I'm getting ready to change my sprockets and chain before heading to South America. I read something earlier about a 520 chain conversion but cannot find it again. Can anyone give me some advice on this. I know I will need to cut this stock chain off and go with a new one with a master link. What is the difference between the 525 and the 520 chain and why is the 520 recommended? Any suggestions for replacement parts? I want to make sure I get sprockets and a chain that match.

Lots written about this on ADV Rider DR thread and on DRRiders forum too. Having done over 60K miles on my current DR and about 15K on two others, I've had a bit of experience with chains/sprockets on long rides over many rides.

For South America go with a 525 chain and sprockets. Start with DID's best X ring chain and with OEM or JT sprockets. Bring 2 spare front sprockets, I like a 14T and 15T. 14T a little help off road, 15T better on fast highway.

Main reason for 525 size is longevity. About 20% longer life than a 520 chain if compared like to like. (both x ring) Don't cheap out, an X ring goes about 20% further than O ring chain.

Change out front sprocket every 7K miles to help extend chain life. Really helps. The first thing to wear is the front sprocket, changing it early really saves chain and rear sprocket for thousands more miles on your chain.

If you buy the BEST X ring DiD chain (the expensive one!) use OEM or JT sprockets, you should easily go over 20K miles on ONE CHAIN. (following above guidelines)

Keep your chain lightly oiled and CLEAN and you will have zero problems.
On tour I try to clean and oil my chain EVERYDAY if doing big days or off road. I use NO LUBE when riding off road.

DO NOT use a clip type link for master link, use what DID recommend: A Rivet link type master link installed buy a PRO. More secure.

Don't worry, you won't be taking that chain off until 20K miles and tires and sprockets ... and just about ALL procedures can be changed without cutting off chain.

If you're really paranoid carry a spare rear sprocket to change out at around 15K miles ... this only if you plan to go much further. But if you do more than 20K miles then really best to plan a chain and sprocket change at that time.
With good lead time, you can have parts shipped in to where ever you may be.

Go easy on wheelies (wears out chain) and running at 80 MPH all day (also wears chain and tires fast) and you will be OK. Keep chain properly adjusted
(not to tight!).

Bring spare hubb/wheel bearing, 1 pick up coil, fork seals, spark plugs (Denso iridium last over 15K miles), fuel filter, filter skins (for dust), good tools, epoxy, oil filters.

Start with NEW everything: Chain/Sprockets, NEW battery (Deka or Lithium Iron like Shorai), new tubes (I carry 4 in Mexico), spare rear tire on back, front tire will last over 10K miles, 2 rear tires will get you to Colombia where tires are available.

As Mollydog mentions, X ring 525 DID with a couple of sprockets, keep it slightly on the slack side if anything - just not tight or it can cause premature wear on the cush drive bearings (poor design) keep it clean and lube it for asphalt, dry for dirt riding.

Some people switch to a 520 as they are easier to find, but its a waste of time, stick with a 525, will last much longer, buy a chain driver/peening tool for the rivet type master links, carry a couple of spares and learn to do the chain
yourself.


Ive been using this chain tool for a few years, expensive yes, but a great bit of kit that works well - and its tiny.


http://terra-x.com.au/chain-breaker/

__________________
Cheers
Grif

'11 KTM 450 EXC
'09 Suzuki DR650
'00 Discovery Series 2 V8
'95 Defender 90 300 Tdi Overlander
http://gipperstravels.blogspot.ca

I live in rural Oz, I changed my DR from 525 to 520 after reading about the conversion & also because my local suzuki bike shop didn't have a 525 chain in stock, neither did the bike shops in 2 neighbouring towns have a 525 in stock. But they all had a 520 in stock.
You'll find that you have a greater variety of sprocket sizes available for the 520 pitch chain.
But if your coming to Oz we have a local manufacturer here called Chaingang. They make any size sprocket for any bike, the sprocket wear longer than stock or other aftermarket sprockets.
As for rivet vs clip, I prefer clip links. They're easier to service (remove & replace) than a rivet joiner.