try this first as it may work, try holding the nut with a ring spanner, use a screwdriver to hold the screw, see if that means you can now remove the nut. If it doesn't and I suspect you may have already tried this then the simplest method is to cut the nut off just behind it, try to keep the cut tidy and file any areas sticking off the thread afterwards or it may jam inside the barrel hole. You should then be able to just push the rest of the bolt through the hole and disengage the tensioner, I'd keep what's left myself as you never know if a part might come in useful at some later date.

Michael Wilson · « **Reply #5 on:** April 19, 2011, 03:17:30 PM »

Here are some photos. I started cutting laterally thru the face of the bolt and nut.

But I think I woiuld be better off cutting thru between the nut and washer as seen here.

Thoughts? Anyone actually performed this procedure before and have some good things to keep in mind?

Oddjob · « **Reply #6 on:** April 19, 2011, 05:26:57 PM »

Cut between the nut and the washer, I've done this a couple of time on various bikes, it's far simpler and usually neater, doing it vertically like in the pic can mean the bolt spreading a little which makes it hard to push through the tunnel in the barrels.

Hush · « **Reply #7 on:** April 20, 2011, 02:59:28 AM »

Yep what Oddjob said, that's how I would do it.

Michael Wilson · « **Reply #8 on:** April 20, 2011, 07:45:35 AM »

Thanks guys. I will give that a shot on Saturday.

minimo · « **Reply #9 on:** July 16, 2012, 02:25:44 PM »

Thanks for this info! I ran into the same problem recently with my '77 CB550. Part of the flathead tensioner screw snapped off and I thought I was stuck because the idea is that you turn the screw clockwise to loosen the tensioner... rendering my Grabit Pro extractor tool useless. I will try to cut off (Dremel) between the nut and washer.
Any success your end?

Michael Wilson · « **Reply #10 on:** July 16, 2012, 02:31:16 PM »

I haven't finished and turned it on yet. I did get the chain tensioner replaced complete. I cut the sucker off.

minimo · « **Reply #11 on:** August 03, 2012, 10:27:38 AM »

Was able to pull the tensioner out utilizing the Dremel method - cutting the bolt off between the nut and the washer - and pried the backing cover to get to the bolt...

I noticed that the groove peaks on the tensioner are slightly bent; I can bend these back so they're semi-straight... Nevertheless, I'm still stuck with a bolt that I had to cut off and I can't find a replacement part for just this bolt

Seems I may have to replace the entire tensioner which nobody seems to have in stock... Any recommendations?

Michael Wilson · « **Reply #12 on:** August 03, 2012, 10:43:41 AM »

I was lucky enough to find one at my buddies garage. They are hard to come by. I don't know what to do about the bolt. Maybe someone can make you a knew one from scratch.

Fritz · « **Reply #13 on:** August 03, 2012, 10:46:59 AM »

I could still get the complete chain tensioner over here. But it would cost $250.
If you are confident that you manage to repair the teeth of your old tensioner, you should bring that bolt to a machine shop. They can weld a mild steel rod to it. Then cut it to the correct length, file or grind it smooth and cut a new thread on it. It's easy and will cost you next to nothing compared to the new tensioner.
On the other hand, you might want to replace the slide, which is at about $100, I think

minimo · « **Reply #14 on:** August 03, 2012, 11:01:59 AM »

Thank you, Michael and Fritz. Response time on this forum is amazing! Thank you!
Fritz, I'm afraid $250 is a bit steep. But I like your idea of machining/welding the part... keep you all posted on the results of this darn tensioner...

LesterPiglet · « **Reply #15 on:** August 03, 2012, 11:03:49 AM »

I had this same problem years ago and was wondering what you were going to do after cutting that bolt. Luckily I managed to fix mine without cutting.
DSS has new tensioners but I wouldn't pay that price for one unless it was my very last option.

minimo · « **Reply #16 on:** August 04, 2012, 02:15:24 AM »

Anyone know if this tensioner (from a '72 CB500) would fit a '77 CB550?:

minimo · « **Reply #17 on:** August 04, 2012, 02:55:42 AM »

...or even one from a '73 CB500?:

Fritz · « **Reply #18 on:** August 04, 2012, 06:00:01 AM »

Yes, Honda part no. is 14500-323-000 and it fits all CB500 Fours and CB550 Fours of all production years.

minimo · « **Reply #19 on:** August 06, 2012, 09:41:48 AM »

Quote from: Fritz on August 04, 2012, 06:00:01 AM

Yes, Honda part no. is 14500-323-000 and it fits all CB500 Fours and CB550 Fours of all production years.

Very useful info, Fritz. Thank you.

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Author Topic: Help me remove a stuck cam chain tensioner 1977 CB550 F (Read 6099 times)