DS900X - Chain Slack Adjustment

The DS900X uses a sealed O-ring chain with no master link. Replacing it needs special tools and is a dealer job. Measuring slack, adjusting tension and lubricating are routine jobs you can do yourself.

Sources: DS900X owner's manual (English), DS900X chassis workshop manual, DS900X engine workshop manual, the Swedish and Hungarian owner's manuals and the Hungarian service schedule. Where the manuals give different values, this page shows every value.

What you're working with

• Chain spec: 525UXI, 122 links, sealed O-ring chain without an opening (no master link) Owner's manual p. 11. The manual warns that a chain with an opening must not be fitted, and that poor riveting when replacing this chain can lead to the chain breaking.
• Slack spec: 35 - 45 mm Owner's manual p. 65. The owner's manual shows the measuring point in a figure on that page. The chassis workshop manual says the tension must be checked and adjusted with the motorcycle unloaded.
• Rear axle nut torque: 100 ± 7 N·m in the owner's manual Owner's manual p. 89, 100 N·m in the chassis workshop manual Chassis manual p. 51.
• Chain adjuster nut torque: 9 N·m (M8) Chassis manual p. 43.

Pre-ride chain check

The manual asks you to check these points "before driving every time" Owner's manual p. 81:

• Flexible (loose) chain pins.
• Damaged rollers.
• Rusty or corroded side plates.
• Jamming when the chain links turn.

If you find any of these, the manual says to contact a VOGE dealer.

Chain wear also wears the sprockets. Check for worn sprockets and for damaged or cracked teeth, and contact a dealer if you find either. When the chain is replaced, check the wear on the driving and driven sprockets and replace them at the same time if necessary.

Measuring slack

1. Keep the motorcycle upright on its stand, unloaded.
2. Measure the chain deflection at the point shown in the figure on owner's manual p. 65.
3. Spec: 35 - 45 mm. The manual says a chain that is too loose can drop off during riding and cause an accident, and a chain that is too tight shortens its life and adds resistance to the drive.

Adjusting slack

Procedure, from the owner's manual Owner's manual p. 65 and the chassis workshop manual:

1. Keep the motorcycle upright on its stand.
2. Loosen the chain adjuster nuts on both sides.
3. Loosen the rear axle nut (nut 1 in the manual figure).
4. Turn the adjusting bolt (bolt 2) until the tension is correct. See the callout below on direction.
5. When loosening the chain, turn the bolts to slacken, then push the motorcycle forward firmly so the axle moves forward.
6. Fine-tune both sides so the scale lines on the adjusting piece and the swingarm line up, and confirm the left and right adjusters are on the same scale line.
7. Tighten the rear axle nut to 100 ± 7 N·m.
8. Tighten the chain adjuster nuts to 9 N·m (M8). Adjust both adjusters first, then fasten the rear axle nut, then fasten the left and right adjusters.
9. Re-measure the slack and confirm it is still 35 - 45 mm.

Cleaning and lubrication

The chain has O-rings at the pins that seal in the lubricant. The manual says wrong washing or lubrication can damage the O-rings and the lubricant and shorten the chain's life Owner's manual p. 81.

Don't

• Wash the chain with a steel brush.
• Clean it with volatile solvents such as paint thinner or gasoline.
• Use a high-pressure washer on the chain.

Do

• Wash the chain with water or a neutral cleanser.
• Wipe off the water or cleanser immediately after washing, then let the chain dry in air before lubricating.

Lubricant

The manual specifies oil made for O-ring chains. Some chain lubricants contain solvents or additives that can damage the seal rings, so use only lubricant made for this type of chain.

If no O-ring chain oil is available, the English and Hungarian owner's manuals allow SAE 90 gear oil as a substitute Owner's manual p. 81 Hungarian owner's manual p. 83.

Application

1. Coat the inner and outer plates of the chain evenly with oil.
2. Wipe off the surplus oil.

Frequency

The manual says to clean and lubricate the chain periodically. The periodic maintenance table marks the drive chain A (adjust) at every service and R (replace) at 20,000 km Owner's manual p. 88. The manuals give no lubrication distance.

When to replace

The manual says only a VOGE dealer should replace this chain Owner's manual p. 81.

• Mileage: the periodic maintenance table marks the drive chain R (replace) at 20,000 km.
• Condition: the chassis workshop manual lists these replacement conditions Chassis manual p. 52:
  • Several dead-locked (seized) places on the chain.
  • A cracked roller.
  • Missing seal rings.
  • The distance between links has reached "2 times of new one" (the manual's wording, unclear in translation).
  • The chain still fails to meet spec with the adjusters at their limit.
• Sprockets: check them when replacing the chain and replace them at the same time if necessary.

Related values

• Chain case bolts: M6, 6 N·m Chassis manual p. 46.
• Chain slider bolts: slider to engine M6, 9 N·m; slider to swingarm M6, 4.5 N·m Chassis manual p. 48.
• Chain slider schedule: first inspection at 10,000 km, then replace every 20,000 km Owner's manual p. 88. The Hungarian service schedule lists inspection at 8,000 km and replacement at 20,000 km Hungarian service schedule p. 1. We cannot verify which is correct.
• Front (driving) sprocket bolt: M10, 50 N·m, thread coated with Loctite 243 Engine manual p. 15. The chassis manual also says the inner ring of the butterfly-shaped washer protrudes outwards, and the flanged side of the collar goes into the washer's inner hole Chassis manual p. 50.

Things this guide doesn't cover

• Chain replacement procedure: the chain has no opening and needs special riveting tools. Dealer job.
• Rear sprocket torque: we have not found a rear sprocket nut torque in the manuals.
• Aftermarket chains: match the 525 size and the 122-link length.

Had a chain wear out early, or fitted an aftermarket chain? Send your experience.