Rear axle issue - 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 4 Old 09-05-2010, 03:23 PM Thread Starter
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Rear axle issue

I just found out that the wheel sprocket was not installed properly last time I had my rear tire replaced. The sprocket is swinging in all directions, like a disk sitting on a flat surface, but with a small bump in the center. See what I mean?

I've removed the wheel and tried mounting the sprocket properly, but I just can't do any better than what had been done by the dealer. I've cleaned up all the parts just in case it would be caused by accumulated gunk, but still the same.

The only way I can get the sprocket to sit properly on the wheel is by not installing the spacer at the back of the sprocket hub. So that spacer seems to be the problem. Mind you it looks in good shape. Could it be that it's very touchy to put back in place properly? I've removed that rear wheel before and installed it back on, and it went fine, though.

Amazingly enough, I've ride over 3000km with a loose sprocket! The chain did wear out much quicker than normal, though. And now, being aware of this issue, I don't want to ride and make it any worst than it is. I'm currently traveling, and camping on the Vancouver island. There's a dealer a few km from where I'm camping, so I'll be heading there Tuesday morning, unless I can manage to fix it myself. I'll be checking back with this forum to see if any of you have any idea about what could be causing the sprocket to sit loose on the wheel.

On the following page:
partsfinder.onlinemicrofiche.com/cycleparts/Kawasaki_OEM/KawasakiDB.asp?Type=13&A=126&B=42
part 42036 is the issue.

Thanks everyone!
Dan
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post #2 of 4 Old 09-06-2010, 12:20 PM
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Quote:
Originally Posted by chatdgouttiere View Post
I just found out that the wheel sprocket was not installed properly last time I had my rear tire replaced. The sprocket is swinging in all directions, like a disk sitting on a flat surface, but with a small bump in the center. See what I mean?

I've removed the wheel and tried mounting the sprocket properly, but I just can't do any better than what had been done by the dealer. I've cleaned up all the parts just in case it would be caused by accumulated gunk, but still the same.

The only way I can get the sprocket to sit properly on the wheel is by not installing the spacer at the back of the sprocket hub. So that spacer seems to be the problem. Mind you it looks in good shape. Could it be that it's very touchy to put back in place properly? I've removed that rear wheel before and installed it back on, and it went fine, though.

Amazingly enough, I've ride over 3000km with a loose sprocket! The chain did wear out much quicker than normal, though. And now, being aware of this issue, I don't want to ride and make it any worst than it is. I'm currently traveling, and camping on the Vancouver island. There's a dealer a few km from where I'm camping, so I'll be heading there Tuesday morning, unless I can manage to fix it myself. I'll be checking back with this forum to see if any of you have any idea about what could be causing the sprocket to sit loose on the wheel.

On the following page:
partsfinder.onlinemicrofiche.com/cycleparts/Kawasaki_OEM/KawasakiDB.asp?Type=13&A=126&B=42
part 42036 is the issue.

Thanks everyone!
Dan



Looks to me that 42036 sits in the inner bearing (601) yes? Is that bearing seated all the way into the hub? Does the long spacer (92143) interfere with the fit? It should just drop into the hub. Silly question but have you tried reversing 42036?

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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post #3 of 4 Old 09-06-2010, 12:30 PM
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Thanx, Spec!

Dan,
Check the rubber shock-cushion too. (That 6-lobe doughnut thingie)
If it's crushed too much, the sprocket'll float around a bit. Some of
the guys replace the unit, others just cram in parts of bicycle tubes to
take up the extra space and slack.

CheapMark

This is my son, with whom I am well pleased." ----God
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post #4 of 4 Old 09-06-2010, 02:16 PM Thread Starter
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Hi guys, thanks for looking into this.

You're right Spec, 42036 sits in the inner bearing (601), but that inner bearing is locked in place by 92033, so it can't really move in or out. No the long spacer does not interfere with it. Your question about reversing 42036 is not silly, but no, it only fits one way, as one side has a smaller diameter than the other.

CheapBassTurd, I don't know if the rubber shock-cushion is worn out or not, as I don't know what it looks like brand new, and I did look at it, but it looked to me like it's there to serve as a cushion for the rotation of the sprocket hub onto the wheel. But maybe you're right. All stores are closed today, so I guess I'll see tomorrow with the Kawa dealer. If they don't have a cushion in stock, I'll try the bicycle tube thing.

Thanks for the comments guys. Much appreciated!
Dan
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