justin_o_guy2 wrote on 11/08/12 at 09:07:04:If I was gonna keep mine, Id have a part built. If I could do it myself in a reasonable amount of time, Id do it, I dont think the radius is quite sufficient as is. But thats me, Im no machinist,.
I concur that there could be a little more meat on it and bigger radius, but not much as there is little room for improvement. The biggest improvement would be proper steel and heat treatment.
Concerning the making your own part, the biggest challenge on that part would be the oval shaped hole in the middle made an exact fit to the shaft. I noticed there was some slop to it, but not from wear. It was that loose when new. A little too much slop for my taste as this aided the fracture point with jamming the edged part of the shaft on the inside of the part right where it broke. Kind of like laying glass on an edge and breaking it off. The tolerances should be tighter than that, no doubt about it. There is no reason for that much slop, not even thermo expansion.
I understand that there might be people thinking what do I know compared to engineers at Suzuki, but I tell you that this part is definitely a shame for any engineer or whoever else decided to put it into mass production like that. The way it broke apart says it all.
If it had been manufactured like the gears in the transmission or some parts in the motor, it wouldn't break like that.
The design of the cam chain tensioner issue just as hideous.
I say it again: I am still convinced that the piece was not properly annealed. I used to make sheet metal stamping tools and during my education we we're shown examples of improper annealing after hardening the stamps and they just busted like that piece here.
Looking at it shows that it broke like a piece of porcelain. Putting the halves together, and they fit almost without a visible fracture line.
That tells it all.