Chain and sprocket replacement: 83-85 200X

[Glenn]

This proceedure highlights changing the front and rear sprockets and chain on a 1985 200X. However, I'm sure the procees is very similar for any chain driven machine.

I replaced the stock sprockets with "Primary Drive" units from rockymountainatv.com...stock sized.

I replaced the chain with a DID X-Ring ATV chain from rockymountainatv.com.

[Glenn]

1. Remove chain cover from engine:

[Glenn]

2. You'll now see the front sprocket:

[Glenn]

3. With the rear end secured, remove the rear wheel:

[Glenn]

4. Using needle nose pliers, remove the clip at the master link:

[Glenn]

5. With the clip removed, you can now remove the master link from the chain.

(Note: depending how tight you chain is, you may want to adjust the chain tensioners to allow an easier removal of the master link. This will also make installing the new master link easier.)

[Glenn]

6. Remove the front sprocket:

[Glenn]

7. New vs. old. The old sprocket is pretty badly hooked.

[Glenn]

8. While you have your front sprocket off, clean out the area. I used an old mountain bike chain cleaner. Any thing stuff bristle brush will do though. You’d be surprised at the amount of “gunk” that’s hiding in there.

[Glenn]

9. Now move to the rear and start loosening the rear sprocket. You may want to loosen the nuts BEFORE removing the chain, while the trike is on the ground. Loosening the nuts will be easier when the rear axle remains stationary.

[Glenn]

10. Remove the snap ring holding the sprocket to the axle.

[Glenn]

11. New vs old: The rear sprocket was pretty worn.

[Glenn]

12. Old master link and the new master link:

[Glenn]

13. New sprockets installed:

[Glenn]

14. Before installing the new link, apply a good amount of white lithium grease to the link and o-rings.

[Glenn]

15. Install the new slide plate:

[Glenn]

16. Use a chain press to press on the plate. Trust me, it’s worth the money to get a chain press. It’s going to make the job a heck of a lot easier.

[Glenn]

17. Install your new master clip. Important: use a new master clip! From what I’ve read, these things lose a lot of strength once installed, then removed. They’re cheap, so buy a lot feel you may need them. Also, make sure the closed end is facing the direction of chain travel.


That’s pretty much it! Make sure you clean the chain with a product that’s specified for your specific type of chain. Not all cleaners are safe for o-ring/x-ring chains. After cleaning, give the chain a coating of chain lube. Again, whatever the chain manufacturer recommend.