Chain Tension KTM Duke 790 Revisited

This video is a follow up to my original video on this subject, to clarify the effectiveness of the method in that original video when compared to the text book method outlined in the KTM bike manual.
I have made this video as I had received a number of comments suggesting that the method contradicted the info in the manual, so I wanted to work the method through and check that it was correct and see if I could identify where the discrepancy was between the two methods. The results are quite interesting.
Link for the Chain Monkey: www.sportsbikeshop.co.uk/#/27...
Link for the Laser Monkey: amzn.to/3tEoS2l
Link for Laser and Chain Monkey bundle: amzn.to/3xXsAXZ

[@gsd32i]

Must admit I looked at the pdf and thought WTF ! I would rather deal with an engine failure in my airbus than try and work out how to adjust the chain ...,don’t even get me started on how the DRL’s work !! 😂 liking the hoodie by the way 👍

[@TheBoltHoleBiker]

They certainly have a way of taking something simple and making it mind-bogglingly complicated! It's a talent!

[@JayPerf]

I have an older 690 but still find your videos on the 7 helpful and really pleasant to watch - thanks for your work!

[@TheBoltHoleBiker]

Excellent, thanks for watching!

[@TheScortUK]

On all my bikes, I sort the alignment - checking along the chain, running the wheel to see if it runs true, and using vernier calipers to make sure both adjusters are aligned. Once you have that sorted, chain tension is a breeze - you just turn your adjuster screws one 'flat' at a time, making sure you add/remove the same number of 'flats' on both sides. Perfect tension, and perfect alignment - only time you need to realign is if you have new tyres fitted.

[@robertgreenacre1573]

Thank you for posting the video and making it a little clearer for everyone. One point I would like to add is that the Laser Monkey is about as much use as a chocolate tea pot as it's impossible to tighten it on the the sprocket even with spacers. I removed the laser part of the device and mounted it on a modified G clamp that allows a degree of movement for the laser along the chain run, alas I can't post a picture of it on here but would cladly post details to anyone. Regards

[@TheBoltHoleBiker]

Yes, I agree, the clamp doesn't work well on the sprocket of the Duke, hence my spacers, but I'd be very interested to see a better solution, because the general concept of the laser monkey is spot on. Please send details to me at [e-mail] Cheers👍

[@bossev]

Thank you very much for going above and beyond to do the research, clarify and explain it again!

[@TheBoltHoleBiker]

No worries, I wanted to make sure I wasn't steering people up the wrong path!👍

[@struthers602]

Brilliant video, KTM certainly didn’t make this task particularly easy but thanks for your explanation much easier to understand than the manual. Cheers

[@TheBoltHoleBiker]

You're very welcome👍

[@stuarthall2523]

Cheers for that mate 👍. My Duke didn’t come with a manual, you now have to download it. What a pain, a manual is great to pick up and refer to. Glad you took the time to make the video, I’m sure many owners will appreciate it.

[@TheBoltHoleBiker]

Et voila... www.ktm.com/ktmgroup-storage/20_3214106_en_OM.pdf

[@stuarthall2523]

@@TheBoltHoleBiker Thanks mate, I hope appreciated. 👍

[@cb1000r_gazzzz]

Thanks you so mutch. It was very helpful for me.😊

[@MotoGoato]

Always more than one way to skin a cat. Cheers for revisiting the subject and clarifying. I've always done it by the manual method but have to say that where you are measuring from makes it easier to see the measurement. Nice work.

[@TheBoltHoleBiker]

Cheers fella, it was a useful exercise for me to check that what I had said was correct as well, so all good!👍

[@MotoGoato]

@@TheBoltHoleBiker It's good info mate and well demonstrated. I've shared this video on the UK Owners facebook page as the confusion of chain tension instructions often arises on there with new and old owners alike 😉

[@TheBoltHoleBiker]

@@MotoGoato That's brilliant, cheers!

[@iSangreVerde]

Not all heroes wear capes, some wear KTM hoodies. Well done mate! Cheers!

[@TheBoltHoleBiker]

Ha, ha, cheers! My kids loved your comment!

[@TheJWC56RSA]

Thanks! Once adjusted correctly and the locking nuts locked on both sides the axle nut gets torqued (90 nm for the 890 R)....however if you now again check your chain tension ( after torque), the chain tension is out of spec again. KTM uses a very crude adjusting method and crude adjusters for a relatively expensive bike.

[@bazza8947]

Good man! You weren't wrong, you were just using the old method KTM originally published then since updated in later manuals. The manual is hard to understand but it does make sense once you get what they mean. I still think the original method was a major factor in leaking countershaft seals. The new method concerns many owners because it's very loose but it needs to be because the bike has a long swingarm i.e. think KTM's dirt bike background

[@TheBoltHoleBiker]

Yes, I have to say, I've been erring more towards the 10-13mm measurement than the 15mm recently. Still don't get why they don't just make a simpler method - apparently some of the other KTM's have a little line/guide on the bike to adjust the chain to. That sounds like a much better idea.

[@windinthewillows6248]

1290 super adventure has a really clever system, where you use a screwdriver in a slot on the chain guide, if it’s too tight or loose, it’s either up or down, when it’s correct it’s horizontal. Much better and easier to do.

[@davem3008]

Nice simple explanation. Well done sir 👍

[@TheBoltHoleBiker]

Cheers👍

[@scottbailey5644]

Agree with Bazzer re the manual, and some of the other comments on here. The problem with the procedure in the manual is the graphic (M01569-10), if it was clearer it would be OK. That said I prefer your alternative method and we know it's sound as 1) the KTM technician advised it and 2) you've tested it. I've used your method already and it seems easier to me and I will use it going forward. Thanks for the update, top info as always, Cheers!

[@TheBoltHoleBiker]

Cheers Scott, I was glad to finally put that one to bed!

[@fraz172]

Bit of a faff just too check the chain imo. Got the 890r myself. Had loads of bikes never had to go through all that. Label under seat gives same info. Thanks for uploading.

[@TheBoltHoleBiker]

No worries! I didn't know about the label under the seat!!!😂

[@insanesheep1]

I purchased the 790 a few months back rode it for a couple of days all was fine. I checked the chain and it was really tight around 5mm of play so I adjusted it as per the manufacturers process and I’m getting loads of chain slap on slow bends. I’ve put a bit more tension into it now and seems fine. Never had any issues on previous bikes. 🤷‍♂️

[@TheBoltHoleBiker]

Yes, for some reason working out the correct chain tension on 790's seems to have been a bit hit and miss, but once you get it right it seems to be fine.

[@blakebaumgart8259]

I've got an 890r with same chain specifications. Can confirm chain slap between 2.5 to 5mm. I found that 7 to 8mm was sweet spot for me especially with quickshifter. May wear out chain faster but more confidence when riding so idk haha

[@jorgemoreano9720]

thank you.. this is a very helpfull, but I just have a question. to find the correct adjustment of the chain, is necessary that the pilot must be on the bike? because probably the different weight of pilots might be affect the the tension? thanks in advance to answer

[@GarHarman]

That is great thank you 👍🏻

[@bazza8947]

I use a Profi Laser CAT (line version) which spreads the laser along the length of the chain. Also a good idea to measure it in a few places so little less fiddly than the tool you are using.

[@TheBoltHoleBiker]

I hadn't heard of those, but I've had a look and they look a lot simpler that the Laser Monkey, I might give one a try. Cheers for that.

[@prrsnikety]

Hey, I recognize those bits of plastic! are they from the rivet puncher you pulled apart to make the sw-motech tank bag fit proper? Love the vids by the way! Congrats on the new motorcycle. I bought an 890R, so if you're selling any parts from the duke, let me know! ha.

[@TheBoltHoleBiker]

They certainly are, you are sharp eyed! Not 100% sure what is happening with the Duke yet, I am hoping to hang on to it if I can, but I'll keep you posted!

[@PIDOFREAK]

I cant find the older video you mentioned

[@lukaslombardo4736]

What windscreen is that on your bike? Really like your videos man .

[@TheBoltHoleBiker]

Cheers!👍It is a Givi fly screen.

[@13conair]

i called my dealer yesterday to book the 790 in for its 10k service and asked them to check the chain tension as i had done it but it was rattling about as i wheel the bike about, they told me the manual as wrong ! no shit there eh! they told me to adjust the chain correctly you need someone sat on the bike while its on a paddock stand to do it ! have you noticed any difference in chain tension if someone is sat on the bike !

[@TheBoltHoleBiker]

Well, when someone sits on the bike the suspension compresses and the swing arm raises, which adds some tension to the chain, but I have never heard of someone having to be on the bike when the chain is tensioned. I'd take that with a pinch of salt if I were you.

[@rogerbanks8280]

For these measurements should the bike be on the side stand or on a paddock stand as in your video ? As I know we don't want the chain to tight as the front sprocket seal fails.

[@TheBoltHoleBiker]

Paddock stand according to the manual.

[@windinthewillows6248]

When I picked up my brand new 901 Husky, got home and noticed oil around the front sprocket cover and on garage floor. Turns out chain was too tight from factory and dealer never checked it on Pdi. Husky UK said they would fix it as a goodwill gesture, but it was my fault for not adjusting the chain correctly! As you can imagine, that really p****d me off. 🤬Turns out that this is a very common occurrence on KTM and Husky 790/890/901 bikes. Again, no paper manual, had to download a pdf, and as you say, you have to use a paddock stand! As the bike doesn’t come with one, nor do I own one, I had to do it on the side stand. How KTM/Husqvarna expect you do chain maintenance while touring (I suppose they expect you to take a paddock stand with you, while travelling on holiday)! Surely the manual should cover chain maintenance, with side stand use, as that’s how bikes come from the factory, and not with a paddock stand!

[@ozboz33]

@@windinthewillows6248 I had the same issue on a husky 450 sm that the dealer adjusted after a service. 2 weeks later the seal shat itself and all the oil flowed out the sprocket seal,I had push the bike 1/4 mile home. Dealer would not admit to adjusting it incorrectly and it was up to me to check it. What they do not realise is once its on the ground with you sat on the bike the chain tightens under the weight on the swing arm shock.

[@gheorghevlad3889]

My friend, please explain to me what does it mean immobilizer failure light? This warning start appearing more often now when I'm turning on the bike for the first time in the day. And the warning light turn off by it self after 10-15 minutes of riding.

[@bazza8947]

Most likely its your battery

[@TheBoltHoleBiker]

I'd have to agree with Bazza, sounds like your battery. I had to get a new battery for mine a while ago.

[@gheorghevlad3889]

The truth is that the battery discharges quite quickly. I will change the battery soon.

[@ozboz33]

I just followed your video for adjustment of my 790 duke,but have you noticed once off the paddock stand the chain gets tighter due to the bike weight on the swingarm ?

[@TheBoltHoleBiker]

Hi, I don't remember mine doing that to be honest, but my paddock stand did support the weight of the bike from virtually the back of the swing arm, so there is probably not much of a weight difference between where mine was supported and when it was back on the tyre. Does your paddock stand lift the bike from further forward on the swing arm? It does obviously get tighter when you sit on the bike and compress the shock, but that is taken into account in the recommended adjustment settings.

[@ozboz33]

@@TheBoltHoleBiker I have the spools in the same place as yours. I might have to slacken it a bit me thinks maybe just a couple of mm. Cheers

[@TheBoltHoleBiker]

@@ozboz33 Might be a good idea, better too loose than too tight.

[@ZiggyW999]

I still think you get this wrong. Shouldn't you push the chain up where the left end of the B dimension line is and just measure where the A arrow is?

[@psts6830]

Pfiou, even with your good explanations, it hard to understant x) KTM is very good everywhere but this time, they screw up with chain tension ^^ c mon guys, is it that complicate to make a handy and clear method ? haha. Thank you for this video anyway !

[@GrtSatan]

I'm also pissed that the a hard copy of the owner's manual is not available even as an extra cost option, other than these minor nits it is a brilliant machine that has connected me to my inner hooligan.

[@TheBoltHoleBiker]

I didn't realise you couldn't buy a paper copy even if you wanted to! Strange. I agree 100% about the sheer brilliance of the Duke, it is such a great bike to ride and my inner hooligan also comes out every time I ride it - that bike just wants to go!!!

[@davydthomas6621]

Very informative BHB. And yes booklet manual can be a little confusing. But very good thanks

[@TheBoltHoleBiker]

Cheers👍

[@richardgowers7659]

Are these measurements the same for the 890?

[@TheBoltHoleBiker]

Hi, I'm not sure I'm afraid, I've not had any time with the 890 yet. Sorry I can't help on that one.

[@andytodd4925]

hi. just made youtube account and subscibed so not sure how this all works. i'm off to put a deposit on a 790 duke this afternoon, so i've been watching reviews on the 790 and some accessories. was chuffed to find your videos as you had the bike and accessories i am thinking about. then was very supprised when i realised that we only live a couple of miles away from each other. so was wondering if you maybe fancy meeting up somewhere local one day for a chat and a bit of advise about accessories. thank you, Andy

[@TheBoltHoleBiker]

Hi Andy, apologies for the delay replying to your message, I was away on holiday last week! Yes, that would be good, when are you thinking?

[@andytodd4925]

@@TheBoltHoleBikergood morning. thank you for the reply and actually great timing as I just took delivery of the 790 last night and will be going for my first test ride today. So very excited, just as nervous though as the the levers and pedal do different functions to what Ive been use to for 10 years.....bet ya intrigued now! 🤔 I’m flexible for meeting up. So day, time and place is whatever’s easiest and best for you. Real happy you replied so big thanks again

[@TheBoltHoleBiker]

@@andytodd4925 I am intrigued! Weekends are probably best for me at the moment, as still really busy at work and the run into Christmas means it probably isn't going to let up any time soon! Have you had your first ride yet then? I love the ride of the 790, it is such an engaging bike, still the most fun bike that I own. If you want to arrange a meet away from the comments then just email me at [e-mail] 👍

[@13conair]

I just tried this method doesnt work for my 790 ! when i have 11mm gap 25mm in front of the plastic chain slider i end up with 13mm from the rear flat plate on the swing arm lol i have always adjusted mine from the flat plate and usually 15mm ish -/+ a mill or so is fine, chain adjustment does effect how well the quick shifter works aswell, baggy chain very jerky quick shifter changes, only thing i can think of is i have gone down 1 tooth on the front sprocket but at the same time i think how the hell will that make a difference !

[@TheBoltHoleBiker]

Yes, you wouldn't think it would make a difference. So long as you get your chain tension right then whatever method you use is good!👍

[@duncanmillar277]

Gap @ 25 mm behind chain slider s/b 2-5 mm (not 11 mm)

[@GrtSatan]

I traded in my 790 for an 890 Duke R and I will never understand why KTM put that plastic guide over the top run of the chain.Makes it impossible to properly check chain tension and transforms a typically easy periodic maintenance job into a convoluted chore.

[@TheBoltHoleBiker]

Yep, seems a bit bonkers! If I'm not mistaken, the Superduke has some measurement markings on it for easy chain tensioning - don't know why the smaller Dukes don't!

[@Brewer_]

I had that laser chain aligner and it is absolute garbage. The laser diode wasn't centred in the housing so it was never correct.

[@rjminear4837]

One thing you neglected to mention is that in the instructions it says to push the chain behind the chain slider and up to the swing arm to take the measurement. If you push the chain up into the chain slider you don't get the correct measurement. Great video otherwise.

[@twotubefamily9323]

Why could they not just put a guide line somewhere ? ... Pita

[@TheBoltHoleBiker]

It would certainly make things easier - I think they do that on the Superduke.

[@josephbailey706]

What a faff. Thanks for clarifying, but how tricky would it be to have an arrow where you take a measurement? If a simple procedure like this needs a vid ...wtf

[@TheBoltHoleBiker]

I agree - bonkers.

[@5davi524]

Too much dithering and too ay adverts

[@ktu668]

Well that looks to loose even looks like its sagging the chain monkeys are good