1983 CSR (now SR resto'mod) 650 / cam chain tensioner

do you have the 1981 FSM pdf? if not. try the jarlef z650 site. files section. or it may be here in the filebase. the 81 tensioner is the same as the 83. follow the instructions in the manual. this isn't everything. but remove the cross-wedge before installing the tensioner body. this will allow the pushrod to float. ie, move back and forth. then torque down the tensioner body mounting bolts. then install the cross-wedge. being sure to align the wedge surfaces on the pushrod and cross-wedge beforehand. I use brake caliper grease to lubricate the pushrod and cross-wedge for installation. ps. if you don't know what you're doing. never ever try to install the valve cover with the cross-wedge already installed. 

Page 6-25 under Cross-wedge Type. Kawasaki sometimes refers to the cross-wedge as the pushrod stop.

kzrider.com/filebase-alias?view=summary&...-kz650-1981&catid=15

aaaahhhhhhhhh ......that make a bit of sense for sure, so remove the side cap & plunger, get the main plunger + spring and tensioner body mounted, then set & install the side plunger, spring & cap afterwards ? ....

yes

TexasKZ wrote:

On the liter bikes, the cap and cross wedge have to be removed for installation. That allows the main plunger to fully retract.

Edit: the above couple of posts were made while I was editing.  sorry...

Before installing, you have to remove the cap, spring, and pull back the wedge.  After install, install the cap and spring.  And remember, never install the tensioner until after the valve cover is installed.

thanks guys, she's all done and back to running fantastic as she always is and has  !!! ....I've owned my 650 since buying it new in '83, have gone thru the engine twice and the entire bike just 3 years ago (swingarm off, front end off, frame painted, etc) ....this is her 4th custom paint job shot by me ....she has been wearing this red since the late 90s ....67,347 original miles .....