Jay,
We run the 420 chain for no other reason than thats what it had.
The 35 chain is smaller giving you multiple choices for your front sprocket, which gives you more gear ratios. (good for racing)
We have been using the Recmotors tensioner in the #716 sled 3 years and the #289 sled 2 years.
Chains are a big problem regardless of pitch, some people have good luck when they bake them, I have not noticed any real difference.
Both of our sleds have gone through 4 chains each this year total of 8.
Belt drives from what I can tell still need a chain and a jack shaft. Oh and are any where between $800.00 - $1000.00.
Instead of doing all the engine changes, you might want to take a look at some used champ sleds. Since the onset of the 8 - 10 year olds being able to race the Freestyle 300 there has been a decline in champ sleds and not a lot of interest in people buying them. The Freestyle is cheaper than what it costs to build a champ sled or a ton of mods to a regular sled.
This is just my 2 cents, as I am not a big fan of modifying sleds.
RMR Classifieds 120 ccThere are not many ads in the RMR forum now but in the next couple of weeks there will be a lot of sleds.