How to Replace a Dirt Bike Chain

A loose chain can rob your dirt bike of valuable power. Replace that loose chain before it becomes a problem.

The chain is an important component of your dirt bike's drive system that can affect the way its motor delivers power. These chains are designed to handle the stress of high-performance dirt track and trail riding, and with regular maintenance, will last for a few seasons. Time and wear, however, will eventually cause the chain to stretch and hang loosely from the motorcycle, losing its effectiveness and delivering less rotational force to the rear wheel. Replacing a worn-out chain is not a difficult project but does require a certain degree of familiarity with your machine and the tools required.

Things You'll Need

• Socket set
• Breaker bar
• Wrenches
• Allen socket set
• Socket wrench
• Grinder
• Chain breaker tool
• New chain and master link
• Chain press tool

Instructions

1. Locate the master link on the chain and rotate the rear wheel to bring the master link to the top of the motorcycle's rear swing arm.

2. Use a socket attached to a long-handled breaker bar to loosen the torque on the rear axle lock nut. Use a wrench to loosen the pair of nuts on both chain adjusters on the rear axle. Push the rear wheel forward to loosen the chain.

3. Remove the front sprocket cover from the left side of the motor, using an Allen socket to remove the cover's mounting bolts.

4. Remove the master link from the chain. Use a grinder to grind off the round pins that secure the master link's side plate to the rest of the master link. Once the pins have been removed, use a chain breaker tool to force the side plate off of master link. Pull the separated master link parts off of the chain. Pull the chain off the front and rear sprockets.

5. Place the new chain around the front and rear sprockets, joining both ends of the chain above the swing arm. Slide the master link into the back of both chain end links, pushing the master link's pins through the back of the chain links until they protrude from the front of the chain. Place the master link's side plate over the pins.

6. Join the master link and its side plate using a chain press, compressing the side plate over the master link's pins. Remove the chain press once the master link pins have been pressed through the side plate and have been compressed into a mushroom-shaped dome over the side plate.

7. Reinstall the front sprocket cover, tightening the cover's mounting bolts with an Allen socket. Pull the rear wheel back to tighten the chain. Tighten the pair of nuts on the chain adjusters with a wrench to maintain the tension of the chain. Tighten the rear axle lock nut with a socket wrench.

Tips & Warnings

• Lubricate the chain thoroughly with an off-road specific chain lubricant and allow it to soak in for an hour before riding the motorcycle again.

• Do not attempt this task if you lack the tools or skills necessary to do the job right. Instead, have the chain replaced by a qualified and well-equipped technician.

References

• "The Professional Motorcycle Repair Program; Professional Career Development Institute;" Prentice-Hall; 1995
• Dirtrider Magazine; How To Maintain Your Chain Quickly And Easily

Resources

• Motion Pro; Chain Breaker Instructions
• Motion Pro; Chain Press Tool Kit Instructions