Manual Cam Chain Tensioner Install

There has been much talk in the DRZ and LTZ circles about the Automatic Cam Chain Tensioner (ACCT) prematurely stretching the cam chain. Possible solutions for the cam chain stretch has been the installation of the DID 3/4 plate cam chain, installation of the DID Heavy Duty 4/5 plate cam chain, and the installation of a Manual Cam Chain Tensioner (MCCT).

So... I've got three LTZ/DRZ motors in the garage. After installing two DID HD 4/5 plate cam chains in the LTZ motors, and seeing them stretch, I decided to order some ThumperTalk Manual Cam Chain Tensioners (MCCTs). Since I have three motors, I ordered three MCCTs.

After seeing the graphic tear-down pics of Kam's LTR (he didn't waste any time at all ripping that thing apart!), I thought the LTR Automatic Cam Chain Tensioner (ACCT) looked exactly like the LTZ/DRZ ACCT, from looking at Kam's pics.

It is.

The three ThumperTalk MCCTs came in today, and I decided to try one out in the LTR. Here is the LTR ACCT, on the left side of the motor, behind the fuel pump:



Here's what the TT MCCT for the DRZ/LTZ looks like:



To install the TT MCCT, you'll need to unmount the fuel pump from the frame, and unplug the electrical connector from the pump, so you can pull the pump up and out of the way. That's the easiest way to get to the stock ACCT. Two 5mm allen bolts mount the pump to the frame bracket, and the electrical connector is an easy deal - squeeze the two tabs inward, and pull the connector up and off. Here it is, disconnected:



This is a comparison of the mounting bolt holes for the TT MCCT (left) and the stock LTR ACCT (right):



Here's the stock LTR ACCT, out of the bike. This is exactly how far it was extended in the motor, and this isn't bad at all. There are either 12 or 13 clicks on the ACCT, depending on how hard you pull the tensioner out. When I checked this one, it was only 3 clicks out, which means 10 clicks left on it's total throw (really great!). This is with only 50-75 motor hours on the bike. Some of the LTZ ACCTs I've pulled out have been at 3 clicks left. At 3 clicks left, it's time to replace your cam chain...



Here is the TT MCCT loosely bolted in place (fuel pump held out of the way). You reuse the stock 5mm allens on the MCCT body, and the two nuts on the MCCT are 17mm. The TT MCCT has a huge o-ring to seal the tensioner against the cylinder, so you don't need to worry about the stock gasket. Simply bolt the MCCT in with the stock 5mm allen bolts (10lb/ft), then set the tension for the cam chain with the center bolt.

*NOTE - ThumperTalk instructions say the mounting bolts go in at 7lb/ft, but the service manual says the stock ACCT bolts go in at 10lb/ft - I went 10lb/ft.



Here it is, finished, and tightened into place. Cam chain tension it set. All I need to do is hook the electrical connector back to the top of the fuel pump, and bolt the pump back to the frame bracket. Sweet!



The directions for setting the cam chain tension are detailed nicely in the included instructions, so I won't go through that here. The tensioner costs less than $48, with free shipping, straight from ThumperTalk.

I don't know if cam chain stretch will be a problem on the LTRs in the future, but it has been on the DRZs and LTZs in the past. I know it won't be a problem on my LTR now...