Actually, this is on a '84/'85/'87 (parts from all) KLR250 dirtbike, but the top end of the engine is the same, so it doesn't matter. Anyway, I rebuilt my 250, with a bottom end with very low miles, that looked almost new. The cam chain couldn't have even been stretched; the engine cases barely have wear marks from boots on them. My issue is, is that, my cam chain seems to be too long. I can get my timing all set right, but my tensioner can't even tension it; it can't go out far enough. My tensioner is messed up and needs to be replaced, but as far as I can even pull it out, isn't far enough. I thought my guides were not right inside the engine, but they are. The only parts that were changed in those years were the cams. Cam gears are the same. This shouldn't be happening. I cannot figure out why it even is happening. My original engine, an '84, that came in the bike, got antifreeze in it, and had some sort of gunk that ruined all of it's bearings, and it was cheaper to buy another bottom end than replace bearings. I really don't feel like taking the flywheel off again, along with pulling all the balancers to change the cam chain. Any suggestions; ie, what am I doing wrong? If I ever buy a Mojave, since I know the engine well by now, I'm not going to buy one with top end issues. [img]i/expressions/face-icon-small-happy.gif[/img]

Thanks.

 

You have a guide stuck under the head. I did it myself. Make sure that the one on the front of the engine is seated in its slot.

 

I made that mistake when I first put it together, but I got it out, and have the described issues. I'm wondering if maybe, I did something to my guide when that happened. But, I would have broken it, rather than bent it.