master link

i am trying to put a new rear tire on my kz900, and i cannot get this stupid master link apart! i tried a screwdriver, pliers, hammer, small wedge inside the link, vise grips...etc. i even tried soaking it in wd-40. nothing. anyone know of a good way to use without destroying the link?

Actually, I can't remember having to take the chain apart to change a tire, at least, not on a 650. Once you get the axle out it's easy to just slip the chain off the sprocket. Maybe the 900 comes apart differently. But, it's not a good idea to reuse an old clip like that, if it is coming off that hard and you have had that much trouble you should replace it. And it should be from the original chain manufacturer so it matches the chain.
Ride safe.

did you put the flat end of a screwdriver against the open end of link and try smacking it?if you can get it to move just a little by doing that you might be able to wedge something between closed end of link and pin to get it off rest of way.just be carefull it doesnt fly off and hit something including you;)

The master link has a plate that pressed over the pins. I used the small, thin blade on my Swiss Army pocket knife, and was able to slowly work it under the plate. Just a little at a time, but then I could get a gap big enough for a thin, flat tip screw driver. Then I could get some leverage on it, and pry the plate off the pins.
I used vice grips to install the new link. Squeeze it down good.

well, i put a 4 into 2 exhaust system off of a police bike on my 900. i cannot get the axle bolt out without taking the exhaust off. i was hoping to slip the tire out of the back of the swingarm. to do that, i have to break the chain at the masterlink. i've tried a thin screwdriver, a knife, a bigger screwdriver with a hammer...etc. nothing. do you think the pins have spread due to stretching?

arobsum wrote:

well, i put a 4 into 2 exhaust system off of a police bike on my 900. i cannot get the axle bolt out without taking the exhaust off. i was hoping to slip the tire out of the back of the swingarm. to do that, i have to break the chain at the masterlink. i've tried a thin screwdriver, a knife, a bigger screwdriver with a hammer...etc. nothing. do you think the pins have spread due to stretching?

Suppose already tried generously loosening axle bolt, setting chain adjuster stops to loosest possible position, kicking backside of tire toward front to gain maximum chain slack, then attempt to slip chain over sprocket.

Patton wrote:

arobsum wrote:

well, i put a 4 into 2 exhaust system off of a police bike on my 900. i cannot get the axle bolt out without taking the exhaust off. i was hoping to slip the tire out of the back of the swingarm. to do that, i have to break the chain at the masterlink. i've tried a thin screwdriver, a knife, a bigger screwdriver with a hammer...etc. nothing. do you think the pins have spread due to stretching?

Suppose already tried generously loosening axle bolt, setting chain adjuster stops to loosest possible position, kicking backside of tire toward front to gain maximum chain slack, then attempt to slip chain over sprocket.

yes sir....first thing i did.

i have another link laying around somewhere...guess i could cut this thing off and be done with it. :whistle: :laugh: no need wasting a lot of time on the little things.

Took my chain off the other day to clean & lube. Discovered the pins of the masterlink were badly worn. Tried to buy a new master link at two local bike shops but neither had a 630.

Got a 630 masterlink THREE (3) pack at TSC for $ 3.23 + tax.

arobsum wrote:

well, i put a 4 into 2 exhaust system off of a police bike on my 900. i cannot get the axle bolt out without taking the exhaust off....

Unfamiliar with the police bike exhaust system, but wondering whether the muffler could be removed from the header pipes on the axle nut side.

Or would it be feasible to just remove one pair of headers?

Have a good easy foolproof technique for reinstalling headers, if you're interested.

Are you quite sure about sliding the tire all the way forward? I've never had to pull the axle bolt on my 650, and in fact the owners manual says to pull the chain adjuster stops out, kick the tire forward and work the chain off. You do have to get it started then roll it off though. Do you have something limiting your travel?

If you can get another masterlink, cutting the clip with a cutoff wheel on a dremel is pretty straight forward if you're careful not to get into the chain.

If all these good ideas don't work you may have to take the shocks loose and either drop the swingarm or jack up the wheel so the axle is above the exhaust or below, whatever works. Don't play with the masterlink, leave it be.