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Showing content with the highest reputation on 12/09/2016 in all areas

  1. Ok, I am not a writer. I don't have the witty banter abilities of great technical writers who pull you into their project no matter the subject. Instead I am a typical desk jockey who rides VFR and fixes stuff if he can. Before I get into the "easy" way to change the CCT, let me point out that I did not come up with the process on my own. I borrowed bits and pieces from lots of people. The best replacement guide can be found here, CCT change by Rad, where it is done "by the book". In the resulting discussion it was revealed that removing the Throttle Bodies and so forth was a waste of time, as the CCT can be removed without it. As a second note, I did not change the rear CCT, and I don't imagine I know or could discover any easier way...it seems simple enough already. See the link above to find how to change that CCT if needed. As a third note (I like notes), I don't believe the CCTs EVER go bad...I think they make noise when the spring loses a bit of tension...more to come on that later (see how I "hook" you...just like the creative writing class said!) So on to CCT removal and replacement (this order works best I have found)...Anyway, I didn't have music playing, I don't drink beer, and I barely remembered to take pictures....so bear with me. Finding the CCT was the first chore. It is located on the right side, kinda behind and back of the R/R. To find it you need to remove: Right Fairing 8 allen screws 1 blind rivet Slider (if applicable) Seat Just use the key, and remove Tank two 8mm head bolts, use 1/4" driver Restraint Cable Two 10mm head bolts at back of tank Air Box Top Hose from top screws around perimeter Air Box Bottom Velocity Stacks, Phillips Head Bolts Sensor connector on bottom Vacuum line going in front of box Small connections at the back When moved, the airbox looks like this: Note the airbox was just rotated away from the CCT. Tank was also rotated the same way and laid across the seat rails. You can see the CCT at the very bottom, just right of center. Now you are almost there....just need to remove those cooling hoses to make it stupidly easy to reach the CCT. Remove the one pointing out first, and connect a short section(2-3 feet) of 1/4" or similar hose (I didn't measure it, just some I had around, but 1/4" should be about right). Route this into a drain pan or later you get this: next remove the second hose....this is what makes the first connection take a bit of a leak not much fluid is lost...a bit more than is pictured here: Don't leave this for the dog/cats to drink, unless you don't like them much.... Now it's time to remove that CCT! Simply use your 8mm socket on extension, and take the center bolt out: This is where the "key" goes in. The keys job is to stop the CCT from extending when you remove it from the engine. Keeping it from extending makes it less likely that you knock a bit off into the motor, and also makes it easier for the CCT to clear the various bits above it. If you are really ambitious you could actually rotate the CCT to shorten it and make it even easier...but that would be over kill. After loosing both mounting bolts, and removing them, the CCT just slides right out: Here is where I have to admit I have a problem. I enjoy seeing how things work. I managed to restrain myself from taking apart my new CCT to see how it works, but the old one was just there....so I had to do it. Initially I planned to try the Reddog idea of tightening the spring....but I screwed up my spring after I removed it, so that was nixxed. Here is a nice picture of my CCT doing it's best Humpty Dumpty impression: you can see where the spring is messed up....yours won't look like that (don't take it apart to see tho). Let me describe the parts, so hopefully this makes more sense to those who want to know. Those who don't want to know can skip to anther thread or something... Clockwise starting from the left you have: CCT Gasket CCT body, with circlip just slid back key Sping(in the middle) bushing/sleeve Worm Drive Shaft with puck on end The sleeve/bushing goes around the worm drive, and over the shaft below the locking tab. The locking tab doesn't come off the shaft (without removing far too much). The way the CCT works is this: The spring is coiled around the shaft, with one end going into the slot at the bottom of the worm drive, and the other end into a slit at the top of the CCT body. As the worm drive is rotated clockwise, the spring winds up....and if allowed the worm drive will rotate counter clockwise to release tension. The worm drive can only rotate 4 times before the Shaft reaches its stopper. I believe the reason you begin to hear CCT noise is that the spring is able to unwind with a bit of Cam Chain stretch, and thus the spring is not as tight as it was originally. This loosness allows a bit more play that normal, and oscillations begin. Whether different oils help or not I don't even want to discuss. If you wish to attempt to modify your CCT to save some cash, here is how you do it: Holding the CCT in such a way that your finger restrains the shaft from advancing, remove the "key". Using a small (probably modified for the purpose) screwdriver, rotate the wormdrive from the access hole clockwise until it stops. Counts the revolutions. It will stop with the shaft all the way compressed. Now reinsert the key, and while still holding the shaft, slide the circlip down so it no longer restrains the locking tab. slide the locking tab carefully up the shaft out of the grooves, noting 2 grooves are wider than the other 2. Then very carefully rotate the shaft counter-clockwise 1-2 times as many revolutions as it took to compress it initially. (this figure is a guess, your results may very, I make no guarantees..written, expressed or otherwise, not available in all locations, subject to rule changes etc). After rotating the shaft counter-clockwise, slide the locking tab back down, and replace the circlip. Re-insert the screwdriver and rotate the gear clockwise to compress the shaft once more. Now you can reinstall the CCT and see if you saved $100. Reinstalling the CCT is the reverse of removal (I hate it when manuals state that, but it's true. Just check and make sure all connections are replaced or you may not like the results...I didn't. That is the connector I forgot. The FI light was blinking when I started the bike. I was able to get it back on without removing the air box again using a long thing screwdriver. Speaking of which, here are all the tools I needed to do the job: 1/4" driver handle 1/4" Rachet 1/4" x3" extension 1/4" x 6" extension 1/4"x1/4" socket for hose clamp 1/4"x8mm socket for CCT bolts and tank bolts Phillips Screw Driver 3/8" Rachet 3/8"x10mm socket 3/8" x 6" extension Needed this time, but not always required: Long Needle Nose pliars Extra Long thin screwdriver Telescoping Magnetic pickup tool Some pictures were not included, you can see them all here: http://www.wiremybike.com/Slideshows/CCT%20Change/
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