[Paul_42]

Hi everyone, ive caught what I believe to be primary chain slap/ auto tensioner on way out. Bike has only travelled 12.3k km. It's at the dealer at the moment hopefully being pulled apart tomorrow(Wednesday), now I don't trust the dealer as far as I can throw him. Previous issues/ warranty. At 4K km the gearbox left me stranded on the side of the road. The Paul Spring let go and was told this was why I couldn't select any gear. Thoughts whether this first breakdown was a catalyst for what's happening now, will post photos if I'm calked when bike is stripped but will post once I find out what's what.
Cheers
Paul.

[gizzo]

What are the indicators that make you think it's on it's way out? I'd look for the same in mine if I knew. I have pulled that cover off a couple times after the report of the primary chain breakages and reset the tensioner because the chain felt super tight. But it just tightened right back up again. A manual tensioner would be a smart modification for those of us that know how to adjust a chain. I wouldn't imagine a pawl spring in the shift mechanism breaking would have any effect, unless they left a bit floating about in there to jam something up. But, who knows? Be interested to hear the result. (You know, you're probably just as qualified as the dealer to R&R that cover. it's a snap).

Otto, do you have a part number for your better quality replacement primary chain?

[Paul_42]

Simon, its a weird ass knocking/ almost slapping noise directly where the gear lever shaft is . Sounds like something is bouncing around inside the case.If it wasn't under warranty I would of stripped it down to have a sticky beak. A manual tensioner would be a lot better if they do one for our Conti.

[gizzo]

That doesn't sound promising. But at least the chain is still inside the engine. That's nice. Good luck mate. I don't reckon a manual tensioner would be hard to make, with the right tools. Anyone listening? 

[longstrokeclassic]

I've replaced the auto tensioning spring with washers in the past.
Every couple of thousand miles I'd check if another washer was required to reduce the slack.

[mathewmerrin]

This is really ridiculous of Royal Enfield, I have come across as many as 10 cases of primary chain breakage on various forum's and FB.The bike is just too delicate to ride.Why don't they give a permanent fix or at least do a factory recall.

I wrote to Royal Enfield India some time back about the situation, they were least concerned.

Maybe we can find a permanent fix why this happening or the root cause of the problem.

[gashousegorilla]

Simon, its a weird ass knocking/ almost slapping noise directly where the gear lever shaft is . Sounds like something is bouncing around inside the case.If it wasn't under warranty I would of stripped it down to have a sticky beak. A manual tensioner would be a lot better if they do one for our Conti.

  Don't ride it !   Remove the left side cover and see if the bolt came out which holds the sprag gear in place on the shaft.   THAT has happened a bunch of times on UCE  Engines.     

[gizzo]

see, I couldn't remember for the life of me why I pulled the cover off the second time, other than that I checked the tensioner while I was in there: it was to check the clutch hub nut and sprag bolt. my bolt wasn't loose, but it wasn't very tight, either, now I think about it. thanks GHG, you rock.

[gashousegorilla]

  That one scares me in particular giz.     Seen some ugly pictures of where that bolt winds up,  getting thrown around in there along the chain, possibly getting drawn in between the chain and the gear's teeth and spit out and etc. ...Spit out if your lucky !   Feck it... very easy to check just to make sure I say.

[Paul_42]

Thanks gashousegorrilla, bout to head out to the shop to see where they are at and what's going on. I will tell them about the sprag gear bolt and see what eventuates. Maybe I should pull my other one apart and check it as well. Thanks for the brainstorming guys.
Paul.

[gashousegorilla]

  Here is one of the examples of it happening....

https://forum.classicmotorworks.com/index.php/topic,19974.0.html

[Paul_42]

Awsome link. Thanks. Mechanic didnt like me snooping and all i got out of the young guy before he got the stare from the other mechanic to shut up  was a loose nut and thatwas it so far. Will wait and see and will report once i get everything.....if im told anything else.

[gashousegorilla]

  Well, if it does turn out to be a "loose nut" ?   OR...  THAT bolt .  You may want to remind them that the  HARDENED bolt should now be torqued down to 50 ft lbs. instead of 35 ft lbs. after applying Red loctite 270.   

[Paul_42]

Will do, thanks heaps gashousegorrilla. My yellow one just had its 15k km service inspection today as well. She said it's the highest km one they have had for only 11 months of age.I just laughed thinking with my quiet voice that's because they all farkn blow up before those km's. 

[gizzo]

Haha ouch!

Or the dealer drags their heels so much when something does need fixing that they don't have a chance to be on the road. Touch wood, we got good ones. 25,000km, me.

[Otto_Ing]

That doesn't sound promising. But at least the chain is still inside the engine. That's nice. Good luck mate. I don't reckon a manual tensioner would be hard to make, with the right tools. Anyone listening? 

Will make a small batch once the season is over and time for hobby projects starts. The chain was so tight in my engine that maybe 0.1234hp can be freed with an manual tensioner. 

My cluch nylock nut was loose too when I changed the primary chain for an IWIS/Elite. HMC got them listed.

[gizzo]

thanks otto. ifyou decided to make them, put me on the List?

[Paul_42]

Please throw me in on that list too otto.

[Guaire]

thanks otto. ifyou decided to make them, put me on the List?

As well.

[Good Vibes]

The slapping sound you describe could be a lose main chain.  When too loose, the bottom loop of the main chain slaps against a small lug on the frame immediately behind the gearbox.  I had that at one point while fiddling around to get the tension correct, which is not easy.  Worth a look.

[Paul_42]

Gizzo. Thats awsome k's. Hopefully by Jindy ill be around those figures and trouble free on mine.

[gizzo]

does that mean you're planning to do Jindy next year? that'd be sweet! not sure yet whether I'm going to make it, depends on whether a family holiday happens or not. if not, seeya there. awesome and beautiful ride.

[Paul_42]

Yep,sure am    only thing that will stop me will be my youngest starting yr7 and working around that. I am chomping  at the bit to get down. After looking at the after thread of Jindy. Your right, those roads look amazing. Kool.

[Narada]

I retorqued and red loctited my sprag bolt, then retorqued and blue loctited clutch nut on my 2015 C5 UCE as preventative maintenance...just in case.

FWIW my bolt had some some kind of black loctite / glue on the threads. I don't think they all do.

[Paul_42]

Update guys and gals. Engine is almost out of frame. Been told by dealer RE wont approve any warranty till they find issue which dealer thinks is a bad bearing in gearbox now. If thats the case and the pawl spring snapped i think it was 4.5k km. Hmmmmm.

[gashousegorilla]

  That certainly sucks.  Hope it works out for you Paul.

[Paul_42]

Thanks mate. Will post back up.once i find out whats happened.

[gavinfdavies]

My primary chain snapped at 7,500 miles, exited via the front of the casing. Oddly, since the front crank cog wasn't obstructed, the engine carried on ticking over nicely, with me watching through the hole! Engine replace under warranty, but took two months, during which time I bought another bike. 12 months later I still haven't quite got round to selling the GT, although I have since paid off the finance. Might end up keeping it and finishing the mods on it!

[Paul_42]

Just a quick update guys and gals. Crankshaft and needle bearings to be replaced. Warranty work apparently only just got approved yesterday by RE. Dealer says bearing over crank was a bit loose?? Hence the replacement, why they don't replace the whole engine I don't know. I will post back when I find out more.

[dginfw]

Just a quick update guys and gals. Crankshaft and needle bearings to be replaced. Warranty work apparently only just got approved yesterday by RE. Dealer says bearing over crank was a bit loose?? Hence the replacement, why they don't replace the whole engine I don't know. I will post back when I find out more.

It does seems like the labor cost to R&R a motor would be less than rebuilding one...maybe they don't have too many spare 535s around and getting one might take a while

[Paul_42]

Maybe dginfw, as long as it doesn't drop another bearing or piston next it should be ok.

[serpico]

As well.

And me please

[Paul_42]

Come on RE. Bike still in shop( August 9th) and still waiting for new flywheel and bearing from India???

[gizzo]

maybe they're going to stall you until the warranty runs out....

[Paul_42]

Lol, would love them to try and keep the bike in there for 12 more months. Got 2 year warranty on the sucker. 12 months parts and labour and 12 months parts only. But the biach had that Spring go on the gearbox after 6 months. Told dad he can have my yellow beast and I'll trade his in and get my Daytona

[gizzo]

Yup, they're not doing the brand any favours, for sure. Maybe they don't realise yet that the only reason a person would buy a RE is because they want to, and there's lots more bike available for the money from other brands. Good luck.