1st Gen CCT Replacement


 * Note: This wiki article is for the 1st gen EX-500

You have likely heard forum members talking about replacing their "CCT". The following is intended as a guide to replace your CCT. It is only a guide; if you notice something wrong, or have questions STOP. This is not a substitute for a service manual.

What is a CCT?
Well, CCT is short for “Cam Chain Tensioner”.

The CCT is what properly tensions the chain that drives your motorcycle’s cams; if it fails, you’re in for a world of hurt.

Why bother to replace your CCT?
Kawasaki re-designed the CCT when they came out with the 2nd Gen EX-500 because the first ones were poorly designed and allowed slack to occur in the cam chain. This causes a noisy top end and premature failure of the top end of the engine. The newer 2nd Gen CCT’s have a positively locking ratcheting mechanism to prevent them from mis-tensioning.

'''In short, if you have a 1st gen CCT on your on your 1st Gen EX-500 replace it immediately with a cam chain tensioner from a second generation (post 1994) tensioner. This will help ensure longer engine life and better performance.'''

As seen below the spring twist on the screw that is threaded into the rod with no positive locking mechanism, simple tension of this spring keep tension on the rod by leveraging the torque of the twisting screw action with the spring which is being held by a tiny hole seen on the side of the tensioner making it at risk of slipping out of hole or breaking off causing tension on cam chain to stop and fail. pics from Brandi aka Aphrodite

How will I know what is on my bike?
The photo below shows both versions of tensioner. You can clearly see the ribs for the ratcheting mechanism on the 2nd Gen tensioner. The 1st Gen also has an O-ring seal that needs to be replaced with a gasket.

If you have a 2nd gen CCT (or a 2nd Gen EX-500), you’re fine. If you have a 1st Gen tensioner, read on. [There were 2 more missing photos on the wayback machine, presumably one of each gen CCT]

Part Numbers
 * 1st Gen - 12048-1067
 * 2nd Gen - 12048-1141
 * Gasket - 11009-1858

Where to get a replacement
You can get a CCT from a few places, such as: You may also need to order a gasket, some suppliers sell the CCT gasket separately.
 * Dealership
 * On-line parts suppliers (Ron-Ayers, Bikebandit, Partzilla, Big C Racing [UK] etc. 2013 price around US$71)
 * The 'For sale' section of this forum
 * Motorcycle salvage yard
 * eBay

In any case, if you're not purchasing a new CCT, you will want to be sure you're getting the right part (especially if buying from eBay).

Aftermarket APE manual CCT
The company APE produces a manual CCT, the KT1100, which fits a number of Kawasakis including the EX500. The product has some positive mention on Kawiforums.com, but here on EX-500.com at least three members (including FOG) recommend against the APE, saying that the Gen 2 OEM CCT is the way to go.

The Most Important Step
It should go without saying, but just in case:
 * The following procedures should be done with the ENGINE OFF (take the key out), and when the bike has COOLED DOWN fully.

Removing the old CCT

 * 1) Locate the CCT (which is on the front of the engine, between the exhaust headers).
 * 2) Remove the two mounting bolts, and remove the old CCT.

Installing the new CCT
Photos and steps compliments of [Scott "Ghostt" Ferguson]
 * 1) Disassemble your 2nd Gen CCT. Leave the pushrod in the CCT body.
 * 2) Depress the ratchet release, and push the pushrod fully in.
 * 3) Install the CCT body (don’t forget the gasket), make sure the small arrow on the CCT body is pointing up (and facing out). Install and torque the bolts (78in*lb/8.8N*m).
 * 4) Insert the rod, then spring, then washer, and finally install the cap bolt.
 * 5) Make sure everything is tightened properly.
 * 6) Start the engine and check for leaks, or anything else that might go wrong.
 * 7) Finish your favorite beverage, and enjoy the peace of mind offered by your new CCT.

[Ratchet]