How To Shorten A Motorcycle Chain

To shorten the motorcycle chain, the most standard method is to use the chain breaker to push out the pin you want to remove. Or, if you plan to change a new magic clasp directly, you can also simply and roughly cut off the chain plate with an angle grinder.

No matter which path you choose, it is an iron law to determine the length first. Remember, usually you have to remove two sections (including one section of the inner chain and one section of the outer chain) so that you can have time to put on the new master links. As for re-riveting the old pins? Unless you are an absolute veteran, be sure to reconnect with new master links for safety.

This video shows the general process of shortening a motorcycle chain:

Method 1: Use The Chain Cutting Device

In the industry, the use of a dedicated chain cutting device is recognized as the cleanest and most professional way to cut the chain. This method can minimize the damage to the surrounding chain links and ensure that the structure of the whole chain does not fall apart.

Watch this video for a demonstration of using a chain breaker tool:

Step 1: Determine The Correct Length

Do the arithmetic well before you move the tools. You have to know exactly how many knots to remove.

Hang the chain: put the new chain on the front and back discs.

Find the ideal length: use your hand to tighten the ends of the chain on the back tray to see where they meet.

Mark the link: identify the link you want to break. Remember the rule of thumb I mentioned at the beginning: usually you need to remove two sections (inner chain piece and a set of outer chain pieces) to leave room for the connecting buckle.

Step 2: Positioning Chain

Alignment is key. If it is crooked, the thimble of the tool will break in minutes.

Place the chain: Tuck the section you marked into the chain cutter.

Calibrate the tool: Make sure that the drive pin of the tool is facing the center of the chain pin. If it is crooked and the thimble is unevenly stressed, it is likely to bend the tool.

Step 3: Eject Pin

After alignment, all that remains is mechanical force.

Rotate the handle: slowly tighten the handle of the chain cutting machine. This will force the thimble of the tool against the chain pin.

Top through: continue to rotate vigorously until the pin is completely pushed out of the outer link plate.

Fine adjustment: Sometimes the hand feels wrong. You may have to return the tool a little, adjust it and then continue to push it to ensure that the pin is completely separated from the chain link.

Step 4: Remove Excess Links

Split the chain: the pin off, the chain is broken.

Clean up the waste: take away the loose inner chain plate and the cut-off section of waste chain. At this time, the fracture should be very neat, ready to install the connection buckle.

Step 5: Reconnect The Chain

The last step is to connect the two ends.

Select magic clasp: Must use new magic clasp. Generally divided into open circlip type or riveting type.

Card spring type: insert the pin, cover the chain plate, and firmly clip the card spring into the groove with pliers.

Riveting type: insert the pin, press on the chain plate, then you need to adjust the chain cutter to the “riveting mode” and forcefully turn the top of the new pin into a “mushroom head” to form a permanent seal lock.

Method 2: Use An Angle Grinder Or Chisel

If you don’t have a chain cut on hand, or if that old chain is badly rusted, you’ll have to go to an angle grinder or a cold chisel. This method is quite violent, and the hand must be steady.

This video shows how to use an angle grinder to cut a chain:

Step 1: Relax And Position

In order to operate the angle grinder safely, the chain must be stable, but it must be palpable.

Loosen the rear axle: Loosen the rear axle nut first.

Manufacturing: Push the rear wheel forward of the rocker arm. This creates enough space to fiddle with the chain.

Positioning link: Turn the wheel and turn the section you want to cut to a position you can safely reach. Never get too close to the frame, otherwise Mars or the disc will easily hurt the car.

Step 2: Grinding Or Cutting

Angle grinder: Grind the head of the pin with a grinding plate until it is flush with the outer chain plate. Be careful not to grind to the inner links you intend to keep.

Cold chisel: If you only have a chisel and a hammer, cut the pin head off with force. It’s a hard job, and it’s on time.

Step 3: Remove The Link

Pry off the chain plate: Once the rivet head has been ground flat or chipped off, use a flat-head screwdriver or chisel to pry off the outer chain plate from the inner link.

Remove the links: the board off and the rest should slide out easily.

Vital Safety Tips

It’s not a joke to cut the motorcycle chain, it’s the core transmission component. For your safety and the life of your car, the following rules must be kept:

It is absolutely forbidden to reuse the old master links: once the master links is removed, the structural strength is gone. When repairing the chain or cutting the chain, always replace it with a brand new magic buckle to prevent the chain from breaking catastrophically during the ride.

Check the tension: the chain connection does not mean it is finished. You have to adjust the tension according to the maintenance manual. This is very important: be sure to sit in the car (or apply the same weight) and then check the tension, because the suspension compression will tighten the chain.

Confirm the alignment of the rear wheels: After adjusting the tension, it is necessary to confirm that the rear wheels are positive. Look at the adjustment scale on the crank to align. If the wheels are crooked, the chains and chainplates wear out surprisingly fast.

Safety equipment: this job involves taut metal and probably the debris from the angle grinder flying around. Goggles must be worn to protect your eyes.

Author: Mark Reynolds

As a certified motorcycle mechanic with over 14 years of experience in the garage, I’ve repaired and adjusted countless drivetrains. I am passionate about helping riders maintain their own bikes safely. In this guide, I’ll walk you through the exact steps I use to shorten chains effectively.