That clicking sound you hear while your Kawasaki ZX-6R is running is generated by a loose camshaft timing chain. This chain is driven by the motorcycle’s crankshaft, turning the intake and exhaust camshafts at precise intervals to feed the engine. The camshaft chain can stretch over time, which can cause the chain to “jump” off the camshaft teeth and break the delicate timing of the engine. To avoid this problem, a spring tensioner is attached to the engine to keep the chain in constant tension. Occasionally, it will be necessary to readjust the tensioner for chain wear.
Remove the seats from your ZX-6R with the motorcycle’s ignition key. Lift the rear seat out of the tail cowling to access the front seat latch. Unlatch the front seat, pull it out of the bike.
Unscrew the fuel tank mount near the front fork with a 5mm Allen wrench. Unscrew the tank pivot bolt and saddle rail nut from the frame, using a 12mm socket and socket wrench. Lift the frame tank off the bike and disconnect the fuel lines. Skip this step if you are working on a 2005 or newer model ZX-6R.
Remove the right center fairing from your ZX-6R, using a 4mm Allen wrench. Pull the fairing away to access the camshaft chain tensioner at the rear of the engine cylinders.
Unscrew the large bolt from the back of the tensioner housing using a 14mm socket and socket wrench. Pull the bolt washer and spring from the tensioner rod out of the housing.
Unscrew the bolt tensioner housing assembly, using a 10mm socket with a socket wrench. Pull the tensioner out of the engine.
Press down on the ratchet plug on the end of the tensioner, positioned just above the flat end of the tensioner rod. Push the rod all the way into the tensioner housing and release the ratchet stopper. Pull the rod until the plug clicks 5 times.
Insert the tensioner into the motor, with the plug facing upwards. Screw the tensioner mounting bolts in place with a 10mm wrench, tighten the bolts to 97 inch pounds with a torque wrench.
Slide the tensioner spring rod into the tensioner housing. Screw the large bolt and its washer into the tensioner housing, using a 14-mm socket. Tighten the bolt to 15 ft-lbs (2.07 kg-m), using a torque wrench.
Replace the right or middle fuel tank fairing and both seats, using the reverse method.