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Introduction
Chain drives fail from numbers you didn’t measure—sag, hot, alignment, and elongation. Set tension by measurement, not feel.
Problem (one line): Mis-tensioned chains ratchet under load, hook sprockets, dust bearings, and create repeat call-backs.
Mechanism (why it keeps failing):
Too tight → elevated bearing load, pin–bushing wear, heat.
Too loose → chordal vibration, tooth impact, ratcheting, accelerated pitch wear.
Misalignment → edge loading and rapid sprocket wear.