ok so my 97 has 30,000km on it. No idea if the chain/tensioner has ever been looked at so its time to take a look. If the tensioner is beyond its limits, whats my next step? From what I read the chain should still be OK but the tensioner may need replaced. I am assuming nothing can be adjusted with the stock setup.  Should I look into just getting a modified tensioner or just go to a suzuki dealer and order a new tensioner and chain?

Nick as you've already figured out,you will need to replace the chain and the tensioner as a set if you go stock again. That is a bit pricey and wastes what may be a chain with plenty more miles left on it. If you go with a Versy modified tensioner you not only can use the full life of your chain but the tensioner should last through another new chain too.

Go back to our main page,then go to the Marketplace,click on Verslagens Place,when the pics come up click on the red "Verslavy Cam Chain Adjuster" just above the first picture. That takes you to Versys page for info on the modified adjuster,including price options and ordering,along with parts for the adjuster too.

ok, I think I'm going to open it up and measure my adjuster, who knows, maybe its in good shape ready to go another summer (wishful thinking i know), i read about 20mm is the max extension allowed before things become ugly  

if things are gettin' worn then ill contact verslavy about one of his magical devices

The only warning you get is the death rattle.
When you've let it go too far and the plungers out 22mm.
It starts tapping on the case right by your ankle on the right side.
you can feel it with your hand just behind the oil filter cover and on top.
That's if you're lucky, it can go up and down too and miss the case entirely.

30,000 km is 19,000 miles

for an average rider (average 25mile per ride minimum)

you can expect that it going to be nearly 18mm out.

short avg rides = shorter life
longer avg rides = extended life

The cost of being wrong is high enough to justify having a look.

Here's what I did with this  winters rack time, knowing that the tensioner was >17mm:
I ordered:
- a cam chain
- clutch disc
- clutch springs
- clutch cover gasket
- circlip for the tensioner (because I'm paranoid)
Once those shipped with a tracking number I:
- drained the oil
- pulled off the head cover.
- pulled the clutch cover.
- removed the tensioner
- lubed the clutch cable.
- sent tensioner on a vacation to the "verslagen resort and spa"  
(wait for 1st  parts order...)
- removed the clutch basket
- pulled the gear from the main shaft. (righty-loosy, lefty-tighty)
- pulled the cam
- replaced the cam chain
- replaced clutch disc and springs.
- check and double check torques.
- quadruple checked cam timing.
- re-seal head plug
- re-torque head.

(by now, the verslavy has arrived, more beautiful than ever)
- re-install verslavied tensioner using the original hole. It's nice having a backup.
This weekend I'll be double checking everything before I sew her back up.

The new cam chain and clutch are arguably excessive, but I always try to get as much done with winter rack time and I also try to make use of the wait time for the parts moving across the continent.

well...it was sitting t 19.5mm with 34,215km on the clock (~21000 miles)..contacting verslagen1 now