How to Fit and Install a Motorcycle Chain

Fitting a new motorcycle chain is a straightforward job with the right tools and a little care. Whether you're servicing a classic bike or finishing a café racer build, getting the correct chain length, master link and tension is essential for safe and reliable operation.

In this Tink Customs guide, we walk through fitting a new motorcycle chain, including removing the old chain, checking the new chain length, fitting the master link, adjusting chain tension and checking the final installation.

Before Fitting a New Motorcycle Chain

Before buying or installing a replacement chain, make sure you have the correct chain size and length for your motorcycle.

If you're not sure what chain size your bike uses, see our guide:

How to Measure Motorcycle Chain Size

The chain size needs to match the front and rear sprockets. If the sprockets are worn, this is also a good time to replace them rather than fitting a new chain to badly worn sprockets.

Tools for Motorcycle Chain Installation

Depending on the motorcycle and type of chain, you may need:

• Correct replacement motorcycle chain

• Chain breaker and rivet tool

• Master-link tool

• Socket set and wrenches

• Rear paddock stand or centre stand

• Vernier calipers

• Chain lubricant

• Cleaning cloth

• Safety glasses and gloves

The tools required will depend on the type of master link being used. Some older motorcycles use a simple clip-style master link, while modern sealed chains commonly use a rivet-style master link.

How to Fit a New Motorcycle Chain

1. Prepare the Motorcycle

Park the motorcycle securely on a level surface and switch off the engine.

Put the transmission in neutral and use a suitable stand if necessary to give you access to the rear wheel and chain.

2. Remove the Old Chain

If you're replacing an existing chain, remove it according to the chain manufacturer's instructions.

A chain breaker can be used to separate the old chain. On some older motorcycles, the existing master link may use a removable clip.

3. Check the New Chain Length

Before joining the new chain, compare its length with the required specification for your motorcycle.

If the replacement chain is supplied longer than required, use the correct chain breaker to remove the necessary links.

Don't simply guess the number of links. Check the motorcycle manufacturer's specification or calculate the required length from the sprocket combination and available adjustment range.

4. Fit the New Chain

Feed the new chain around the front and rear sprockets, making sure it is correctly seated on both.

Bring the two ends of the chain together at a convenient point and fit the appropriate master link.

5. Install the Master Link

The master link must be installed according to the type of chain.

Older motorcycle chains may use a clip-style master link. The clip must be fitted in the correct orientation and fully seated.

Modern O-ring and X-ring chains commonly use rivet-style master links. These require the correct chain riveting tool and the manufacturer's specified rivet dimensions.

Never substitute a different type of master link simply because it fits the chain.

6. Check Chain Alignment and Tension

Once the chain is installed, adjust the rear wheel according to the motorcycle manufacturer's specifications.

Correct chain tension varies between motorcycles, so don't rely on a generic measurement. Check the owner's manual for the correct amount of chain slack and the correct method of measuring it.

Make sure the rear wheel remains properly aligned while making the adjustment.

7. Inspect the Installation

Rotate the rear wheel by hand and check that the chain runs smoothly over both sprockets.

Look for stiff links, tight spots, incorrect master-link installation or anything that causes the chain to bind.

Recheck the master link, chain tension and wheel alignment before riding.

Chain Lubrication

Once the chain has been installed and adjusted, lubricate it using a suitable motorcycle chain lubricant.

Follow the chain manufacturer's recommendations, particularly if the chain uses O-rings or X-rings.

Regular cleaning, lubrication and tension checks will help extend the life of the chain and sprockets.

A Real-World CB750 Chain Installation

This guide comes from a Tink Customs Honda CB750 project, where we fitted a replacement chain to a classic Honda using an older-style clip master link.

The same project also included repairing a damaged thread in the crankcase cover. We initially attempted to use a Helicoil insert, but ultimately decided that retapping the hole to the next size up provided a stronger solution for this particular repair.

The chain installation and thread repair are both shown in the video above.

As always, when working on a motorcycle, follow the manufacturer's specifications and the instructions supplied with the chain and installation tools.