Steve - I have a press device to push the side plate on before sliding the clip on with a pair of pliers.

nikroc - The link and clip are correctly fitted on the outside of the chain and in the correct direction.

I looked at the rear of the split link and the pins definitely protrude a bit more than the rest of the chain. I have another brand new split link I can use and see if there is any difference.

With regards to the tightness of the chain - I will intentionally make it a little slack to see if there is any difference as well.

__________________
Bike: 2008 XT660Z Tenere with various bits and bobs added or subtracted