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Hi Guy's, when upgrading the CCT for the more modern type from the ZZR 1100. Can you tell me if the engine has to be in a certain position when removing the old one and installing the new one ? Many thanks.

Hm. I could've swore that the engine was supposed to be top dead center, but a quick peek at the Service Manual doesn't say anything about a certain engine position. Just to not move the engine with the tensioner out.

I also have a ZZR tensioner sat on the bench and the original removed at TDC while rebuilding top end.I'm still unsure whether to fit it without alteration and risk overtensioning the chain or stick with the original as it has worked fine for the life of the bike?

I fitted a ZZR unit about 18 months ago; I cut he requisite 10mm off the spring and made sure I did not move the engine position whilst replacing the CCT's. Pretty sure one of the "old hands" off the forum told me the simple approach would be fine, and all seems to have worked ok.

Cheers Tim

You dont need to be at TDC.

Just make sure the bike is in a safe solid position and in gear.

Remove the old tensioner very carefully loosening both bolts evenly (not one out then the other) then throw it in the middle of a lake.

After cutting 10mm off the spring inside the new tensioner body, push the tensioner plunger all the way BACK INSIDE the body.

Now fit the tensioner body very carefully tightening both bolts evenly (leaving the spring, pin,copper washer and bolt out of the body).

Once the tensioner body is in position, slip the spring inside, then the pin in the middle of the spring. Now have the washer and bolt ready to push against the spring and get onto the first few threads of the tensioner body (this can be a little tricky)so take your time.

As you now begin to tighten the bolt into the end of the tensioner body, you will hear the plunger ratchet begin to push its way out of the body and against the tensioner arm inside the engine.

Job done !

Pete F
UK

Excellent, a foolproof set of instructions again, thanks Pete.