How do i install a factory manual-type tensioner??

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21 May 2013 16:17 #588565 by firechicken
My cam chain tensioner went out on my 81 kz650, it was the automatic-type tensioner, i bought a manual tensioner from a 79 kz650 to replace it, what i can't figure out is how the hell to keep it compressed for the install, every time i try to put it in the springs push the plunger to the maximum position and the little ring with bearings in it(if you have taken one of these apart you know what i'm talking about) holds it in place and makes it impossible to retract without taking it back apart. i'm baffled, i understand how it works once installed but how can you install it with no way to hold it in place? hopefully someone has had the same troubles as me and knows the secret. also i turned the crank a couple times to loosen the cam chain (as stated in service manual) but i did this without the tensioner installed, think i will run into any troubles here? it didn't sound like the chain jumped or anything... sorry this is so confusing, someone please help me install this tensioner.

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21 May 2013 16:46 - 21 May 2013 17:02 #588568 by turboking
bolt and lock nut on the side of it..... push tensioner all the way back and tighten the locking bolt and nut.. after you have installed it to the cylinder release the lock bolt to take up cam chain slack.....retighten tensioner lock bolt and nut..... adjust cam chain per manual :dry: ..... er hope your cam chain hasn't jumped time. make sure before you start turning it over as you may bend valves........ :huh:

2005 Kawasaki mean streak
2000 325 H.P. mcXpress turbo Hayabusa
1979 kz 1000 mk II ATP turbo
1975 Z1 960 cc Mr. Turbo
1975 Z1 1428 big block ATP turbo
1976 Kz900 1103 cc ATP turbo
1985 GS 1150E
1983 GS 1100E
1997 Suzuki Bandit 1200S
2001 Kawasaki EX 500 Ninja
1972 Honda cb750 (836cc turbo)
Last edit: 21 May 2013 17:02 by turboking.

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21 May 2013 17:08 #588572 by firechicken
Replied by firechicken on topic How do i install a factory manual-type tensioner??
thank you for the speedy reply, that makes perfect sense to me, the tensioner i bought is so worn out that the lock bolt no longer holds it in place, which was the cause of my confusion. i will use a longer bolt and i'm sure it will work. is there an easy way to see if i'm still in time before i crank it if i take the valve cover off? I'm sure that sounds like a stupid question but i'm learning as i go.

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21 May 2013 18:39 #588585 by Powerstroke_fan
Replied by Powerstroke_fan on topic How do i install a factory manual-type tensioner??
Are the kz 650 manual adjusters diffrent from 79 to 81? The reason i ask is because i know the 1000's are diffrent. I wasnt sure if the 650s were also

1980 kz1000B4 LTD- 1327cc 9-1 comp
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Welded MK11 crank
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Complete frame brace kit installed
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21 May 2013 23:29 #588647 by baldy110
The 650 never came with a manuel adjuster The tensioner does not wear out the cam chain does and the tensioner then goes beyond it's adjustment range.

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22 May 2013 02:27 #588687 by APE Jay
Why not just get a real manual cam chain tensioner?

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22 May 2013 14:54 #588763 by firechicken
Replied by firechicken on topic How do i install a factory manual-type tensioner??
yes, the 79 and 81 models were different, the 79 did not have a true manual adjuster, it has an automatic adjuster that just needs to be manually activated occasionally, the 81 came with a terrible autotensioner that is self adjusting, mine would slip all the time and when i took it apart showed no signs of wear. I installed the new-to-me tensioner and am about to fire this thing up, its been sitting for over a year so wish me luck!

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