Super Tenere Cam Chain Tensioner Failure

airheadpilot

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A couple of weeks ago I went to hop on my 2012 Super Tenere (54K miles) to ride home from school. I hit the start button and it fired for a few times and then abruptly died. Bummer. Tried again - nothing. Tried WOT - nothing. Tried letting it sit for 20 minutes - nothing. Tried roll-starting it on a hill - nothing. Tried every combination of starting routines that I could think of doing in a parking lot with no tools, basically until the battery was dead. Solid cranking, but not one single combustion event. As the battery grew more dead, it displayed the "14" error code on the dash, but I think that has more to do with the dying battery than anything else. In the end, my buddy came and rescued me and took me and the bike to my dealer. I was thinking fuel pump, TPS, or some other EFI failure.

Last Friday, I got a call from the dealer. They had a hell of a time diagnosing the problem. The bike's computer didn't tell them anything revealing, the EFI system seemed to be fine, the bike had spark, etc. It was only when they took the valve cover off that they realized the problem. The cam chain had jumped a few teeth on the sprockets and the cams were out of phase with the crank. What's more, this had resulted in piston-on-valve interference and I now had bent valves. I'm looking at a complete top-end rebuild and many pennies.

The bike is out of warranty. Of course I didn't spring for the Y.E.S. coverage - it's a Yamaha, not a BMW after all. The service manager asked me what I wanted to do. I told him to fix it. I figure that, whatever I decide to do next, the bike is worthless to me broken. If I decide to sell it, I want to be able to say that it's totally fixed and in good condition. He's going to work with Yamaha to see if they'll cover some or part of it. He's had some luck with them doing that in the past for "shouldn't have happened" failures, even when the bike is out of warranty. As of this writing, no word yet on the total repair estimate or timeline, and no word whether Yamaha is going to chip in, and for how much.

I've taken really good care of this bike. It hasn't been babied - it's my year-round do-everything commute and touring bike - but I rarely run it to redline or excessively lug it, I change the oil and filter on schedule religiously, and it gets every maintenance on time and in full. I always let it warm up a little when it's cold before riding away - at least until the "LO" on the temperature gauge changes to a numerical value. When I had it in for the 50K service, it got a clean bill of health. I have been noticing over the last few thousand miles that, when cold, sometimes there would be a little cam chain clatter on start-up for one second, then go immediately away once the oil pressure came up and the tensioner did its thing. The consensus from both the dealer and what I've read here and elsewhere on the Interwebs is that, as long as the clatter goes away immediately there's nothing to worry about. It would seem that is not the case.

The thing is, I feel kind of let down. Not by my dealer - they have been a fabulous shop in the sales, parts, and service departments. But by Yamaha. Of all the motorcycles I have owned, I've purchased exactly two brand-new from a dealer. Both were Yamahas and both were higher-end, expensive models that were intended to be Yamaha's attempt at "flagships" in their respective classes - my 2005 FJR1300 and my 2012 Super Tenere.

The FJR was a fantastic motorcycle. Other than a rear shock when the stock one wore out, I never made any performance modifications of any kind; probably the only motorcycle I can say that about. It was everything I wanted in a sport-touring motorcycle, and I only sold it because I wanted something a little more nimble for my urban commuting and I wanted something a little more open to exploring unpaved roads and dealing with the East Bay's pothole-infested roads. But it was a ticker. Around 45K miles, it started developing the ticking that some of the 2005's became known for - caused by faulty valve seals that caused the guides to wear out and the valve stems to wobble around in the head. I ended up needing an entirely new cylinder head, which Yamaha covered every penny of despite the bike being out of warranty, which was awfully nice of them. Still, between the negotiations with Yamaha, waiting for parts from Japan, and the actual shop work time, I was without my bike for nearly six months. I thought that every manufacturer is entitled to slip up occasionally and that was the exception that proved the rule, if you will.

While I like the Super Tenere a lot, it has not been as good of a bike as the FJR was in its particular market segment. The suspension was pretty good, but not as good as I thought a full-size adventure bike should be, and I ended up upgrading both the forks and the shock. The fuel injection was really disappointing, however. The throttle-by-wire was really abrupt and jumpy, and it surged right where I wanted to cruise on the freeway. At the time the ECU re-flashes weren't available yet, so I went with a full Arrow exhaust system and a Power Commander V with Autotune. That helped a lot, although it still surges sometimes at slow speeds, mostly at the transition between on-throttle and off-throttle, which is annoying. Plus the Arrow muffler is pretty loud, and I wish it was quieter. All in all, I was a little disappointed that I had to spend a few thousand more to get the bike as good as I wanted it to be off the showroom floor, but I consoled myself with the knowledge that at least it was a Yamaha and would go for 200K miles as long as I took care of it. And now this.

I honestly don't know what I want to do with the bike when I get it back. Some of that decision will probably be influenced by how much I have to pay out of pocket for the repair. I'm unemployed right now while I'm going back to school full time, and a several-thousand dollar repair bill is really going to hurt my savings. But even if Yamaha elects to pick up the bill, I'm not sure whether I will still trust the bike or not. I'm wondering if I really need shaft drive, 100-hp, traction control, and all the bells and whistles, and I'm looking at the new KLR650 with its reputation for bulletproof reliability (not to mention a carburetor!) and thinking that might be all I need after all, at least for the time being while I'm a student.

I'm not really looking for help here, although I'm happy to read your opinions, and I'll keep you updated on how it turns out. But I wanted to share at least, and if you start hearing cam chain slap on start-up, you might want to take it in right away and have the tensioner replaced, even if it's not due for a service yet.

Andrew
1972 R75/5
1983 R80ST
2012 Super Tenere
 

Ironhand

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That really sucks. I worked at a Honda/Yamaha shop for about 10 years and saw them make a lot of out of warranty exceptions for people. Good luck. Hopefully they treat you right.
 

avc8130

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I've been waiting for the reports like this to start. My Tenere is knocking on 40k mile's door and it has been a noisey starter for longer than I've felt comfortable. Most seem to call it "normal", but I understand what is happening and it concerns me.

I know Yamaha has been concerned also as they came out with a new tensioner for 2014 and show it as the proper replacement for the 12/13s also.

Keep us posted. Hopefully, nothing was damaged as the chain slipped. If you didn't hear any crashing and bashing you are probably "ok" as far as valves becoming intimate with the pistons. Most likely a new tensioner and you will be on your way. That new tensioner is $135 plus gasket and labor.

EDIT: Just re-read your massive post. I see you said they found piston/valve love. That's not cool. This happened to another member. I think he was in close to $2k by the time it was all fixed.

Good luck!

ac
 

avc8130

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Somewhat. Mine is much more pronounced than that and stops after ~10 seconds. I'll try to get a video next time I start the bike. It is worst after the bike sits over night.

One thing that is VERY important: DO NOT rev the engine if it is making clicking/clacking cam chain noise. Let the oil pressure build and the noise subside before even considering any throttle input. Lots of guys don't understand it, but cam chain drive is quite a crazy world. It really isn't that difficult for things to go very wrong, very quickly.

ac
 

Koinz

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Hard to believe that the tensioners at fault for the chain jumping a tooth. Once the tensioner is released and extended, it can't be pushed back in, so the clearance is minimal. 8)
 

avc8130

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Koinz said:
Hard to believe that the tensioners at fault for the chain jumping a tooth. Once the tensioner is released and extended, it can't be pushed back in, so the clearance is minimal. In my opinion it's not enough clearance to cause the chain to jump. 8)
I agree, but this guy might be living proof.

With the slapping noise it makes at startup, that chain is pretty darn loose until the oil pressure builds.

What we have is a spring pushing on the chain guide. There is a ratcheting mechanism of sorts to prevent the plunger from retracting once it has extended. The oil pressure provides the damping to the system between ratchet "clicks".

I wouldn't imagine Yamaha (or whoever did the design for them) would have had the ratchet "clicks" far enough apart to allow the chain to jump a tooth...but you never know.

If you do a Google search for cam chain tensioner issues you will find this is one of the most common issues across the board for any chain driven OHC engine...bike, car, anything. Cam chain drive is a nightmare.

ac
 

MarkM

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avc8130 said:
If you do a Google search for cam chain tensioner issues you will find this is one of the most common issues across the board for any chain driven OHC engine...bike, car, anything. Cam chain drive is a nightmare.
Yep, this all sounds very familiar. On my 1995 BMW R1100RS I upgraded the left cam chain tensioner to a newer design due to a similar issue. Problem solved. I hope the 2014 CCT works great because that's what I'm aiming to buy.
 

k woo

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Andrew, thanks for posting.

Your problem prompted me to get mine replaced before my yearly coast to coast run. My Tenere has 45,000+ miles and rattles at almost every start if it has been sitting for more than a hour. My dealer had the updated part #, said he saw tensioner problems on R1's and other models. My cam chain will be replaced only if needed.

Kent 8)
 

EricV

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Koinz said:
Hard to believe that the tensioners at fault for the chain jumping a tooth. Once the tensioner is released and extended, it can't be pushed back in, so the clearance is minimal. 8)
If the tensioner is working properly, that is.

I have the same issue with my '12 at 82k. It's under warranty though. Hopefully we are not competing for limited parts resources. :-[ Mine has been torn down, but is in review still with Yamaha as to what they will authorize in terms of parts replacement and repairs. Took a week to get approval from Yamaha to tear it fully down. It's been almost a week now, waiting for the next step.

As far as I'm concerned, this is just a CCT issue. No reason to suspect the bike will fail again. Though I'll be more sensitive to the CCT noise.

FWIW, the FJR was easier to hear it getting worse. The S10, once it pressurizes, goes quiet, even if it's having issues. So it's most noticeable during cold start ups, and especially after an oil change when it takes a few seconds longer to build oil pressure.
 

longride

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Pretty simple here. A cam chain tensioner is certainly a wear item like tires, clutches, brakes.......you get the point. To say that 'Yamaha' let you down after hearing cam chain noise and doing nothing is stretching the truth. Actually, you let the bike down by not changing out a worn out item that you knew was going bad. Since all wear items wear differently for different bikes and riders, it's up to the owner to know when to change these things, or things like this will happen. For about 130 bucks, you could have changed the CCT and been done with it. Just like when a clutch is acting up, or brakes squealing, or tires are affecting handling, a little common sense goes a long way to avoid disaster.

Oh, and the new KLR you are looking at? It needs the doohickey changed out pronto, or it gets lunched and metal pieces are scattered through the motor. You also need to check the valve lash right out of the factory, because you could have a tight one and burn a valve. I know. I had a 2010 KLR and avoided both those problems by attending to them before they turned my engine into a paperweight.
 

scott123007

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longride said:
Pretty simple here. A cam chain tensioner is certainly a wear item like tires, clutches, brakes.......you get the point. To say that 'Yamaha' let you down after hearing cam chain noise and doing nothing is stretching the truth. Actually, you let the bike down by not changing out a worn out item that you knew was going bad. Since all wear items wear differently for different bikes and riders, it's up to the owner to know when to change these things, or things like this will happen. For about 130 bucks, you could have changed the CCT and been done with it. Just like when a clutch is acting up, or brakes squealing, or tires are affecting handling, a little common sense goes a long way to avoid disaster.

Oh, and the new KLR you are looking at? It needs the doohickey changed out pronto, or it gets lunched and metal pieces are scattered through the motor. You also need to check the valve lash right out of the factory, because you could have a tight one and burn a valve. I know. I had a 2010 KLR and avoided both those problems by attending to them before they turned my engine into a paperweight.
You're talking out of your ass dude. You don't get to decide what is a wear item or not, the maker does. It doesn't have to be checked periodically according to the service schedule. Wear items do. Modern day cam chains and tensioners should easily go minium 100 -200 thousand miles if they are designed correctly.
 

EricV

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longride said:
Pretty simple here. A cam chain tensioner is certainly a wear item like tires, clutches, brakes.......you get the point.
<snip>
Actually, I'll be more tactful, (which is un-common for me), but when you find the maintenance interval for the CCT, let us know. Until then, it's not a "wear item".

This motor has a very long cam chain, relative to most other types of motors. The FJR's cam chain tensioner, when going bad, would rattle to beat the band at idle, go quiet when you gave it throttle, then get loud again when the engine returned to idle. The S10, OTOH, only rattles on start up, then goes quiet, even when it's got some major issues. That makes it more difficult for both owner and dealer techs to listen to it and say if it's normal or in need of attention. And I can tell you, only a fool and a damn fool tries to "re-tension" a CCT, regardless of if there is a procedure for it in the service manual. I know of at least three FJR engines that grenaded from doing that. In the FJR's original design, the internal spring was often broken, so it was never going to be re-set by following the re-tensioning procedure.

Good on you for catching known issues that you probably read about before dealing with. There have only been a hand full of CCT replacements on S10s so far, and even fewer failures.
 

autoteach

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After the clatter that I had from mine, I would say that it has failed. I did, however, ride 700 miles after the fact. I do have the new tensioner, and it is going in before the bike sees any more riding.
 

BWC

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http://www.yamahasupertenere.com/index.php?topic=11572.msg190059#msg190059

For anyone who might have missed this bit of info. I posted regarding changing out my cam chain tensioner on my 2012 for the 2014 2BS model unit.
Its been installed now about 8000 km (bike just coming up on 70,000 km) and I can report that since its been done there has been no more chain noise on start up hot-cold or after sitting for awhile. With the cam chain itself priced at about $25.00, I intend on replacing it and the chain dampers if needed when the mileage gets a bit higher at a valve adjust.
 

Big Blu

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scott123007 said:
You're talking out of your ass dude. You don't get to decide what is a wear item or not, the maker does. It doesn't have to be checked periodically according to the service schedule. Wear items do. Modern day cam chains and tensioners should easily go minium 100 -200 thousand miles if they are designed correctly.
+ 1

What he said!

Paul
 

Karson

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avc8130 said:
Here is a video of my bike starting. 37,500 miles. Fresh 15w50 synthetic. The bike had been parked for ~2 hours.

https://www.youtube.com/watch?v=JrQH3g4BRJI&list=UUxbOlxpK-dt5luqX4rVO09A

I'll take a new video this morning after the bike has sat ~14 hours overnight.

ac
Definitely more pronounced than the video I posted earlier. Wonder if it lasts longer now that all the oil has drained back overnight...

Has anyone inquired with their dealer on using Y.E.S. on this as a preventative measure rather than after the fact?
 

Koinz

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Karson said:
Definitely more pronounced than the video I posted earlier. Wonder if it lasts longer now that all the oil has drained back overnight...

Has anyone inquired with their dealer on using Y.E.S. on this as a preventative measure rather than after the fact?
Yes, I had mine replaced using the YES Warranty. The dealer had no problem replacing it. They called Yamaha and they said, "if he has warrantly, replace it". No issues.
I did notice mine rattling more as the miles piled on. At first it was a rare occurance. Eventually, it was everyday after the bike was sitting around for awhile. I figured I would ask. Biggest issue for me having the time to drop the bike off.
 
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