DID Chain Installation - Triumph Bonneville Chain T100 LC
52 Speedshop stocks DID Chains for Triumph LC applications in our Triumph Motorcycle modern retro parts range; as you most likely know, DID are a world leading chain manufacturer for motorcycle applications. DID supply chains for everything from street applications to championship winning race teams globally.
Which tools did we use for the Triumph Bonneville DID Chain Installation?
For the DID Chain fitment to the Triumph Bonneville T100, we used the following tools:
- DID Chain (See Our Guide to Triumph LC Motorcycle Chain Sizes article)
- Chain breaker/rivet tool
- Angle Grinder / Dremmel Tool
- Wrench set
- Allen Keys
- Torque wrench
- Centre Stand / Lift
- Chain lubricant
- Gloves, safety goggles, fire extinguisher. (If using grinding tools).
1. Check the existing Triumph Bonneville Chain and DID Chain Sizes
Before dismantling the motorcycle, double check that you have bought the correct Triumph Bonneville chain size, this applies both in terms of links and also that the chain you have purchased in appropriate for the power output of the motorcycle. If you are ensure, please read Triumph Motorcycle Chain Sizes Explained article before proceeding.
2. Preparing the Motorcycle
Lift the rear wheel using the centre stand if you have one or alternatively use a motorcycle lift as pictured. Ensure the motorcycle is in neutral to make the Triumph Bonneville chain removal easier.
Check the condition of both sprockets whilst you are replacing the chain - replace if necessary.
3. Removing the Triumph Bonneville chain guard
Remove the chain guard from the motorcycle using an allen key. Store all parts and fixings in a safe place, label if the bike is going to be left disassembled over a longer period of time.
4. Removing the chain
Locate the master link on the old Triumph Bonneville chain - if it has a clip-style link, use pliers to remove the clip. If it has a rivet-style link, use an angle grinder to remove the dome on the top of the link pin before applying the chain breaker tool to push out the pin. (By removing the dome head on top of the pin, the chain breaker tool is under far less tension and you can avoid breaking the tool). Take necessary precautions and use PPE to carry out this work.
5. Breaking the Triumph Bonneville chain
Follow the instructions on your chain breaker tool (all tools vary) to ensure it is setup for chain breaking mode. Slowly proceed to drive the pin out from the original chain. Take this step slowly and ensure the breaker tool is lined up with the pin in the chain link, otherwise you will more than likely bend or break the chain breaker tool.Leave the existing chain on the motorcycle as we will use this to pull the new chain around the front sprocket.
6. Installing the new DID chain
Take the new DID Chain and thread over the rear sprocket. Use the link supplied in the kit to temporarily connect the new DID Chain to the existing chain. (You don't need to worry about O/X rings at this point, as this is only a temporary measure to thread the new DID Chain around the front sprocket).
Proceed to pull the old chain from the bottom to thread the chain around the front sprocket and loop back to the rear sprocket as per the image below. 
Apply grease (supplied in the DID Chain kit) and X rings to the master link as per the below image. (Image shows one X ring installed for reference, you will need to install two before pushing the link through the chain).
Proceed to push the link through the chain to complete the chain loop. Add more grease and install the X rings to the other end of the master link pins, before pushing on the chain plate to complete the master link. 
Set your chain tool up as per the chain tool instructions to clamp the master link plate on the outside of the chain (Just pushed on at present) to the same diameter as the existing links.
Use measuring calipers to measure the diameter before you begin to tighten the chain install tool with the ratchet, go 1/4 turn at a time, continually check with the calipers to make sure you are within the manufacturers tolerance recommendations. (Found on the back of the DID Chain packaging - varies according to chain size).
Do not over tighten as you will crush the X rings and cause the link to be stiff when rotating.
The final step is to set your chain riveter to 'rivet' mode and proceed to rivet the master link pins over the top of the previously pressed chain link plate to secure it in place.
Measure the existing pin diameter using the calipers and proceed to tighten the tensioner a 1/4 turn at a time whilst continually stopping to measure the pin diameter. Continue until the riveted head of the pin is in tolerance with the manufacturers recommendations.
For the DID 520 chain, a tolerance of 5.5mm to 5.8mm was recommended.
(Instructions found on the reverse of the DID Chain packaging). Be careful not to over tighten as you will crack the flare on the pin.
6. Chain Tension and Alignment
Adjust the chain tension according to the recommended slack in your motorcycle manual, for the DID 520 chain a 20-25mm chain sag was recommended. Align the rear wheel by adjusting the axle adjusters on both sides of the swing arm. (An alignment tool is a useful investment).
Tighten the rear axle to the specified torque settings. Ensure that the DID Chain has the correct tension after tightening. Lubricate the new DID Chain thoroughly with chain lubricant for optimal performance.
Take a short test ride and inspect the chain again for proper tension and alignment.
PLEASE NOTE: The information in this article is to be used as a guide only. If you are not a qualified mechanic, please instruct a professional to carry out work on your behalf.