My Rinny has had quite the engine knock and I found this thread. First of all, I'm not all that mechanically inclined but thought I could handle this. I tried the original method posted by corndog by removing the tensioner, removing circlip, letting plunger out a bit, and then tightening the spring about 3 full rotations, then reassemble. My gasket was not in great shape, but I did not have a spare, so I installed it anyway to see if the problem went away. I also did not have the installation KEY so I tried with a small screwdriver, which did not fit in there well. I had problems fitting the tensioner back in place while keeping the plunger retracted with the screw driver. Basically, I could not keep the plunger fully retracted while fitting the tensioner. I ended up tightening it in there anyway and it seemed to be flush. I started the rinny and it sounded great. No knock at all. I then throttled it up a bit and it started to KNOCK LOUD. I shut off the bike. I started it again at idle. Very quiet, no knock, sounds better than ever. Rev up, and LOUD KNOCK. I shut off immediately and it remains off. WHat did I screw up? I just ordered a new OEM tensioner with key and gasket.
2005 Black Rincon. 27" Zillas, Clipped carb spring, re-routed vents on carb, diffs, and water pump