NB: These instructions are given for guidance only and cannot engage the author's liability in the event of misinterpretation, failure to assess the vehicle's actual condition and/or non-conformity, unsuitable mechanical practice or the use of inappropriate tools.
Fitting the chain kits (chain + output sprocket + rear sprocket).
Gearbox output sprocket
The sprockets are machined slightly undersize to compensate for wear on the layshaft seat. On low-mileage bikes it may be necessary to lightly re-machine the sprocket splines to ease fitting: work carefully, evenly and in successive passes (file or Dremel) until the sprocket goes on "tight but not excessively". Ideally use a suitable reversible puller for removal and refitting.
- Never strike the sprocket hard with a hammer to fit it.
- Never machine the sprocket too much, or the layshaft may be damaged by sprocket rock.
Chain
Chains are supplied in 530 pitch in 106, 108, 110 or 112 links depending on the model. Links may need to be removed depending on the machine (104 to 110 links; e.g. 106 for a 750 SF in 530 pitch). For safety, avoid a spring/clip link and use the rivet link supplied with the chain.
Lock tabs
Always use new lock tabs: one to secure the gearbox output sprocket, and two more to lock the rear-sprocket fixing bolts.