Sounds like you need to change your cam gear.

When you installed the cam did you use the gear that came on the cam?

Try installing the stock gear onto the cam, bet it solves your problem.

If you don`t have the stock gear you need to determine what size gear is on the cam and get a gear one or two sizes smaller. You don`t have to get the gear from Andrews.

If you go by the color code on the gear remember the color code/size is different on `89 and earlier engines.

The color code/size chart is in the service manual under “Gearcase Cover and Timing Gears”.

 

With any cam change, your suppose to check the pitch of the gears, if not, they may wine, i had two seperate indys tell me not too put too much emphasis on that, that it may wine a lil bit, but i can live with that, did you check cam end play, both emphasized that had to be correct.

 

The end play has been shimmed to be correct. After it runs a bit it seems to quiet down somewhat. I just got everything back together with no leaks and runnin great......I would like to ride a little without crankin a wrench. So what your sayin Doc is the indy's say it's not a big problem to worry about? I can live with it especially not havin to break back into the cam chest again for now. I think I chucked the OEM cam. If I do need a smaller gear, where should I look for that?

 

It's not unusual to have noisy gears. The fact that they quiet down when warm is likely due to the expansion of the aluminum cases, bringing the distance from the gears apart just a little bit, opening up the clearance. It sounds to me like you are good to go. You have had two? indys tell you not to worry. If that's the case, (so long as they have actually listened to your motor's whine) I'd say just ride. There certainly is a point where if the gears are too tight they will get hot and failure is eminent but it sounds from what you write that yours is not in that group.

If you are dead set on getting rid of the whine, you can get odd size gears from Andrews. You also would need to have .003" or less crank shaft run out. You'll also need an dial indicator to theck run out and gear lash. Check the gear lash at four points of roataion of the cam gear, 90 degrees apart. Get advice from the guys right here for what the tollerance should be at the closest point in the rotation. The bigger the run out the bigger the variance from the tight side to the loose side. If your gears are too loose, they will clatter like the dickens and that too gets worse when the motor heats up.

 

If you put the right size gear on the cam it will not whine or clatter, I have an EV27 in my evo and it is very quiet. If an expierenced mechanic listened to it and said it is ok then you might be good,but he has nothing to lose if it is too tight...Anything over a slightly noticeable whine is too tight and should be fixed.

 

I'm going to look at this from a different perspective. The new cover causes it to whine the old one doesn't, correct? What kind of "new" cover are you using? Maybe the bushing in the cover is not aligned properly and "pushing" the cam tighter against the pinon. That sounds a little more likely. Maybe a new bushing in the new cover, and have it reemed to match the end of the cam.

 

I bet the new cam was put in using the old cover that already had a worn out bushing, so it didn`t whine, until the new cover/bushing was installed...

 

Dan's right, and what you guys are saying makes sense. The machine shop guy did not want to charge me at pickup. He called me the same day I dropped it off to say it was done though that morning he was "swamped"... which leads me to believe it was ballpark so he didnt touch it. The bottom mainshaft hole looked very similar before and after come to think of it. I think that is also why that cover fits so almost too snug. My guess is if I can polish or open that bottom hole up a hair the gear teeth won't be squeezed the way they are now. At least I'm getting good at adjusting pushrods as this will be the fourth time I'v done it in the past three weeks.....here we go again.

 

I pulled the cam cover. Nothing looks chewed up but man it was tight and certainly could be binding. Looking at the bushings....doesnt look like any brass was reemed. Probably the only thing that got reemed that day at the shop was me! I shoulda checked it better before I put it on. I am going to get the bushings to slide on the shafts then reinstall and see what happens.
I'll keep you up.

 

Cleaned the untouched brass finish off the bushings with a strip of sponge and a 4" long strip of emery cloth wrapped around a drill bit until the bushings slid on the cam and shaft easily. Put it back on and readjusted pushrods. Runs great...whine gone, nice ride today, I think I am set. Time to put the tools away and start riding!

Thanks for your help.