Kawasaki Ninja 250R Camshaft Chain Tensioner Guide

 

Introduction

I learned this the hard way.  It would seem that Kawasaki neglected to mention lubricating the tensioner before reassembly and refit. After researching the cam chain tensioner by speaking with several Kawasaki mechanics I have developed this modification of the Ninja 250R service manual for the 2007 and earlier models.  I clean and lubricate the tensioner assembly every oil change (3,000 miles).  Many consider this over kill and advocate more extended periods such as every 6,000 to 10,000 miles.

 Camshaft Chain Tensioner Removal

• Remover 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 on each side at a time so the tensioner assembly does not become "cocked". Take special care toward the end of the mounting bolt's travel.
• Carefully extract the tensioner assembly while watching for any parts that may fall.

Camshaft Chain Tensioner Disassembly

• Remove the ball bearing and retainer spring.
• Loosen the push rod locking screw about 2 mm.
• Carefully pull the pushrod and tensioner spring from the tensioner body.
• Remove the ball bearing and retainer assembly and tensioner spring.
• Clean all parts.  Toothpicks and Q-Tips can assist with hard to reach locations.

Camshaft Chain Tensioner Assembly

• Lubricate the pushrod and tensioner spring with a good quality grease before insertion in the tensioner body.  I use Silkolene Pro RG2 Synthetic while others have good results from a molybdenum grease.  Assure that any grease you select is safe for use with aluminum.
• Compress the pushrod and tensioner spring fully into the tensioner body.
• Turn in the lock screw so the pushrod remains in  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

Camshaft Chain Tensioner Installation

• Place the assembly over the crankcase mounting position and insert the tensioner pushrod in to the hole.
• 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. Tighten the lock screw again.
• The stiff spring in the push rod should now be firmly against the rear cam chain guide.

God Bless America

 

This site was constructed using