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Inexpensive aluminum chain guard upgrade/modification.

Posted December 23rd, 2014 at 12:23 PM by Ghostt
Updated March 7th, 2015 at 07:40 PM by Ghostt

This is another inexpensive upgrade/modification, that not only IMHO Looks better, and might offer some added safety.

Let's all take a look at the OEM black plastic chain guard on the 88~07 models,
and it's plastic, which if the chain does break, doesn't do a damn thing except break.

Awhile ago I took mine and wrapped it in genuine imagination carbon fiber wrapping, and spayed it in non-visible clear coat. While this helped the looks, did nothing for the safety aspect.

So now what Ghostt?

*Then I remembered something from the EX500 world. There was a bolt on upgrade, using the aluminum chain guard from of all things, a Suzuki Bandit 1200, perfect! IMPORTANT!!*must be from a 2nd generation 2001~2005

So after doing some measurements, it will, and does bolt up exactly the same as the OEM, bolt holes are 275mm apart, at the swing arm attaching points.

A quick search on EBay, and I found one, and most importantly with the rubber and metal sleeve grommets IMPORTANT!! make sure it has these, if not, keep looking for one that does, and made my purchase for $15.99 USD shipped.The part arrived, and was in excellent condition.

Now the install is fairly simple, BUT, some words of caution and advice.
A member from the EX-500.COM forum report that the tabs on the swing arm are weak, and the welds might crack, and/or break, so inspect yours before mounting the new chain guard, and also keep an eye in the future. Some members just re-welded the tabs to assure they held up, since the OEM welds were a little cheesy, and the new chain guard is aluminum, not plastic, more mass.

Another IMPORTANT thing is to use metal washers on the outside of the mounting point, this will assure that the rubber and steel sleeves grommets stay put, and the bolts don't pull thru!!!. It's also been reported that some have had to shim the guard between the tabs and guard to space the guard away from the chain, I did not have this issue.

As I said the install is straight forward, two bolts, remove the dull and boring OEM guard, and install the new one, with ALL the above recommendations, and your set.

Overall the look is awesome, and goes well with my bike's color scheme. For those of you whom prefer it can be painted, or powder coated to whatever color you like, some even trim the end, because they feel it's a bit too long, I didn't.

The pictures don't have the washers on the bolts, due to I didn't have ones, at the time I did this BUT, the washers are needed otherwise the bolts will pull thru the rubber grommets and metal sleeves!!!!!!!

Also not one comment about my dirty chain, and sprocket.
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