CHAIN DRIVE

Removing the drive chain

Order

Job/Parts to remove

Q’ty

Remarks

1

Drive chain

1

 

2

Drive sprocket cover

1

 

3

Drive chain guide

1

 

4

Drive sprocket nut

1

 

5

Lock washer

1

 

6

Drive sprocket

1

 

REMOVING THE DRIVE CHAIN

1.Stand the vehicle on a level surface.

Securely support the vehicle so that there is no danger of it falling over.

Place the vehicle on a maintenance stand so that the rear wheel is elevated.

2.Remove:

  • Drive chain

Cut the drive chain with the drive chain cut & rivet tool. (Use goods on the market.)

CHECKING THE DRIVE CHAIN

1.Measure:

  • 15-link section of the drive chain

    Out of specification → Replace the drive chain.

  • 15-link length limit

    239.3 mm (9.42 in)

a.Measure the length “a” between the inner sides of the pins and the length “b” between the outer sides of the pins on a 15-link section of the drive chain as shown in the illustration.

b.Calculate the length “c” of the 15-link section of the drive chain using the following formula.

Drive chain 15-link section length “c” = (length “a” between pin inner sides + length “b” between pin outer sides)/2

  • When measuring a 15-link section of the drive chain, make sure that the drive chain is taut.

  • Perform this procedure 2–3 times, at a different location each time.

2.Check:

  • Drive chain

    Stiffness → Clean, lubricate, or replace.

3.Clean:

  • Drive chain

a.Wipe the drive chain with a clean cloth.

b.Put the drive chain in kerosene and remove any remaining dirt.

c.Remove the drive chain from the kerosene and completely dry it.

  • This vehicle has a drive chain with small rubber O-rings “1” between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain. High-pressure methods could force dirt or water into the drive chain’s internals, and solvents will deteriorate the O-rings. A coarse brush can also damage the O-rings. Therefore, use only kerosene to clean the drive chain.

  • Do not soak the drive chain in kerosene for more than ten minutes, otherwise the O-rings can be damaged.

4.Check:

  • O-ring “1”

    Damage → Replace the drive chain.

  • Drive chain roller “2”

    Damage/wear → Replace the drive chain.

  • Drive chain side plate “3”

    Damage/wear → Replace the drive chain.

5.Lubricate:

  • Drive chain

  • Recommended lubricant

    Chain lubricant suitable for O-ring chains

CHECKING THE DRIVE SPROCKET

1.Check:

  • Drive sprocket

    More than 1/4 tooth wear “a”→ Replace the drive sprocket and the rear wheel sprocket as a set.

    Bent tooth → Replace the drive sprocket and the rear wheel sprocket as a set.

b.

Correct

1.

Drive chain roller

2.

Drive sprocket

CHECKING THE REAR WHEEL SPROCKET

Refer to CHECKING AND REPLACING THE REAR WHEEL SPROCKET.

INSTALLING THE DRIVE CHAIN

1.Install:

  • Drive chain

Be sure to put on safety goggles when working.

Install the master link with the drive chain cut & rivet tool. (Use goods on the market.)

a.When press fitting the master link plate “1”, make sure the space “a” between the end of the connecting pin “2” and the master link plate is 1.2–1.4 mm (0.05–0.06 in).

b.After riveting, make sure the diameter between the edges “b” of the connecting pin “2” is 5.5–5.8 mm (0.22–0.23 in).

c.After riveting, make sure the space “c”, which is inside of the master link “3” and inside of the master link plate “1”, is 12.1–12.3 mm (0.476–0.484 in).

2.Lubricate:

  • Drive chain

  • Recommended lubricant

    Chain lubricant suitable for O-ring chains

3.Install:

  • Drive sprocket

  • Lock washer

  • Drive sprocket nut

  • Drive sprocket nut

    75 N·m (7.5 kgf·m, 55 lb·ft)

Never install a new drive chain onto worn drive chain sprockets; this will dramatically shorten the drive chain’s life.

After the drive sprocket nut has been tightened to specification, firmly bend the lock washer tabs “a” along the flat of the drive sprocket nut.

4.Adjust:

  • Drive chain slack (Maintenance Stand)

    50.0–60.0 mm (1.97–2.36 in)

A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the specified limits.