Installed new chain

[movenon]

This is for those that haven't done a chain rivet job or at least in my case have never done it "properly". You know the old hammer and home made punch deal.

Today I installed a new EK ZZZ 530 chain. I used a Cycle Gear "Stockton Chain Breaker & Riveter Tool Kit".  Bought on sale for 29.95. And used an inexpensive digital caliper from Harbor Freight (you can get them on sale for 15 - 20.00 often).

I was a little suspicious of the cheap Stockton kit using it on the heavy duty ZZZ 530 chain. But I am glad to report it works great. The most trouble I had was getting the master link plate initially lined up to be pressed on. It takes a little patience to ensure it is square before pressing it on.
I used the digital caliper to measured the width of the existing ZZZ chain plates and used that as a reference of how far to press on the master link plate. Press it on a bit , take the tool loose, measure, press some more, measure etc. taking it slow as to not over press the plate. (This is important).
Then set up the tool with the correct 530 riveter pin and did the same routine. I took about 7 or 8 press and measure cycles to get the head spread to where I wanted it to be on each pin. I used the Stockton turning rod tool (in the kit) until the very last then I used a 14mm wrench at the end. I recommend using the rod to start with as it will hopefully prevent you form over spreading the pin to start with.

I pressed my pins to a 5.70mm diameter spread. There is not that much side load and it will not pull through a 5.38 -5.40 hole. If you over spread the rivet it can split at the head and or force the side plate to tight.  Max pin spread is 6.00mm.

EK for some reason will not give you the spec's with there instructions on the box with the chain, but here they are from the factory:

EK 530 ZZZ CHAIN
Pin diameter.....................................5.38mm
Pin end rivet diameter goal..................5.70- 6.00 (max)  (here is where it is nice to have a digital caliper)
Avg installed pin end rivet diameter.......5.70 - 5.80

Tips and thoughts: (boy I don't want say that real fast after a few beers)

Doing this is similar to rebuilding carbs, its a simple job, just take your time and don't do it when you are in a hurry. Slow is the word.

If you over press the master link plate, the chain will bind. Take it slow to do it right, good. If your in a hurry and "ripp" it on, it binds and now you get to grind it off and another opportunity with a new master link to do it again. 

Read the tool instructions at least once. Make sure to lube the threads on the tool with a light grease or oil. This really helps the feel.

Sprocket cover and clutch Cly TQ 7.2 lb's.

The chain comes with one rivet master link, 4 "O" rings and a small package of chain wax/grease to prelube the master link pins and "O" rings. (also lube the chain pin head where the tool makes contact). Did I just say "pin head".... ?  Must have been looking in the mirror .

All is good now I have a nice new chain with new sprockets. It took me a casual hour to do the job. (and 139.95 plus 17.00 shipping for the chain)
That's what I did and learned today.
George

[yamaha fj rider]

Well done George, good information. Bike is getting closer to being ready for WCR.

Thanks for the review on the Stockton chain tool.

Kurt 

[keand3]

Thanks George.

This is helpfull information for us who never has change the chain and will be doing it soon!

Cheers
Ken

[fj11.5]

Pfffft good quality chains and rivet links,, who needs em,  bah humbug,  , I dooo

[markmartin]

Nice write up George.

This would be a good addition to the General Maintenance Files??

[movenon]

Nice write up George.

This would be a good addition to the General Maintenance Files??

Thanks, because a lot of us do our own service work it would be a shame not to relay "how to" and experiences (good and bad). Even if you don't or can't do your own service work it is nice to know the spec's and how it's done. I was told many years ago that "if you were lucky enough to get a day older then you should get a little smarter". Learning never stops.
George   

fj11.5:   Hey, your the one that motivated me to do this........   Cheers my friend.

[fj11.5]

And I'm bloody glad you did mate  ,, wouldn't want two of us crying in our coffee,s 

[racerman_27410]

EK ZZZ     



KOokaloo!