ZR 800 Chaincase Tensioner - HCS Snowmobile Forums

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Old 11-08-2005, 10:06 PM   #1 (permalink)
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Current Sled(s): '08 MXZ Renegade 600SDI
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As I discussed in an earlier topic, I wanted to gear down a bit (for the 136 track). After seeing my chain, Micro-Belmont strongly suggested a new chain. Stock gears are 24/39. I was going to go 23/41 (1.783 ratio), however, it wouldn't fit with the 72-pitch chain, so I decided to go 23/40 (1.739 ratio). Then I thought, since I'm going to have to buy a new chain, why not buy a 74-pitch chain, stay with the stock 24 top gear and go with a 42 bottom gear (1.75 gear ratio). Saves me $$ and gets me bigger gears (less rolling resistance).

They fit nicely in the chaincase with not much tension needed from the tensioner. However, when I hook the tensioner spring from one side to the other, it seems pretty tight, maybe even too tight.

Can anyone see any issue with the leaving out one of the tensioner pulleys? Just using the one I can adjust? Instead of my chain following an hour-glass shape, it will follow a "B" shape. I attached a parts diagram to show exactly what I'm thinking of leaving out. Any help is appreciated, as always.
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Old 11-08-2005, 10:18 PM   #2 (permalink)
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on my stretched zr i went with 22/41 gearing and i put the 15 wide chain in because i broke a 13 before and i left that part of the tensioner out . i had no problems with it last year. :div20:
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Old 11-09-2005, 12:03 AM   #3 (permalink)
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I have removed mine from both the old 700 and 900 I have now with no problems. They are only a unnessary noise maker when it hits the side of the case as the chain flexes.
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Old 11-09-2005, 08:42 AM   #4 (permalink)
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Yeah, definately leave it out. My '03(late release) only has the one. Still, I think you should go with a 15 wide chain and top sprocket(23-40).
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Old 11-09-2005, 08:59 AM   #5 (permalink)
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I just did it a few weeks ago.. You need to look at the DROPCASE CHAIN TENSION ASSEMBLY (OPTIONAL).. It can be found on the ZR800 or ZR900 Cross reference the parts.. There are 2 things you can reuse the roller and I think the bearing.. Then buy the rest.. I think it was about $50-$60CAD.. Then just use the bolt that was already there for doing the adjustment much more simple simple setup.. And less parts to break and fling around in your chaincase.. :div20:

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Old 11-09-2005, 09:11 AM   #6 (permalink)
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My '03 ZR8 only has one like you are thinking about. I bought it new and now has 5800+ miles on it with no problems. Last year (2700+ miles) was with a 136 x 1.25 track and a 900 top end. :banana:
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Old 11-09-2005, 09:36 AM   #7 (permalink)
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Cool! That thing is coming out! I didn't even think of the added benefit of saving about 12-16oz. BONUS!

Thanks guys!
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Old 11-09-2005, 01:28 PM   #8 (permalink)
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I ran my 580 without the other half ,and had no problems.
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Old 11-09-2005, 03:32 PM   #9 (permalink)
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I took mine out last year, I could see the marks were the other half was hitting! :cn:
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Old 11-09-2005, 08:48 PM   #10 (permalink)
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Heres the formula for your chain size if it is any help. Add teeth on top and bottom gear and divide by 2 than add 40, round up to next even number and that is your chain size needed . If you hit it by .5 under this is the best chain fit,1.5 under is max you can use but will have a lot of slop and maybe your chain tensioner will look a little strange, use this formula to see if you need 72p or 74p possible why your having tensioner issue. Steve Bigtwin
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