Suzuki DRZ 400 cam retainer...BROKEN

Discussion in 'Motorbike Technical Discussion' started by chiefsleepingdog, Oct 22, 2006.

  1. I've got an '01 DRZ400E with a broken cam retainer and am being told
    the most effective way to fix the problem is to replace the cylinder
    head completely. Obviously that's gonna be more expensive than I'm
    thinkin' it needs to be. Anyone had experience with this problem?
    Maybe throw some advice my way, I appreciate it...CSD
    chiefsleepingdog, Oct 22, 2006
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  2. chiefsleepingdog

    B-12 Guest

    If you broke the cam bearing retainer by trying to torque oily bolts,
    it's an expensive lesson. Maybe there is somebody who already has a kit
    to repair such screw ups?

    The bearing cap was originally bolted to the head at the factory and
    the parts were line bored to ensure perfect alignment.

    Maybe you could find a machine shop that would make a sleeve that would
    slip over the camshaft, providing the necessary clearance.

    What do you make the sleeve out of? Bronze?

    Then they could take a new bearing cap and bore the cylinder head out
    to provide clearance for the sleeve.

    But what keeps the sleeve from spinning out of alignment with the oil
    pressure hole?

    A press fit steel dowel pin sticking through the cap from above?
    B-12, Oct 22, 2006
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  3. No, I didn't break the retainer (the first time anyway) best guess
    is that the decompression ring broke (somehow) and when it spun off it
    broke the retainer.
    That's what I'm hoping for.
    Excellent questions...AND is all this machining/hassle going to
    actually save me any money from buying a new head? I just wanna
    chiefsleepingdog, Oct 22, 2006
  4. chiefsleepingdog

    B-12 Guest

    To be sure we're talking about the same thing, I went to the CYLINDER
    HEAD parts diagram at

    The camshaft bearing caps don't have any part number, because they are
    part of a machine matched set of three parts that is the $500 cylinder
    head. The camshaft bearing caps are complicated thin castings that are
    easily damaged.

    There is another part on the diagram that is called RETAINER DECOMP.
    It's item # 27, but I don't think it's what you are talking about.
    Yeah, I know what you mean about needing to get your habit in motion.

    Japanese motorcycles are great for getting a lot of riding in, during
    the season. Then, when they break down, you either have to get a whole
    new ride, fork out a lot of ca$h for
    expen$ive part$, or find a friendly old machinist who is willing to
    make new parts out of
    raw materials just to prove he can still do it.

    You might be able to get a used cylinder head from a motorcycle salvage

    And, check the dualsport and offroad forums for messages concerning
    your particular machine. If this is a common problem, there may be a
    recall on the model, or some aftermarket company may have a fix it kit.
    B-12, Oct 22, 2006
  5. chiefsleepingdog

    Paul Cassel Guest

    THE source on all things DRZ:

    see the DRZ400 section.
    Paul Cassel, Oct 23, 2006
  6. Any competent engineering shop should be able to sort out a fix.
    The Older Gentleman, Oct 24, 2006
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