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F4i CCT Swap - pictures/directions

Jdub

Jdub

New member
Joined
Jun 6, 2004
Location
Sacramento
Moto(s)
01 CBR F4i
Ok peoples I did another CCT this weekend and thought id give my how-to with some pics to help describe it.

Tools:
I use a 1/4 inch extension with a 45 degree attachment. On the end of that I have a socket that will hold the 5mm alan key. I also wrap the alan key with tape onto the socket so it wont come out of it and drop somewhere in the bike.

1162203-zcct_tools.jpg
 
Step 1:
NOTE: Im not responsible if any mistakes are made, always consult with your dealership if you are not sure about something.

Important: Have your bike on some stands where the wheel will not move. Have the bike in Neutral when performing this and do not move the chain or wheel.

Remove the right fairing and air intake cover. Lift the tank and just rest it on the air box so it is out of the way.
The big yellow circle is where you will need to do most of the work at. Its between the airbox and the frame. The little yellow circle is where you put the tool through the frame at an angle to get to the bottom bolt holding the CCT on.

1162206-zcct_step1.jpg
 
Last edited:
Step 2:
Unplug this part of the harness so you can get to the CCT, dont forget to plug this back in when youre all done or your bike will sound and feel like its running on 2 cylinders.
Here is another shot of where the hole in the frame is to get to the bottom bolt.

1162208-zcct_step2.jpg
 
Step 3:
Here is the automatic Cam Chain Tensioner. You can see where the top bolt was and right below that is the bottom bolt.

1162209-zcct_step3.jpg
 
Step 4:
Here is the angle that you will use to get the top bolt off. Be patient and use your finger to guide the alan key into the bolt, once on and snug you can attach the ratchet to the extension and start turning. NOTE: Make sure you are using a 5mm metric alan key, if not the standard one WILL strip the bolt and then youre in major trouble.

1162212-zcct_step4.jpg
 
Step 5:
Here is the angle that you will use to get the bottom bolt off. Same thing here, use your finger to guide the alan key into the bolt, once on and snug you can attach the ratchet to the extension and start turning.

1162213-zcct_step5.jpg
 
Step 6:
Once the bolts are out go ahead and pull the CCT out. This is what it should look like. NOTE: Notice that the stock gasket came off with this one. If it didnt come off with it, or has part of it still stuck to the engine, you will need to scrape that off so the new gasket will seal correctly.

1162214-zcct_step6.jpg
 
Step 8:
Back the Tension bolt all the way out and have the middle bolt about halfway. Make sure the rubber ring is about halfway too because if its sealed in the CCT already its hard to tighten the tensioner bolt.
I use some gasket seal to hold the gasket on to the CCT.
This is the APE Manual CCT from APE:
http://www.cbrzone.com/sprockets.html
You can order this from them by going to the website. Make sure you get the gasket.

1162222-zcct_step8.jpg
 
Step 9:
Here is the manual CCT connected to the bike. Use the same techniques to put this on as you used to take the automatic CCT off.

1162225-zcct_step9.jpg
 
Step 10:
Tighten the "yellow" tensioner bolt with your hand or a tool until you feel it start to get a little snug. I then back it out a 1/4 of a turn and start the bike. Hold the bolt so it wont back out from vibration. You should notice that the noise is gone when revving the engine. If you hear a "pinging" sound it could be too tight, back it out some more. If you hear the normal CCT "cling cling" sound tighten some. This step could take a few tries getting to the correct tension, but once you have it in the right spot it should sound smooth all the way.
Once you have found the right tension, tighten the locking nut. This part could frustrate you but just take your time with an open end wrench. I also use some type of lock-tite to help.
Once this has been done youre good to go, put your bike back together and take it for a test run.

GOOD LUCK
~JDUB~

1162242-zcct_step10.jpg
 
cool of you to take pics and write up such great directions.:thumbup
 
just did this today. THANK YOU SO MUCH!!!!!!
an excellent how to. that thing was buried in there.

:Port :toothless :Port
 
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