Tensioner
Hey robotman,
This is a very common problem and I've posted my solution for it 3 or 4 times.
The kit factory tell's you it will fit MOST bikes, of course that means it will not fit SOME bikes. This includes the tensioner. Some bikes have a thinner lower rear frame and the thing will just not ever get tight enough. The curved parts are too large to clamp on it. I've tried rubber, that was a joke. I've tried metal shims, just more places for it to slip on. tone2crazy's idea will work but if you've got a custom bike it kinda throw's off the look of the bike.
MY SOLUTION is to throw the smaller curved piece in your junk box, take a flat peice of good steel, cut it to size, drill your 2 or 4 holes, which ever one you have, and bolt it TIGHT to the tensioner. I've been building for a while and have done this to 10 or 12 bikes and it is the best way I've found so far.
The factory's will NEVER fix this problem as long as we keep buying chinese engines and they keep making a profit. THEY don't have a problem.
Hope this helps, Happy riding.
Big Red.