Manual Cam Chain Tensioner (CCT)
Installation and adjustment.
(last updated 3-14-2017)
These are generic instructions for the installation and adjustment of a manual cam chain tensioner (CCT). If an example is required, it will be a four cylinder air cooled Kawasaki KZ.
The installation of the CCT is pretty straight forward. You must remove the ignition cover (points cover on a KZ) to access a bolt on the crankshaft which will allow you to rotate the motor. On a KZ, this cover is on the right side of the motor and is held on with two 6mm allen head or phillips head bolts. You should try to only turn the motor backwards if absolutely required. The normal rotation of most straight four motors is clockwise from the right side of the motor. So, on our KZ, the crankshaft will be rotated using a 17mm wrench on the right side of the motor in the clockwise direction. For those of you with digital watches who do not know what clockwise rotation means, put the ignition cover back on and take your bike to a reputable mechanic. Slowly rotate the motor in the forward direction to get a feel for the required force, and to take out any slack that may be present anywhere except on the tensioner side of the cam chain.
Remove your original CCT. If the gasket is to be replaced, be sure all of the old gasket is removed from the cylinder. If your stock cam chain tensioner is hydraulic and operates on oil pressure, then you must clean the hole where the CCT is installed with acetone, brake cleaner or some other solvent to remove any oil from the hole. Then smear a small amount of high temperature RTV in the hole to block the oil passage. Loosen the jam nut (all the way) on your CCT and back the adjustment bolt out all the way. Install your new gasket and CCT. If you have a torque wrench, 6mm bolts should be tightened to 75-80 inch pounds. If you do not have a torque wrench, then make them snug. Run your CCT adjustment bolt in, by hand only, until it contacts the chain tensioner assembly.
Slowly rotate the motor forward (clockwise from the right) and rotate the CCT adjustment bolt in, by hand only. By rotating the motor forward, you are putting tension on the chain except in the back of the motor where the CCT is located. By rotating the CCT adjustment bolt by hand, you are taking up all of the slack in the chain. When complete, tighten the jam nut to prevent the adjustment bolt from backing off.
To check your final adjustment, you can rotate the motor very slightly in the reverse direction. There should be almost no free travel. The camshafts should begin to rotate backwards immediately and the tension rotating backwards should feel the same as rotating forward.
Adjust every 1000 miles.
