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Join Date: Nov 2007
Location: Chandler, Arizona
Just for another suggestion, I was afraid of damaging the oil line by bending that tab, because it is fairly thick and hard to bend. If you do damage the oil line, not only is a new one expensive, but you have to pull the motor to replace it.
I removed the bolt that goes through it, which allowed it to move out just a tiny bit, then took a Dremel with a reinforced cutoff wheel, and very carefully cut the tab off, far enough away from the oil line to avoid the possibility of damaging the line, but enough to allow the tensioner to come out. Once I got the tensioner out, and had the room, I used the Dremel to cut it back just a little more, and smooth the rough edges. The oil line is still solid without the tab.
Doing it either way requires a lot of care not to damage the oil line. If you kink it from bending, or cut it, it will have to be replaced.
I think this was just another bad design by Kawasaki, because according to the manual, you have to remove the engine and the oil line to replace the tensioner.
I am a motorcyclist, NOT a biker.
1997 Vulcan 750, purchased about a week ago
2006 Sportster 1200 Low
2013 Royal Enfield Bullet 500, converted to carb
2001 Yamaha XT225, heavily modified
2004 Honda Rebel 250
1979 Vespa P200E
2002 Vulcan 750 parts bike
1994 Yamaha XT225 parts bike