Don't know if this issue has been raised before but figured I'd sound off on it since I just saw it on my bike a few minutes ago.

The 2009 Kawi Service Manual, 2nd edition of 25 July, 2008, calls out two different chain sizes between the Periodic Maintenance and Final Drive sections: Page 2-31 calls for a size 525 chain but page 11-4 calls for a size 520 chain.

Based on the manual's p/n callout on pg 2-31, a while back I ordered a 2nd chain (525, it turns out) so that I could do a quick swap when full blown chain cleaning and lubing is necessary. This is usually done once a month with weekly inspection/wipedown/lube between replacements. For me, 10 miles of an 18 mile commute are on dirt roads so I like to keep up with chain condition. Summer, especially, since the dust where I am here in KS can be very fine like talcum powder and get into everything.

Right now I'm running the 525 chain and noticed tonight that when I press it against the outer face of the CS sprocket, it seems to just brush against but not fully rub into the engine case. I was using a flashlight and inspection mirror with the chain cover/guide removed when I checked. I did this check right after I noticed the book discrepancy.

Looks like the 520 is the correct way to go but the 525 probably would do OK in a pinch. I'm gonna run the 525 until the end of the month as scheduled and pull the chain and do a more in depth inspection. I'll post results of what I find.

Maybe Kawi has already caught the error and revised but I wanted to let everyone know, anyway.

 

Yup! 525 is the wrong size for the sprockets on this bike. The fit would be a bit loose and the risk of damage to cases is a real issue.

 

It figures! The first page in the manual that I turn to for the size I need to order would have the wrong one listed...

 

That's funny, an in depth inspection. Like the depth of the grooves that will be machined into your cases because you ran the wrong chain. Get that 525 out of there ASAP, save the sprockets and even the cases.

520 is the standard bike chain. Has been for a long time.

 

Point taken. Chain is replaced. Another 520 is on order for quick change. Up until I discovered and investigated the issue, it was a case of the incorrect part for the application called out in the manual combined with a noob's lack of knowledge on chain sizes. After that moment, it was an incorrect part deliberately left on the machine.

Post-525 removal, no marks noted on the case and everything else looked OK, too. No more 525's on my bike, though. Lesson learned.

Thanks, Sgt Highbeam!