Garage Basics
Replacing the secondary chain

Replacing the secondary chain

1) Set bike on stand.

If your beer crate is needed elsewhere, use e.g. Becker Minilift, 97-441 so that the rear wheel can be turned freely.

2) DO NOT remove chain.

3) Count the number of chain links.

Look it up in your bike’s manual (manuals are extremely helpful, even if you have done the job before). If your bike is a heavily modified chop, you’ll have to count the number of links anyway though. Mark the chain with a piece of string, wire, or a sharpie to avoid counting errors. Count twice. If you get numbers above 150: stop counting at the mark. Our chains have between 100 and 120 links.

4) Order a new secondary chain.

Decide on type of chain. Normal, o-ring or x-ring chain? If in doubt, call W&W, we'll advise. For less time spent on the phone, send us a close up of your chain and your master link. If you can't find one, you have a riveted chain. 'Cos we want you to get the right chain first time.

5) Shorten chain length. In the case

that the chain can not be ordered to your specific length, you may need to shorten it. Mark chain, double check length. For best results, use Kellermann breaking and riveting tool 91-961. Jump to 10).

6) An alternative, if more rustic method

of shortening a chain is this: Get out your angle grinder. Mark chain (double check length!)

7) Place new chain in vise.

Grind through the marked rivet heads down to the metal.

8) Use punch 88-211 and punch rivets out.

Alternately punch both rivets to avoid jamming.

9) Open rear axle nut and loosen chain tensioners.

10) Open the old (non-riveted) chain.

Use pliers to carefully remove the safety clip, remove link plate, remove link using flat screwdriver. Use chain puller 98-087 to keep the load off the link. If you have a riveted chain, use Kellermann breaking and riveting tool 91-961.

11) Remove the master link.

This works best when master link is positioned on rear sprocket. Connect the new chain to the old chain, using the open master link. Pull out the old chain, the new chain will take its place smoothly. Be sure the new chain rides squarely on both sprockets.

12) Bring both ends of the new chain together

using chain puller 98-087. How’s the chain tension coming along? Too much slack? Check again number of links in old and new chain. If necessary, remove another link. If chain ends can't be joined, open rear axle nut and loosen chain tensioners.

13) Install master link. Install o-rings, if applicable.

If using Kellermann breaking and riveting tool 91-961, use instructions that came with it. If not: Join chain, close with link plate, gently install new safety clip with pliers. Closed end shall point in the direction of travel. Clip must be positively engaged in groove, so take your time here. A badly installed clip may mean major trouble.

14) Adjust chain tension.

Place bike on its own wheels, have a helper sit on the bike. The chain should be movable up and down 1/2" or 12,5 mm to 15 mm in all. Keep an eye on chain alignment. The rear wheel should be parallel to the bike's longitudinal axis. Refasten rear axle nut, using recommended torque setting (see manual).

Bingo. Have a pleasant ride!

One moment, though. From long and painful experience we know, that it is never advisable to use brute force on a Harley. Harleys, though reminiscent of agricultural equipment in many ways, were designed to be treated gently, just like any other mechanical appliance. If excessive force seems to be needed, double check if there is something you overlooked that needs to be loosened or taken out of the way before proceeding.

If you can’t figure it out, give our experts a call.

They have heard everything. Twice. We don’t want you to ruin your weekend cruise. And we all don’t need discussions over broken parts.

Here’s our little collection of recommended tools for successful chain reactions:

Becker Mini-Lift for Big Twin
Becker Mini-Lift for Big Twin
The Becker company manufactures a mini lift for the heavy Big Twins, too. Same sturdy quality, with rollers for easy action and with removable lever for easy stowing.
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Becker Mini-Lift for Sportster
Becker Mini-Lift for Sportster
This is the only proper and affordable mini lift for Sportster models that we know of. Easy action and secure stand are just what the doctor ordered. Avoid dangerous tire changes like in the past. Sturdy quality and completely zinc plated for lasting service.
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Harley-Davidson Service Manuals
Harley-Davidson Service Manuals
Original factory Service Manuals with detailed repair and maintenance instructions plus charts for trouble-shooting, fluid requirements etc. All subjects are covered, from oil change to flywheel rebuild procedures. Available in English language only.
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Clymer Service and Repair Manuals
Clymer Service and Repair Manuals
The most complete repair manuals available besides the factory versions. They offer straight-forward, easy to follow information in English language. All subjects covered from A to Z, illustrated with hundreds of photos, drawings and charts.
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Service Manuals in German Language
Service Manuals in German Language
German language service manuals for various models by the Motorbuch Verlag which provide detailed instructions for the maintenance and repair of the respective models. Clear illustrations of all work steps and exploded views show the complete technics from engine, transmission, chassis and brake system to the motorcycle’s electrics. Trouble charts help to localize problems and additional lists summarize vehicle data, tolerances and adjustments.
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Kellermann Breaking and Riveting Tools for Secondary Chains
Kellermann Breaking and Riveting Tools for Secondary Chains
The Kellermann chain tool allows for easy breaking of the worn chain and precise assembly of the new chain with rivet link. It is designed for chains of all common brands. Besides the main tool the kit contains a patented, magnetic positioning tool for the assembly of the connecting link. This positioning unit consists of two magnetic plates that are coupled together via a guide. This design allows a precise and comfortable positioning of the parts of the connecting link. The plates stick magnetically to the connecting link, so you have your hands free to work. Crucial for the assembly of the connecting link is, that you don't press the side plate too far onto the pins. To prevent this reliably, the plates act as a limit stop and extend to the adjacent chain links. You can see through the cut-outs in the push plate, if the side plate of the connecting link is in the correct position and when you have to stop pushing. Thus connecting link assembly errors are largely excluded and the assembly of the connecting link is becomes a straightforward task.
The basic tool works with hollow rivet chain links. An accessory insert is available for full rivet chain links (e.g. Tsubaki).
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Chain Breakers
Chain Breakers
The compression screw features an extremely durable heat-treated steel tip to press out chain pins. However, we recommend the side pin heads to be ground off flush.
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Grace USA Steel Punch Set
Grace USA Steel Punch Set
For meticulous work on detailed projects. These punches are made from high carbon molybendenum tool steel and properly heat treated with tempered striking end. They are also centerless ground for complete accuracy and we have incorporated a reverse taper from tip of punch to help prevent punch from sticking in the work piece. The punches are manufactured from hex stock steel vs. round which helps stabilize punch from rolling away from user.
The 7-piece set comprises the following punches:
center-punch 3.5 mm, length 107 mm, tapered punch 1/16”, length 114.5 mm, punch 1/16”, length 108.5 mm, punch 5/64”, length 114.5 mm, punch 3/32”, length 121 mm, punch 1/8”, length 127 mm, punch 5/32”, length 134 mm,
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Tsubaki Alpha RQ2 530 Secondary Chain
Tsubaki Alpha RQ2 530 Secondary Chain
The Alpha type chain by Tsubaki is smooth running with a minimum of power loss combined with the benefits of X-sealed inside lubrication that provides a longer chain lifespan. A great chain for hi-torque, hi-horsepower performance bikes. Available as Alpha XRS in plain steel and RQ2 with gold coloured outer links. Same chain, same quality.
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Tsubaki Sigma 530 Secondary Chain
Tsubaki Sigma 530 Secondary Chain
The Sigma XRS 530 is the highest strength chain available from Tsubaki. While the steel coloured version keeps this name, the version with gold coloured outer plates changed it to RQ1. Quality and strength of course stay identic. The X-seals keep the factory-applied lube inside the bushings and minimize friction caused power loss. The choice for top horsepower bikes.
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Tsubaki RQ2 520 Narrow Secondary Chains
Tsubaki RQ2 520 Narrow Secondary Chains
The Alpha type chain by Tsubaki is smooth running with a minimum of power loss combined with the benefits of X-sealed inside lubrication that provides a longer chain lifespan. A great chain for hi-torque, hi-horsepower performance bikes. The narrow 520 size comes in with gold coloured outer links and is handy in all applications where space is a problem.
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Chain Pullers for Secondary Chains
Chain Pullers for Secondary Chains
This handy tool pulls chain ends together for easy chain link installation.
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Press-on Tools for Master Link Side Plates
Press-on Tools for Master Link Side Plates
Great little tool used to press on the side plates of chain links. Especially recommended for O-ring chains. Solid tool steel.
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Kellermann Rivet Head Molders
Kellermann Rivet Head Molders
Use this insert when using your Kellermann chain tool to close full rivet chain links. Works perfectly with the W&W selection of Tsubaki 530 rivet type master links.
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Profi L-Cat Laser Alignment Tool
Profi L-Cat Laser Alignment Tool
After chain adjustment or maintenance work that required loosening or removal of the rear wheel axle it is necessary to realign the drive chain or belt. If you don´t want to rely on inaccurate sight controls you can check chain or belt alignment precisely with state-of-the-art laser technology. Remember: correct alignment noticeably improves dynamics and significantly reduces friction and wear.
A laser tool with increased performance for frequent users or professionals. It creates a laser line for faster and more accurate control of chain or belt alignment.
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Bel-Ray Super Clean Chain Lube
Bel-Ray Super Clean Chain Lube
Bel-Ray Super Clean Chain Lube is a unique premium product designed exclusively for motorcycle chains. It has superior anti-wear additives which provide exceptional protection against metal-to-metal contact for longer chain life. It sprays on evenly and provides complete coverage of the chain creating a waterproof barrier that prevents rust and corrosion. Bel-Ray Super Clean Chain Lube will not fling off and repels dirt and sand.
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Tsubaki Chain Lube
Tsubaki Chain Lube
This chain lube is specially formulated for use on both sealed and non-sealed chains. A combination of oils, greases and solvents prevents corrosion and extends chain mileage.
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