DRAFT MALAYSIAN

STANDARD 05L015R1

RELEASED FOR PUBLIC COMMENT

Secretariat: Standards Management Department

SIRIM Berhad (Company No. 367474-V)
1, Persiaran Dato’ Menteri
P.O. Box 7035, Section 2
40911 Shah Alam
Selangor Darul Ehsan
Malaysia

Comment begins on Comments terminates on

01- April 2006 31- May 2006

MOTORCYCLE CHAINS AND SPROCKETS –

PART 1: MOTORCYCLES CHAIN –
SPECIFICATION (FIRST REVISION)

THIS DOCUMENT IS A DRAFT CIRCULATED FOR COMMENT. IT IS THEREFORE SUBJECT TO

CHANGE AND MAY NOT BE REFERRED TO AS A MALAYSIAN STANDARD UNTIL PUBLISHED AS
SUCH.

(NAR/rz)

ICS: 43.140
Descriptors: Motorcycles chains, chains number, chains construction, chain performance requirement,
chain dimension and chains test method
ii
 CONTENTS
Page

Committee representation ……….……………………………………………………… iii

Foreword………………………..…………………………………………………………. iv

1 Scope………………………..…………………………………………………………….. 1

2 Nomenclature, Designation and Construction ………………………………………… 1

3 Performance Requirement…………….………………………………………………… 4

4 Dimensions ...……………………………………………………………………………... 7

5 Test Methods………….…………………………………………………………………… 7

6 Rust Prevention ……….………………………………………………………………….. 10

7 Marking…………………….….…………………………………………………………… 10

Annexes

A Fatigue strength test method……………………………………………………………. 12

B Wear resistance test method……………………………………………………………. 13

Tables

1 Chain number, recommended use and type…………………………………………… 2

2 Breaking load……………………………………………………………………………… 5
3 Fatigue limit……………………………………………………………………………….. 6
4 Hardness of the pin, bush and roller……………………………………………………. 6
5 Chain dimensions………………………………………………………………………… 8
6 Load for length measurement…………………………………………………………… 9
7 Testing conditions for chain wear resistance………………………………………….. 11

Figures

1 Roller chain, bush chain, seal chain and silent chain………………………………… 3

2 Outer and inner link of chain parts………………………………………………………. 3
3 Connecting link of chain parts…………………………………………………………… 3
4 Chain dimension………………………………………………………………………….. 7

i
Committee representation

The Road Vehicles Industry Standards Committee (ISC L) under whose authority this Malaysian Standard was
developed, comprises representatives from the following organisations:

Automobile Association of Malaysia

Department of Environment Malaysia
Department of Standards Malaysia
Jabatan Pengangkutan Jalan
Malaysian Automotive Association
Ministry of International Trade and Industry
Motosikal dan Enjin Nasional Sdn Bhd
Perodua Manufacturing Sdn Bhd
Perusahaan Otomobil Nasional Berhad
Polis DiRaja Malaysia
Proton Vendor Association
Universiti Putra Malaysia
Universiti Teknologi Malaysia

The Technical Committee on Motorcycles which developed this Malaysian Standard consists of representatives from
the following organisations:

Armstrong Auto Parts Sdn Bhd

HL Yamaha Motor Research Centre Sdn Bhd

Jabatan Pengangkutan Jalan

Kawasaki Sunrock Sdn Bhd

Kayaba (M) Sdn Bhd

Kilang Rantai S.A Sdn Bhd

KL 21 Sdn Bhd

Motorcycles and scooter Assembler and Distributor Association of Malaysia

Motosikal dan Enjin Nasional Sdn Bhd

MZ Motorrad Sdn Bhd

Polis DiRaja Malaysia

Pusat Pemeriksaan Kenderaan Berkomputer Sdn Bhd

SIRIM Berhad (Secretariat)

Universiti Teknologi Malaysia

Universiti Putra Malaysia

ii
 FOREWORD

This Malaysian Standard was developed by the Working Group on Chain and Sprocket under
the authority of the Road Vehicles Industry Standards Committee.

This MS XXXX consists of the following parts, under the general title Specification for
Motorcycle Chains and Sprockets:

Part 1: Motorcycle Chains

Part 2: Motorcycle Sprockets

This Malaysian Standard is the first revision of MS 996: Part 1 (P) 1985, Specification for
Motorcycle Chains and Sprockets -Part 1: Motorcycle Chains.

Major modifications of this revision are as follows:

a) additional to the scope as its also covers seal chain and silent chain;

b) additional to the chain numbers , recommended use and type of chain in Table 1,
Table 2 , Table 3 , Table 5, Table 6 and Table 7;

c) change to a new figure 1 and figure 4; and

d) rename a new Table 4 and additional notes to Table 4 as to covers seal chain and
silent chain.

This revised Malaysian Standard cancels and replaces MS 996: Part 1: 1985 (P).

Compliance with a Malaysian Standard does not of itself confer immunity from legal
obligations.

iii
 MOTORCYCLE CHAINS AND SPROCKETS
PART 1: MOTORCYCLE CHAINS - SPECIFICATION

1. Scope
1.1 This Malaysian Standard specifies dimensions, material and performance requirements
for chains for use on motorcycles.

1.2 This standard covers bush chains, roller chains, seal chain and silent chain.

1.3 Chains covered by this standard are suitable for use as drive chains, cam chains, oil
pump chain or balancer chains as specified.

2. Nomenclature, designation and construction

2.1 Nomenclature

For the purpose of this standard, the nomenclature given below and in Figures 2 and 3 shall
apply.

2.1.1 Roller chain

A chain constructed with rollers around the bushes.

2.1.2 Bush chain

A chain constructed without rollers.

2.1.3 Seal Chain

A chain constructed with seal and roller around the bushes

2.1.4 Silent Chain

A chain constructed with pin and plate only

2.2 Designation

Chains specified in this standard shall be designated by chain numbers as given in Table 1.
The recommended application for each chain type is also given in Table 1.

2.3 Chain construction

2.3.1 A chain shall be assembled by fitting inner links and outer links alternately.

2.3.2 Chain components, referred to in this standard, are illustrated in Figure 1.

2.3.3 Details of outer and inner link shall be as illustrated in Figure 2.

2.3.4 Details of the types of connecting links that shall be used are illustrated in Figure 3.
Connecting links shall be either of the spring clip-type or rivetted-type.

1
 Table 1. Chain number, recommended use and type

Chain Recommended use Type

number
2X3 Cam chain, balancer chain, oil pump chain Silent chain

3X4 Cam chain, balancer chain, oil pump chain Silent chain

4X5 Cam chain, balancer chain, oil pump chain Silent chain

25 Cam chain Bush chain

25H Cam chain, balancer chain, oil pump chain Bush chain

25-2 Cam chain, balancer chain Bush chain

219 Cam chain, balancer chain Bush chain

219H Drive chain Bush chain

05T Drive chain Bush chain

270 Drive chain Bush chain

415 Drive chain Roller chain

415H Drive chain Roller chain

420 Drive chain Roller chain

428SL Drive chain Roller chain

428 Drive chain Roller chain

428H Drive chain Roller chain

520 Drive chain Roller chain

525 Drive chain Roller chain

530 Drive chain Roller chain

520H Drive chain Roller chain

525H Drive chain Roller chain

530H Drive chain Roller chain

630 Drive chain Roller chain

428KRO Drive chain Seal chain

428HKRO Drive chain Seal chain

520KRO Drive chain Seal chain

2
 Roller chain, Bush chain & seal chain Silent chain

Figure 1. Roller Chain , Bush Chain , Seal Chain and Silent Chain

Link Rough sketch Chain parts Remarks

nomenclature
Number Nomenclature
Outer link ℵ Pin An outer link
ℑ consists of two
Outer plate pins assembled
with two outer
plates

Inner link ℜ Inner plate An inner link

℘ consists of two
Bush rollers around two
⊗ Roller bushes assembled
with two inner
plates

Figure 2. Outer and Inner Link of Chain Parts

Link Rough sketch Chain parts Remarks

nomenclature
Number Nomenclature
Spring clip type ℑ Outer plate A spring clip
connecting link ⊕ connecting link
Connecting pin consists of two
∅ Connecting plate connecting pins
∩ press fitted in an
Spring clip outer plate and
riveted. At the
other ends they
are either a press-
fit or a slip-fit in a
connecting plate
and secured by a
spring clip.
Riveted type ℑ Outer plate A riveted
connecting link ⊕ connecting links
Connecting pin consists of two
∪ Connecting plate connecting pins
press fitted in an
outer plate riveted.
At the other ends
they are either
heavy or light
press fitted in a
connecting plate
and secured by
riveting
Figure 3. Connecting Link of Chain Parts

3
3. Performance requirements
3.1 Breaking load

The minimum breaking loads of chains, when tested in accordance with the method specified
in 5.1 shall be as given in Table 2.

3.2 Length

3.2.1 The length of the chain, when measured in accordance with the method specified in
5.2, shall be the nominal length with a permitted deviation of -+00.15% . However, for Seal

Chain, the permitted deviation is + 0.25%

-0

3.2.2 The nominal length as defined in this standard shall be the product of the nominal
pitch (p) and the number of links.

3.3 Fatigue strength

The chain, when tested as specified in 5.3 and in accordance with the method specified in
Appendix A, shall have fatigue strength at or above the limit specified in Table 3.

NOTE. The fatigue strength, in Table 3, is the max. load referred to in 5.3.

3.4 Wear resistance

The wear resistance of chains shall be determined by the method specified in 5.4 (details in
Appendix B). The acceptance levels shall be fixed as the elongation cannot be exceeded as
specified value for a testing duration as specified in Table 7, in reaching the specified testing
duration, there shall be no defects such as stiff or cracked chain joints, bushes or rollers.

4
 Table 2. Breaking load

Chain Number Breaking load (min.)

kN
2X3 5.2
3X4 7.8
4X5 10.4
25 3.5
25H 4.8
25-2 7.1
219 6.6
219H 8.8
05T 6.9
270 9.8
415 15.7
415H 15.7
420 15.7
428SL 15.7
428 16.7
428H 20.6
520 26.5
525 26.5
530 26.5
520H 31.4
525H 31.4
530H 31.4
630 35.3
428KRO 20.6
428HKRO 22.6
520KRO 26.5

5
 Table 3. Fatigue limit

Chain Number Fatigue limit (N)

2X3 980
3X4 1080
4X5 1180
25 780
25H 980
25-2 1280
219 1080
219H 1570
05T 1080
270 2260
415 3730
415H 3730
420 3730
428SL 3730
428 3730
428H 4410
520 5880
525 5880
530 5880
520H 7840
525H 7840
530H 7840
630 9810
428KRO 4900
428HKRO 5880
520KRO 6860

NOTE. Fatigue limit values specified are for chains without connecting links.

3.5 Hardness

The hardness of the pin, bush and roller shall be as specified in Table 4.

Table 4. Hardness of the pin, bush and roller

Component Hardness Case depth mm

Surface Core
Pin mHv 200 g mHv 200 g 0.25 ~ 0.45
700 ~ 900 400 ~ 500
Bush mHv 200 g mHv 200 g 0.10 ~ 0.25
700 ~ 900 320 ~ 480
Roller mHv 200 g _ 0.15 ~ 0.40
450 ~ 700
NOTES:
1. For Pin Hardness and Case depth mention above not applicable for seal chain and silent chain
2. For Pin and bush the case depth means the effective case depth
3. For Carburizing roller the case depth means the total case depth
4. For Hardening roller the case depth is not applicable

6
3.6 Other requirements

The finished chain shall be free from stiff joints and rollers.

4. Dimensions
4.1 Dimensions of chain components shall comply with the values specified in Figure 4 and
Table 5.

5. Test methods
5.1 Breaking load

A gradually increasing tensile load shall be applied to the ends of a length of chain containing
at least five free pitches. The chain shall be prevented from bending or twisting during the
test. The ultimate tensile load shall be measured.

NOTE. Ultimate tensile load is taken to be equal to breaking load because of the small difference between the two.

Roller chain, Bush chain and Seal chain Silent chain

Figure 4. Chain dimension

5.2 Length

A standard length of finished chains not less than 610 mm shall be measured under load as
specified in Table 6. When measured horizontally, the chain shall be supported horizontally
throughout.

7
 Table 5. Chain dimensions (in mm)

Chain Pitch Roller Width Pin Pin L Part Inner Plate

P dia- between Length Dia- of con- plate thick-
meter inner L meter necting depth ness
Dr. plates max. d pin H T
max. W max. length max. (Refer-
min. (Refer- L ence)
ence) max.
2X3 6.35 - 3.05 6.2 2.45 - 6.9 1.0
3X4 6.35 - 5.10 8.3 2.45 - 6.9 1.0
4X5 6.35 - 7.15 10.4 2.45 - 6.9 1.0
25 6.35 3.30(*) 3.10 8.0 2.31 4.8 6.0 0.75
25H 6.35 3.30(*) 3.10 9.0 2.31 5.3 6.0 1.0
25-2 6.35 3.30(*) 3.10 14.4 2.31 4.8 6.0 0.75
219 7.774 4.59(*) 4.68 12.0 3.01 7.3 7.6 1.2
219H 7.774 4.59(*) 4.68 12.6 3.01 7.6 7.6 1.4
05T 8.00 4.73(*) 4.55 12.5 3.05 9.4 7.8 1.3
270 8.50 5.00(*) 4.75 13.3 3.28 7.8 8.6 1.8
415 12.70 7.77 4.68 13.3 3.97 8.5 12.5 1.5
415H 12.70 7.77 4.68 13.3 3.97 8.5 12.5 1.5
420 12.70 7.77 6.25 15.0 3.97 9.0 12.5 1.5
428SL 12.70 8.50 7.85 15.5 4.51 9.9 12.5 1.2
428 12.70 8.50 7.85 17.0 4.51 10.6 12.5 1.5
428H 12.70 8.50 7.85 18.9 4.51 11.6 12.5 2.0
520 15.875 10.16 6.25 17.6 5.09 10.9 15.5 2.0
525 15.875 10.16 7.85 18.9 5.09 11.6 15.5 2.0
530 15.875 10.16 9.40 21.0 5.09 13.0 15.5 2.0
520H 15.875 10.16 6.25 19.0 5.25 11.6 15.5 2.3
525H 15.875 10.16 7.85 20.6 5.25 12.3 15.5 2.3
530H 15.875 10.16 9.40 22.5 5.25 13.0 15.5 2.3
630 19.05 11.91 9.40 23.2 5.96 13.5 18.6 2.3
428KRO 12.70 8.50 7.85 21.5 4.51 11.5 12.5 1.8
428HKRO 12.70 8.50 7.85 22.3 4.51 12.3 12.5 2.0
520KRO 15.875 10.16 6.25 20.5 5.10 11.1 15.5 2.0
NOTE. * Dimension for bush diameter

5.3 Fatigue strength

A cyclic load, with a ratio of mean load (Pm) to load amplitude (Pa) of 1.2 shall be applied on
a chain. The maximum load shall be that specified in Table 3. There shall be no failure at the
end of 5,000,000 cycles.

Details of test method are given in Appendix A.

5.4 Wear resistance

A chain shall be driven under conditions specified in Table 7 and the elongation after specific
time shall be measured. Details of the method are specified in Appendix B.
8
 Table 6. Load for length measurement

Chain Number Load (min.)

N
2X3 30
3X4 50
4X5 50
25 80
25H 80
25-2 160
219 80
219H 80
05T 80
270 80
415 140
415H 140
420 140
428SL 140
428 140
428H 140
520 220
525 220
530 220
520H 220
525H 220
530H 220
630 310
428KRO 140
428HKRO 140
520KRO 220

Pm is the mean load

Pmin. is the minimum load
Pa is the load amplitude
Pmax. = maximum load = Pm + Pa

9
6. Rust prevention
6.1 Chains shall be appropriately treated to prevent rusting.

7. Marking
7.1 All chains shall be marked with the manufacturer’s name (or trade-mark) and chain
number on the outer plate.

10
 Table 7. Testing conditions for chain wear resistance

Chain Number Number of teeth in rpm of Chain Pull Testing Specified

sprocket
number of links drive Duration elongation
shaft (Hour) (%)

Drive Driven N Lubrication

2X3 390

3X4 640
82 ~ 98 17 34 6000
4X5 930

25 17 34 200

25H 14 28 220
Oil bath 200 0.2
25-2
219 6000
219H 82 ~ 98 290
05T 17 34

270 5000

415
415H 780
420
428SL 148 41 19 730
428 980
428H
520 No 60 0.5
lubrication*
525 1180
530
120 33 17 730
520H
525H 1960
530H
630 96 17 15 730 2650

428KRO
148 41 19 1500 780
428HKRO

520KRO 120 33 17 1500 1960

* Chain submitted for ‘No lubrication’ tests are to be applied initially with lubricants or rust preventatives that are used
on chains for sale.

11
 Annex A

Fatigue strength test method

A1. Chains for test

Chains submitted for this test shall be those which have been manufactured and tested as
required by this standard.

A2. Testing machine

The testing machine shall be capable of subjecting the chain to a cyclic load, as required in
5.3 of the standard. In addition, it shall have the following auxiliary devices:

a) an indicator to show the load applied;

b) a counter to indicate the number of cycles completed;

c)a device to prevent the machine from being restarted, following a stoppage due to
breakdown in electricity supply or any other reason; and

d) an automatic stoppage device.

The machine shall operate at between 500 cycles and 3000 cycles per minute.

A3. Method of test

A3.1 A chain for test shall contain 5 to 7 free pitches excluding those for shackles.

A3.2 The chain shall be fixed to the shackles in such a manner that when loaded in
tension, the load is evenly distributed on every link, with no twisting or bending. Counting shall
start only after the chain is loaded as specified.

A3.4 There should be no break in the test. In the event that the chain does not fail at the
end of 5 x 106 cycles, the test shall be stopped. The machine should stop automatically
should the chain break during the course of the test.

12
 Annex B

Wear resistance test method

B1. Chains for test

Chains submitted for this test shall be those which have been manufactured as required by
the standard.

B2. Testing machine

The testing machine shall contain the following components.

a) a power source to drive a variable speed motor;

b) a driver shaft and sprocket which can be easily assembled and disassembled;

c) a driven shaft and sprocket which can be easily assembled and disassembled;

d) a device capable of loading the chain as required; and

e) a device capable of adjusting the taut span of the chain.

The machine shall be so designed that the chain is subjected to taut and slack spans thus
preventing the overheating of the chain.

B3. Testing method

B3.1 A chain for test shall be mounted on the testing machine after its length has been
measured as specified in the standard.

B3.2 The chain shall be driven under conditions specified in Table 7. The test shall be
continued until the specified elongation is reached. During the test, the chain shall be
measured at least twice.

B3.3 Measurement of length shall cover at least 1 5 pitches.

B3.4 Measurements shall be taken when the chain is at room temperature.

B3.5 Chains for which the testing condition specifies that no lubrication is required, shall
not be lubricated during intervals when length measurement is carried out.

B3.6 When lubrication is required, lubricants of grade SAE 10W 30 to 40 or equivalent

shall be used.

13
B4. Treatment of test results
B4.1 A graph of chain elongation against time shall be plotted.

B4.2 The time required for the specified elongation shall be obtained from the curve
plotted.

B4.3 In the event that the chain cannot be driven up to the specified elongation due to
chain failure, stiff links or roller cracks, the test report shall indicate the duration for which the
test had been carried out and the reason for non-completion of the test.

14
Acknowledgments
Technical Committee on Motorcycles members:

Y. Bhg. Dato’ Syed Mohammad Aidid (Chairman) Motorcycles and scooter Assembler and
Distributor Association of Malaysia
Puan Nor Anisazila Bt Abdul Rahim (Secretary) SIRIM Berhad
Encik Khalili Zulkifli Armstrong Auto Parts Sdn Bhd
Encik Tan Teik Ghee HL Yamaha Motor Research Centre
Sdn Bhd
Ir Mohamad Dalib Jabatan Pengangkutan Jalan
Encik Lim Chee Sing Kawasaki Sunrock Sdn Bhd
Encik Che Muhammad Kamil Mukhtar Kayaba (M) Sdn Bhd
Encik Lee Thian Chai Kilang Rantai S.A Sdn Bhd
Kapten Mohd Sabri KL 21 Sdn Bhd
Encik Chee Kok Leong Motorcycles and scooter Assembler and Distributor Association of
Malaysia
Encik Mohd Fadzil Abdullah Motosikal dan Enjin Nasional Sdn Bhd
Encik Mohammad Huzaini Haron MZ Motorrad Sdn Bhd
ASP Zainal Abdul Hamid Polis DiRaja Malaysia
Encik Azlan Abu SamahPusat Pemeriksaan Kenderaan Berkomputer Sdn Bhd
Cik Nurulakmar Abu Husain Universiti Teknologi Malaysia
Prof Madya Dr Wong Shaw Voon Universiti Putra Malaysia

Working Group on Chain and Sprocket members:

Encik Lee Thian Chai (Chairman) Kilang Rantai S.A Sdn Bhd
Puan Nor Anisazila Bt Abdul Rahim (Secretary) SIRIM Berhad
Encik Teoh Ching Hua Kilang Rantai S.A Sdn Bhd
Encik Lim Chin Yong Kilang Rantai S.A Sdn Bhd
Encik Heng Jeng Sheng Excel Rim Sdn Bhd
Encik Tang Chiang Bu Kilang Rantai S.A Sdn Bhd
Encik Tan Eng Chun Kilang Sprocket S.A Sdn Bhd