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Old 02-14-2012, 11:13 AM   #136
TwIsTeD OfF
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A KTM cam chain looks like a mini drive chain. no "extra" link plates in the center. If you can reuse those a masterlink and a rivit tool are easy to get. Munn racing (ktm dealership in TX) stocks both.

*** edit**** I didn't see until after I posted those are newer year models than I have worked on. ****
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Old 02-14-2012, 02:14 PM   #137
chadams
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I have ordered a stock cam chainand have been playing with the old one. If you use a chain press and slide the pin to the outer plate it can be re-used / re-linked. I've had about nine practice runs on the old chain without any problems. Worst case the chain has a tight spokt and runs a few links driving the valves through the piston. I'd rather give it a shot first then stripping the motor down and removing the crank.
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Old 02-14-2012, 03:11 PM   #138
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Quote:
Originally Posted by chadams View Post
I have ordered a stock cam chainand have been playing with the old one. If you use a chain press and slide the pin to the outer plate it can be re-used / re-linked. I've had about nine practice runs on the old chain without any problems. Worst case the chain has a tight spokt and runs a few links driving the valves through the piston. I'd rather give it a shot first then stripping the motor down and removing the crank.
So you just drive it out to the outer plate then push the pin back in?
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Old 02-14-2012, 06:33 PM   #139
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Originally Posted by Motorfiets View Post
So you just drive it out to the outer plate then push the pin back in?
Yes, that's what I've done on my practice runs, once the chain turns up, hopefuly soon (6 weeks express from Germany) I'll post some pics.
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Old 02-14-2012, 06:59 PM   #140
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Originally Posted by chadams View Post
Yes, that's what I've done on my practice runs, once the chain turns up, hopefuly soon (6 weeks express from Germany) I'll post some pics.
6 weeks!?! ouch.... where are you located?
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Old 02-21-2012, 02:19 AM   #141
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Cam Chain Master Link - Use at your own risk....

Given I'm not riding at the moment waiting for a new cam chain I've started playing with the old one that I've taken off the bike. So I've been able to split and rejoin the stock chain, only issue is the joined link is a bit tight. It should loosen up over time but it might reduce the life of the chain / guides / etc.
So next Option now I know the chain model type 98 XRH 2015 was to hunt for a master link. Firstly no matching part for 98XRH2015 even K&L supply doesn't have one. If they don't no one will. So next I started to go through all the cam chain specs I could find and came across the 82 RH 2015 which has many similar specs.
In the below link catalog 82 RH 2015 is CMM-A and 98 XRH 2015 is CMM-K15
Pin Center to Center
6.35
Number of plates
9
Inside width distance between outside plates
7.2
Pin diameter
2.6
http://www.xmas1.at/xneu/KATALOG/200...euerketten.pdf

Now I'm getting excited as 82 RH 2015 has master links available
So I bought one (a K&L supply one) from http://www.z1enterprises.com


Fast forward a couple of days and I receive my new 82 RH 2015 master link. So with no delay I test fit it to my old timing chain and as expected from my measurements it fits As can be seen from the 2nd picture the outer plates are thicker on the master link but all inner plates are from the original chain. The master link is only two pins and two outer plates with the pins fixed in the outer plate. The 82 RH 2015 is only 0.6mm wider at the pins then the 98 XRH 2015, so I'm not going to worry about it but if you were worried you could file down 0.3mm from each side.

So next step for me is to wait for the cam chain to turn up then fit it up, I'll take some photos and post it up once done. Al


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Old 02-21-2012, 03:17 AM   #142
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Quote:
Originally Posted by chadams View Post

...Fast forward a couple of days and I receive my new 82 RH 2015 master link. So with no delay I test fit it to my old timing chain and as expected from my measurements it fits As can be seen from the 2nd picture the outer plates are thicker on the master link but all inner plates are from the original chain. The master link is only two pins and two outer plates with the pins fixed in the outer plate. The 82 RH 2015 is only 0.6mm wider at the pins then the 98 XRH 2015, so I'm not going to worry about it but if you were worried you could file down 0.3mm from each side.

So next step for me is to wait for the cam chain to turn up then fit it up, I'll take some photos and post it up once done. Al
...
Exciting development.

I look forward to seeing the final results. Keep us posted.
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Old 02-21-2012, 05:13 AM   #143
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Warning: I've done zillions of bicycle chains and a few m/c chains, never a cam chain so keep that in mind.

What are the clearances like around the chains path? i.e. Through the guides, etc. Any chance that the wider link could catch?

And kudos for tracking this down - - it could be a huge help for a lot of riders in the future!
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Old 02-21-2012, 06:00 AM   #144
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Originally Posted by NCD View Post
Warning: I've done zillions of bicycle chains and a few m/c chains, never a cam chain so keep that in mind.

What are the clearances like around the chains path? i.e. Through the guides, etc. Any chance that the wider link could catch?

And kudos for tracking this down - - it could be a huge help for a lot of riders in the future!
Although I have not been in there..... If it is anything like other bikes... Then there is plenty of clearance. That thing slaps and bangs around...thus plenty space is needed....... But looking at it with the valve cover off.... There is plenty of room....

Erling
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Old 02-21-2012, 12:37 PM   #145
chadams
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Originally Posted by ebrabaek View Post
Although I have not been in there..... If it is anything like other bikes... Then there is plenty of clearance. That thing slaps and bangs around...thus plenty space is needed....... But looking at it with the valve cover off.... There is plenty of room....

Erling
I test fitted to the front guide and there is a lot of room
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Current ride:- 2002 KLX400R
Previous rides:-09 f800gs, 05 z750, 81 z1000j, 84 gpz1100, 98 dr250, 99 dr250, 96 dr350, 93 rf900, 93 nx650, 98 xtz660, 97 dt200r
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Old 02-21-2012, 06:02 PM   #146
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That's awesome man.
A lot of people are going to be thanking you for many years to come if this works out well!
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Old 02-23-2012, 11:25 AM   #147
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Quote:
Originally Posted by chadams View Post
So I've been able to split and rejoin the stock chain, only issue is the joined link is a bit tight. It should loosen up over time but it might reduce the life of the chain / guides / etc.
So next Option now I know the chain model type 98 XRH 2015 was to hunt for a master link. Firstly no matching part for 98XRH2015 even K&L supply doesn't have one. If they don't no one will. So next I started to go through all the cam chain specs I could find and came across the 82 RH 2015 which has many similar specs.
In the below link catalog 82 RH 2015 is CMM-A and 98 XRH 2015 is CMM-K15
Pin Center to Center
6.35
Number of plates
9
Inside width – distance between outside plates
7.2
Pin diameter
2.6
http://www.xmas1.at/xneu/KATALOG/200...euerketten.pdf

Now I'm getting excited as 82 RH 2015 has master links available
So I bought one (a K&L supply one) from http://www.z1enterprises.com


Fast forward a couple of days and I receive my new 82 RH 2015 master link. So with no delay I test fit it to my old timing chain and as expected from my measurements it fits As can be seen from the 2nd picture the outer plates are thicker on the master link but all inner plates are from the original chain. The master link is only two pins and two outer plates with the pins fixed in the outer plate. The 82 RH 2015 is only 0.6mm wider at the pins then the 98 XRH 2015, so I'm not going to worry about it but if you were worried you could file down 0.3mm from each side.

Good show, chadams!

When you say "0.6 wider at the pins" do you mean that the 82RH2015 link has it's pins placed 0.6 wider centre to centre than the 98RH2015? Or do you mean wider at the pins just referring to the thicker plates, when the link is installed as shown?

I'm assuming/hoping that "wider at the pins" means wider outside to outside link "thickness"and not a pin centre to centre difference.


LOL that the 82RH2015 does end up being the one to use, it's the one I posted the err...link to, (sorry) back on page 4
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Old 02-23-2012, 03:54 PM   #148
chadams
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Originally Posted by L.B.S. View Post
Good show, chadams!

When you say "0.6 wider at the pins" do you mean that the 82RH2015 link has it's pins placed 0.6 wider centre to centre than the 98RH2015? Or do you mean wider at the pins just referring to the thicker plates, when the link is installed as shown?

I'm assuming/hoping that "wider at the pins" means wider outside to outside link "thickness"and not a pin centre to centre difference.


LOL that the 82RH2015 does end up being the one to use, it's the one I posted the err...link to, (sorry) back on page 4
Correct outside to outside, the 82RH2015 has thicker outer plates, but all the original inter plates will be retained/ reused.
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Current ride:- 2002 KLX400R
Previous rides:-09 f800gs, 05 z750, 81 z1000j, 84 gpz1100, 98 dr250, 99 dr250, 96 dr350, 93 rf900, 93 nx650, 98 xtz660, 97 dt200r
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Old 02-27-2012, 01:49 AM   #149
chadams
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Theory to Practice....

Well the theory worked, chains on and timings done. Tomorrow I'll put the covers back on and all the plastic back together. To do the job you'll need a cam chain tool, I used a cheap one off ebay with no problems.

Apologies to DIeselboy for hijacking his thread and also for not finding this information earlier to save him some time.


Edit: tensioner & spring were replaced approx 4 weeks ago. I did not measure the new chain but the new one was extremely tight to fit over the camshaft sprockets and the old chain was so slack it came off with out needing to move the cams. The main issue I see with the cam chain is the length and load (driving the water pump). I'll be chaining it next time as soon as I hear any chain slap at start up.



Cam chain tool TL0003
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Current ride:- 2002 KLX400R
Previous rides:-09 f800gs, 05 z750, 81 z1000j, 84 gpz1100, 98 dr250, 99 dr250, 96 dr350, 93 rf900, 93 nx650, 98 xtz660, 97 dt200r

chadams screwed with this post 02-27-2012 at 03:39 AM
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Old 02-27-2012, 03:07 AM   #150
Dieselboy OP
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Quote:
Originally Posted by chadams View Post
Well the theory worked, chains on and timings done. Tomorrow I'll put the covers back on and all the plastic back together. To do the job you'll need a cam chain tool, I used a cheap one off ebay with no problems.

Apologies to DIeselboy for hijacking his thread and also for not finding this information earlier to save him some time.
Not a hijac. IMO Making this a more useful thread. I put an edit on post #1 to link to your work.

In fact, please post a pic ofthe the chain tool. What's the make? (EDIT: thanks for adding that pic.)

Also, did you mention the tensioner? I may have missed it but is it replaced or are you running the old one still?

And definitely come back with an update.

Well done!
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Dieselboy screwed with this post 02-27-2012 at 05:30 AM
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