Chain Replacement


Getting ready

It is advised to wear suitable protective personal equipment (PPE) and be in safe working environment. Before starting this maintenance process, below tasks must be completed:

  • Disconnect the battery / power supply

Tools required

5mm Allen KeySS324-6 | Bahco Hex Key, L Shape 6mm Ball End | RS Components
Circlip PlierNWS 175-42-A21 Circlip pliers angled for external circlips, 165.0 mm 

Parts required

You will need to prepare the listed parts for this maintenance procedure.

Replacement Chain
x 1 unit

Steps to follow

Step 1 Crank Removal

For this step, Kindly refer the Crank removal by clicking the link below.

Crank Removal


Step 2 Kickstand Removal

For this step, Kindly refer the Kickstand removal by clicking the link below.

Kickstand Removal


Step 3 Housing Removal

For this step, Kindly refer the Housing removal by clicking the link below.

Housing Removal


Step 4 Removing chain tensioner & chain

4.1

Using an 5mm Alley Key, loosen up the Chain Tensioner’s screw.

Remove the shoulder screw & set aside.
4.2

Carefully release the Chain Tensioner and remove it from the chain.
4.3

Now the chain is loose, carefully unhook the chain from the driven sprocket.
 

Step 5 Removing driver sprocket

5.1

Using a circlip plier, remove the 35mm circlip. 
5.2

Once the circlip is removed, gently slide the driven sprocket out along with its keyway.

Step 6 Replacing & installing new chain

6.1

Take the replacement chain & align it with the driver sprocket. 

Make sure that the chain is correctly hooked to the sprocket.
6.2

Carefully insert the Driver sprocket along with the new chain by aligning it with the BB Shaft.

Make sure that the Driver Sprocket’s face is correct (recessed face is facing front)
6.3

Insert the Driver Sprocket until it is fully flushed.

Make sure that the keyway is aligned correctly.
6.4

Re-install the 35mm circlip into its
designated groove to secure the sprocket.
6.5

Continue to wrap the chain around the driven sprocket.

Ensure that all gear teeth are fully hooked.
 
6.6

Make sure that the top part of the chain is tensioned and at the tightest point. 
 

Step 7 Reinstalling chain tensioner 

7.1

Re-install the chain tensioner by aligning to its screw hole.

Make sure that the spring is slotted into its designated slot.
7.2

Push the tensioner down to compress and hook the chain to the tensioner.
Diagram, engineering drawing 
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7.3

Once the chain is fully hooked, secure the tensioner by screwing in the shoulder screw.

Firmly tighten the screw.

Step 8 Testing new chain

8.1

Visually inspect the installed chain and ensure that chain are hooked perfectly onto both driven & driven sprockets. 
8.2

Spin the rear wheel and ensure that the installed chain is rotating smoothly.
8.3

Finally, twist the throttle or rotate the crank.

Make sure that the sprocket is rotating smoothly without any further issue indicating the chain is working well. 

Step 9 Re-installing Housing

For this step, Kindly refer the Housing installation by clicking the link below.

Housing Installation


Step 10 Re-installing Kickstand

For this step, Kindly refer the Kickstand installation by clicking the link below.

Kickstand Installation


Step 11 Re-installing Crank

For this step, Kindly refer the Crank installation by clicking the link below.

Crank Installation


End of Article

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