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yup..
there is an aluminum boss on the inner left hand crankcase, right below the stator. a pivot pin juts out from this boss providing the anchor point for the front of the spring steel/rubber adjuster. the inherent problem I see with this set up is that as you adjust the chain adjuster, Pushing chain up from underneath,
it transfers a lot of load to the boss that holds the pin. Imagine the differance between holding a 10 pound sack at arm's length, compared to holding the same weight close to your chest.
over the years i tried to reinforce this boss with JB weld. Then when I had the cases split, I sent the left side to have the boss properly replaced, (new one welded in to recieve pin).. I thought I had it licked, but alas, after 2 seasons, this new boss fractured.
so last weekend we executed a re-engineered design.
I didn't want to split the cases, and felt it might just end up failing again.
We ground down the remnants of the boss, which still left the hole for the end of the pin. Then with some careful measuring, we took a piece of angle iron, and proceeded to make a 'foot' underneath the pin that sat on the lower inner lip of the crankcase. the upper part of the angle iron sits against the inner crankcase with a hole in it to allow the pin to run through it and sit in the original crankcase hole. then we welded the pin to the angle iron foot.
then drilled two holes through the bottom of the lip of the inner crankcase to recieve bolts and secure foot to the inside crankcase lip. Now the load as the tensioner pushes up, the stress is transfered directly underneath the pin, as opposed to the end of pin.
I am hoping this works. I think the design is sound, and it seemed very strong on installation. I will let all know how it works out.
I would love to know if any other 500 owners have had the same hassle.
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