I bought a few things recently and just got around to installing it all. My old 525 chain and sprockets had about 25,000 Kms and were beginning to show signs of wear. Knowing it would soon be time to replace the it, I've been neglecting the chain drive gear.
I decided to go with a 520 conversion mostly because 520 chains are much easier to come by, and the sprocket selection (for different gearing) offers far more choices. The only difference between the 525 and 520 chains is that the 520 is slighly narrower. The links are the same length, just thinner rollers. I went with a medium quality DID 520V O-ring chain. These sell for about $75 in the US ($99 here in Canada). And 520 sprockets are cheap, only $20 for a front, and $33 for a rear.
Two new sets of CR10E spark plugs
rear brake rotor from eBay - $49
Suzuki OEM clutch cable
DID 520V chain (to replace the existing 525 chain)
JT 14 & 15-tooth 520 front sprockets
JT 43-tooth 520 rear sprocket
Polisport RMZ250 fork guards
new cush drive bearings
new bearing seal
new rear sprocket bolts
I cleaned up the cush drive with a wire wheel on my Makita driver/drill
New rear sprocket installed with shiny new bolts
Used my Dewalt 5" angle grinder to remove the old 525 chain's master link
I also installed new wheel bearings and cleaned up the cush drive rubbers
New rotor installed using shiny new bolts
Use the Dewalt angle grinder again on the new chain to remove 10 links.
10 links equals 10 pins. Gotta be much more careful on the new chain.
The master link for the new 520 chain is the c-clip variety. Some
say the rivet type master links are safer, but it's extremely rare for
the c-clips to fall off. Use the packet of grease provided in the
box with the chain.
When using a c-clip master link, I like to finish it with
a blob of brightly coloured silicone. This helps to make
sure the c-clip doesn't fall off, plus the visual of seeing
the bright red link is quick to spot. If you don't see it,
then there could be trouble.
Shinko 705 front, size 90/90-21"
These $69 tires will serve as my asphalt rubber.
Much better than wearing down my Michelin T63 knobbies
riding back and forth to work in the city. With two sets of wheels,
swapping between street tires and knobbies will take 30 minutes.
Shinko 705 rear, size 130/80-17"
This is a really meaty tire, yet very quiet on the road
compared to the Michelin knobbies.