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Chaincase Help Needed!!

1330 Views 14 Replies 5 Participants Last post by  6000RXC
2015 HCR 800 153
New to the forum, looking for some
Opinions!
So I broke my auto tensioner last year and had to ride out 10-15 miles to get back to the truck, the pad broke off and chain was riding on the metal arm of tensioner. So I replaced the new arm and bought BDX HYVO chain and gear replacement to get rid of the aluminum gear.

Everything installed good up until the tensioner, with this setup the chain is so tight I had to pry very hard on the tensioner to get it into the first notch of the auto tension block. There was barely ANY slack in the chain and everything was so tight it was unrideable.

The gears I bought was 21/49 so I swapped out top gear to a 20 just for some more slack and now the tensioner is roughly half way down the tensioning block.

I know that the chain will stretch slightly once ridden, and would like the 21 top gear in there but is this just too tight to run? Need some opinions other than the parts desk who didn’t offer much help!
The first two pictures are the 21/49 gear ratio with new chain and the tensioner being so tight.
Second pic is the 20/49 with new chain.
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21 is way too tight. It won’t stretch much when you ride. IMO, it will break the new pad, or something anyway. The 20 looks perfect. I don’t have my chart here, but was 21/49 ever a AC factory ratio? There are also two different length tensioners, however, I don’t remember what year they changed. ‘17 or 18 I believe. I also don’t remember if they were Longer, or Shorter. But that could be what you have going on. I am certain that your 21/49 combo is Too tight though.
 

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You are welcome. I have installed the roller style tensioners and the manual threaded adjusters before, I can’t say for sure if one of them would fit into that space and give you any more slack in the chain or not, but I would feel better about running a combo that tight with that set up opposed to what you have now. I just wouldn’t do it. Going to a 48 on the bottom would gear you “up” ever so slightly as opposed to going down like you did with the 20. If you were interested in that mph option. I’d guestimate less than 3 mph difference on paper either way
 

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What year did the chain tensioner change? Are you saying he has the proper one?
I never much use recommended ratios anyway, but I have modified tensioners and prefer the manual style for such application
 

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I don’t know which one is longer or shorter. I believe the later ones are shorter, ‘18 and up. Maybe 17. I have my parts gearcase parts all in a basket…not too organized. I just put ones together that fit.
 
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