TaoTao TBR7 Motorcycle Chain Upgrade.

As I read about doing upgrades for my TaoTao TBR7 dual-sport motorcycle, I read about motorcycle chain failures are common with the additional stresses we placed on the bike performing upgrades.

So, it was time I did a TBR7 Motorcycle Chain Upgrade.

I Finally Got Around To Upgrading My TBR7’s Motorcycle Stock Chain.

Before showing the steps I took to change my TaoTao TBR7’s motorcycle stock chain, I will quickly review some questions that might arise from this upgrade.

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FYI, the new motorcycle chain I picked up for my motorcycle: JT Motorcycle Chain (428 Series) Heavy Duty Non O-Ring.

Why Did I Do The Motorcycle Chain Upgrade?

I have almost 4,000 kilometers, with no problems. I frequently clean(wipe it down with a rag) and lube the chain(with chain wax). I did not see any failures in the chain. However, I have read posts the chain quality is questionable. Now one can argue that the overall quality of the whole TBR7 and any of the cousins(HAWK 250, Raven 250, etc.) is questionable, which I have been addressing with increased maintenance, item replacement, and complete upgrades.

The chain. There are many posts I’ve been seeing about the stock chain failing without warning. Also included in some of those posts are photos. Many of the images show the significant damage the broken ends of the chain has done to the bike. I’ve seen no rider injury, but those photos still show considerable energy released from the broken chain.

These posted problems motivated me to replace my stock chain, especially since it has almost many kilometers.

Why I Bought A Non-O-Ring Motorcycle Chain.

Speed. With no o-rings, the chain is lighter and has less internal friction. This design allows more energy to be transferred from the engine to the wheel.

One drawback requires increased maintenance when compared to o-ring type motorcycle chains. I take steps to maintain and lube my stock chain properly, so the increased care is not a problem.

So Speed is my motivation.

Why I Bought A New Upgraded JT Motorcycle Chain For The TBR7.

I have upgraded both the front sprocket( TBR7 Front Sprocket Upgrade ) and the rear sprocket( TBR7 Rear Sprocket and Studs Upgrade )and used JT sprockets both times. I am happy so far with the sprockets, so it only makes sense I go with the JT made chain.

Steps I Took To Replace and Upgrade My TBR7’s Motorcycle Chain:

FYI: Building My List of Must-Have Tools For Motorcycle Owners

Let’s not forget basic motorcycle garage steps: My FAQ – Motorcycle Garage Safety Rules

Step 1.  Elevated and Secure The Motorcycle.

I used my hydraulic lift jack ( I Use: Motorcycle Lift Jack ) and had the motorcycle high enough to allow the rear wheel to remain off the ground. With the wheel off the floor, and of course, in neutral, ensure the motorcycle is on a stable surface and cannot be turned on(disconnect the battery is needed).

My Motorcycle Chain Tip: I put down newspapers to let the old chain lie on paper instead of my floor. The chains are greasy/waxy, and grimy. I also used gloves to minimize how dirty I got in the process.

Step 2.  Remove Motorcycle Chain Guard.

This step is an excellent time to check the condition of your chain guard. It is a rather flimsy piece of plastic that can be easily damaged while performing its essential function.

Step 3.  Disconnect The Old Motorcycle Chain Master Link.

Rotate the rear tire, be off the ground, and bike in neutral until you see the master link. I positioned the master link over the top of the rear sprocket to remove the master link, and both chain ends would remain over the end.  

Step 4.  Connect The New Motorcycle Chain To The Old Old Chain.

I used the old motorcycle master link and connected the new motorcycle chain. The old and new chains were joined together at the end of the old chain’s lower free end lying on the floor.

By doing this step, I rotated the motorcycle wheel backward to feed the new motorcycle chain around the front sprocket without removing the front sprocket cover.

Step 5. Feed The New Motorcycle Chain Backwards Through The Chain Path.

Rotating the rear wheel backward, the rear sprocket will put the old chain out of the front sprocket housing while feeding the new chain in. Once you get the master link to the rear sprocket again, stop.

Step 6.  Remove the Old Chain and Test The New Chain Ends.

The old chain can be recycled. I tossed even the old master link since the new motorcycle chain kit came with a new master link.

I moved the motorcycle’s rear axle into a mid-position on the lower swing arm’s axle slide grove. After making the chain connections, I have room to move and adjust the rear axle, back and forth, to set up for proper chain slack.

Now testing, The ends of the chains could be too long or too short.  

Step 7. Trim The Motorcycle Chain Length (Only if the new chain ends do not meet).

My new motorcycle chain is too long by a couple of links. I did TBR7 motorcycle upgrades, I have reduced the rear sprocket size 46-T to a 42T sprocket (TBR7 Rear Sprocket and Studs Upgrade) and had to break off a couple of links with a chain breaker in my upgrade.

My front sprocket upgrade (14t -> 17t) might have taken up some chain slack created from my rear sprocket size reduction, but not enough (TBR7 Upgrade: Front Sprocket Change).

Step 8.  Connect The New Chain Ends With New Motorcycle Chain Master Link.

Installed the TBR7’s new chain’s master link.

The locking clip for the motorcycle’s master link should have the closed end in the direction of the motorcycle chain’s travel( FAQ: What Direction Does A Master Link Clip Go On? ). This way the locking clip cannot strike something and pop off.

One completed, the chain could need adjustment.

Step 9. Check New Chain Slack.

If the motorcycle chain is too tight or too loose, make chain tension adjustments as needed. Please read my post about chain tension adjustment My Posts: TBR7 Chain Adjustment and How To Adjust Your Motorcycle Chain.

Step 10. Reattach The TBR7’s Motorcycle Chain Guard.

As with any threaded fasteners on my TBR7, I used a thread locker.

FYI, the new motorcycle chain I picked up for my motorcycle: JT Motorcycle Chain (428 Series) Heavy Duty Non O-Ring.

Done, TBR7’s Motorcycle Chain Is Installed!

Now with the new motorcycle chain is on, I took some common-sense steps:

I lubed the new chain. The new motorcycle chain came with a coat of heavy grease, but I still sprayed it down with motorcycle chain wax. I like the self-cleaning actions of motorcycle chain wax. I have also been using a similar product on my mountain bikes, which keeps them lubed and reasonably clean.

I tested the bike out, slow rides while doing frequent chain slack checks on my TBR7 Motorcycle and occasional chain readjustments.

The new motorcycle chain seemed to do the most ‘stretching’ during the first several rides.

I plan to post a follow-up about this new motorcycle chain’s feel and operation.

The plan is to research more about Chonda stock motorcycle alleged chain failures and summarize my findings in a later post.

In the meantime, thank you for visiting, and remember, motorcycle maintenance can be a dangerous operation; consult with a professional before you do your upgrade.

Ride Safe, Ride Fun.

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TBR7 Upgrades

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