You guys that have experience with other engines need to chime in here.
But what I do believe is that we need a new tension adjuster design.
I would need a glass sided engine to know for sure. But what I think is the serrations on the pawl are probably too fine. I don't know if it's the temperature cycles that progress the pawl or actual wear or motion. But I think something is causing premature wear on the guides by overtensioning the chain.
I will surmise that rapid change in rpm's causes a wave of tension/slack in the chain. And this is why we have a rachet and pawl.
I also noted that there's quite a bit of room behind the adjuster and it could have been twice as long.
And I'm also concerned with the present chain.
Especially Yonuh's experience of the chain actually snapping on him. He noted that there was spots in the chain that would kink and stay that way. That may be the reason why the spring in the tensioner is made stiffer now. All it would take is for one of these kinks to engage the case jamming the gear... and snap goes the chain.
I also want to map the wear against the TDC to see if there is more stretch/wear at certain point in the cycle. My chain has been r&r'd once so it might have 2 patterns of stretch. I need a chain for someone who's never had it off. It needs to be marked while the engine is at TDC at a know location such as BDC of the chain.
And Justin... the answer to your question is here.
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1192027390