Making your stock tensioner adjustable.
i recently had a clutch basket failure and a timing tensioner failure, here was my solution to the timing tensioner problem, instead of paying $65 for a stock one to go out again or waiting for an adjustable one to come out, i spent about $3.50 at the hardware store and made my own, and it works perfectly.
first remove the tensioner from the bike, then disasseble it completely, throw away the washer, sleeve,screw and spiral band that acts as a spring becuse you will not need them.
where the screw was threaded into the plunger, drill it out smooth with an 11/32 or 3/8 drill bit to accept an 8mm threaded bolt.
drill the hole in the back of the housing where the 6mm bolt used to be with a 1/4" drill bit and tap it with an M8X1.25 tap.
clean everything really good and reassemble the plunger into the housing using only the retainer plate and C clip
next, put the backup nut onto the M8 bolt then the nylon washer, and screw the bolt into the back of the tensioner until it touches the inside of the plunger.
assemble it on the bike and adjust as you would any other manual tensioner using the backup nut and nylon washer to seal the oil in and lock the adjustment, see pic below.
i have a cad drawing of it but the forums limits will not let me upload it.
2008 TRX 700XX (Black/Charcoal)
13T,Stage 1 hotcam,11:1 CP piston,L8ton Sway bar,Orange Maier Plastics,21" razr 1 front,ITP Sandstars on 10" ITP T9 Pro Series,FMF powerbomb/powercore.EHS programmer next.
2007 GSXR 1000 (Orange/Black)
-1,+2 Driven Kit,K&N, Full Leovince stainless exhaust,PcIIIUSB/Dyno tune,Hyperpro Damper,ASV Levers,Woodcraft Engine covers,Woodcraft Clipons,Xenon HID,Carrozzeria Wheels,Galfer Rotors(gsxr.com 2010 bike of the year)
Last edited by Simplyorange; 01-07-2011 at 12:00 PM.