I recently picked up a 04 outlander XT 400 with the decompression weight sticking through the valve cover. I removed the broken weight and related parts and cleaned a bunch of aluminum shavings out of the oil filter housing and oil pump pick up housing and screen. (If you must make this repair, I strongly recommend taking the time to lift the engine and cleaning the oil pump pickup screen! There was a ton of shavings in there and the screen was about a 1/3rd blocked.)

Last night I reassembled it and started it for the first time. It runs perfectly with the exception of timing chain noise. The tensioner has no spring pressure against it however it is in contact with the guide and the guide is in contact with the chain. The guide on the back side of the chain is not in contact with the chain. The top of this guide is about a 1/8" away from the chain. I’m thinking this guide is cracked near where it mounts. I cant see that far down in the engine. It feels "floppy" for lack of a better word. I did find a piece of the decompression weight between the chain and the guide when I pulled the cover.

My questions are….

1) What is the proper chain tension adjusting procedure?

2) Does the head have to come off to replace the guides?
(I have read that head removal is required & I have read that it can be replaced with out removing the head).

3) How are the timing marks aligned? I assume the cam marks get lined up to the head surface at the valve cover flange. Do you use marks on the flywheel or is there a special tool that engages with the flywheel through a hole in the case to align the crank to TDC?

4) What are the torque specs for the head, cam gear, primary clutch, and any other components that must be removed for this repair?