Chain Maintenance

Importance of Lubrication


Problem caused due to insufficiant lubrication

1. Wear of Pins

  • Shorten Chain Life

2. Rough Contact with Sprockets

  • Increase Noise

3. Stiff Links

  • Low-Mileage

We recommend to check your chain regularly for your safety.

Lubrication Intervals


  • Every 500km
  • After ride in wet weather conditions
  • Chain should be cleaned every 1,000km
Lubrication Intervals

Ultravilet rays, dust and antifreezing agent can damage to X-Ring.
So cleaning and lubricating are very important for your chain life.

Lubricating


Lubricating Point

  • Between outer links and inner links for the prevention of elongation.
  • Between bushings and inner plates for noise reduction and protection against wear and impact damage on bushings and rollers.

1. Lubricate shortly after riding

  • While the motorcycle is moving, the chain temperature is 20-30 degrees higher than air temperature. As a result of the higher temperature, the lubrication oil reaches every parts easily.

2. Over-lubrication is not necessary

  • If there is too much lubrication oil on the chain, it will splatter when the chain starts to move.

3. Check your chain after tough riding

  • Circuit racing or long riding on a highway will result in stress on the chain. We recommend checking your chain and subsequently lubricating it after such riding.

Sag Adjustment


To use a chain for a longer period of time, ensuring proper sag is important. if the chain tension is too high, the oil film between pins and bushings is lost, shortening chain life.

If the chain sags are too much, it will vibrate or be caught on the sprockets.

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Wear Elongation of Chain


Note

  • Chains are subject to wear since the pins and bushings are worn by mutual contact. After long term usage, the wear result in an increase of chain length. Wear elongation is an important factor in deciding the timing of chain replacement.

For maximum long life and safty, we recommend that you maintain your chain as outlined here and replace it when wear and elongation is evident.




Chain Replacement Instructions

ZJ Rivet Connecting Link


D.I.D's ZJ Rivet Connecting Link has comparable strength to that of the other links that compose the factory assembled chain body.

This tremendous strength is the result of the new pin head designed to be precisely riveted in a uniform circular configuration with the KM500R chain tool.

A Word on Sag Adjustment

A drive chain that is too tight speeds up wear by excessive pressure on the sprocket teeth, the chain joints and the shaft bearings. A chain that is too loose will wear quickly and may have a whip action that can cause it to snap.

A chain that is too tight or too loose will result in excessive elongation. Normal sag(see diagram) is 3/4". To check, press down on the top strand of the drive chain with fingers. Tighten or loosen to achieve 3/4".

This is normal sag. However, your specific motorcycle requirements may vary. Please consult your dealer or owners manual. For motocross motorcycles, please consult the owner's manual or a qualified mechanic.

D.I.D KM500R tools

These unique tools are designed to cut chain, press fit connecting link side plates, and rivet pin heads. These tools are for use with D.I.D's ZJ rivet connecting link only.

The KM500R tools may also be used to cut any 520, 525, 50 (530) or 532 chains. They may also be used to press side plates on to FJ press fit clip type connecting links.

Chain Cutting


1. Before cutting your chain, loosen it using your motorcycle's rear wheel adjusters. Position your KM500R over your chain on the bottom side of your swingarm; cut the pin on the right side of the link you choose first. If your chain has a master link, it is easier to cut the chain at the master link.

2. Set the Cutting pin location on your chain tool's U-shaped holder to the point A position.

3. To align the tools Cutting pin with the chosen pin head, turn the tool's large bolt head clockwise "by hand" until the Cutting pin comes in contact with the pin head. At this point, make sure that cutting pin is lined up with the center of the pin you wish to push out.

4. Use a 27mm closed in wrench on hold firm the body of your chain tool while using a closed end 19mm wrench on the tool's hexagan bolt head to tighen.
It will be easier to tignten the bolt if you position you wrenches 30° apart.

5. Turn 19mm wrench clockwise on the tool's Hexagon bolt head to push the pin completely out.

6. After pushing the pin out, disassemble the chain tool from the chain.

Press Fitting Connecting Link Side Plates


7. Connect the new chain to the old chain using either a wire or connecting link. Shift transmission into neutral and slowly pull the old chain from under the swingarm towrd the rear which then pulls the new chain from the top towards the countershaft sprocket. When new chain goes completely around the front sprocket and out under the swingarm, disconnect the old chain and pull both ends together under the center of the swingarm.

8. Before installing the connecting link, be sure to put a heavy coat of the supplied grease into the holes of the bushings of the new chains' links, and on the surface of the connecting link's pins. If you are installing an O-Ring or X-Ring chain, don't forget to put heavily greased O-Rings or X-Rings on the pins between the sideplates on both sides of the chain.

9. With the inside of the connecting link pushed into place holding the chain together with the pins sticking out the outside of the chain, slide the O-Rings/X-Rings into place and temporarily press the other side plate on the pins by hand.
Set the Cutting pins location on your chain tool's U-shaped holder to the point A position.

10. Slide the U-shaped portion of the tool over the inside of the connecting link.
Carefully line up the dimples on the inside of the U-shaped holder with the pin heaads of the connecting link.
The Cuting pin also needs to be flipped over to where the rivet side is pointed out.
Fit the tool body together and position the Plate holder onto the sideplate that needs to be pressed on.
[For FJ clip type links, flip Plate holder over.]
Slide the pin's riveting side into the Plate holder and slide the pin side into be inside of the tool.

11. Hold the hexagon part of the tool body with a 27mm closed end wrench and turn the bolt with a 19mm closed in wrench clockwise until the top of the pins make contact with the groove in the Plate holder.

12. After pressing the sideplate of disassemble the chain tool and remove it from the chain. The next step is to flare out the pins heads for ZJ[Rivet type] or installing the slide clip for the FJ[Clip type] master link.

Riveting ZJ Connecting Link Pin Heads


13. Position the U-shaped holder as seen above.
For clip type (FJ) install the open end of the clip so that it faces in the opposite direction of the chain drive direction.

14. Set aside the Plate Holder and set the pin on the tool body to the B position to flare out the pin heads.

15. Hold the hexagon part of the tool body by with a 27mm closed in wrench, and the bolt head with a 19mm closed end wrench; turn clockwise until the flare part of the pin head makes contact with the surface of the side plate.

16. Example of proper flared pin head. If your pin heads are not flared to extent, reailgn chain tool and flare pin heads until they look the above photo. If your pin heads have cracks or the connecting link is stiff when flexed, remove connecting link and install a new one.