Chain Repair/Replacement

This easy repair can be performed in just a few minutes if you complete the task correctly. We have arranged a list in chronological order for task completion.

Supplies needed: Chain tool, replacement pin (for shimano chains), Powerlink(for Sachs chains) or a new chain.

Broken Chain

• Most chains consist of: An outside link and pin(A.), and an inside link(B.)
  
  
  
  
• Put bike chain on small chainring and small cog to allow for slack in the chain.
• To temporarily fix a broken chain you must remove any broken pieces that are left over from the break. You should have an inside link at one end and a outside link at the other end (hopefully with a pin sticking out of one side of it). See picture #1 above.
• If you have a replacement pin (Shimano chains only), join chain together (inside link and outside link), push pin into vacant hole and begin pushing it through by tightening the chain tool until it is flush with the side of the chain.
  
  NOTE* The Shimano replacement pin is longer than it needs to be to allow for easier installation. The excess pin will protrude out of the other side of the chain after you tighten it with the tool so you will need to break off the end of Shimano Replacement Pin with pliers.

• If you don't have replacement pin you must use an existing pin by partially pushing a pin out of the one end of the chain (push out of the inside link but NOT out of the outside link, see the picture #1). If you push it all the way through it will be very difficult to get it to go back into the hole. Connect the ends (inside link and outside link with pin sticking out of one side) of chain together and use the tool to push pin through until the pin is flush with outside of chain.

• Remove tool and make sure the link is operating smoothly. If it has friction, try to adjust the pin from either side using the tool to alleviate the friction. If this does not work, work the chain back and forth from side to side the opposite way of design to loosen the connection.

• If you are using a "Sachs Powerlink" to fix a broken chain, well, you probably do not need to be reading this instruction guide due to the convenience of the Powerlink

• . All you need to do to connect the chain is remove the outside links with a chain tool from both ends of the chain. Then, using just your hands, insert both pins (from each side of the Powerlink) through the inner links and snap into place. It is really simple! See picture #3
  

New Chain
Sachs Chains w/out a Powerlink

• Remove old chain by using the chain tool and popping out an existing pin.

• To properly size the chain, compare the old chain length and size chain to that length. OR........

• Size the new chain, (a new chain will be too long and need to be shortened) wrap the chain around the biggest chainring in the front and the biggest cog in the rear. (Do not go through the derailleur to size-by adding two links, you are compensating for it by not going through the derailleur) Bring the two ends together and add two links. See Picture #4

• See "Cut Here", this is where you cut the chain to size. If there is a pin partially sticking out of the outside link on one end of the new chain, don't cut this end, use the other end to size. You will use the end with the pin sticking out to reconnect the chain.
  

• Once you have the proper size, thread the chain through the derailleur and put on the small cog and small ring to give you some slack.

• Join the inside link of one end of the chain to the outside link (with the pin sticking out) of the other end of the chain.

• Use the chain tool to push the pin through the hole until the pin is flush with side of chain.

Shimano Chains

• Use old chain to size the new one and cut to length OR.........

• Cut the chain to length by wrapping the new chain around the big chainring in the front and biggest cog in the rear without going through the derailleur. (This is the same sequence as above) Line up the ends and where they come together and add two links to make up for the derailleur routing. See Picture #4 Cut the chain here by using the chain tool and popping-out the pin. Since a pin is supplied with Shimano chains you do not have to worry about accidentally pushing the pin all the way through the outside link.
  

• Connect the two ends of the chain together and use the pin supplied by Shimano to connect the ends.
  NOTE* The Shimano replacement pin is longer than it needs to be to allow for easier installation. The excess pin will protrude out of the other side of the chain after you tighten it with the tool so you will need to break off the end of Shimano Replacement Pin with pliers.

• Push the pin through until it is flush with the side of the chain.

• Break off the portion of the pin that sticks out of the other side of the chain with some pliers..

• Make sure the chain moves freely at that new link.

• Work it side to side and back and forth to loosen or keep adjusting the pin from both sides with the chain tool until it is loose.

Sachs Chains with Powerlink

• Remove old chain by using the chain tool and popping out an existing pin.

• Match old chain length and size chain to that length OR........

• Size the new chain (a new chain will be too long and need to be shortened). Wrap the chain around the biggest chainring in the front and the biggest cog in the rear. (Do not go through the derailleur to size-by adding 1.5 links, you are compensating for not going through the derailleur) Bring the two ends together and add 1.5 links by eyeballing it, this is where you cut the chain to size. Since the Powerlink connector acts as half of a link, you will only add 1.5 links. You should have inner links at both ends now. The Powerlink will connect these two together.

• Once you have the proper size, thread the chain through the derailleur and put on the small cog and small ring to give you some slack.

• Join the inside links together with the Powerlink and you are now finished.

• Ride!

DISCLAIMER: Please understand that by working on your own bike you are taking responsibility for the adjustments. Most adjustments require expert service and the descriptions above are written for reading purposes only and are not factory directions. Bikeparts.com claims no responsibility for any adjustments made by the reader and recommends that you take your bike to a shop for proper adjustment.