Cam chain tensioner removal: Difference between revisions
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*Remove the right hand "knee grip pad" (side panel). You will most likely find the combination of a 1/4" socket drive, a 1/4" extension, a 1/4" drive universal joint, and an 8mm socket to be the most useful means of removing the mounting bolts. | *Remove the right hand "knee grip pad" (side panel). You will most likely find the combination of a 1/4" socket drive, a 1/4" extension, a 1/4" drive universal joint, and an 8mm socket to be the most useful means of removing the mounting bolts. | ||
*The tensioner is under pressure from a rather strong spring, so be sure to back the mounting bolts out a little at a time on each side so the tensioner assembly does not become "cocked". Take special care toward the end of the mounting | *There are 2 bolts that hold the tensioner to the crankcase. The tensioner is under pressure from a rather strong spring, so be sure to back the mounting bolts out a little at a time on each side so the tensioner assembly does not become "cocked". Take special care toward the end of the mounting bolts' travel. | ||
*Carefully extract the tensioner assembly while watching for any parts that may fall. | *Carefully extract the tensioner assembly while watching for any parts that may fall. | ||
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*Remove the ball bearing and retainer spring. | *Remove the ball bearing and retainer spring. | ||
*Loosen the | *Loosen the pushrod locking screw about 2 mm. | ||
*Carefully pull the pushrod and tensioner spring from the tensioner body. | *Carefully pull the pushrod and tensioner spring from the tensioner body. | ||
*Remove the ball bearing and retainer assembly and tensioner spring. | *Remove the ball bearing and retainer assembly and tensioner spring. | ||
*Clean all parts. Toothpicks and Q-Tips can assist with hard-to-reach locations. | *Clean all parts thoroughly with brake cleaner. Toothpicks and Q-Tips can assist with hard-to-reach locations. | ||
====Camshaft chain tensioner assembly==== | ====Camshaft chain tensioner assembly==== | ||
*Lubricate the pushrod and tensioner spring with a good quality grease before insertion in the tensioner body. Silkolene Pro RG2 Synthetic is a good choice. Any good [[Servicing the swingarm|molybdenum grease]] will also work. Assure that any grease you select is safe for use with aluminum. | *Lubricate the pushrod and tensioner spring with a good quality grease before insertion in the tensioner body. Silkolene Pro RG2 Synthetic is a good choice. Any good [[Servicing the swingarm|molybdenum grease]] will also work. Assure that any grease you select is safe for use with aluminum. | ||
*You can also pour a little of the same kind of oil you use in the engine into the tensioner. | |||
*It would seem that Kawasaki (in the service manual) neglected to mention lubricating the tensioner before reassembly. So, make sure that you don't skip that part. | *It would seem that Kawasaki (in the service manual) neglected to mention lubricating the tensioner before reassembly. So, make sure that you don't skip that part. | ||
* | *With one hand, squeeze the piston/pushrod and springs into the bore until they bottom out. With the other hand, tighten the set screw until it stops (don't torque it down!). This will hold the piston up during installation. | ||
*Grease the ball bearing and retainer assembly before placing it over the pushrod and pressing it into the tensioner body. | *Grease the ball bearing and retainer assembly before placing it over the pushrod and pressing it into the tensioner body. | ||
*Slip the ball bearing and retainer spring over the pushrod | *Slip the ball bearing and retainer spring over the pushrod | ||
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====Camshaft chain tensioner installation==== | ====Camshaft chain tensioner installation==== | ||
*Place the assembly over the crankcase mounting position and insert the tensioner pushrod | *Place the assembly over the crankcase mounting position and insert the tensioner pushrod into the hole. | ||
*Assure the ball bearing and retainer spring and the O-ring remain in place as the mounting bolts are progressively tightened. | *Assure the ball bearing and retainer spring and the O-ring remain in place as the mounting bolts are progressively tightened. | ||
*After installation of the tensioner, loosen the lock screw enough to free the pushrod (about 2 mm). You should hear a click as the pushrod releases. | *After installation of the tensioner, loosen the lock screw enough to free the pushrod (about 2 mm). You should hear a click as the pushrod releases. | ||
*Tighten the lock screw again. | *Tighten the lock screw again. Put a drop of blue Loctite on both bolts. | ||
*The stiff spring in the push rod should now be firmly against the rear cam chain guide. | *The stiff spring in the push rod should now be firmly against the rear cam chain guide. | ||