I'm wondering if there is a spec for the Cam Chain Tensioner length. Like if it is extended "X" mm, then the chain needs to be replaced due to excessive wear. Anybody know the answer? I don't have the manual, unfortunately. Don't even know if that is in the manual. Mine is a 2003 636.
Thanks,
Kevin

 

You won't be able to accurately measure the tensioner length because it is spring loaded. I checked the 03-04, 05-06 and the RaceKit manuals but did not find any cam chain wear specs or limits. Seems that when the engine needs a rebuild, the cam chain gets replaced. As far as the tensioner, go to www.onesecondfaster.com and buy the APE tensioner for $39.95.

 

Thanks for checking into the specs for me!
Actually, if you take out the spring before removing the CCT, it remains where it was in the motor. Also a good starting point for when you are installing a Manual CCT. Gets you in the ballpark. One of the other forums posted a few complaints on the APE leaking oil. The Kawasaki Manual CCT is supposed to work better, and costs less.
What the heck, I might as well get a new chain. Going to tear down the head anyway...

 

The Factory Race tensioner is $70 and is better but you can put thread sealer on the APE ($50 or less)to keep it from leaking oil around the adjuster bolt. Also, you'll hve to split the cases to replace the cam chain because there is an aluminum chain guide cast into the lower case that will prevent removal of the chain.

 

Well crap. I had the cases split last year to rebuild the transmission.