Posts Tagged ‘rally’

Today I have finally fund some time to install a proper chain guide to my 640. Thanks to inmates for pointing me in the right direction for the parts I needed for this.

Parts needed:
-54607066100 CHAIN GUIDE REAR ’94
-1 large M6 washer
-1 M6 nut

Note: On KTM 660 Rally they only use the chain guide without retaining plate

This is what we will be replacing

With this

Remove the 2 bolts that hold the old chain guide on the swingarm and be careful, there is a spacer back there.

That spacer will be replaced by the retaining plate front bolt hole.

The bad thing about this upgrade is that you have to take the chain apart. So if you are changing your chain, now it is a good time to add a proper chain guide if you wish.

Once the chain is threaded through the guide, you can start bolting everything back together. Tighten the front bolt just enough so that the whole thing doesn’t fall apart, now align the rear bolt for desired hight.

Now this is where I have been playing around and swapping parts. Since there is really small gap between the rear bolt and sprocket (5mm or 0,20 inch) I have used a collar nut from the front bolt to save on space, and used a new nut and washer on the front as there is more than enough space. Once both bolts are tightend (don’t forget to use Loctite) the thing is rock solid.

That is it. You are done. I feel this is a worthy upgrade to anyone that rides more off road.

Stay safe!