Originally Posted by
evan&sue
The hanger was checked and realigned early in its lifetime. Can the alignment change over time from wear?
All it takes is a bad knock against the derailleur, such as from the tandem falliing over on its right side or the like. However, in light of the other info you've shared, I don't think that's the problem: you're trying to get too many miles out of your drive chain.
Originally Posted by
evan&sue
The theory here in Australia is that you should be able to get 8000kms from your chain and cassette which are the parameters we have been working within
That sounds like even a tough benchmark for a single bike ridden hard by an average size cyclist. Cut it in half for a tandem and it will be a bit more accurate unless where you ride is dead flat and you and your stoker don't weigh much more than 250 lbs. Seriously, the only way to know when your chain needs to be replaced is by checking it for wear every few hundred miles (see below).
Originally Posted by
evan&sue
We don't have any experience with cable ferrules, length or other to even know where to start looking.
http://www.sheldonbrown.com/cables.html
Originally Posted by
evan&sue
It is also quite possible that the cables we are using are inferior bearing in mind we get very little tandem gear in Australia.
You might consider getting cable splitters, as they allow you to use two regular length derailleur (and brake) cables instead of searching out a tandem-length cable. Just for reference purposes:
http://www.sandsmachine.com/ac_cable.htm
Originally Posted by
evan&sue
The cassette is an IRD 11-32 Shimano compatible, 10 speed, not available in Australia.
Perhaps the strongest argument for running 9 speed would be lower-cost for cassettes, as 9 speed LX and XT cassettes or house-branded models from places like Nasbar Bike are readily available and much less expensive. Of course, if you change your drive chain when it stretches past 1/16" your cassettes and chain rings will last much longer. It's the chain's enlogation and change in pitch that causes wear on the cassette cog and chain ring teeth. So, if you don't let the chain stretch too far, it doesn't wear down the teeth: pretty straight forward.
Measuring Chain Stretch:
http://www.bikeforums.net/showthread...-chain-stretch