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Discussion Starter #1
I am in the process of installing some new tensioners, I am hung up at the moment however due to the retaining clip on the forward ACCT. It appears to be attached (the clip) to the oil tube. Is there any handy tricks to free this up so I can swap the tensioner out? I ask because I'm trying to do it at work and will need the bike to get home :doh:
 

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Discussion Starter #3
:beerchug:10-4 Thanks Swagman
 

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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.
 
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