Design and Fabrication of Chain Tightener – Mechanical Project

Design and Fabrication of Chain Tightener – Mechanical Project

We have noticed that the chain on nearly every chain-driven bike we’ve inspected in the parking lots of long-distance events, including the Iron Butt Rally, is incorrectly adjusted. They are almost always adjusted too tight. Even if the chain is lubricated properly and the rear wheel is aligned correctly, running a chain with too little slack leads to pre-mature wear of the chain and sprockets, suspension binding, and can even result in damage to the bearings supporting the countershaft and sprocket carrier in the rear hub.


At the other extreme, running the chain with too much slack can create excessive drive train lash. This makes smooth throttle transitions and shifting more difficult, adds higher shock loads to the rear hub and gears in the transmission, and, in extreme cases, can actually “saw” into the swing arm or frame. A mal-adjusted chain is also more prone to failure, which could leave you stranded. In extreme cases, it could wrap around the rear axle and sprocket and lock the rear wheel, leading to a crash. Which begs the question: Since the consequences of an improperly maintained chain can be so costly, why don’t more riders ensure that their chains are adjusted correctly? We suspect the main reason for chain problems is the result of owners not taking the time to thoroughly inspect their drive train or understand the procedure behind properly adjusting the chain on their bike. This article is for those riders who fall into the latter category adjusting the chain is not difficult, but it does require some patience to set every-thing up correctly the first time.

chain tightener mechanical project
chain tightener mechanical project

Now that the chain is cleaned and aligned properly, it is time to start the adjustment process. The first step is to determine how much play is in the chain. This is measured as the vertical deflection at the midpoint of the lower run of the chain, with the bike in gear (but the engine off) and the rear wheel rotated to the rear to remove any slack from the top run of the chain.


• To increase the millage of the vehicle
• To reduce wear of the sprocket
• Smooth running of the vehicle
• Soundless rotation of the chain
• Less friction loss


• More time taken to adjust the chain


• All two wheeler Application

Sachin Thorat

Sachin is a B-TECH graduate in Mechanical Engineering from a reputed Engineering college. Currently, he is working in the sheet metal industry as a designer. Additionally, he has interested in Product Design, Animation, and Project design. He also likes to write articles related to the mechanical engineering field and tries to motivate other mechanical engineering students by his innovative project ideas, design, models and videos.

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