First of all, I cut my chain down to fit my stock 42 sprocket and now I want to buy a Vortex sprocket. Problem is, the smallest size they make is 48. I'm not sure if my chain will extend that far to fit this new sprocket so I was wondering if its safe to use 2 master links?

 

Master links tend to wear and stretch faster than solid links,don't they? I would think ones the limit.

 

gwalleye,
Yeah. . . . I just installed a new EK brand chain on my Yamaha XT225 and after re-installing my original 15T countershaft sprocket (I had an aftermarket 14T, JT Sprockets on it) my chain is just a little too short. That bike creates all of 18HP. . . . I can't imagine how a second master link could be dangerous. Does anyone have any "Real" evidence that this is a dangerous practice?

 

I can't see why it would hurt its just a way of connecting the two ends why not four ends? I would be more worried that the piece of chain you add is worn equally to the chain on the bike now.

 

I have 2 master links in my chain after making a mistake, I haven't had any problems with it. It's not a perfect solution but beats buying a new chain. These chains are used on 50hp motorcross bikes I don't think a 18hp 250 will bother the chain. If your going from a 42 tooth to a 48 tooth you will need more than an extra link, you will need at least 2.

 

Yeah, I have a 5" section of chain to use and only have about 200 miles on the current chain. Thanks for the input, guys. Anyone else with "real-world" experience on this subject?

 

When I didn't have a M-link and the stores were closed I would weld chain togeather. Did it on a 250x atv (21hp). You could always nix the clip and peen the ends over, the factory did it why cant you.

 

Don't worry about it....that chain can easily handle a 200 hp bike. BUT the klx is a torque monster thou.

 

It's actually part of the brand new chain I bought.

 

Yes it's fine.