Tiger Chains & Parts

Top gear at 4000rpm has me going
about 100km/hr, so it looks like I have
stock sprockets on the Tiger.

A one tooth more relaxed front sprocket
knocks a couple of hundred RPM off
the bike at 100km/hr and takes the
edginess off low speed throttle.

Chain & Agony: The Return

Now that I'm off a shaft driven bike, I'm back into the black magic that is chain geometry!  A trip to Gearing Commander has me working out the details of an '03 Triumph Tiger 955i's chain and sprockets.  The stock set is a 18T (eighteen tooth) front sprocket and a 46T (forty-six tooth) rear sprocket.  The chain is a 530-50 114.

A number of riders suggested a 19T (nineteen tooth) front sprocket to calm the bike down a bit.  The chain and sprockets are happy right now, but when it finally comes to a change, I think I'll go the 19T way.  Motorbike sprockets run backwards from bicycle ones - the smaller sprocket is attached to the engine, so the more teeth, the bigger the gearing.

LINKS & CHAIN INFORMATION

The 530 114 chain on the Tiger has a pitch of 5/8 of an inch (the 5 is 5 x ⅛" - a 4 series chain would be 4 x ⅛" or half an inch of pitch).  Five-eighths pitch chains have a  roller diameter of 0.400".    The 30 part of the 530 refers to roller width, which in this case is 3 x  ⅛" or 3/8th of an inch.  A 520 chain would have a roller width of 2 x ⅛", or a quarter of an inch.  If you want to understand chain sizes, get a handle on that rule of 8 (all the numbers refer to eighths of an inch).

The 114 refers to the number of links in the chain (its length).

Sprocket Centre

How to change a chain on a Tiger (video)
Triumph Tiger 955i parts list

Gearing Commander

Chain Specifications

Sprockets & Chains explained

<- 520 and 530 chains & sprockets widths compared

Tiger Changes of Oil

A fifty dollar US ($300CDN) magnetic
oil drain plug.

Triumph magnetic oil drain plugs.
M14x1.5x16
(that's a metric 14mm width, 1.5mm distance between the threads, 16 mm long drain plug).

Entertaining Triumph oil drain plug banter (and the idea to put hard drive magnets on your oil filter, which is what I'm doing instead of ordering an expensive custom drain plug from The States).

The Tiger has been using a bit of oil (which is evidently within spec) but I don't know what the previous owner's mechanic put in it - putting in not Mobil 1 Synthetic (which Triumph states is the preferred oil) would be a great way to make money on an oil change.  If I swap in the good stuff, then I know what's in it.

I'm also putting on a K&N oil filter with a higher spec than the stock one and putting a couple of hard drive magnets on the bottom of it to catch any metal shavings dancing around in there.

I did the oil change yesterday. I've done thousands of oil changes (it put me through university).  If that oil was changed last fall I'm a monkey's uncle.  The Triumph filter on it had rust on it, the drain plug didn't look like it had been taken off any time recently.  Either the previous owner didn't do it, or his mechanic lied to him.  The oil was black and punky too, looking like it had been in there a long time.

With that all done I'll now look to see how much oil I'm missing every thousand kilometres (it's 3-400ml at the moment - but goodness knows what was in it or for how long).  The moral here is change the oil when you buy a used bike - you can't trust what happened before it was yours and oil is vital to keeping an engine running well.  I'm looking forward to seeing what new, correct oil does for the bike moving forward.


Other than keeping it shiny and lubricating cables and controls, there isn't much more needs doing.

It's supposed to be a beautiful long weekend.  I'm hoping to get out for some time on my very orange Tiger in my very orange Tiger shirt.

Evolution of Motorcycle Ownership and a Triumphant Return

Back in August of 2014 I wanted to take a more active role in my motorcycle maintenance.  At that point I'd been riding for just over a year on my first bike, a very dependable 2007 Kawasaki Ninja 650r.  I learned a lot on that bike, but it was a turn-key experience, the bike needed very little in the way of maintenance.   

The Ninja went from flat black to metallic blue and orange.  It was the last bike I rode that people commented on (I'd often get a thumbs up or have someone stop and chat in a parking lot about how nice the bike looked, which was satisfying as I'd been instrumental in restoring it from angry-young-man flat black).  The Ninja was, without a doubt, a good introduction to motorcycling, and was the king of the roost for my first two seasons.

As a first bike, the Ninja led the way both on the road and at the top of the blog.

I wanted my next bike to be one that ran because of my mechanical skills rather than one that didn't need them.  I found a 1994 Kawasaki Concours sitting in some long grass about twenty minutes away.  I quickly discovered that sense of satisfaction I was looking for.  The Concours was an eager patient who rewarded a winter of mechanical work with a rock solid five thousand miles of riding the next summer.

The Concours has offered some memorable rides, especially looping Georgian Bay and riding on the Indianapolis Motor Speedway.  For a bike that looked like it was being permanently parked with only 25k on it, suddenly it was back in the game, going places other bikes only dream of.

That busy season of long rides took its toll on the Concours though.  It isn't a spring chicken and after having spent the better part of two years parked before I got to it many of the soft parts on the bike were getting brittle.  I parked the Concours early and began winter maintenance knowing that the bearings and brakes both needed attention only to miss out on a late season warm spell at the end of November and into December.  I took that one on the nose figuring that's what happens when you ride an old bike as your daily rider.

The header on this blog for the past eighteen months, but running a twenty-two year old bike as your daily rider
makes for frustrations.  Time to be less sentimental and more rational in how I manage my stable.

That summer we were touring on the Concours I picked up a KLX250 to experience off road riding, but doubling insurance costs for a bike that I only managed to get out on a handful of times didn't feel very efficient.  That I struggled to keep up with traffic on it didn't support the way I like to ride.  Motorcycles are open and unprotected, but they are also agile and powerful enough to get out of a tight squeeze - except when they aren't.  The Concours was always there and the preferred ride, owning the road when I was on it.  When I went out with my co-rider he also loved the big red Connie, not so much the rock hard, under-powered KLX (he only ever rode on it once for less than five minutes).

Over the winter I put some money into the Concours, doing up the rims and getting new tires.  With the rims off I also did the bearings and brakes.  As everything came back together again, suddenly the carburetors weren't cooperating.  They're since being rebuilt and the bike should be back together again this weekend, but instead of always being there, suddenly the Concours wasn't.  As winter receded I could hear other bikes growling down the road, but I was grounded (again), even though I was paying insurance on two machines and longing to get back out on the road after an always too long Canadian winter.

The KLX was the first to go.  I'd never really bonded with it and, even though I always figured I'd run this blog with my most recent bike in the graphic at the top, the KLX never made it there; it never felt like the main focus of my motorcycling.  In the same week my son's never-ridden PW-80 got sold, and suddenly I had some money aside.

Ready to go with a new header, but it never took.

As days of potential riding keep ticking by and the carburetor work drags on, the Concours started to feel like an expensive anchor rather than the wings of freedom.  I had a long talk with my wife about it.  She asked why I don't unload it and get something dependable.  Keep the old XS1100 for that sense of mechanical satisfaction, but have a bike that's ready to ride.  I think sentiment was paralyzing me.  Hearing a rational point of view with some perspective really helped.

Many moons ago,
a pre-digital Triumph

With cash in an envelope I began looking around.  Before Easter we weathered an ice storm, but only two days later it was suddenly in the teens Celsius and bikes could be heard thundering down the road.  Meanwhile I was waiting for yet more parts for the Concours.  Online I was looking at sensible all purpose bikes that would fit a big guy.  Vstroms and Versys (Versi?) came and went, but they felt like a generic (they are quite common) compromise, I wasn't excited about buying one.

Since I started riding I've been on Triumph Canada's email list even though I've never come close to owning one (out of my league price-wise, no one else I know had one, no local dealer... pick your reason).  As a misguided teenager I purchased an utterly useless Triumph Spitfire, and in spite of that misery I've always had a soft spot for the brand (your adolescent brain makes your teenage experiences sparkle with emotion even when you're older, that's why we all still listen to the music from our teens).

A Tiger?  On Kijiji?  Must have
escaped from a zoo!

While trawling around on Kijiji looking at hordes of generic, look-a-like adventure bikes I came across an actual Tiger.  It was (as are all Triumphs I've mooned over) too expensive for me, but that Lucifer Orange (!) paint haunted me.

Another rare warm afternoon wafted by with the sounds of motorcycles on the road so I thought, what the hell, and emailed the owner.  He'd been sitting on the bike for the better part of two months with no calls.  He was going down to the Triumph dealer on Thursday to trade it in on a new Street Triple and knew he was going to get caned by them on the trade in price.  He emailed me back and said if I had three quarters of what he'd been asking, he'd rather sell it to me than give the dealer the satisfaction.  Suddenly this fantastic looking machine was plausible.

The garage is 100% more functional than it was last week,
100% more glamorous too!

A trip up to Ontario's West Coast and I got to meet a nice young man who was a recent UK immigrant and a nuclear operator at the Bruce Plant.  The bike was as advertised (well looked after, second owner, some minor cosmetic imperfections), and suddenly I owned a freaking 2003 Triumph Tiger 955i!

Most used bikes offer up some surprises when you first get them, and they usually aren't nice surprises.  The Ninja arrived with wonky handlebars the previous owner told me nothing about.  The XS1100 arrived with no valid ownership, something the previous owner failed to mention during the sale.  So far the Tiger has had nice surprises.  It arrived with a Triumph branded tank bag specific to the bike.  Oh, by the way, the previous owner said, the first owner put a Powercommander on it, and then he handed me the USB cable and software for it.  It had also been safetied in October, less than two hundred kilometres ago (paperwork included), so while I didn't buy it safetied, it shouldn't be difficult to do.  The bike has fifty thousand kilometres on it, but I then discovered that the first owner did two extended trips to Calgary and back (10k+ kms each time) - so even though it's got some miles on it, many of them are from long trips that produce minimal engine wear.  After giving it a clean the bike has no wonky bits under the seats or anywhere else.  I cannot wait to get riding it.

So, here I am at the beginning of a new era with my first European bike.  I've finally picked up a Triumph from the other side of the family tree (the bike and automobile manufacturing components of Triumph split in 1936), and I've got a bike I'm emotionally engaged with.  It might even be love!  Like the BMW I rented in Victoria, the controls seem to fit my hands and feet without feeling cramped and the riding position is wonderfully neutral.  When I'm in the saddle my feet are flat on the ground - just. Best of all, I don't look like a circus bear on a tricycle on it.


With the Concours officially decommissioned and awaiting (what are hopefully) the last parts it needs before being road worthy again, it's time to update the blog header:

What's next?  The Concours will be sold with only a modicum of sentiment, the Tiger will be safetied and on the road (it cost $90 a year more than the Concours to insure), and I'll enjoy having an operational, trustworthy machine made in the same place I was with lots of life left in it.  The fact that it was getting me thumbs up and one guy stopping to say what a nice bike it was when it was on the trailer on the way home doesn't hurt either.  Riding a tiger has a certain magic to it.

When I want to turn a wrench I'll work on the XS, getting it rolling again for the first time in years.  I'll get the ownership sorted on it (affidavits are required!) and eventually sell it without losing a penny, and then I'll go looking for my next project bike.  Maybe a scrambler Versys, maybe an old Interceptor, maybe something I haven't thought of yet.

Time for some unbridled Tiger enthusiasm!

Tyger Tyger, burning bright, 
In the forests of the night; 
What immortal hand or eye, 
Could frame thy fearful symmetry?

In what distant deeps or skies. 
Burnt the fire of thine eyes?
On what wings dare he aspire?
What the hand, dare seize the fire?

And what shoulder, & what art,
Could twist the sinews of thy heart?
And when thy heart began to beat,
What dread hand? & what dread feet?

What the hammer? what the chain, 
In what furnace was thy brain?
What the anvil? what dread grasp, 
Dare its deadly terrors clasp! 

When the stars threw down their spears 
And water'd heaven with their tears: 
Did he smile his work to see?
Did he who made the Lamb make thee?

Tyger Tyger burning bright, 
In the forests of the night: 
What immortal hand or eye,
Dare frame thy fearful symmetry?

Bike Bucket List: Ironbutt Glory & MotoGP photography redux

almost 1600 miles diagonally across North America.

My motorcycle bucket list includes earning the Ironbutt basics.  The first two rides are the Saddlesore (1000 miles in 24 hours) and the Bunburner (1500 miles in 36 hours).  The Austin MotoGP race happens to be just over fifteen hundred miles away, making it an ideal target for these badges of long distance endurance riding.

I'm not sure that I'd ever do an Ironbutt again, but it'd be nice to have done it once.

The MotoGP race in Austin is on April 10th this year.  Leaving on a Tuesday night would get me there for the event.  Even with a (more) relaxed ride back, I'd still only be on the road for seven days - 3 of them at the GP.

I roughed out hotel stops based on ideal distances, but it would probably be significantly cheaper to pick a hotel chain and stay with them throughout.  My hotel of choice would be Hampton Inn, so a revision based on where I can stop at those might be in order.

After Indy got cancelled, this is the only other race on my continent, so my only chance to ride to a race event.  It'd be nice to see the circus in action again this year, and Austin, while much further away, offers a chance at Ironbutt glory!

Video of MotoGP practice through the esses at Indianapolis.

I'd be nice to go down there with some good camera kit and see what I can capture.  I did pretty well with my little Olympus last summer, but another go with more effect gear would net even better results.

Many of the images I took had to be photoshopped a bit to hid the poor resolution and light intake of my camera (creating a simplified painted look in Photoshop hides these weaknesses).

 
 

I'm also getting frustrated with the lack of lens availability with the Olympus I've got.  I'm thinking of going back to a superzoom on my next camera.  The Nikon P610 has enormous reach (4x what the Olympus telephoto can manage with similar light loss).  What would be even better would be a full 1" sensor superzoom like the Pentax FZ1000, then I'd have a multipurpose camera with excellent low light ability - though they are three times the price of the smaller sensor superzooms.

I had a fixed lens superzoom a few years back and loved the flexibility, though it was one of the first electronic view finder cameras and lagged annoyingly.  It's light intake wasn't great either.  The new ones will benefit from much faster electronics and dramatically larger sensors letting more light in.

The Olympus PEN is an entry level mini-SLR.  I've enjoyed the size and convenience but the lenses are expensive and hard to find, and the kit lens has broken.  The body itself also broke under warranty when I first got it.  A second failure in three years has me thinking about moving on.  I'm looking for the simplicity and flexibility of a fixed lens superzoom again.  This would be especially handy when travelling on a bike where all the SLR clobber takes up too much space.

As a photographer I've always enjoyed being able to do more with less.  I've often seen people with suitcases of gear worth ten times mine take worse pictures.  As long as it can keep up with my eye and offer the control I need, a quality fixed lens superzoom will let me do that in spades.


Rough Planning Maps:

• Elora to Super 8 Airport North Austin: (20 mins from Circuit of the Americas)
• Elora to Best Western outside of Little Rock: 1045 miles 
• Little Rock Hotel to Austin Hotel:  535 miles
• CotA to Hampton Inn Marion (outside of Memphis) 654 miles
• Memphis to Fort Wayne:  584 miles
• Fort Wayne to home:  354 miles

Yamaha XS1100: The Midnight Saga

Buddy Jeff gave me a hand getting the XS1100 home the other day; he's an enabler.

Getting it on the trailer was a bit tricky as the front calipers were seized.  A couple of whacks with a rubber hammer loosened them up enough to get the wheel rolling.  It took three of us to get it up onto the trailer - it's heavy (600lbs), had mostly flat tires and was still grabbing the brakes, but we finally got the job done.  We ended up settling on $400 as is, which gives me a working budget of about $1500 to get the bike back on the road.  It think it's doable.  The only other one like it for sale at the moment is asking $3300.  After looking at the bike again critically before agreeing to buy it, it's in surprisingly good shape for what it has been through.

Once home we had a victory beer after wrestling it off the trailer.  A bit later I had a go at it with a garden hose and some S100 cleaner.  The ride over had blown away most of the cobwebs, but the rest of the bike is quite astonishingly clean considering it has been sitting outside.  The S100 also has a corrosion inhibitor, but I also soaked the bike in wd40 in preparation of trying to remove any fastener on the thing.

Trying to muscle the 600+ pound bike into the garage earned my my first Yama-scar, but I eventually got it nestled in there.

In other news, here's something to know about bike ownership in Ontario (and probably elsewhere): if you're buying a bike off someone who bought it and never transferred ownership to themselves, you need to make sure you've still got chain of ownership intact.  This means either a piece of writing from the legal owner saying that the bike was sold to the intermediary or a signed ownership.  The kid I bought the bike off had neither (can't find them).  He's looking.  More updates to follow.

It's getting crowded in there - once the season ends
the garage will only need to hold the Concours &
the Yamaha, everything else will winter in the shed.

In the meantime, the history of this old bike is long and storied.  I'm the fourteenth (!) owner (almost).  It's a 1980, not a '78 as the kid selling it thought it was.  In the early '80s it went through three owners before finding itself at Norwich Collision Service in South West Ontario in the spring of '82.  The crash owner had owned it since Christmas and had probably been on the road for a few weeks in the spring before spilling it.  Idiots buying bikes too powerful for their experience level isn't a new thing then.  He got the bike back from repair and immediately sold it.

After the n00b crash and the repairs it got picked up by a guy who owned it for six years.  He then sold it on to a series of owners through the '90s and zeroes, the longest being eight years by a guy in Halton.  The last legal owner was a guy from Stoney Creek in 2009.  

Whoever said the Ontario vehicle history was boring or a waste of money?  This one reads like a Jane Austen novel!

I'll update the ownership situation as I hear more, hopefully it'll be resolved by the end of this weekend.  I'll hold off on working on the bike until I know I can own it, that seems prudent.

Road Trip Insanity

Over thirteen hundred kilometres in two days? Bring the pain!

I'm still looking for a DRZ-400.  I just found one way up in Thunder Bay.  Here's a stupid but interesting idea:  fly up Friday, pick up the bike Saturday morning and ride it home by Sunday night.

Leave Saturday morning from Thunder Bay and trace the north shore of Gitchegumee to Sault Ste. Marie where I'd overnight Saturday after my first nearly 700km day.

Sunday morning would have me up early to tackle the final 650kms home.  At least I'd be able to pass out on the ferry from Manitoulin to Tobermory.

Insane?  Probably, especially on a 400cc dual sport bike mainly designed for the dirt, but that's also what would make it interesting.

Pearson to Thunder Bay late on a Friday night, about three hundred bucks

It's nearly June and they are still below zero overnight in Thunder Bay, so it'd be a bag of layers I'd be bringing up with me.  The riding temperature range may go from around zero all the way up into the thirties, so flexibility is key!  A water proof duffel bag for the back of the bike would work as carry on luggage and a universal way to carry gear on the bike.

In that bag I'd chuck a helmet and goggles, a face scarf, motorcycle jacket, pants and rain gear.  I'd wear bike boots onto the plane.  Repair wise I'd bring a mini tool kit and some chain lube.  Clothing would have to be everything from polar fleece to thin cotton to cover the possible temperatures.

A nice, clean, low km bike ready for an insane trip home?

It's buying an unknown bike from a stranger, though this particular one is low kms and looks very well looked after.  There are things I could do to ensure the bike is ready to go.  With some emails between the seller I think I could convince them to prep the bike for the trip as part of the purchase price.  I'm not sure about the legal requirements but if they safety it and scan it to me I could appear up there with plates, ownership and insurance ready to go.

So what would this buy-a-bike-instant-road-trip insanity cost?  They are asking $3500 for this '07 Suzuki with 14,000kms on it.  I'd be ok with the asking price if it includes the safety and prep for the return trip.  On top of that I'm looking at about $300 for the flight up there, $300 for hotels on the way back down and sundry costs (gas, food, ferry, etc).  Lets say another $300.  Forty four hundred bucks for the DRZ I'm looking for and an insane road trip to boot from The North?  Sounds like a fun weekend!

If I had more disposable income I'd be dangerous!

Track Day Planning

I'm pretty keen to go do a track day, and I have a buddy who is the same.  The Grand Bend Motorplex does motorcycle open lapping on its track.   I found GBM through motorcycletrackdays.ca.  The upcoming SOAR racing event at Grand Bend offers open motorcycle lapping prior to their weekend events.  That might be a good time for two nØØbs to go as there will be experienced track day people on hand to help us fumble through the technical inspection.

I figured it would be a show up on what you rode here on and go on the track, as you would with a car, but bikes seem a bit more involved.  Here is the list of motorcycle specific technical requirements:

• Is your kickstand secured? Your spring return isn’t enough on a racetrack. Use a plastic strap tie or duct tape to secure your kickstand in the up and locked position before you come to tech. 
• Tape over your speedometer. It’s the rule.
• Make sure your throttle returns quickly and positively. We want to see it snap back when you release the grip. 
• Change your antifreeze for straight water. If your bike puts antifreeze on the surface, it shuts the entire track down and may result in suspension. Antifreeze is 100 times worse than water on asphalt (It’s like wet ice). Swap it out for water before you proceed to tech. 
• Tape over or remove lights, signal and mirrors. They all shatter and they all puncture tires. 
• Brakes: Make sure they’re properly functioning, front and back, with no leaks, because we’ll check. 
• Chain: Check your drivechain adjustment. Too tight or too loose means breakage. Refer to manufacturer’s specification. Also, check your master link. A rivet style link is preferred, but a standard ‘slip on’ while suffice if you put a dab of silicone on the key to secure it. 
• Now that you’ve ensured your brake lines don’t leak, check the rest of the bike. Your engine and suspension components must also be leak free. 
• Overall track worthiness: These are the small things that can lead to disaster. Loose lines can snag. If it can flop around, it can be snagged and lead to a crash. 
• Body: All body parts must be secured or removed. 
• Mechanical: Check your fasteners and ensure they’re secured at recommended torque. 
• Tires: Properly inflated, with structural integrity intact (sidewall, tread, steel-belts, bulges).

Most of that is common sense/maintenance, but there are a couple of bits that will require some thought.  Tying up the kickstand is all well and good, but that means you're bringing a rear stand to keep the bike upright.  Swapping out the antifreeze also means you need to bring some distilled water.  Some tools, disposable gloves and fluids would probably be a good idea too.  Suddenly the back of the bike I want to ride to the track day is looking like a hardware store.  You wouldn't want to ride an hour and a half to a track to find out you don't have what you need to go around it.  Short of asking for a pit crew to accompany you in a four wheeler, riding solo to a track day seems difficult if not impossible.

Of course, this leads you down the road to a trailer, which then begs the question, why use your road bike for track days when you can pick up an older sport bike for not much, not have to pay for road insurance on it and spec it out specifically for track days.  Stripped of lights and needless accessories like rear foot pegs and indicators, you'd be ready to ride as soon as you roll it off the trailer, and the machine would be tailored for the track.

I've been to several racing schools, but the one time I really got into it was while living in Akita, Japan.  Kyowa Race track was a small carting track deep in the mountains south east of the city.  Kazutoyo, a student of mine, was an avid racer (he came to Canada for a summer to participate in a Mosport racing mechanics program).  We'd go up there half a dozen times in the summer and spend the day hauling the carts around that bendy circuit as quickly as we could.

The vehicle of choice for the carts and the paraphernalia that went with them was a cargo van.  We'd be able to fit three people, the tools, the disassembled cart and spare tires and other odds and ends all in the van and head to the track.  Riding around at break neck speeds was awesome, but I have fond memories of all the fettling that when on in the pits too; it's all part of the race experience.

Ford Canada's handy Transit Van Builder got me all
set with a customized utility van that could carry two
bikes and gear with ease... things I'd do if I were rich!

Now that I'm thinking about doing a track day on two wheels I'm tempted to imitate those Japanese carting guys and get what I need to make a track day possible.  I've been wishing for a trailer several times this summer to haul lumber.  Having one on hand and a vehicle to haul it would be handy for more than just track days.  

Or just win the lottery and get the full on racing support van.

If Mechanical Sympathy were to go full on into racing, I'd grab that 1000cc VFR from Angus (in my Transit race van) and prep it for racing.  Stripping off all the lights and extras and minimizing it down to a race bike.  I'd be a dangerous man if I had more money.

In the meantime I'm still trying to look for ways to ride my Ninja to the track and do some laps without dragging along someone in a cage to support the activity.

Links:

Motorcycle track day primer: a good explanation of track days.
Beginner's Guide to Track Days in Ontario: a great checklist on how to approach track days - renting a bike is what I'm now looking into...

KLR Curiosities

A super high mileage KLR, but it's pretty new (mid-00s).  Unclear on its mechanical details, other than it's very tired and the plastics and tank don't match.  

$1300 seems like a lot to pay for a bike in such condition with unoriginal parts (probably because it's been dropped hard).

If I got it I'd shelf it for a year while I broke it to pieces and rebuilt it.  I might go as high as $800, but I'll be spending a lot to give this tired old bike a second life.  I've asked the owner for info...

Followup:  I got a fantastic response from the owner.  The bike has been fettled to within an inch of its life.  The first owner took it from Alaska to Tierra del Fuego, and did the Demptster Highway.  The second and current owner has taken it to James Bay and various off-road adventures in the past couple of years.  It hasn't been dropped recently, but it's an off-road capable bike, so it's been down, once in Chile where they rider had to order in a new instrument cluster, the mileage is uncertain with the replacement instruments.  This bike has had a life, and now it's for sale in Southern Ontario.  

I suggested he sell it back to Kawasaki, this KLR shows what KLRs are capable of.

The mods list is extensive:
EM Doohickey
Upgraded headlight wiring harness with relay
Headlight cut out switch
Glass fuses replaced with blade fuses
Oversized side stand pad
Subframe bolt upgrade
Scott chain oiler
Progressive 420 Series rear shock
Instrument and idiot lights converted to LED
Choke relocation mod
Stainless front brake line
Headlight modulator (not hooked up but still in the fairing)
UNI air filter
LED plate light
Perelli M21 tires with lots of meat on them
Shell Rotella every 2500km or so

Chain and no Agony

Follow up to Chain & Agony and How to Size and Replace a Motorcycle Chain...

The whole process of breaking the chain and installing it took about half an hour this time around.  The o-ring chain I got was easy to break using the tool I picked up, and installing the new master link on the chain took only moments.  The three in one DRC Chain Tool I got (chain breaker, outer plate presser, rivet presser) was easy to use and looks good doing it.  It might be my favourite tool at the moment.

The chain-breaking tool comes with two sizes of /privet pushing bit.  The blue bit was for 500 sized chains (the Ninja's is
a 520).  You back off the big bolt and install the push pin, then use the smaller outer bolt to push the pin into the rivet on the chain. The tool automatically centres the rivet, so you're true all the way through.

The new chain was a 120 link chain, the Ninja takes 114 links, so that's 6 links off the end.  The hole in the
top is where the chain pin falls out once you've pushed it through.

Close-up of the blue chain bit .  There is a pin inside it that the outer bolt pushes through, pushing the rivet
right out of the chain.  Once the pin falls out the chain falls apart.  You end up with a clean break and two
inner chain links ready to be re-attached on the bike with a master link.

Six links of the 120 link chain removed.  One pin is pushed right out, the other was pushed
out far enough to dismantle the chain.

I installed the master link on the sprocket - it keeps everything lined up and made installation easy.  After
pressing on the side plate (gently, checking that it's in line with the other links and the chain has play in it),
the only tricky bit was installing the retaining clip, it took a few tries.  When you get it though you know for
sure because it makes a very satisfying click.

With the chain back on and lubricated, everything is tight.  The change to how the bike feels is subtle
but very satisfying.  The engine feels much more firmly connected to the back wheel now.  No sags and tight
spots like on the old chain.

I got this mighty DRC Pro chain
tool at Royal Distributing in
Guelph.

Now that I've got a handle on this and the right tools for the job, chains don't worry me any more.  This process also emphasized how surgical bike mechanics are.  I started off doing heavy equipment repair as a millwright and then did a couple of years in automotive.  Compared to that kind of work, motorcycle mechanics feel more like surgery than butchery.  Patience and a careful hand are more important than brute force.

Now more than ever I'm looking for an old bike to dismantle and rebuild to get an inside feel for how motorbikes go together.