Drive Chain Type
The Kawasaki KLR650 uses an endless drive chain (no master link), which means it either has to be cut in order to remove it and replaced with a master link type chain, or the swing arm must be removed. It is best to replace both sprockets when installing a new drive chain to get maximum life from the chain and sprockets.
The drive chain size for the Kawasaki KLR650 is 520 X 106 links endless O-ring type.
SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
Drive Chain Inspection
Before riding, the drive chain should be checked to make sure that it’s adjusted and lubricated properly. The best time to lube a chain is after a ride when its hot, the lubricant will penetrate the rollers and pins better.
When cleaning the drive chain use a suitable cleaner that will not destroy the O-rings. Kerosene will do a good job cleaning most chains but pay particular attention not to soak your O-ring chain in the solvent for too long. After a long soak, the solvents can get inside of the O-rings and destroy whatever lubricant remains, while the O-rings can confound your attempts to re-lubricate the chain. It is best to just brush off an O-ring chain with a stiff bristle brush and at most wipe it down with a solvent-soaked rag.
Always use a good chain wax or chain lube that is recommended for O-ring chains.
Check the chain tightness by lifting up on the chain with your finger half-way between the front and rear sprocket under the swingarm. Measure how much slack is in the chain with a ruler or caliper. If the slack is out of specification you will need to adjust the chain.
Drive chain slack: 50 to 55 mm
You can measure the links of the drive chain to see if they have stretched beyond their limit. Count out 21 link pins and then measure between the 1st pin and the 21st pin – the measurement shouldn’t be more than 317.5 mm long. If your measurement is greater than this, the chain needs to be replaced.