Honda Hobbit PA-50 Moped Pedal Chain Tensioner

Hondas revised version of the Honda Hobbit/PA-50 chain tensioner. 

Parts List: Gear Washer x4, Gear X2, Gear Bushing X2, Baseplate x1, Top Bar x1.

Tools needed: M8x1.25 Tap, vise

Hardware needed: M8x1.25-20mm, M8x1.25-25mm, OEM bolt (M6x1.0-12mm) and OEM Washer

Print bushings and washers in PETG. The baseplate and top bar need to be cut from 11 gauge steel (.1196"/3mm) metal (cnc router, laser or water jet). The gears and either be printed or cut from steel.

Step 1: Tap large baseplate with M8x1.25 tap (img1).

Step 2: Pre-fit entire assembly as seen in (img2 & 3). Note the longer bolts location. File/sand parts as needed. Gears should spin freely on the bushing and have side to side play, other parts should be snug fitting.

Step 3: Unscrew baseplate from assembly. Feed chain around both gears. Slide baseplate between subframe and assembly. Apply locktite to and hand tighten the two M8 bolts to the baseplate. Secure baseplate with OEM retaining bolt (img 4 & 5).

Step 4: Tighten the two M8 screws so they are snug. Be careful not to strip out the threads or crush the PETG bushings.

Step 5: Adjust chain tension and tighten the OEM bolt (img 6).

Note: The OEM gears fit on this model and work better than the printed ones. Use locktite on the M8 threads