I'm well within spec. Coincidently the top cam chain guide was well worn. WTF? I'm replacing that guide and ordering one of the manual can chain tensioners. (FYI, the other two guides were in excellent condition)
hmm,.. lookin like there might be a camchain for sale in the for sale section in the near future, eh?
If IIRC, in our tear down:
1. The cases -must- be split.
2. How good are your calipers? That's what kicked us in the butt. There's a chance they're not accurate enough if it's a cheapie pair. (Just a hint so others can learn from our mistake.)
3. The side guides, IIRC, put pressure on the chain, the top one, not as much. So if the chain were loose, it would flap more against the top than the sides, causing impact wear?