Chain and Sprockets Replacement Pictorial
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Thread: Chain and Sprockets Replacement Pictorial

  1. #1
    Senior Member n2o2diver's Avatar
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    My 2005 TW has 4500 miles on it and the chain is about shot. I'm at #8 on the adjuster and decided to go ahead and change out the chain and sprockets. I went with stock replacement sprockets (14/50) and an RK 428 O-Ring chain.



    I took some photos as I went. Hope this helps someone out. It is a pretty straight forward task, just take your time. You are going to remove the side cover which means draining all the oil so plan on doing this at your next oil change cycle.



    Here is the excellent oil change guide.






    I started by draining the oil. Oil drain plug 19mm.











    It was really windy today so I used a piece of cardboard to keep the draining oil from blowing everywhere.











    Next I removed the Oil Filter Cover, 2 - 8mm bolts and 1 - #5 Allen











    When you get the cover off the short bolt is on the left and the longest on the right.











    The lower Allen bolt has a o-ring behind it, be careful it doesn't fall out and replace if necessary.











    Make sure your new oil filter has these 4 holes. There are bad filters out there with out them and you will RUIN your motor from lack of oil flow.











    I put in the new filter and replaced the Oil Filter Cover O-ring as well as the smaller Allen bolt O-ring during this change. Then re installed the cover.







    Next I removed the Left foot peg 17mm.











    Next remove the shift lever and skid plate each has 1 - 10mm bolt.















    I used a screw driver to spread the shift lever a little and it came right off.



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    2013 DR650

  2. #2
    Senior Member n2o2diver's Avatar
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    Now remove the left side cover. I tried to clean all around it first, I probably should have given the bike a good wash and let it dry first.



    There are 10 - 8mm bolts, the wrench in the picture is for illustration, I ended up using a small 1/4" drive 10mm ratchet, a larger one won't fit into some of the spots.















    As I removed the bolts I pushed them into a piece of cardboard so I wouldn't mix them up, some are longer than others.















    I used a zip tie to hang the cover out of the way and not put stress on the wires.











    Next I removed the chain guard and removed the master link. Pay attention to way the master link is on the chain. The closed part goes to the front in the direction of rotation.















    With the chain removed I now remove the counter shaft sprocket. There are 2 - 8mm screws holding the keeper to the sprocket.







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  3. #3
    Senior Member n2o2diver's Avatar
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    There are two seals under the side cover and it is recommended that you change them while you are in here. Installing an O-ring chain means you might not have to take this off for another 20K miles so might as well change them now while you have it all apart.



    I cleaned up the area as best I could then used a pick to get out the old seal and replace them with new ones. Make sure you put even pressure around the shaft seal so it goes in straight. A piece of pipe or a large socket the same diameter of the seal makes it very easy.







    Inner Seal















    Outer Seal















    With the new seals in, I then installed the new sprocket and used new 8mm bolts in the keeper. You can see the old sprocket is pretty worn compared to the new one.



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  5. #4
    Senior Member n2o2diver's Avatar
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    With the front side done I next put the bike on the stand and my neighbor helped out here. The wind was really kicking so he held the bike on the stand while I removed the tire and changed out the back sprocket.







    It is pretty straight forward. The back tire has a 22mm nut on the right side and the axle is a 19mm. After removing the nut, undo the brake line wing nut and then pull out the axle and slide the rim aft. Take note of the wheel spacers as they may fall out at this point.







    Next I used a screw driver to flatten the tabs on the sprocket bolts.















    Remove the bolts, you have to hold the nuts on the backside with a 14mm wrench and I used a 14mm ratchet on top to remove the bolts. Install new locking tabs, replace all the bolts then bend the new tabs.



    The old rear sprocket is worn but not as bad as the front was. Remember you can't see the front without removing the cover. So if your rear is worn you can count on the front being bad as well.








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  6. #5
    Senior Member n2o2diver's Avatar
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    At this point I was getting pressed for time. Sun was setting and GF had plans and was letting me know to pick up the pace.



    I don't have any pictures of the reassembly but I figure if you got it all apart it is pretty easy to put back together.



    Re install the rear tire, don't forget the brake rod. Put the new chain on. Make sure you put the master link on the new chain correctly. Adjust the chain tension in accordance with the manual. If you haven't done so go down load the manual and supplement. I had mine printed and bound and used it for reading in the house. I print out the pages I need for a particular task as they tend to get dirty quickly.



    I put the pins for the engine cover, in the engine side. Then put the new side gasket in place on the engine. We took the bike off the stand and tilted the bike to the right so the side cover gasket stays in place. Make sure the wires are tucked where they need to be.. Refer to the Manual!!! Install the side cover carefully and realize that big magnet is going to pull it on as you get it close so watch yer fingers. Re install the oil drain plug. Refill with your choice of oil (I'm not even gonna go there LOL )



    I hope everyone can read through this and add comments and suggestions. Hopefully this can become a sticky in the Tech section for future reference.
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  7. #6
    Senior Member Omega Man's Avatar
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    Very Nice! Should be a big help. OM
    "It's more fun going fast on a slow bike than going slow on a fast bike" UK

    1994 TW200, 2009 F800GS loaded,

  8. #7
    Senior Member PalmStateCrawler's Avatar
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    Thanks for taking the time to do this! This should be pinned.
    '13 690 Enduro R too many frickin farkles...
    '07 KLX250 farkled (wife's bike)
    '86 BW80 farkled to size
    '10 TW200 you will be missed

  9. #8
    Senior Member Jay64's Avatar
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    'Preciate this as I'll be doing the same soon.
    The greatest trick that Jay64 ever pulled was convincing the world he did exist.

  10. #9
    Senior Member Rainman's Avatar
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    Very nice job. Thank you.
    If you can't find it, grind it

    1990 TW200

  11. #10
    Senior Member STEVE IN SOCAL's Avatar
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    Quote Originally Posted by Jay64 View Post
    'Preciate this as I'll be doing the same soon.




    X2...thx
    black widow likes this.
    “One final paragraph of advice: do not burn yourselves out. Be as I am - a reluctant enthusiast....a part-time crusader, a half-hearted fanatic. Save the other half of yourselves and your lives for pleasure and adventure. It is not enough to fight for the land; it is even more important to enjoy it. While you can. While it’s still here. So get out there and hunt and fish and mess around with your friends, ramble out yonder and explore the forests, climb the mountains, bag the peaks, run the rivers, breathe deep of that yet sweet and lucid air, sit quietly for a while and contemplate the precious stillness, the lovely, mysterious, and awesome space. Enjoy yourselves, keep your brain in your head and your head firmly attached to the body, the body active and alive, and I promise you this much; I promise you this one sweet victory over our enemies, over those desk-bound men and women with their hearts in a safe deposit box, and their eyes hypnotized by desk calculators. I promise you this; You will outlive the bastards.”

    ― Edward Abbey

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