Engine started ! - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 13 Old 02-17-2017, 12:09 PM Thread Starter
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Location: Watford. England. UK
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Engine started !

Evening all.
So I fired her up last night having fitted the rubber slipper in the cam cover (slipper was missing). Engine sounds real sweet and I was very happy. My next issue is the final drive chain. All my previous restorations (old Triumphs) have a chain with a removable link, like on a push bike. So this is my first encounter with an endless chain. Any tips on 'breaking the chain and refitting would be appreciated, assume I can select any link? looks like its yet another tool I have to purchase, the chain breaker? Don't really feel like dropping the swing arm.
Comments please.
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post #2 of 13 Old 02-17-2017, 01:53 PM
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Your call, but . . . I went with a Cycle Gear chain breaker kit (on sale). Has all the tools needed for breaking, pressing, riveting, etc., that you might need.

Used riveted master link, but nothing wrong with a clip-style master link, properly installed.

WAIT! You're in the UK! No Cycle Gear stores on every corner, I should think! That said, I'm certain the technicians at your friendly local motorbike shop can assist you in the common task of chain-breaking and re-installation.
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post #3 of 13 Old 02-17-2017, 04:08 PM
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zooltan,
A grinder will make short work of 2 rivet heads, a center punch and hammer will then tap the rivets out of the outer link plate.

Replace chain with your favorite brand (o-ring sealed) which comes with clip style master link.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1.
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post #4 of 13 Old 02-17-2017, 05:59 PM Thread Starter
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Chain looks in great shape and cogs. The brand is , wait for it, REGINA. Research indicates this is a top brand? It just needs a good clean, maybe I'll just unhitch it from cogs and clean in tub below and slowly rotate round.
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post #5 of 13 Old 02-17-2017, 06:06 PM
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Quote:
Originally Posted by pdwestman View Post
zooltan,
A grinder will make short work of 2 rivet heads, a center punch and hammer will then tap the rivets out of the outer link plate.

Replace chain with your favorite brand (o-ring sealed) which comes with clip style master link.
pdwestfield is right. I don't even use the center punch. I just pry the side plate of with a flat blade screw driver after grinding the pins down flush with the side plate.

I have done it in the woods with a file, but the filing was not fun. An angle grinder or even a Dremel makes quick work of the job. If you can't get the exact 106 link chain needed, you can cut a longer one down the same way. 105 links plus the master link = 106 links.

If you don't have access to an angle grinder, go to a muffler shop. They can do it for you in five minutes cheap. You can put the new chain on in their parking lot and ride home.

A chain press is handy for pressing the side plate on against the o-rings, but a pair of Vice-Grips or Channellocks will do in a pinch. I have done that in the woods too, but I now carry a chain press it makes the job much much easier. Motion Pro Chain Press Tool - Motorcycle Superstore

Last edited by GoMotor; 02-17-2017 at 06:09 PM.
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post #6 of 13 Old 02-17-2017, 06:31 PM
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Since you're in the UK and that swingarm pivot is known for getting cruddy/stuck, it might not be a bad idea to pop that swinger off and lube up all the bolts anyway.

Two birds, one stone.
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post #7 of 13 Old 02-17-2017, 07:26 PM
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Quote:
Originally Posted by zooltan View Post
Chain looks in great shape and cogs. The brand is , wait for it, REGINA. Research indicates this is a top brand? It just needs a good clean, maybe I'll just unhitch it from cogs and clean in tub below and slowly rotate round.
zooltan,
Sounds to me as if you need to just clean the chain while still on the sprockets. Kerosene or lamp oil, is 'o'-ring safe. WD-40 is good cleaner and lube for o-ring chains. No need to remove the chain.

Regina probably sells a clip style master link to fit, maybe you ought to check.

pdwestman
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post #8 of 13 Old 02-17-2017, 07:34 PM
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Regina chain-and-sprocket set is high quality, in my experience.

My set came with both rivet- and clip-style master links; I used the former (hey; gotta exercise my really terrific Cycle Gear chain-breaker kit! ).
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post #9 of 13 Old 02-18-2017, 02:16 AM Thread Starter
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Thanks all for posts. I will try a clean with chain on first, see what the result is.One more question. My KLR is an 89 gen 1. The rims are painted black, looks like a good quality factory finish, should they be black unpainted. My front rim looks like an alloy metal, the rear looks chrome finish. I took some paint off both to reveal what was underneath.
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post #10 of 13 Old 02-18-2017, 10:14 AM
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OEM in 1989 was natural aluminum color.
First black oem rims were about 2012 Gen 2, with larger gauge spokes.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1.
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