Funny, I've never lost a master link on the Xt or my 250 two strokes. If its an O ring chain and you use a link press it is as good as a any other link on the chain. Install it with the open pointed away from the direction of travel.

Only reason to loose a chain that quick is mis-alignment or its just to tight. I run DID O Ring chains and never had an issue. The chain will last as long as the sprockets.

Save yerselves the £45 odd on a chain breaker/riveter. Here's how....
Drill out the holes on an old split link side-plate an extra 0.5 to 1mm, then use a G clamp with this plate as a 'spacer' to press on the rivet link side-plate.
Don't press on too tight though........

Now...this is a great idea! very clever, spot on!
that's how I used to do it before!
"Now" I got a separate link. no problem of anykind!

Vando

Good idea - Many a time I've used some vice-grips and a pair of 12mm nuts to press the fish-plate on.

back to the spring clip..... The fish-plate takes all the strain/force. The spring clip is only a device to stop the fish-plate falling off, it doesn't have to be particularly strong. I've snapped a spring clip before, and as a "stop-gap" jambed a small washer over the link end and crimped it on to stop the fish-plate falling off. Did a few hundred miles no probs! Not ideal, but anything goes in an emergency!

btw... I just don't see how a split link can easily fall off... mine is a Bch to put it in and take out


Vando

I did have one come off - but it was my fault for fitting it the wrong way round, and it caught on the chain guide !

I think the failiure was due to the previous owner shortening the chain by a link to get a bit more life out of it. I looked to see there was plenty of adjustment left and left it at that - didn't bother pulling it away from the sprocket to check for streach for sure untill it was too late. Stupid of me really, but a lesson learnt. I was lucky the chain just got spat out the back rather than through my engine casing/luggage/leg.

Looking back from the UK, it added a funny little aside to our trip though.

**The curtain rises to a hot Croatian motorway on a Sunday afternoon. Two motorcycles, one blue one red, round the bend to enter stage right. Suddenly, a loud bang disturbes the scene and the blue motorcycle coasts to a halt on the hard shoulder. The red rider disembarks and walks to the blue, talking animatedly.**
Ross: Ralph - your chain's come off!
Ralph: Not now mate. Something's wrong with my bike.
Ross: Yeah - I just saw. Your chains come off.
Ralph: Just give me a minute. I think it's serious.
Ross: Yes it is. I just saw... oh sod it.
**The red motorcycle rider throws his hands up in dispair and walks off to lean on the armco. Time passes. Leaves turn from green to brown, glaciers retreat and the hamster wheel of thought squeaks slowly round in the blue riders head.**
Ralph: Oh. I see what you mean.

Strangely enough, my mate at work had a bit of CHAIN hassle yesterday!
He came in on his A7 (BSA) and said it was clanking a bit

We had a look at it, checked to see if the sprox were loose - NO
Checked r/wheel bearings for play - NO
Checked s/arm for play - No

Then we spotted the split link

Not the best of photo's (my naff camera phone) but you can just see the back of the SPLIT LINK has broken - snapped right through

He rode in about 2 miles with it clanking - so who says they ain't that tuff, coz it managed to get him into work - half broke

On the other hand - it wasn't great that it broke in the first place

Soft links are usually best but if you are using a 'split link' then a tip is every few hundered miles give the split link pins a tap with a ball paine hammer. Andy B