I installed a manual CCT on my bike yesterday. Here's how I did it:
1. Remove right rear tail fairing.
2. Remove screws for bottom right fairing. You don't have to remove it all the way. Just "peel" it back to gain access to the right side of the motor.
3. I used a 10mm deep socket to remove the top bolt on the stock tensioner.
4. The socket was too big to get to the bottom bolt, so I had to use a 10mm boxed-end wrench to get to that one.
5. Remove the stock tensioner.
6. I used 2 dots of gasket maker to hold the new gasket to the manual tensioner, and I used fresh oil to coat the bolt of the new tensioner (on the end that contacts the cam chain).
7. I installed the new tensioner with the bolt all the way backed out, and the tightening nut and rubber ring about halfway down the bolt. The new tensioner didn't come with new installation bolts, so I re-used the stock 10mm ones. I couldn't find a torque spec on the bolts, so I just snugged them down really good.
8. I started the bike and cringed at the horrible sound of the cam chain slapping around. I tightened the tensioner bolt while keeping my ear close to the motor so I could listen for the rattling to go away.
9. When I got to the point where the noise went away, I tightened another 1/4 turn.
10. I then tightened the middle nut all the way down, being careful to make sure that the tensioner bolt didn't move.
11. After the nut was tight, and I was sure the rubber ring was seated, I squirted some thread-lock on the nut and bolt so it won't back out.
12. Then all you have to do is re-install your fairings, and your done!
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