Broken countershaft sproket, time for winter maint. to begin - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 22 Old 11-29-2006, 07:39 AM Thread Starter
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Broken countershaft sproket, time for winter maint. to begin

Bike in question. 2005 with 13,500 miles.

Coming home last night and my front sprocket finally gave way. It has been on thin ice for the last few thousand miles :roll: I hear some metal to metal clanking/grinding and look down and see metal coming off and soon I am loosing power and had to walk it the last two blocks home :lol:

Here you can see the stripped front sprocket and my nifty holder to get the rear removed without busting knuckles. I had lost a chain a while back and the nuts holding on the rear were mangled pretty good. Some 2x4's and screws to the bench and it was planted





Also picked up my new shifter from the dealer. I got am MSR unit. Part number 07-0714 and it was only $22, local and I get 10% off usually (Dual Star wants $28 ) and looks to be real nice quality. Pictured is my 2nd stocker and it broke at the welds and I got it fixed until the MSR came in. FYI, new 07's have a sifter similar to this and it's not some stamped steel POS like previous years. :roll:





Also on the bill is some greasing of the swingarm, adjust valves, install IMS tank when it arrives with my new chain and sprockets.

My front Kenda 270 is "bubbling" at the lugs I noticed also. It has maybe 6-8K on it and tons of tread left, but I might just retire it and get a Duro Median up front to match the rear. I have really liked the Duro for my riding (90/10).

Going to order some goodies from Dual Star today.
Chain Adjuster Nuts 32-00520-008 $2.95 http://www.dual-star.com/index2/Bran...uster_nuts.htm
Locking Axle Nut (Front) 20-39110 $6.95 http://www.dual-star.com/index2/Bran...s_kawasaki.htm
Locking Axle Nut (Front) 20-39111 $6.95



Then I went to Taco Tuesday, got stuffed and had some 0008
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post #2 of 22 Old 11-29-2006, 09:58 AM
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Wow,...WOW! Could you tell me why you went so long before changing it? I think you're likely to cause more dollars in damage than you'll save in going that long. That's one seriously overworn sprocket set.

IMHO if I had a sprocket that looked like that I'd......
Change it earlier. It's really not safe to go that long.
Change my maintenance routine....At 13000mi, your chain/sprockets are wearing too fast and you should check the tension (when on the sidestand it should just barely touch or come close to the swingarm), lube routine (500mi clean and apply lube of choice) , or the alignment (verfy the bushings are in the proper place and equadistance from the pivot bolts or use the string alignment method.)
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post #3 of 22 Old 11-29-2006, 10:07 AM Thread Starter
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Why? No reason other than pure laziness and not wanting to spend $$ on the bike due to lawyer exspenses and other personal BS.

What damage did I do other than waste my sprockets and chain that are getting replaced as a set now?

That is chain #2 and it's a cheap non oring unit. I did not change sprockets at that time either. I know that is not right, but I didn't care as it just needed to last me until the winter.

I can not keep my chain adjusted worth a shit as well. The double nut method stinks and I am getting the dual star ones. With the stock chain i waxed it and adjusted it regularly and it was stretched out before 10K. I wheelie a lot and downshift/brake hard at times ops:

Hoping to adjust my riding style this time around and hope it lasts me a bit longer.

I now have a 43 (or is it 45 stock??) tooth Chinese throwing star :lol:
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post #4 of 22 Old 11-29-2006, 12:06 PM
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Gave out 2 blocks from home! Can't beat that.

Yeah, it's about that time of year:

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post #5 of 22 Old 11-29-2006, 12:10 PM Thread Starter
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Have you done the valves yet? I'd be happy to help ya out and learn a few tips/tricks before I do mine.

How are the 606's treating you?
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post #6 of 22 Old 11-29-2006, 12:48 PM
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I really like the 606's. In that picture, they actually have a little over 2000 miles on them. So it seems like they are holding up well.

I haven't tackled the valves yet. It is really a matter of deciding which shims to buy and stuff like that. Right now I am putting on an accessory outlet and heated grips and generally tightening and retorquing stuff.

This is definitely a good week in KC to be doing some maintenance. This weather sucks!
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post #7 of 22 Old 11-29-2006, 12:57 PM Thread Starter
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I am planning to check mine before this weekend and order the shims I need and have them early next week.
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post #8 of 22 Old 11-29-2006, 09:27 PM
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Quote:
Originally Posted by Bones
Why? No reason other than pure laziness and not wanting to spend $$ on the bike due to lawyer exspenses and other personal BS.

What damage did I do other than waste my sprockets and chain that are getting replaced as a set now?
I'm not throwing stones.... I'm just safety conscious. My personal motto is "Everyone comes home safe or it's not worth doing." The owners manual says replace them much sooner as there is a risk of the chain coming off at speed. Not good if it gets wrapped around the axle.

I went six months without a stator/regulator/rectifier providing a charge to the battery on my Yamaha back in the early eighties until I completed ETS's out of the Army at Ft. Bragg and moving home to California. I used it for a 7 mile commute and put the bike on a charger overnight, cranked it on the charger and bump started most of the time. It sucked but I had no other options until I was employed by someone other than Uncle Sam.

I'd bet that some folks around here would mail you their old takeoff sprockets rather than see you go to that level of wear again. I have mailed parts before for worse reasons to guys who could use them.


http://www.advrider.com/forums/showthread.php?t=3646
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post #9 of 22 Old 11-30-2006, 07:15 AM Thread Starter
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Quote:
Originally Posted by kbetts
Quote:
Originally Posted by Bones
Why? No reason other than pure laziness and not wanting to spend $$ on the bike due to lawyer exspenses and other personal BS.

What damage did I do other than waste my sprockets and chain that are getting replaced as a set now?
I'm not throwing stones.... I'm just safety conscious. My personal motto is "Everyone comes home safe or it's not worth doing." The owners manual says replace them much sooner as there is a risk of the chain coming off at speed. Not good if it gets wrapped around the axle.

I went six months without a stator/regulator/rectifier providing a charge to the battery on my Yamaha back in the early eighties until I completed ETS's out of the Army at Ft. Bragg and moving home to California. I used it for a 7 mile commute and put the bike on a charger overnight, cranked it on the charger and bump started most of the time. It sucked but I had no other options until I was employed by someone other than Uncle Sam.

I'd bet that some folks around here would mail you their old takeoff sprockets rather than see you go to that level of wear again. I have mailed parts before for worse reasons to guys who could use them.


http://www.advrider.com/forums/showthread.php?t=3646
I appreciate it, but I am not that poor. I was a real lazy SOB this summer for some reason. I am usually on top of things, but this I just let slide with all my other life drama going on.
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post #10 of 22 Old 12-02-2006, 04:01 PM
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Bones u crack me up man! I did the same thing a couple of years ago except I didn't know enough then to know what was wrong. 2 blocks from the house and it sounded like a machine gun going off. I actually limped it the last two blocks in 2 gear however. Now I know all about sprockets and chains. Somepeople learn the hard way I guess. Im one of em.
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