First step is grind down the pins on one link. If you don't you will break the pusher pin on the tool. Trust me, it's left me saying a few four letter words out loud and a chain I couldn't get off for days while I had to wait for a replacement pusher to show up.So why not just remove one pin you ask!! I could but I find it simpler to look at on the floor when cutting the new chain to length and a screw up is a $135.00 for another chain.
RK So these picks are the before measurements.
Top link riveted and flared to spec. Again take your time and take the rivet tool on and off while riveting to make sure your not over doing it!!
Chain slack is interesting per the book on the KLR. If I set it to what they call for I would damage the chain or ruin the output shaft bearing. I always set it on the loose side and then have someone sit on the bike and recheck. With a long travel suspension bike the slack will be very different loaded or unloaded.