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Can anyone advise me on the best way to install a manual CCT on my gen 2 ? The instructions are very vague.
Yes on the older higher mileage motors to be safe its quite a lot of work im afraid. The reason being the accumulated wear on front back and top chain guides can add up to more than the depth of chain. You need plugs out and top cover off, turn engine to TDC (presents least resistance to timing chain) zip tie the chain to both cam sprockets (prevents chain jumping on sprocket) remove the spring and pin from the centre of the auto adjuster then loosen the the 2 bolts and remove the auto adjuster body, adjust the manual tensioner so its the same length as the auto adjuster fit manual adjuster remove the zip ties and turn the engine over slowly a few times back and forward, now look very carefully for any play when the crank starts to turn and the cam sprockets moving, i use a really long breaker bar on the starter gear bolt so i can go slow so slowly and keep an eye on the outside edge of the exhaust cam sprocket that is where you will see the smallest movements. If there is movement then just tighten in the manual tensioner 1/4 turn at a time until the movement stops, if there is no ,movement first few times you try back out the manual tensioner 1/4 turn a time until you see movement and then tighten in 1/4 turn a time and until there is no ,movement. That is the safest way and the way i do it, however people will just pull the auto out and bolt in the manual tensioner start the bike and adjust the tension until what is described as noise goes away.
 

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Discussion Starter #3
Yes on the older higher mileage motors to be safe its quite a lot of work im afraid. The reason being the accumulated wear on front back and top chain guides can add up to more than the depth of chain. You need plugs out and top cover off, turn engine to TDC (presents least resistance to timing chain) zip tie the chain to both cam sprockets (prevents chain jumping on sprocket) remove the spring and pin from the centre of the auto adjuster then loosen the the 2 bolts and remove the auto adjuster body, adjust the manual tensioner so its the same length as the auto adjuster fit manual adjuster remove the zip ties and turn the engine over slowly a few times back and forward, now look very carefully for any play when the crank starts to turn and the cam sprockets moving, i use a really long breaker bar on the starter gear bolt so i can go slow so slowly and keep an eye on the outside edge of the exhaust cam sprocket that is where you will see the smallest movements. If there is movement then just tighten in the manual tensioner 1/4 turn at a time until the movement stops, if there is no ,movement first few times you try back out the manual tensioner 1/4 turn a time until you see movement and then tighten in 1/4 turn a time and until there is no ,movement. That is the safest way and the way i do it, however people will just pull the auto out and bolt in the manual tensioner start the bike and adjust the tension until what is described as noise goes away.
Fucks sake, all that to do the CCT, it just gets better. As much as i love this bike, its a fucking nuisance lol. On one hand i wanna sort it so that i know its been sorted for its duration of ownership, on the other it makes me want to pour petrol all over it and watch it burn :crackup:
 

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Oh and on the other hand i DO want to start doing this shit, just so I know I can do it in future if needed, i learn stuff like this pretty quick and arnt scared of trying by all means.
 

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Fucks sake, all that to do the CCT,
No.

Easy to do and barely have to remove anything.

You should be able to push rad hose out of the way or remove one
end and push out of the way.

Remove timing cover on right so you can turn engine over.

Remove old CCT

Take new CCT, remove the oring off CCT. Now it will slide
in and out of cylinder easily.

Adjust inward so won't sit flat.

Start backing out and turning engine over and you will see
CCT moving in and out.

Keep backing out until it just sits flat against cylinder.

back out 1/2 turn on pro series and lock down.

put oring back on.

install and you are done.
 
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