This posting is from the zx14ninja.com forum. It was made by bugsey on 9/7/2007.
This from Phil....I'll let him answer the questions, if any.
Remove tensioner and disassemble.
Use a punch to drive out check fitting in plunger.
Reinstall check fitting in plunger without the retaining cap. Use some grease to hold it in place.
Drill a 1/4" hole in the center of the tensioner body.
Use a punch to drive out the check fitting.
Final drill the hole to 17/64" and tap hole 8 mm x 1.25 mm.
Use an 8 mm x 70 mm full thread bolt and 8 mm flange nut for the adjuster assy.
Grind down the last 1/4" of the end of the bolt until it will fit inside the plunger and seats against the check fitting.
Screw the nut on the bolt with the flange facing away from the head of the bolt.
Use grease on the threads and slip on 7 1/4" x 1/16" O rings on the threads. These will seal the tensioner bolt when sandwiched between the flange nut and the housing.
Reinstall the two spring retainers in the housing, install the plunger and push into the housing until it locks in place flush with the housing.
Screw the bolt into the housing until it bottoms against the plunger.
Reinstall tensioner and adjust the bolt to add tension to the chain. Look at the pic, you should be fairly close to the final adjust point before you start the engine. You will feel some resistance from the O rings as they slip over the threads of the bolt. But since you don't want to put excessive pressure on the cam chain, at no time in this step should you use a wrench to tighten the tensioner bolt. A nut driver works perfectly for this step but if one isn't available use an open end wrench held parallel to the bolt.
Start the engine and adjust the bolt in until the cam chain noise just stops. Hold the bolt and lock down the nut.
All done, enjoy the quiet start up's!
* Last updated by: bgordon on 2/8/2009 @ 1:40 PM *