jdugen wrote:Make your own. 2 10 cm x 8mm bolts. 2 8mm locknuts. 1 6.75mm drill. 1 8mm tap. 1 8mm drill. Cost £5-£10 (local engineering supplies shop).
Drill and tap the CCT body. Drill out the worm gear of the tensioner piston with the 8mm drill. Reassemble and tension untill firm by hand. Job done forever.
Works fine if you can be sure to tap the holes straight. That was my problem early on. I probably threw away a half dozen tensioner bodies with angled threaded holes. Fact is I've had my supplier who cuts and taps the bodies have problems when they weren't careful.
It wasn't particularly easy on the KLX when I converted the OEM body. I had access to the drill press and all, but it just took some time and effort to make sure to do it right and tap the hole straight. Having the materials, equipment, time, and skills can be a problem for some riders. If you have them, it's kind of an adventure. I just provide the alternative for those without the materials, equipment, skills, time, or patience. And I made them exactly how I would want them - including the gaskets. I wouldn't discourage anyone from doing the work if they have the right stuff though. Heck, I did it twice and posted the directions ten years ago on the Yahoo KLX650 group. Riders there still buy the kit from me.
I will tell you the second time I was ready and willing to pay the $51 (in the US) plus shipping from APE, but they ignored my question if the GPz tensioner bolt was long enough or if they'd put in a longer one. They ignored my email. I made my own, the rest is history - about 400 tensioners for Kaws and Hondas in 23 countries and $20 less costly on the single tensioner. There's a lot of people who had my attitude - I'd rather just buy it - and now I serve them. By the way, now APE lists one for the Zephyr... a bit late. They still don't list one for the KLX, even though one of them fits.
By the way, thanks guys for keeping it going. I'm not getting any closer to that little cottage in the Keys (Florida), but it's helping out with some bills and making it fun to know that there are bikes that are still going, maybe even having the sticker on them. It's been a lot of fun, it is amazing how the internet and forums make things happen. I use this little business as an example of the use of CAD, CNC work, and use of the internet in my Industrial Tech classes I teach in a middle school.