Here's what I did to install the APE:
Theoretically you should never have to adjust your tensioner because it is "automatic". Of course in the real world that automatic tensioner is a piece of crap. My cam chain was making all kinds of nasty noises and I finally replaced the automatic tensioner with a manual tensioner. It took me about 20 minutes and it got rid of all the cam chain noise completely. It was very easy to do on my bike ('08). Just had to pull the right side center fairing back (I didn't even remove it completely) and it is easy to get to. This is the manual tensioner I got for my '08:
ZX Zone - Cam Chain Tensioners
The stock tensioner is a spring loaded ratcheting device, that doesn't always ratchet when it should. I probably could have forced my automatic one another notch very easily by pulling the center cap bolt and spring out and using a small screwdriver to push the ratcheting mechanism one more notch (you would probably want to do this in a quiet location so you can hear the click as well as feel it). With the manual tensioner you can be very precise with the adjustment though so if you don't mind spending the 50 bucks that's a good way to go.
If you find some actual directions follow those but my new tensioner didn't come with directions and I couldn't find much on their web site. Here is how I installed mine for what it's worth:
Remove old automatic tensioner:
1) remove the center cap bolt and spring from the old tensioner
2) remove the 2 mount bolts from the old tensioner
3) remove the old tensioner from the engine
Install new manual tensioner:
1) Loosen the center adjustment bolt all the way and back the lock nut all the way to the head of the bolt.
2) Install the new tensioner
3) Install the two mount bolts and tighten bolts
4) Screw in the center adjustment bolt with fingers until you feel it get tight (finger tight, NOT gorrila finger tight), then back it off a little until it just gets loose again (1/4 to 1/2 turn)
5) Start the engine and you should hear your cam chain noise, if you don't then back the adjustment bolt off a little more until you hear the cam chain noise (not more than another 1/2 turn at most)
6) Now tighten the center adjustment bolt with fingers until the noise just barely goes away (while the bike is running). This should only take light to medium finger torque on the adjustment bolt by a weak human. Do NOT adjust the tension with a wrench or you will do major damage!
7) If you are comfortable with the adjustment then lock down the lock nut. Of course the lock nut should be tightened with a wrench but make sure the adjustment bolt doesn't turn when tightening the lock nut.
Again, you want to make sure you don't get it too tight, just barely tight enough to stop the chain noise. You definitely do not need a wrench for that, if you do then you have something more serious than cam chain noise. When I say finger tight I don't mean turn it as hard as you can with your fingers. It should only take light to medium torque with your fingers at most.
If you have the service manual there is a small section that tells you how to remove and install the stock tensioner (section 5-15 in my book).
Linear Mode
