A couple of months back, I bought a pre-owned 2017 Mahindra Mojo with 16,000 kms on the Odometer from Guwahati, Assam and rode it to my current station in Pasighat, Arunachal Pradesh. It is a beautiful motorcycle and I am enjoying it every bit.
After covering around 2000 kms in the past couple of months, I observed the chain would lose its slack within a few kms and was making some noise. On closer observation, the rear sprocket too seemed worn out.
Initially, I thought of riding back to Guwahati (600 kms from Pasighat) and getting the sprockets and chain replaced. However, it was time consuming and needed leave of at least one day from work.
I learnt that my Mojo comes with a riveted master link in the chain as opposed to clip on type master link in my RE Classic 500.
I showed it around to local mechanics here and was not very sure about their ability to do a clean job. Most showed me big hammers for riveting the chain pins while online tutorials suggested riveting to be a delicate job. I decided it would be a DIY.
My father sent me the Mojo Chain Sprocket set (Chain, rear sprocket and front sprocket) from Guwahati . I ordered a chain breaker tool from International Tool Company from their website. (
https://international-tool.co.in/). The reason I chose them is that delivery was promised to me within 7 days while Amazon was showing more than a month for tools of some other make.
ITC Chain tool
So, without any further delay let’s get right into it. Please bear in mind that I am doing chain and sprocket replacement for the first time (with some help from my 2 year old) and my methods may not be perfect. So, I welcome any suggestions on what could have been done better.
Step1:
Loosen front sprocket bolts using 8 mm socket after removing the sprocket housing cover. I believe this is done first as there will not be sufficient torque to loosen the bolts (sprocket will start spinning) once the chain is removed.
The patient and the operating tools
Took this opportunity to clean up the gunk accumulated in the area with liberal diesel spray.
Front sprocket after removing the cover. Loosening the bolts using 8 mm socket
Step 2:
Break the chain using the tool.
I followed the instructions of the tool manual. There are different size pins and dies for different chains. I took the master link from the new chain and got the right size pin and die for the Mojo chain.
Getting the right size pin and die
The pin is inserted in the body bolt and the die is inserted in the main body of the tool. Basically, the chain breaker tool pin will push out the chain pin from the chain and the displaced pin will fall through the die.
Set it up for illustrative purpose on the new chain. Tool fitted on the bike’s old chain. I fit the tool on the sprocket to gain some leverage.
The chain breaker’s body bolt (with pin inside) needs to be hand tightened on the chain pin you plan to dislodge. This is crucial as a misaligned pin can deform or break.
Using a 19 mm socket and a spanner, the Chain breaker’s bolt is tightened. Initially, some pressure/ resistance will be felt which reduces as the chain pin starts moving out
Turning the chain breaker fully and the chain pin pops out from the other hand. You have a broke chain now. Removed the chain from the sprockets.
Chain pin popping out. Old chain removed