I was thinking make the mount hole more sloted and, as you said, cross drill, set a small diameter, Mean little spring in the hole, slide it on the mount and have enought of a slot and enough spring to allow the tensioner to be pressed away from the chain enough to absorb the chains pressure. I think this , along with the Versy mod will change the cam chain issue. You Might sell it to Suzuki..

justin_o_guy2 wrote on 05/27/16 at 08:51:34:

Aha, you get it now.  

The new spring is a little stiffer, not much.

Hard part is installation.  pushing back the spring enough to slide it on the pin maybe an issue for some.  I'm thinking a bullet shaped dowel that is pushed in 1st to hold back the spring, then shove it out to mount it.

I think this new concept has some real potential!

The slotted mount on the backside should provide the needed movement......now a system to provide a spring in that location is needed.

Counterboring may be the easiest way, and a dowel in the hole that gets pushed out as the tensioner is pushed over the pin could work, and the user would need to keep that dowel if they ever needed to remove the tensioner and not have things fall apart.

I was trying to think of a way to install a small flat "piston" in the plunger cavity - the piston could have a pin that poked out the backside of the plunger cavity to apply the force to the pin in the new slot.  The problem with this scenario is I can't figure out how to make the spring apply more pressure out the backside....rather than to the plunger.

It might also be possible to adapt some king of angular spring on the back of the tensioner.  

While it's true that I'm not a degreed engineer, I did design a tool to capture the broken casing downhole when two engineers failed. I've built things and solved problems for decades. If you read the post above the one that you agreed with you'll see effectively the same point made.
I became The copier repairman for a small business after the other guy quit. I had seen a few repaired, been generally busy on calculators and cash register s. I couldn't even run some of the copiers. I would have someone show me what buttons to push, watch it fail, then repair it. I envisioned the necessary mods to solve this problem. So, let's try to not be looking down the nose at me.
Tapering off the end of the mount pin, using a thin, stiff piece of metal, like a shoe horn, press it on.

How much does the cylinder expand vertically when hot compared to cold?

Today I tried to find out.

Last night I measured the height of the cylinder when cold. I rode the bike about 100 miles so it was certainly warmed up. When I got home I measured again expecting that expansion would make the cylinder taller. No sh## Sherlock! I was surprised at the increase! My cylinder grew .5mm!!

I measured from the cylinder base gasket area to the bottom of the head cap. I would think that the change in the distance between the crank center and the camshaft center would be more than this.

I haven't attempted to do Versy's calculation concerning the effect on the cam chain but it seems that the cam chain would be bow tight if the tensioner had just taken up a new tooth on the ratchet when cold. :'(

My measuring method was not really the best ( a caliper) but I'm certain that my numbers represent something close to reality.

Versy thinks that 1.5mm is in the ballpark and I think he is being conservative. I know his doesn't solve anything but at least It seems to show how much unwanted  tension is on the chain at certain times.

soooo, vasimatteryou can't snap a pic?

snap a pic
upload it on yer computer
then upload it when you post.
if you can, rescale to 800x600 or 640x480.