D.I.D KM500R Chain Cut and Rivet Tool Instruction Manual

1. Introduction

The D.I.D KM500R Chain Cut and Rivet Tool is a professional-grade, forged steel tool designed for heavy-duty use in motorcycle chain maintenance. This versatile tool allows for efficient cutting of chains, precise press-fitting of connecting link side plates, and secure riveting of pin heads. Its compact size and included plastic storage case make it convenient for both workshop and on-the-go use.

This manual provides essential information for the safe and effective operation, maintenance, and troubleshooting of your D.I.D KM500R tool.

Figure 1: D.I.D KM500R Chain Cut and Rivet Tool in its protective case.

2. Safety Information

WARNING: Always wear appropriate personal protective equipment (PPE), including safety glasses and gloves, when operating this tool.

• Read and understand all instructions before using the tool.
• Ensure the tool is clean and in good working condition before each use.
• Use the correct size pins and anvils for your chain to prevent damage to the tool or chain.
• When breaking a chain with pressed-in pins, it is highly recommended to grind off the back of the pin head flush before attempting to push it out with the tool. Failing to do so can cause the tool's pin to break.
• Do not apply excessive force. If the pin is difficult to remove or rivet, re-evaluate your setup or consider grinding the pin head.
• Keep hands and fingers clear of moving parts during operation.
• Store the tool in its case in a dry, safe place when not in use.

3. Components

The D.I.D KM500R Chain Cut and Rivet Tool kit typically includes the following components:

• Main C-frame tool body
• Various breaking pins (for different chain sizes)
• Rivet pin
• Press plates/anvils
• Lever/Drive handle
• Plastic storage case

4. Setup

Before using the tool, ensure you select the correct components for your specific chain size and desired operation (cutting or riveting).

1. Identify Chain Size: Determine the size of your chain (e.g., 520, 525, 530, 532).
2. Select Appropriate Pin: Choose the breaking pin that matches your chain size for cutting, or the rivet pin for flaring.
3. Install Pin and Anvil: Insert the selected pin into the tool's screw mechanism and the appropriate anvil/press plate into the opposing side of the C-frame. Ensure they are securely seated.
4. Attach Handle: Secure the drive handle to the tool's screw for leverage.

5. Operating Instructions

5.1. Chain Breaking (Cutting)

This tool can cut any 520, 525, 530 (50), or 532 size chains.

1. Prepare the Chain: Identify the link you wish to break. For chains with pressed-in pins, it is crucial to grind off the flared head of the pin flush with the side plate. This significantly reduces stress on the tool's breaking pin and prevents breakage.
2. Position the Tool: Place the chain link into the C-frame of the tool, aligning the breaking pin directly over the center of the chain pin you intend to push out. Ensure the anvil is supporting the opposite side of the chain.
3. Apply Pressure: Slowly turn the drive handle clockwise to advance the breaking pin. Apply steady, firm pressure until the chain pin is pushed completely out of the link.
4. Remove Tool: Once the pin is removed, loosen the drive handle and carefully remove the tool from the chain. The chain should now be separated.

5.2. Chain Riveting

This tool is designed to press fit connecting link side plates and properly flare pinheads, eliminating over-riveting or off-center riveting.

1. Prepare Master Link: Assemble the master link with its O-rings (if applicable) and outer plate onto the ends of the new chain.
2. Press Fit Side Plate: Position the master link in the tool with the appropriate press plate/anvil. Slowly turn the drive handle to press the outer side plate onto the master link pins. Ensure the plate is pressed evenly and to the correct width, typically matching the other links. Avoid over-pressing.
3. Flare Pin Heads: Replace the press plate/anvil with the riveting anvil and the breaking pin with the rivet pin. Align the rivet pin over one of the master link pins. Slowly turn the drive handle to flare the end of the pin. Repeat for the other pin. The flared ends should be slightly wider than the pin shaft to secure the plate.
4. Inspect Rivet: Visually inspect the flared pin heads to ensure they are properly formed and secure. The master link should have the same flexibility as the other chain links.

6. Maintenance

• Cleaning: After each use, clean the tool thoroughly to remove any chain grease, dirt, or metal shavings. Use a clean cloth and a suitable degreaser if necessary.
• Lubrication: Lightly lubricate the screw threads and moving parts of the tool with a general-purpose lubricant to ensure smooth operation and prevent corrosion.
• Inspection: Regularly inspect the breaking pins, rivet pin, and anvils for wear, bending, or damage. Replace any worn or damaged components immediately to maintain tool effectiveness and safety.
• Storage: Store the tool in its original plastic storage case in a dry environment to protect it from dust and moisture.

7. Troubleshooting

8. Specifications

• Brand: DID
• Model: KM500R
• Item Weight: 8 ounces
• Product Dimensions: 5.9 x 4.3 x 2.2 inches
• Compatible Chain Sizes: 520, 525, 530 (50), 532
• Material: Professional forged steel
• Functions: Chain cutting, side plate press-fitting, pin head riveting

9. Warranty and Support

D.I.D is known for manufacturing top-quality products with a goal of perfection and outstanding performance. For specific warranty details, product support, or replacement parts, please refer to the official D.I.D website or contact their customer service directly. Keep your purchase receipt for any warranty claims.