Normal to have shavings like this. The drain plug is also a gear case tensioner as you've noticed. You have to loosen the tensioner lock nut and back it out several turns then turn the tensioner bolt inward toward the drain plug untill it almost bottoms out.Then you can loosen the drain plug and pull it out with the tensioner bolt still inside.When you reinstall the drain plug and tighten it, turn the tensioner bolt out until it touches the frame,turn it half a turn more then tighten the lock nut.

 

How exactly does the tensioner work? The bolt moves in and out but I don't see anything on it that would physically adjust the chain. Thanks for all your help by the way. I appreciate it.

 

Doesn't have anything to do with the chain. All it does is brace the gear case to keep it from flexing side to side.They just incorporated this brace into the gear case drain plug.

 

Is there a way to adjust the silent chain?

 

Nope,you have to replace it..Chain is only 38 bucks,but takes more time to tear the gear case out and put back in than it does to change it.Dirt Cheap Yamaha, Polaris, Suzuki & Kawasaki OEM Parts & Accessories – Cycle Parts Warehouse

 

Finally got back to post an update. I ordered a new silent chain. Taking it apart was easier than I anticipated, even easier to get the chain out once inside. Internals looked fairly mint to my surprise. Only has the slightest wear ring on the shift fork (think that's what it's called). My question is what do you guys recommend to seal the casing when putting back together? From what I found researching, there is no gasket. My gear case was leaking a little when I got it before I found out the silent chain was bad. Just want to make sure she's sealed up good. Thanks again for all the help old polaris tech.

 

Three bond 1194,Yamabond,Permatex Motoseal,etc. Almost all of these type products are a gray type case sealer/gasket eliminator. Don't be stingy with it. Coat both sides of the cases. After it sits for a while you can remove the excess with a razor blade.

 

Ok, got the gear case back together and sealed up awhile ago. Just haven't had time to get on here. Works great now. I ran into a starting problem when the temps started dipping over the past week or so. It's gotten harder and harder to start since it's been cold out. Today, I couldn't get it to start. Think it was in the 20's. Anyway, plug is always wet when I pull it. Seems to be getting good spark. Thinking maybe a compression test and leak down. Any other ideas? I appreciate the help.

 

Compression test first. You can have good compression,but if crank seals are leaking it wont matter as it wont crank and will usually just foul plugs. Just eliminate a top end problem first. Anything less than 100 psi on compression isn't good and even 100psi is kinda pushing it as far as minimum compression goes..

 

what's the ideal compression on a new top end?