Decathlon cargo bike R500e chain tensioner

The chain tensioner of R500e version 1  cargo ebike is a bad joke. Mine was not bearable anymore, but the order of the replacement part took quite a long time. So I made a replacement part that mimics the new version of this part. It uses a sprocket and a 608 bearing - so you need one 608 bearing for this model

Mine is a temporary solution until original part arrives. My experience so far is, that this solution might be more durable as I initial thought, so I cautiously recommend it for continuous use.

I use PETg, but if you have some reinforced materials available then I would recommend to print at least the sprocket with this material.

update: I used the printed version for a while, despite I have the replacement part available. It holds very well! I examined the original sprocket and this is also plastic. So I'm confident that my solution will hold a wile. Nevertheless I would print it from PETg-CF

Print Instructions

• print in PETg or other reinforced material
• use paint-on support for the sprocket

Assembly

• press bearing into the sprocket. it's very tight, use e.g. a clamp
• remove original tensioner
• use the bolt, the screw, distance thingy and washer from the old part
• put bolt and distance thingy back on the bike frame
• put first disc on the bolt. chamfer should point to the sprocket
• then put the sprocket, then the other disc and then the washer on the bolt
• lock this assembly with the screw and tighten it firmly
• put chain onto the sprocket

Additional notes

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Hope you enjoy my models.