DRZ400 chain shortening? Also, how to remove triples?

[firebladejr]

I've managed to get 90% of the motard transplant done on the weekend. I've now realised that the standard chain is about 2 links too long. Can the stock chain be shortened? If so, how much should this cost if I were to take it to a mechanic?

Also, I've got a UFO headlight setup which uses rubber-band type fasteners. The bands won't fit around the forks as there are still 2 brackets there which used to hold the standard headlight setup. To remove the brackets I'm going to need to take off the triple clamp... Is this hard? How do you do it?

[Wobbly]

Splitting a chain is easy if it's a link type - just go to a bike store and buy a chain breaker and a chain tool for fitting the joining link (looks like a G clamp but usually much sturdier). Use the breaker to push out the pin of the link you want to remove and just use a standard clip that is already on the chain (one of the links most likely should have a clip link on it with a retainer).

If it is a linkless chain you can either take it to a bike shop and have them do it or just pick a spot to split it yourself and try and find a spare link clip somewhere (again, bike shop may have one handy). Or you can buy another chain for SM and keep the original for the dirt rims.

Removing the top tripple is easy. Just take the bars off and then undo the big nut underneath them. Undo the pinch bolts holding the fork legs and then use a mallet and a drift (bit of wood etc) to knock the tripple up and off the forks and steering stem. That easy.

[firebladejr]

Removing the top tripple is easy. Just take the bars off and then undo the big nut underneath them. Undo the pinch bolts holding the fork legs and then use a mallet and a drift (bit of wood etc) to knock the tripple up and off the forks and steering stem. That easy.

Will the forks change position/height or anything when I remove the top triple? Not too keen on having to re-adjust the forks... And how hard is it to get back on?

[Wobbly]

Nope, nothing will move, because the pinch bolts on the bottom triple clamps will keep everything else in check. Getting the top yoke back on is easy - just stick it back on and use your drift and rubber/plastic mallet to tap it back on. Just work around it like you would a bearing so it goes on square. Easy as!

[Muzzard]

Once this babies running FBJr.
We will have to get a few blokes together for a 'Spurs Ride' and discuss the finer points of your DRZ as there is a few in here now.
Neil, Kimo, Steve, Cal and you, so tech info will be coming outta ya ... by the time your finished... :lol:

[firebladejr]

Once this babies running FBJr.
We will have to get a few blokes together for a 'Spurs Ride' and discuss the finer points of your DRZ as there is a few in here now.
Neil, Kimo, Steve, Cal and you, so tech info will be coming outta ya ... by the time your finished... :lol:

So I'm guessing you blokes are coming up to Sydney then :?:

[firebladejr]

ok, did the triples last night... I also dropped them 10mm and it feels much better now. The new headlight is on (test fitted), now I've just got to wire it up, which should take a whole of 10mins tonight.

Looking more closely at the front wheel, it looks like I'm going to need more clearance on the disk rotor side. I'm thinking I need a spacer about 4mm thick... can you buy these from a bike store? Does anyone know the diameter of the DRZ front axle?

Just a few more steps and the beast is finished...
- wire headlight
- fit TrailTech (hasn't arrived yet)
- add spacer to front wheel
- shorten chain 2 links (I bet this stuffs me up, all this breaking/joining looks tricky)

[Tom]

Where abouts in sydney are you?

I have a small chain breaker you can use, can be fiddly though.

You can get spare links from ballards, or MCA i think?

Tom.

[firebladejr]

I'm in Greystanes, which is about 10mins from Parra... I guess I'll be making my millionth trip to MCAS in parra again this Thursday night.. I bet it takes me over an hour to do the 10min trip due to the late night shopping at westfields, the week before xmas.

[Muzzard]

:oops:
No we arent coming up there...
Maybe though. :-k Cousins in Guilford...

[firebladejr]

:oops:
No we arent coming up there...
Maybe though. :-k Cousins in Guilford...

well guildford is only about 15mins away :) so when are you coming up :D

[firebladejr]

ok, just thought I would vent a bit before breaking everything in sight :evil:
I bought a RK 520 O-Ring jobbie from Port Macquarie (whilst up there on holidays, which also cost me a car full of hail damage)

I've put the chain on and removed the required links with the grinder. I put the master link on and everything was looking great until I tried to put the tension clip on. That motherF@#$ was sooo damn fiddly, It was almost completely on, then it snapped and the damn clip flew all over the garage. Now I'm without a clip for the chain, and all the bike shops in Sydney are closed for the public holiday. I'm soooo pissed right now I could put my head through the monitor... I;m just hoping that the bike shops sell those clips seperately.

[dicky]

FBJ,

If you haven't already busted your monitor, here is how I do it.

To remove the clip, get a pair of pliers and squeeze the open end of the clip and the link pin...

http://members.iinet.net.au/~dotzen/Clip_removal.jpg

Don't try to lever the clip off the end of the pin, this will warp it.
To re-fit the clip, make sure it is pointing in the right direction. The closed end goes first in the direction of travel. My sprocket turns clockwise.

http://members.iinet.net.au/~dotzen/Clip_placement.jpg

To get the clip on, squeeze the open end against the link pin...

http://members.iinet.net.au/~dotzen/Clip_fitting.jpg

By the time you get your 'tard on the road you'll be an ace mechanic ;)

dicky.

[Wobbly]

That looks w-a-y too well thought out dicky ... personally I get a large flat bladed screwdriver and a mallet. Takes 1/2 the time to remove and fit on. Takes 3 hours to find the clip after you ping it off and around the garage :lol2:

[firebladejr]

thanks Dicky for the pics and the advice, it would have been very handy a few days ago.

I bought a new clip this morning and managed to get it on the same way as last time ie. mallet and a chisel

That means the bike is now on the road!! I've been giving it a bit of a beating around the local streets to test it out... to be quite honest, I think I'm already used to the power of the DRZ. It doesn't matter though, as I'll keep trying to improve my skills before searching for more power.

Motarding is sooooo much fun. I used to have 1cm chicken strips on my R6.. I've already marked the new rubber on the motard right down to the edges.. I can't wait to ride it to work :D

Hey, how do you put pics in the gallery? I've taken some pics of the finished beast but I'm not sure how to upload them in here.. I always get an error message.

[Flash]

That looks w-a-y too well thought out dicky ... personally I get a large flat bladed screwdriver and a mallet. Takes 1/2 the time to remove and fit on. Takes 3 hours to find the clip after you ping it off and around the garage :lol2:

To stop that just put a rag over the chain then it will just drop to the floor.

[Wobbly]

Ash: Party pooper :lol2:

firebladejr: Nice work :up: See my rebuild threads for engine mods :D There seems to be something up with the gallery atm, which I'll check up on when I get home...

[DEAN]

FBJ,

If you haven't already busted your monitor, here is how I do it.
http://members.iinet.net.au/~dotzen/Clip_fitting.jpg


when putting the clip back - do it from right to left when clip is on the lower side of wheel sprocket (when chain is on the left side). this is important.
if the clip touches smth - it will not loose, but sit tighter

[Wobbly]

Except on a right hand chain drive LC4 ;)