Periodically inspecting and replacing the chain on your motorcycle or ATV is part of regular maintenance. Here, we go over steps and key tips for replacing your worn out chain with a new one.
The necessity to periodically replace the chain on off-road machines comes as a byproduct of operating in harsh environments containing dirt, mud, sand, etc. On road machines aren’t exempt from this maintenance task either, however, their replacement intervals are longer. Replacing your machine’s chain isn’t a tough job if you’re well equipped and prepared to take on the task.
Replacing your machine's chain is part of normal maintenance and should not be neglected.To start, it is essential to have a copy of your machine’s factory service manual. Within the service manual, you’ll find specific instructions and torque specifications that may be required to complete the job. For example, if either of the sprockets requires replacement, it is imperative the nuts and bolts that secure them are torqued to the outlined specifications.
Before purchasing a new chain, you’ll want to confirm that the sprockets are in good condition. Pairing a new chain to worn sprockets will accelerate the rate of chain wear and be counterproductive. You’ll also want to inspect components that come in contact with the chain such as chain slides and rollers. Replacing these components at the same time as the chain is advantageous.
Inspect your sprockets before beginning the new chain install process. Notice how the grooves in the worn sprocket are asymmetrical in comparison to the new sprocket.Inspections
Sprocket condition can be checked visually by looking at the sprocket teeth.
Sprocket teeth take on a hook shape when they become worn, and in severe cases, shorten and round off when service has been severely neglected.
If funds allow, it’s always best practice to replace both sprockets when replacing your chain. This will allow for the most life possible out of your drive system.
The condition of the chain can be assessed by putting the bike on a center stand. Rotate the rear wheel and visually inspect the chain’s condition. As you rotate, feel the chain for tight spots or links that are stuck together. Attempt to pull the chain away from the rearmost part of the rear sprocket. If the chain can be pulled off the rear sprocket by a half sprocket tooth or more, it is time for a replacement. Similarly, if the chain moves significantly side to side when pushed and pulled on the sprocket, wear has occurred.
Check your chain's wear level by attempting to pull it away from the back of the rear sprocket.
If it's half a tooth or more, it's time for a replacement.Check any chain slides to ensure they have ample life left. Rotate chain rollers to ensure they spin freely.
Check your chain rollers and sliders as well. These are normal wear items, and they should be replaced when they show signs of excessive wear.ProX also offer OEM replacement chain rollers in addition to chains and sprockets.
Chain Sizing and Options
Off and on-road chains used for powersports applications come in various sizes based on chain pitch and length. Before purchasing a new chain, you’ll need to confirm the appropriate pitch and size for your machine.
Chain pitch defines the distance between the chain pins. Common pitch options are shown in the table below along with their corresponding dimensions.
| Chain | Pitch | Width | Roller Diameter |
| 420 | 12. | 6.35mm | 7.75mm |
| 428 | 12.70mm | 7.75mm | 8.51mm |
| 520 | 15.88mm | 6.35mm | 10.16mm |
| 525 | 15.88mm | 7.85mm | 10.16mm |
| 530 | 15.88mm | 9.53mm | 10.16mm |
There are a couple of ways to determine the type of chain your machine utilizes. First, your factory service manual should contain this information. This is usually found in the rear wheel specification table.
Second, most chain manufacturers denote the chain’s pitch on the side of the chain. You can obtain the chain’s length simply by counting the number of chain links it has.
Once you’ve determined the chain pitch and length you need, you’re ready to order. When it comes to ordering, you’ll need to decide on the type of master link connection you want and whether the chain is a standard chain or a sealed chain.
The most common chains in dirt bike and ATV applications are 420 (for minis) and 520. ProX offers both sizes of chains. ProX 520MX chains are available in both standard and X-ring, in standard and gold finishes. The gold finish is the result of a rust-resistant coating. ProX chains are made in Japan from high-quality Japanese steel. These chains come with master link style connections, which is the most common in modern off-road applications.
520 is the most common size for modern off-road motorcycles, and 420 is a common size for minis.
Master Link Connection
Clip Type - Clip type connections are widespread nowadays and are notable for their ease of installation. Clip type master links are not quite as strong as rivet type. However, they can be installed with no special tools.
A clip type master link.Rivet Type - Rivet type master links require a special rivet tool to install but offer a more permanent connection.
Replacement chains will either come with both of the connection types or one or the other so ensure you know what you’re ordering.
Chain Seals
The difference between a standard chain and a sealed chain is that the former does not use any type of seal to retain chain lubricant. Sealed chains, often referred to as O-ring chains, utilize O-rings or similar variants to retain lubricant which helps reduce wear and prolong chain life.
There are different styles of O-ring chains available, such as ProX’s X-ring chains.
ProX’s X-ring chains are a sealed O-ring chain but have less O-ring surface area touching the link surfaces to reduce the drag in comparison to a normal O-ring chain. The advantage is in the design of the O-rings themselves.
Tools
To replace a chain that utilizes a clip type master link, you’ll need the following:
To replace a chain that utilizes a rivet type master link, you’ll need the following:
Chain Removal
On chains utilizing a clip type master link, chain removal is as simple as prying off the master link clip and removing the master link. Through use, the master link plate usually wears enough so that it can easily be slid off the link. If the master link plate is tight, the master link should be driven out by using a punch and hammer or chain break tool.
For clip style chains, one easy way to remove the master link clip is to use a pair of pliers to push the clip off by using the chain pin for leverage.Chains utilizing rivet master links will require pin grinding so that one of the links can be removed. Grind the rivets that retain one of the links flat, then use a punch and hammer or chain break tool to push the chain link out.
Chain Installation
If necessary, resize the chain to your machine by removing the appropriate number of chain links.
Remember to count the chain links of the old chain to establish the length of the new chain. Don’t lay them side by side and try to set the length because the chain stretch that occurred in the old chain will lead to an incorrect chain length of the new chain.
Chain links can be removed by carefully grinding the rivet flat to the chain side plate, then driving the pin out with a punch and hammer. Alternatively, a chain break tool can be used.
Sizing the chain can be done by grinding and punching, but the easiest way to remove links is to use a tool made specifically for the job.Loosen the rear axle nut and slacken the chain adjusters. The new chain will necessitate this since it has not worn or stretched.
Position the two chain ends on the rear sprocket.
Next, install the master link whether clip or rivet type. Be sure to include the o-rings when installing sealed chains.
Clip Type Master Link Install
Once the master link has been installed, install another pair of o-rings (on sealed chains) followed by the master link plate. The master link plate will need to be pressed onto the master link. Use a pair of pliers to squeeze the plate onto the master link. Press the plate on far enough so that the grooves that retain the master link clip become exposed. A pair of small c-clamps can sometimes be helpful when installing the plate, or a master link plate installation tool can be utilized.
Next, install the master link clip. The master link clip is directional and should be oriented so that the closed end of the clip leads the direction of rotation.
By orienting the clip this way, should the clip hit an object during operation, it will not become dislodged from the master link. To install the master link clip, position it in its mating grooves on the master link. Use pliers to seat the clip fully in its grooves.
Rivet Type Master Link Install
To install a rivet type master link, you will need a master link rivet tool. It’s recommend to follow the instructions provided with the tool to perform the rivet operation. The chain manufacturer will also provide specifications which govern the appropriate amount of flare to add when deforming the rivets.
Setting Chain Slack
Once the master link has been installed the chain tension should be adjusted so that the machine has the appropriate amount of chain slack.
Your machine’s service manual will outline how to measure the chain slack and define the slack range. Most manufacturers recommend measuring chain slack with the bike on a center stand. Slack is then measured by pulling up on the chain near the center of the swingarm and measuring its displacement. Most dirt bikes require 30 - 60mm (1.18 - 2.36 inches) of chain slack. Carefully manipulate the chain adjusters so that they tension the chain evenly and align with the same reference points from side to side. Once chain slack is correctly set, torque the rear axle nut to the specification outlined in your service manual.
Post Installation Tips
Most chains are pre-stretched to reduce the amount of initial chain stretch that occurs once the chain is put in use, however, it is never a bad idea to keep an eye on the chain slack after the first few rides.
New chains come pre-lubricated from the factory. However, you should always ensure your chain stays lubricated throughout its life. Lubing your chain before or after every ride, especially muddy or rainy ones, should become habitual.
Find ProX chain and other components for your bike HERE!
Does your ATV chain keep coming off? It’s a safety hazard and can ruin your day of riding. Here’s how to diagnose the problem and how to tighten the chain as a solution.
Hopefully, you can diagnose a loose chain long before it comes off. Noticing the common symptoms of a loose ATV chain can allow you to fix it. As you are riding, watch out for these signs.
You will also likely experience power loss as this happens. There are a few reasons why all of this could be happening, from failing bearings to loose carrier bolts to a stretched-out chain. For the purposes of this article, we will consider the problem a loose chain that needs to be tightened. If you still encounter chain slippage or similar issues after tightening the chain, it’s worth a second look.
Here’s an important thing to know: just as an ATV chain can be too loose, it can also be too tight. If you have overtightened your chain, you will also experience problems with performance. Common signs are excess wear, suspension issues, and power loss.
The easiest way to know how tight your ATV chain should be is to consult the owner’s manual.
It will indicate the recommended slack in the chain, which usually sits somewhere between one and one and a half inches. Have someone sit on your ATV so you can see how the chain tension is with someone riding, measuring from the chain guard as the chain rests naturally.
Then, measure again while pulling up on the chain to get the measurement at the highest point. When you take the difference between those two measurements, you will know what the slack is.
If you have determined that your ATV chain is too slack, it’s time to tighten it! First, loosen the bolts on the bearing carrier at the back of your ATV, as well as the jam nuts on the chain adjuster. Then, locate the chain adjuster bolts and tighten them. This will tighten the chain.
Again, you will need a partner for this. With someone sitting on the ATV, take the measurements that indicate slack again. Keep doing this until you have the slack in the correct range according to your owner’s manual.
When the slack is correct, remember to go back and tighten the jam nuts and bearing carrier bolts.
What if you do not have adjuster bolts? You will need to take a different approach. First, loosen the bolts on the bearing carrier, just as you would if you were working on a machine with adjuster bolts.
Now, instead of looking for the adjuster bolt, you will be looking for a hole that gives access between the carrier and sprocket. Insert an Allen key in that hole while spinning the rear wheel forward, ultimately rotating the bearing carrier and tightening the chain.
You will still need someone sitting on the ATV to take slack measurements, repeating the above process until it is correct. Again, remember to tighten any hardware you loosened to make this adjustment.
Regular inspection and maintenance of your ATV chain will prevent issues like slippage. If you want your ATV to run smoothly, make this a regular part of your pre-ride routine.
Any time you experience resistance, power loss, or strange sounds, be sure to check out the chain.
Clean your ATV chains regularly with the ATV up off the ground on a stand or jack. Remove any accumulated mud or grime with a cloth and lubricate the chain with an appropriate product. While applying ATV chain lubricant, spin the sprocket, then wipe off any excess lubricant, taking care to avoid the brake parts.
Sometimes, even with maintenance and inspection, you will need a new chain. If you hear those chain slap sounds, feeling loose sections of the chain, notice rust, or can’t keep it tight, consider a new chain. Still, knowing what to watch for and committing to maintenance should ensure that chain replacement is not a regular part of your ATV experience.
Disclaimer: While we endeavor to keep the information on our blog up to date and correct, Maxtrade (Coolster) makes no representations or warranties of any kind, express or implied about the completeness, accuracy, reliability, suitability, or availability with respect to the website or the information, products, services, or related graphics contained on the website for any purpose.
Any reliance you place on such material is therefore strictly at your own risk.
To keep the ATV running like clockwork, the rider needs regular maintenance. And one of the main elements of the maintenance of the device is checking the chain on the children's ATV. Ignoring this procedure can lead to a number of problems. After prolonged use, the chain may begin to fly off, sag and even break, damaging the crankcase or axle. Therefore, if you decide to buy an ATV for your child, it is important to understand the maintenance technology of this unit.
Many ATV owners are faced with the fact that the chain falls off the machines. Typically, this problem occurs during the active operation of the ATV (after passing 500-1000 km). The cause of the problem can be:
Tensioning and lubricating the chain will solve the problem. And in case of severe wear, the element will need to be replaced. Also, the rider needs to inspect the sprocket and make sure that the chain has not “eaten” its teeth.
So, we figured out why the chain flies on a children's ATV. But what if maintenance, stretching or replacing the element did not help? In this case, you need to pay attention to the roller, it may be very worn out. If so, then it needs to be replaced.
But what to do if there is no video, but the problem with the flight could not be solved? Then you can show your imagination and install the chain tensioner yourself. To do this, you need to make a plate with a mount for the roller, and install this design under the chain. In addition, this "miracle" can be supplemented with a spring, which will improve the tension.
Ideally, chain tensioning on a children's ATV should be done 2-3 times per season. Although there are other reasons for service, among which:
Finding the problem is quite simple, the rider needs to visually inspect the knot. If any deviations from the norm are noticeable (star wear or chain sagging), it is necessary to carry out maintenance.
Experienced riders recommend maintenance 2-3 times a season or after every 250-400 km. This will prevent the chain on the children's ATV from flying off or breaking the component, as well as increasing its operational life.
The first thing to do is clean the assembly (chain and sprocket) of dirt. This can be done with a soft cloth, a household brush and everyone's favorite WD-40.
It is highly undesirable to use sandpaper, metal brushes, aggressive products and any solvents for cleaning. The use of such products is almost 100% likely to damage the rubber elements.
After that, you can start lubricating the unit. Almost all (even cheap) products marked “off-road” are suitable for this. Special oils not only protect components from dust and dirt, but also minimize their wear.
Note: Before processing, it is recommended to “warm up” the chain a little. And to remove excess oil, you should use a soft rag.
First, you need to make sure that the ATV chain is really slack. To do this, grab the link near the sprocket and pull the chain towards you. If you manage to pull more than 4 links, you need to carry out maintenance.
The rider should read the documentation before tensioning the chain. The fact is that some children's ATVs are equipped with tension bolts that simplify maintenance.
With their help, you can tighten or "release" the chain.
But on powerful teenage devices (125-200 cubic meters), the procedures look a little different. Owner needs:
It is worth noting that such an operation is relevant for relatively new chains, on which 400-800 km have been skated. But the old components just need to be changed. Although a worn chain can be used as a spare, it must first be derusted and shortened.
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Chain care (lubrication and tension) is one of the key elements of ATV maintenance.
If the rider ignores this procedure, the component will begin to wear and sag, and the sprocket teeth will fail. This will all lead to serious problems and break the element. Therefore, the motorist needs to figure out how to pull the chain on the ATV.
Inspection of the unit is recommended every 2-4 weeks, depending on the operation of the machine. It may seem like this is quite common, but ignoring the procedure can lead to serious problems. For example, if the chain breaks far from the garage, the rider will have to push the quad home. But this is a trifle, in comparison with the fact that if a component breaks, the crankcase may suffer or the axle may jam.
The critical problem for the chain is:
But how do you know when you need to tighten or replace a chain on an ATV? Everything is simple. The rider needs to grab one link of the chain in the region of the rear sprocket and pull it towards him. If it turned out to pull off more than 4-5 links, then the node needs service.
Even if you have bought a reliable ATV, it is recommended to service the component every 300-400 km. This will not only increase the life of the circuit, but also detect the problem in a timely manner.
Since the quad is used for off-road driving, dust, dirt and moisture are constantly deposited on its nodes. All this leads to increased wear of the elements. By the way, experienced riders advise cleaning and lubricating the chain after each race.
First you need to find the right oil. In principle, even inexpensive lubricants can be used, but they will have to be applied more often.
The oil marked "off-road" is best suited for an ATV. Such compounds are designed for off-road driving, and perfectly protect the assembly components from dirt and moisture.
Before putting the chain on the ATV, it must be completely free of dirt. However, for this it is highly recommended not to use aggressive chemicals, hard brushes, solvents or high pressure washing. All this can lead to damage to the rubber seals.
Cleaning can be done:
After the dirt has been removed, the chain must be thoroughly wiped with a soft cloth and dried. Only then can you start lubricating.
It is worth noting that it is recommended to apply oil on a warm chain. But the removal of excess lubricant is carried out with the same soft brush.
ATV chain is recommended to be changed every 500 km.
But what to do with an old part that is slightly worn or torn? You can make a spare wheel out of it, after shortening it by 1-2 links. Of course, this "modification" will increase the likelihood of its rupture, but in an emergency, such a spare tire will allow you to get home.
To shorten the chain:
Important: Remember that an old shorter chain will increase the wear on the sprockets.
To tension the chain, the vehicle must be parked on a level surface in neutral.
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