Just chiming in to express my sympathies for what you've gone through with this, you've had every possible thing that could go wrong, go wrong. Huge kudos for @Linkin for sharing his considerable knowledge and @maelstrom that KTM chain link tool is a gem, something which I'd read previously but forgotten about. Always nice to see that this is still the friendliest and most helpful site on the net, you guys are all awesome!
Ok, got the EMGO, got the pins in, not peened I can't see anyway to peen them though as the anvils are too deep so using the rivet pin would just push the pin back out Might try some nimble hammering but if the general consensus is that it'll be ok then I'll send it as is!
Managed to peen a tiny bit with the hammer, very happy with it, chain is much better, not slack like the old one
Hope you've got a complete new tensioner as well They are a wear item on the ZXR, when I had mine I replaced the chain and tensioner, after 10,000km it needed a new tensioner as it got noisy. Mind you those kilometres were NOT gentle at all.
I shall chuck one on order haha Mine seems quite nice and clean but yeah I probably should! What part of them actually wears? I presume the spring might get weaker, but does the end of the "rod" actually wear down too?
The plunger, bearing and body tend to wear. Complete tensioners not available for ZXR, but just order the parts individually for a GPX250 as it's the same unit.