$.00 mod and 16T - 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 13 Old 04-28-2009, 05:25 AM Thread Starter
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$.00 mod and 16T

Well, I did the $.22 mod yesterday, only it didn't cost me a cent! Already had some washers from doing the same thing to my XS650.

WOW!, what a difference! Turned pilot screw out 2 turns, but didn't drill the slide and don't feel it necessary. Really woke this bike up, and seems smoother and really revs out with an urgency it didn't have before.

Well worth the 1/2 hour spent to do it.

I hadn't planned on raising the gearing, but now I think I'll give it a shot. Couple questions, though. For those of you that have done the sprocket swap, How much did it lower your RPM's on the highway? I'd like to be turning about 300 rpm less at 60 or so. If you made the change, did you like it?

I figure if I know I'm going to be doing some more serious off-roading, I'd just put the 15 back on. For most of my normal riding, I think the 16 will be the way to go. Oh, and what size is the C/S nut?

I already have 36mm and 32 mm sockets from previous gearing changes on other bikes. Hard to tell looking through the sprocket cover what it might be.

One more thing. Where are you guys getting your 16T's from? Is there certain brand/part# I could order from the dealer or out of Dennis Kirk or something?

Thanks!

Jay
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post #2 of 13 Old 04-28-2009, 07:27 AM
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Jay -

The counter shaft nut is a 27 mm. For some long, lost reason, I have a 1 1/16" socket, and it fits fine.

Going to a 16 tooth sprocket will reduce your RPM at any given speed by 7%. (16/15 = 1.0666).

If you found yourself turning 4000 RPM at 65, you'll be turning 3750 with the 16 tooth sprocket.

My sprocket (I went the other way and lowered my gear ratio with a 14 tooth) came from Arrowhead Motorsports - Fred Hink. It was a JT. No issues with it at all. I'm given to understand that there are other brands that are more "universal" in application that require a spacer to fit properly, so beware of that.

Tom

Last edited by Tom Schmitz; 04-28-2009 at 07:34 AM.
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post #3 of 13 Old 04-28-2009, 07:37 AM
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I just installed a 16 tooth sprocket yesterday. Didn't get to go for much of a ride because our weather kinda stinks right now but had to see how it felt. Small adjustment required for starting out. At highway speed, 60 MPH, the RPMS were about 300 lower.

Where to buy. I spent a whole lot of time on that looking at a number of catalogues online. Neither JT or Sunstar actually list a 16T sprocket for the KLR post 1990. A number of the KLR outlets sell the 16 tooth sprocket with a spacer washer. Basically those sprockets are from pre 1990 KLR's and made to work with a spacer. I wasn't keen on the spacer. Preferred the sprocket to have that machined onto it. I figure it would make it stronger, but I'm no engineer. Also didn't like the idea of adding another part.

Long story short. Only found one manufacturer that makes a properly machined sprocket for the 1990+ KLR and that was AFAM. Unfortunately the part number I have is a catalogue number from a Canadian wholesaler. European company that seems heavy into sport bike gearing.

I have the JT catalogue pages on my desktop. Tried to upload them but had no success.




Semi-success but had to turn it.

A friend of mine ordered a 16T from the dealer. He sold him a JTF512.16 with no spacer. The JT catalogue list that as the sprocket for a Kawasaki ZR550 B2-B8 Zephyr, whatever that is. It is 4mm thinner than the one I have. I mic'ed my stock and the Afam and they were the same.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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Last edited by klr4evr; 04-28-2009 at 08:05 AM.
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post #4 of 13 Old 04-28-2009, 07:47 AM Thread Starter
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Thanks, Tom!

Pulled the trigger on a 16T from here:

http://www.tpimotorcycleparts.com/

I've raised the gearing on the last couple chain drive bikes I've had with good results

Wee Strom- (sold it, great bike, though. not "dirty" enough")
15T to 16T- great for the road, and never did anything more than gravel, anyway

XS 650- Stock-17/34, 1st step-18/34, 2nd step 17/30, final step 18/30.

With a tip from a fellow XS rider, I retarded the timing a bit, and now it really pulls off idle and made it smoother. [email protected]

After owning MANY Jap bikes over the years, I've always felt that most of them were undergeared. Most notorious were the Yamaha shafties.

I've turned into one of those tall gear guys.

My buddies call, me "Sprocket Man".
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post #5 of 13 Old 04-28-2009, 07:55 AM
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Jay -

Good deal, I'm sure you'll like it.

klr4evr -

Thanks for the bit about the older sprockets being the ones that require a space to work on the newer bikes. Arrowhead is now listing a PBI 16 tooth - I wonder if it is a properly machined part or if it requires a spacer... there's a different part number of the ones that fit pre-'96.

Tom
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post #6 of 13 Old 04-28-2009, 08:03 AM
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Unfortunately it is not clear from the TPI listing what you will be getting. The price is around what I paid so maybe it is machined. Otherwise it's a very expensive washer.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #7 of 13 Old 04-28-2009, 09:54 AM Thread Starter
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Go to the KLR section, click on "chains and sprockets".

They have 14,15, and 16's.

Here's a helpful link from the "other" forum.

Looks like 16T is just what I need!

http://www.motodyn.com/media/utils/o...ear-ratios.xls

Last edited by indyjay; 04-28-2009 at 11:00 AM.
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post #8 of 13 Old 04-28-2009, 04:42 PM
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Quote:
Originally Posted by indyjay View Post
Go to the KLR section, click on "chains and sprockets".

They have 14,15, and 16's.

I figured that much out. What isn't clear from their pictures, because it doesn't show the sprocket front and back, is which sprocket you are actually getting.

Both of these will fit a KLR, one with a spacer one without. The JT511 is the correct KLR sprocket as shown on the catalogue page I previously posted but they only are showing it as available in 14T and 15T.



My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #9 of 13 Old 04-29-2009, 05:24 AM Thread Starter
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Thumbs up

Got my front sprocket off with no major drama last night after getting a 27mm socket from Sears. Took chainguard off so I could put a pipe through the wheel to hold it while I torqued down on ratchet.

Supposed to be nice this weekend, should have my sprocket by then so I'll be able to do a test run!


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post #10 of 13 Old 04-29-2009, 10:06 AM
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My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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