KLR650 DID "X-ring" chain (riveted master link) install step-by-step walk thru

Discussion in 'Thumpers' started by klm4755, Apr 13, 2008.

  1. klm4755

    klm4755 Been here awhile

    Joined:
    Jun 19, 2006
    Oddometer:
    577
    Enclosed is a walk thru install of the DID 520VM rivet style chain on the KLR650. The DID 520VM is the top of the line chain and is rated at 8,120 lbs tensile strength, where as the stock chain is rated at 6,200 lbs. The stock KLR650 uses 106 links. The chain is also an “X” ring style where as the stock is an “O” ring style. It is recommended that any replacement chain master link not be the “C” clip style.
    This master link is the rivet style. A rivet style master link is abit more difficult to install. However the likelihood of unintentional disconnect is highly remote if the master clip is installed correctly. The chain and extra masterlinks can be seen here:
    http://www.tpimotorcycleparts.com/ for $112.50. Extra “X” ring master links sell for $7.95
    Kawasaki recommends the chain be inspected and replaced at an interval of 7,500 to 20,000 miles. This walk thru will consists of 3x
    parts:
    1. Review of tools needed
    2. Removal of the OEM chain.
    3. Master link plate and rivet install
    Start of part 1...tools needed
    [​IMG]
    packaging of the chain to install
    [​IMG]
    master link included
    [​IMG]
    chain pin press and master link plate press
    [​IMG]
    chain puller, if needed, this tool helps pull the links together to get the master link installed
    [​IMG]
    master link rivet upset squeezer
    [​IMG]
    tool out of kit
    [​IMG]
    new chain weight ~3lbs 10.5 oz
    [​IMG]
    master link pin to squeeze upset on installation, closeup
    [​IMG]
    X ring close-up
    [​IMG]
    X ring side view
    [​IMG]
    need 4x for master link install
    [​IMG]
    grease for master link install...Don’t eat this!
    [​IMG]
    pin removal tool diameter = .177 inches, This part gets installed on the master link install tool to either drive the master link pin out, or the thick end is used to upset the master link rivet on install.
    [​IMG]
    master link pin diameter = .205 inch
    [​IMG]
    with X ring installed
    [​IMG]
    closeup of link
    [​IMG]
    work area, bike on center stand, pannier off for access
    Part 2 Remove OEM endless chain
    [​IMG]
    Since the OEM chain has no master link...endless style...a pin head needs to be removed and a pin pushed out...get out the Dremal kit
    [​IMG]
    metal cutting wheel
    [​IMG]
    get out Dremal rotary tool
    [​IMG]
    get proper collet
    [​IMG]
    attach cutter
    [​IMG]
    any link will do....keep on rear sprocket to help stabilize the link pin head
    [​IMG]
    and cut from the side...fast dremal speed....no issues...cuts thru in 20 seconds
    [​IMG]
    like so
    [​IMG]
    use this pin removal tool to push the pin thru the link
    [​IMG]
    now the chain can be removed
    [​IMG]
    old and new side by side
    [​IMG]
    small overall stretch after 7,500 miles
    [​IMG]
    OEM dirty Chain weight 3 lbs 10.5 oz
    [​IMG]
    closeup view of O ring and X ring
    [​IMG]
    another view
    Now for part 3 rivet master link install
    [​IMG]
    Configure the rivet tool master link bucker to this configuration
    [​IMG]
    add 2x X rings and lube pins with the grease
    [​IMG]
    re-thread chain on drive sprocket and place ends on rear sprocket, install master link pins thru chain link
    [​IMG]
    add more grease, remaining master link X rings, and add outer plate
    [​IMG]
    rotate assy till master link is between sprockets
    [​IMG]
    use this tool to press fit the link cover on the pins
    [​IMG]
    Measure distance between non master link plates = .678 inches
    [​IMG]
    Master link press fit distance = .675 inches
    [​IMG]
    need to buck, by squeezing, the pin ends as shown here in un squeezed state
    [​IMG]
    will use this upset mandrel tool to form the driven head
    [​IMG]
    backing plate, kinda like a bucking bar
    [​IMG]
    engage tool
    [​IMG]
    apply co-linear forces with crescent and socket wrench to squeeze the master rivet pin head
    [​IMG]
    keep going till totally squished down like in this view-
    [​IMG]
    measure non-master link rivet distance =.791 inches
    [​IMG]
    measure master link rivet 1 distance =.781 inches
    [​IMG]
    measure master link rivet 2 distance =.782 inches
    [​IMG]
    master link pin bucked head should look like this!
    [​IMG]
    off set view of properly installed master link pin bucked head
    [​IMG]
    chain view
    [​IMG]
    as installed on bike
    [​IMG]
    ready to ride!
    Keithm
    #1
  2. waltermitty

    waltermitty Banned

    Joined:
    Apr 7, 2008
    Oddometer:
    55
    That's the cleanest KLR I ever seen. You a protologist?
    #2
  3. klm4755

    klm4755 Been here awhile

    Joined:
    Jun 19, 2006
    Oddometer:
    577
    Is this the view of the bike you speak of??
    [​IMG]
    left side view?
    [​IMG]
    or right side view?
    [​IMG]
    or front view
    hehehehe
    Keithm
    #3
  4. johnjen

    johnjen I've Been Resigned

    Joined:
    Nov 28, 2001
    Oddometer:
    16,262
    Location:
    Seattle
    This belongs in thumpers

    JJ
    and when it's sufficiently played out, if you want, I can add it to the HoW
    Let me know…
    #4
  5. Oly

    Oly Deadlines whooshing by

    Joined:
    Jan 6, 2004
    Oddometer:
    8,099
    Location:
    Underground Gardens
    so why did you replace the OEM chain after only 7500 miles?

    and why not at least replace the front sprocket at the same time?

    A well maintained OEM chain should go at least twice that mileage and if you are running the same front sprocket then you will shorten the life of your new DID.

    nice write up and great pics by the way. :thumb
    #5
  6. El Guero

    El Guero V4 Whore

    Joined:
    May 8, 2007
    Oddometer:
    9,727
    Location:
    Iowa City, IA
    +1 on replacing the chain early. I can understand your excitement about your new chain, but what kind of KLR owner are you? :lol3 I got 15000 miles out of the stock chain and sprockets, and that was even after 2000-odd miles of riding it completely taut after me and GSbiker tightened the shit out of it :rofl

    Very good write-up though. Was the Dremel tool removal of the old chain so you could save it for later? I might have missed that.
    #6
  7. a1fa

    a1fa Throttle Jockey™

    Joined:
    Nov 1, 2006
    Oddometer:
    13,924
    Location:
    Arkansas
    damn dude. you made rocket science out of cave man job! thanks :)
    #7
  8. Mercury264

    Mercury264 Once you go Triple...

    Joined:
    Nov 7, 2005
    Oddometer:
    22,423
    Location:
    Masshole
    Great write-up :thumb

    Instead of removing the pin in the old chain I have heard of people just cutting it off since it's toast anyway.

    Ironically I replaced the chain on the XR today for the first time - same chain actually.

    I have a Q for you - I didn't use the link that came with the chain (i.e. the same one you installed) but instead used a clip type master link since that what was on the chain I replaced. Curious as to why you recommend the link you used over a clip type ?
    #8
  9. Bad Company

    Bad Company Don't call me Shirley

    Joined:
    Nov 1, 2006
    Oddometer:
    1,339
    Location:
    Leavenworth Kansas
    Great writeup!!:clap
    #9
  10. klm4755

    klm4755 Been here awhile

    Joined:
    Jun 19, 2006
    Oddometer:
    577
    The chain was delivered with a rivet style X ring master link. I don't believe you can get an X style 520 style C-clip master link. I installed the master link that came with the chain.
    Keithm
    #10
  11. Mercury264

    Mercury264 Once you go Triple...

    Joined:
    Nov 7, 2005
    Oddometer:
    22,423
    Location:
    Masshole
    I originally ordered this for my XR:

    http://www.sprocketcenter.com/p/478622/rk-520xso-steel-chain-and-sprocket-kit-honda-xr-650l-93-06.html

    and it would appear you can get a clip master link with an X ring chain.

    Unfortunately (or fortunately) they sent me this:

    http://www.sprocketcenter.com/p/310561/did-520vm-x-ring-chain-steel-sprocket-kit---honda-xr-650l-93-06.html

    so like you I got the rivet style link.

    I am going to remove the clip link and install the rivet link.

    Again, great write-up.
    #11
  12. svwayne

    svwayne Been here awhile

    Joined:
    Aug 31, 2004
    Oddometer:
    945
    Location:
    Lawrenceville, Jawja
    Great write-up. Thanks for taking the time.

    I usually measure the distance between the insides of the plates since some master links have a different side plate thickness than the rest of the chain. I also repeat this measurement after riveting the link pins. Too much compression on that X ring will contribute to early failure of the master link.
    #12
  13. klm4755

    klm4755 Been here awhile

    Joined:
    Jun 19, 2006
    Oddometer:
    577
    [​IMG]
    this master link plate = .080 inch
    [​IMG]
    real chain plate gage = .080
    They seem to be of the same thickness.
    Keithm
    #13
  14. Doghouse_Riley

    Doghouse_Riley Wannabe Adventure Tourer

    Joined:
    Mar 22, 2006
    Oddometer:
    2,019
    Location:
    The Second, CA
    Am I the only one that doesn't do all the measuring done here?
    #14
  15. dancolin

    dancolin Weeeehaaa!

    Joined:
    Jul 22, 2007
    Oddometer:
    1,004
    Location:
    Lake George, NY
    I never even seen half of those tools..:augieI think the cost of those tools alone is worth more than my KLR..but great right up!
    #15
  16. ChuckUFarley

    ChuckUFarley Scr00ge

    Joined:
    Mar 13, 2008
    Oddometer:
    53
    Location:
    Boulder, CO
    Is that a Corbin dual platform seat I see? Can you give your opinions? I've been looking at one and am having trouble deciding between that, the dished, or just taking an electric knife to the foam on the stocker.

    Great write-up on the chain replacement.
    #16
  17. klm4755

    klm4755 Been here awhile

    Joined:
    Jun 19, 2006
    Oddometer:
    577
    The seat was custom made by Rich's motorcycle seat shop in Seattle.
    Keithm
    #17
  18. klm4755

    klm4755 Been here awhile

    Joined:
    Jun 19, 2006
    Oddometer:
    577
    here is the upset diameter measured= .229 inches.
    [​IMG]
    I have nothing to reference the value to.
    Keithm
    #18
  19. thecanoeguy

    thecanoeguy just a yobbo from oz

    Joined:
    May 25, 2006
    Oddometer:
    1,936
    Location:
    Albury N.S.W.
    go and wear your bike out first(or at lest get it dirty) your old chain should not be the same length as your new one ,this is when the cheap aussie changes his sprockets

    Attached Files:

    #19
  20. klm4755

    klm4755 Been here awhile

    Joined:
    Jun 19, 2006
    Oddometer:
    577
    Thanks! The pin head seems a tad overdriven, but a visual inspection indicated no cracking, so should be good to go!
    Keithm
    #20