A tensioner with style and functionality

Hello from Lansing Michigan,
This is a tensioner that I made for my very first MB build, I wanted nice tensioner on a low budget, solid and beautiful, I finally got to use my degrees in art. I added an led light to add to the appeal.
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No, not to crazy about that one either. I'm the mechanical type, and like mechanical parts to look like mechanical parts. I have never really been one for decoration. As for the rest of it, it is hard to really get a good look at it from your pictures. I did not know you used a skateboard wheel. You didn't say so, and it isn't obvious from the picture. Actually a skateboard wheel sounds like a pretty good idea for a tensioner roller. Certainly a lot better than what comes in those kits. I have a lot of issues with those. One, they are way too flimsy for the job they are meant to do. Both the bracket and the roller. They mount to the bike in a way that allows them to rotate on the frame. Mine was very tight, yet it still wound up in the rear wheel spokes, breaking several spokes and locking up the wheel, and dumping me on the road in front of oncoming traffic. Also, while they are adjustable, they are not spring loaded and they cannot pivot to maintain constant tension on the chain. You seem to have solved many of those problems. I'm not putting down what you did. But you had to build it. What I would like to see is a well made commercially available part. As an auto mechanic, I like precision. A derailleur is a precision made component, And I just think that something of similar design but bigger and stronger would be just what we need. But I guess it really doesn't need to be that complex. Just overbuilt for what it needs to do, and attach solidly to the bike without clamping around a frame tube.

I have so many issues with these Chinese kits. I know they are cheap, and people like that. But they never fit properly, the tensioner and method of attaching the sprocket to the rear wheel is terrible, The engine and gas tank mountings almost always have to be rigged. I'm not saying that I think all this should go away, other than the tensioner, which is downright dangerous. But I would like to see motorized bikes come out of the stone age. I would like to see a company build upscale kits, including a frame and rear wheel specifically designed as motorized bike parts, so that everything fits. A motorized bike is such a cool idea, both as transportation and fun, that can be ridden in most places without all the red tape hassles of a motorcycle. I think they deserve better than what we have today. I'm also on the 4 stroke bandwagon, and am using a Honda GX35 with a friction drive. I would love to use that same engine, only frame mounted, with a shift kit. A shift kit eliminates many of the problems with the Chinese kits. But there are still usually engine mounting problems. Many are caused by the way bicycles are built today. Whatever happened to bicycles built with small diameter round steel tubes? All the tapered and oval shaped frame tubing certainly complicates mounting things. But again, a frame designed for a motor, with welded on mounts for everything (engine, gas tank, and tensioner) would solve a lot of problems, and would be so simple to build. Ultimately I would like to see complete factory made motorized bikes, made to high quality standards, just like real mopeds were back in the '70s. A motorized bike would solve so many of the issues mopeds had. They would not require registration, insurance, motorcycle license, etc. and the most important part, they can be ridden in bike lanes where mopeds can't. They are perfect for someone like me, who loves to ride a bicycle, but are physically unable to pedal anymore. They can be parked at bike racks (if you want to take the chance, I had one stolen) and they could still be customized by the owner. Sorry about this "rant" but I am very passionate about this. I am a lifelong cyclist, and perfectionist, who is no longer physically able to ride a pedal bicycle. And I can see no technical obstacles to building a high quality motorized bike. I think it would be nice to see someone like Honda, with all their engineering expertise, build one.
 
A good tensioner can be made any number of ways. Roller skate wheel would great mounted on a 3/8" axle. I use hard plastic washers that roll freely on a 3/8" clevis.

Using a 415 chain or heavier, one could fashion a piece of mild steel. With a touch of grease, the side plates would quickly eat into the mild steel and once you are down to the rollers the chain would slide smoothly by with very little resistance. Spring based tensioners look cool but they are not the best way to roll.
 
No, not to crazy about that one either. I'm the mechanical type, and like mechanical parts to look like mechanical parts. I have never really been one for decoration. As for the rest of it, it is hard to really get a good look at it from your pictures. I did not know you used a skateboard wheel. You didn't say so, and it isn't obvious from the picture. Actually a skateboard wheel sounds like a pretty good idea for a tensioner roller. Certainly a lot better than what comes in those kits. I have a lot of issues with those. One, they are way too flimsy for the job they are meant to do. Both the bracket and the roller. They mount to the bike in a way that allows them to rotate on the frame. Mine was very tight, yet it still wound up in the rear wheel spokes, breaking several spokes and locking up the wheel, and dumping me on the road in front of oncoming traffic. Also, while they are adjustable, they are not spring loaded and they cannot pivot to maintain constant tension on the chain. You seem to have solved many of those problems. I'm not putting down what you did. But you had to build it. What I would like to see is a well made commercially available part. As an auto mechanic, I like precision. A derailleur is a precision made component, And I just think that something of similar design but bigger and stronger would be just what we need. But I guess it really doesn't need to be that complex. Just overbuilt for what it needs to do, and attach solidly to the bike without clamping around a frame tube.

I have so many issues with these Chinese kits. I know they are cheap, and people like that. But they never fit properly, the tensioner and method of attaching the sprocket to the rear wheel is terrible, The engine and gas tank mountings almost always have to be rigged. I'm not saying that I think all this should go away, other than the tensioner, which is downright dangerous. But I would like to see motorized bikes come out of the stone age. I would like to see a company build upscale kits, including a frame and rear wheel specifically designed as motorized bike parts, so that everything fits. A motorized bike is such a cool idea, both as transportation and fun, that can be ridden in most places without all the red tape hassles of a motorcycle. I think they deserve better than what we have today. I'm also on the 4 stroke bandwagon, and am using a Honda GX35 with a friction drive. I would love to use that same engine, only frame mounted, with a shift kit. A shift kit eliminates many of the problems with the Chinese kits. But there are still usually engine mounting problems. Many are caused by the way bicycles are built today. Whatever happened to bicycles built with small diameter round steel tubes? All the tapered and oval shaped frame tubing certainly complicates mounting things. But again, a frame designed for a motor, with welded on mounts for everything (engine, gas tank, and tensioner) would solve a lot of problems, and would be so simple to build. Ultimately I would like to see complete factory made motorized bikes, made to high quality standards, just like real mopeds were back in the '70s. A motorized bike would solve so many of the issues mopeds had. They would not require registration, insurance, motorcycle license, etc. and the most important part, they can be ridden in bike lanes where mopeds can't. They are perfect for someone like me, who loves to ride a bicycle, but are physically unable to pedal anymore. They can be parked at bike racks (if you want to take the chance, I had one stolen) and they could still be customized by the owner. Sorry about this "rant" but I am very passionate about this. I am a lifelong cyclist, and perfectionist, who is no longer physically able to ride a pedal bicycle. And I can see no technical obstacles to building a high quality motorized bike. I think it would be nice to see someone like Honda, with all their engineering expertise, build one.

I guess part of what I'd like to convey is that not all of us were born with a silver spoon, or lucked out and got a great pension , if the market doesn't have what you want or just can't afford it, you can always build your own,
As for Chinese kits, I've Never had an issue with the fit, sure sometimes you may need to pick up an angle grinder or a drill, face it,
If you can't overcome an oversized tube then the alternative is buying a scooter, it seems that's what you've described. Everything all nice and neat ready to buy off the shelf with everything pre engineered with all the high tech welded and powder coated bells and whistles.
 
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The stock kit is workable. The motors are dependable and want to run. The rag joint is fine and, when properly attached ( with locknuts) to a true wheel with tight spokes, will provide several thousands of miles of good service. The stock CDI is nicely insulated and will perform dependably for a long time. Get an NGK spark plug. The 415 chain is bombproof. The Sprockets are good quality. The clutch is simple and easily adjustable, lasting a long time.

What won't work? The stock motor mounts. Not nearly beefy enough. Attach the engine using big metal. The NT carb. The needle slide is just too simple and even with the right jet it will frustrate you. Get a dellorto clone for about $30. The stock tensioner is too frail but the support bracket is fine. Affix a 3/8" axle into the bracket and use heavy nylon washers as the contact surface. You can surround these washers with 2" steel fender washers. Tighten the bracket like crazy and use blue Loctite.

The magnetos will fail so it's always good to have an extra on hand. Keep an extra CDI around, too.
 
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Can anyone tell me what happens if you remove the tensioner all together,
And set the tension with the rear tire the same way the peddle chain is adjusted.
I believe I know what you will say, the 415 kinks up around the drive sprocket.
 
There are many good mechanics on here who will tell you that this is the way to do it, by optimizing chain length by placing the rear axle so that no tensioner is needed on the motor chain. I tried that method and it did not work for me. But many do that and they find success with that method.
 
So what if it coast $1200 or $1500 for a quality motorized bicycle. That is not really a lot of money anymore. And it could last a long time, probably over 10 years. It would not be for everybody, but I think someone should make such a bike, or the parts to build it. Look at the late Taiwan made Whizzer. To bad it's engine displacement made it illegal as a motorized bicycle in my state, and it was not DOT and EPA approved so it could not be registered as a moped or motorcycle. I have a Taiwanese made scooter, an SYM HD200 (actually 163cc) it is registered as a motorcycle. But it is big and heavy and awkward compared to a bicycle.

You CAN buy factory made electric bicycles. I actually rode a Pedego. Excellent engineering and build quality, but for the range I wanted, nearly $3500. You could build a gas powered bike for a third of that, with unlimited range. The main thing is that it be 48cc, and look exactly like a bicycle, not a scooter or a moped. You should be able to pick it up and carry it around. It should have bicycle wheels and fully functional pedals, not like a moped. Ever try to pedal a moped?

This is a Puch moped I used to own. I would have worked fine for me except for one thing. It was not legal in the bike lanes, which made it a suicide machine in traffic. You can't ride a bike that slow in traffic. You have to ride to the far right, bicycle lane or not. A motorized bicycle IS legal in bike lanes, and that makes all the difference.

 
So what if it coast $1200 or $1500 for a quality motorized bicycle. That is not really a lot of money anymore. And it could last a long time, probably over 10 years. It would not be for everybody, but I think someone should make such a bike, or the parts to build it. Look at the late Taiwan made Whizzer. To bad it's engine displacement made it illegal as a motorized bicycle in my state, and it was not DOT and EPA approved so it could not be registered as a moped or motorcycle. I have a Taiwanese made scooter, an SYM HD200 (actually 163cc) it is registered as a motorcycle. But it is big and heavy and awkward compared to a bicycle.

You CAN buy factory made electric bicycles. I actually rode a Pedego. Excellent engineering and build quality, but for the range I wanted, nearly $3500. You could build a gas powered bike for a third of that, with unlimited range. The main thing is that it be 48cc, and look exactly like a bicycle, not a scooter or a moped. You should be able to pick it up and carry it around. It should have bicycle wheels and fully functional pedals, not like a moped. Ever try to pedal a moped?

This is a Puch moped I used to own. I would have worked fine for me except for one thing. It was not legal in the bike lanes, which made it a suicide machine in traffic. You can't ride a bike that slow in traffic. You have to ride to the far right, bicycle lane or not. A motorized bicycle IS legal in bike lanes, and that makes all the difference.


But anyways, back to the subject of the tensioner, does anyone have pics or descriptions of a tensioner that they have made ,bought or seen that they feel works better than the standard kit tensioner?
(I honestly have no issue with the kit tensioner, you just need to drill a hole through it and the frame to bolt it in place).
 
I like this one. It mounts to the motor, not the bike, is spring loaded, and has a toothed sprocket.

http://www.ebay.com/itm/BBR-Tuning-...ash=item2a5c87e2de:g:-XgAAOSwv-NWVBnl&vxp=mtr

I like this one, basically the same concept as the ones that I built but light weight and with a sprocket and a hefty price I'm sure junkyard dog will approve as well including the price ,myself I think I would rather copy the design (not difficult at all) I would prefer a steel sprocket but overall looks like it would work well.
 
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