Front Sprocket Wear - 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 6 Old 04-07-2008, 05:24 PM Thread Starter
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Question Front Sprocket Wear

Has anyone experienced excessive wear on the front sprocket? I replaced the OEM on my 2004 last November with 8800 miles on it, along with the rear sprocket and chain. All replacement components came from DualStar, sprockets were steel (no aluminum). The OEM sprockets were well-worn. Now, after less than 2000 miles, the front sprocket again is wearing prematurely. I've had many chain-driven bikes over the years, but have never seen wear like this. I'm accustomed to getting 15-20K out of a set. Chain and sprockets have been routinely cleaned and lubed; adjustment is on the loose side, not quite touching the swingarm w/o rider.

Any thoughts or similar experiences?
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post #2 of 6 Old 04-07-2008, 06:24 PM
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I don't know, not quite touching the swing arm without rider sounds a little tight. But I do tend to like mine on the looser side.
I know this might sound like an elementary question, but you did assure of rear and front sprocket alignment. Those factory marks are not quite dead on, I don't like relying on them.

The front sprocket nut, Front Swingarm nut, and the rear axle nut should all be in perfect horizontal alignment when adjust the chain. This point is the Longest point the chain will have to stretch, anything else up or down will be shorter. I usually like at least an inch of lower chain movement when these three points line up.

Oh I do know, that when I ordered a 16 tooth front sprocket, the forgot to mention the spacer washer needed to go to the inside to shim the sprocket out enough. Just another thought if yours came with one. Some people like me, ahem, thought they went to the outside of the sprocket.

I know, probably not much help, but I am trying.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #3 of 6 Old 04-07-2008, 07:24 PM Thread Starter
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The chain is about 3-4mm from the swingarm with the swingarm sitting on wooden stands. The service shop I occasionally use commented recently that is was "a bit loose". It's more loose than the new '08 sitting on the floor. I'll check the tension after I get the new rear tire mounted and back on the bike, with me sitting on the bike. There are no tight spots in the chain, so if it has stretched, it has done so uniformly.

Washer is on the inside of the sprocket (good thought, though).

Alignment looks pretty good. I don't rely 100% on the swingarm marks either, although it appears that mine are reasonably close.

I used PJ1 Blue, Bel Ray, and Maxima Chain Wax on the OEM chain. I'm trying AliSyn Synthetic Chain Lube on this one.

Keep the thoughts coming...never know when you might hit upon something.
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post #4 of 6 Old 04-07-2008, 07:30 PM
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WOW.. I am out of suggestions other than maybe subpar chain and sprocket.
Yes, a lot of owners of new bikes have found out the chain was too tight when they went to a tech day and some of the veteran guys checked their chains. Though I think usually what you will get is a shaft seal gone bad and leaking instead of a worn sprocket.

2008 DL650 VStrom Yellow and Black
Previous ride was a 2007 KLR Black/Silver, I miss it..
Looking to get back into KLR's sometime soon.

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post #5 of 6 Old 04-19-2008, 08:23 AM Thread Starter
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I used a top of the line D.I.D. X-chain and AFAM steel sprockets. I was talking to a service manager in St. Louis on Thursday who suggested that perhaps the chain and sprockets were not "matched". As the wear is on the back side of the countershaft sprocket, he felt this was indicative of the pin/roller distance being less than the distance of the low point between each sprocket tooth.

Thoughts?
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post #6 of 6 Old 04-22-2008, 11:10 AM
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hmmm...like the chain shrunk instead of stretched?

I would've thought the premature wear would have been caused buy a new sprocket mated an 8800 mile chain that is slightly stretched. I would expect that to cause wear oposite what you're describing though.
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