Josh Morgan, Tool Maker

October 29, 2006So I decided it was time to change my sprockets and chain, as well as some general maintenance like replacing the air filter.  Here's how it went:

Sprockets and Chain: my initial research indicated that it was going to cost about $280 for parts and another $120 for installation.  That, of course, was very high, so I kept looking.  I found that the original chain was a D.I.D O-ring chain, which I could by for about $20 less if I didn't go through an official Honda Parts Provider.  It's the same chain, but it doesn't have that OEM stamp.  The sprockets were a little different.  I wanted a smaller rear sprocket because I do so much interstate driving.  The smaller ratio will help my gas mileage a bit by dropping my engine RPM's.  This, though, meant that I couldn't get the OEM sprockets because the OEM only came in the original size.  After finding what was available, I started digging into manufacturers to find out what their sprockets were made of and how they were made.  I ended up going with JT sprockets, because they use very strong, durable steels and a CNC machine for precision cutting.  And, they're heat treated, so I was sold.  I got them below OEM prices too.

For the installation, I decided to do it myself.  Getting off the front and rear sprockets was pretty easy.  The new sprockets fit just like the old ones, and all the components were easy to reach.  The chain was harder, so I did a lot of reading before I committed to doing it.  To get the old chain off, I just used my dremel with a cut-off wheel.  Didn't take long at all.  The new chain came with a rivet-style master link, meaning that it's more secure than a clip, but harder to get on.  I also had to remove a link from the new chain because the smaller sprocket made it slightly too long.  And thus began the tool making.  I needed a way to press out an old link and a way to mushroom out the ends of the rivets on the master.  I ended up making a series of pins that I could put in a C-clamp and use to push out the old pins.  It worked great.  I ground off one end of the pin I was removing, and then used the clamp, the pins I made, and a socket (as a spacer).  It came out without a problem.  I also mounted a ball bearing in a cylindrical piece so I could spread the ends of the master link rivet's.  This didn't work as easily, because it kept trying to roll.  In the end, though, I got the ends expanded, and I have a fancy new chain and sprocket set.

Air Filter: I replaced the stock air filter with a K&N air filter.  It comes with a 1,000,000 mile warrantee, and just says to pull it out, clean it, and reinstall it every 50,000 miles or so.

Everything is back together and properly adjusted.  As far as projects go, this one seemed to be particularly successful.  And I got to make my own tools and save a LOT of money.  :)