What year model is your AT (and it´s an RD04 or RD07)? How many kms on the clock?

In any case, check your chain tightness very carefully. The AT´s rear end geometry almost resembles a motocross machine, and especially if the chain is adjusted too tight, it will put a lot of strain on the chain and your drive shaft bearing. The AT needs more chain slack than your average streetbike. (Actually I´ve had this bearing once go bad on my AT´s, it started to make horrible noise on engine braking, I was lucky that the whole engine did not grenade, and I think the mechanic was able to replace it without actually removing the engine, although this is what the workshop manual instructs to do). Note, that a worn chain will usually be unevenly worn, and you need to have enough slack for its whole length, including its tightest spot.

Removing chain links sounds like it could have been adjusted way too tight after this.

Also do check, that the swingarm adjusters do not have different setting on left/right side, this mostly kills driveability, but could lead to other problems as well, including rapid chain wear.

New chains could be available from big cities in India (..or Kathmandu, maybe) ... but looking up a place from a big city in India will no doubt be fun! If you have to have parts flown in with DHL, the customs process could be slow & costly. Some have adviced to make new parts look like they´re used (discard packages, put some oil & dirt on them) to help with the customs, but of this I have no personal experience, as I´ve been lucky enough to never really need any parts sent to me while on a trip.

And do NOT let your engine oil level drop too low – oil starvation will kill your engine very quickly! It´s been several years, since I was in India on my own bike, but I seem to remember, that finding suitable (well, suitable enough!) oil was never a big problem. There are lotsa small cc 4-stroke bikes, what they use in them should be good enough (although I halved the oil change interval on my Vstrom, when I used some local oil, so I changed it every 3000 kms).

“I did 1100Km in one go two days back “ - wow, that´s crazy, you´re a hard rider! A bit more than 400 kms is all I ever managed in one day in India, and even that felt like doing a few back-to-back Iron Butt-rides!! S*it I hated the traffic on Indian highways.

Here´s hoping you´ll get it fixed with no further drama or issues!

(BTW, if you´ll need something from Thailand, I´ve got a friend who lives near BKK, and actually has several AT´s on his +20 bike fleet, I´ve also rented AT´s from him to tour Thailand, Cambodia & Laos... his health is not good, so has to spend time in hospitals, but I´m sure he´d also be willing to help you, if his situation allows.)

The 750 engine used in the RD04 and 07 has the bearing press-fitted from the inside. The only way to replace this bearing without splitting the engine, is to completely drill our the crankcase from the outside to the same size as the bearing, but: will you get oil seals to plug the hole? You can always add a retainer plate to the casing to prevent it from coming out, but I think it'll be hell to remove the bearing to the outside with the shaft in place without damaging the casings or the shaft.

And the final drive bearing is a double roller-bearing, which I could not source through our local bearing supplier- had to get OEM sent from Singapore/Japan.

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Squily

It was almost 20 years ago.. but if my memory serves me right, he did not take the engine off. I don´t know what tricks he had to do to achieve that.

But yeah, this is definitely a problem you do NOT want to get, while you´re in India.. and if that bearing goes, and you´re not as lucky as I was, there may be a long list of other stuff, that needs fixing!

Definitely get a new chain, and a Japanese quality chain if possible. I've had a cheap chain snap before which left me stranded

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DRZ400 and Africa Twin