Front sprocket removal (difficult) - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

 
LinkBack Thread Tools Display Modes
post #1 of 9 Old 01-27-2015, 08:56 AM Thread Starter
2nd Gear
 
NH Thumper's Avatar
 
Join Date: Jun 2011
Location: Ashland, NH
Posts: 285
Front sprocket removal (difficult)

I am replacing the chain and sprockets on my '09. I am having a heck of a time getting the nut off the front sprocket. It won't budge.
The last thing I tried (with my son holding down the brake) was an 18" breaker bar with an additional 16" of pipe on the handle. It still won't move.
Yes, I have pried the washer out of the way (where it was flattened against the nut).
I have access to a pneumatic impact gun. Would that be safe to use, and not risk damaging the shaft bearings?
NH Thumper is offline  
Sponsored Links
Advertisement
 
post #2 of 9 Old 01-27-2015, 09:17 AM
5th Gear
 
Join Date: Jan 2011
Posts: 4,285
Quote:
Originally Posted by NH Thumper View Post
I have access to a pneumatic impact gun. Would that be safe to use, and not risk damaging the shaft bearings?
Yes, IMHO. Used electric 7.5-amp impact wrench on mine.

Mind the NEUTRAL SWITCH WIRE CONNECTOR; there's a whole lot of shakin' goin' on (apologies, Jerry Lee); could come loose.
Damocles is offline  
post #3 of 9 Old 01-27-2015, 09:54 AM
OverDrive
 
Join Date: Nov 2009
Location: Lander, Wyoming
Posts: 5,456
NH Thumper,
DO NOT put the Transmission in gear when using Air or Electric Impact wrench. Very hard on gear teeth.
Put a screwdriver or a rag in between the chain and sprocket, and roll the system tight.
Sometimes we have to Quickly Heat the nut with an acetylene torch, then loosen.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
pdwestman is offline  
 
post #4 of 9 Old 01-27-2015, 12:21 PM
Moderator
 
CheapBassTurd's Avatar
 
Join Date: May 2009
Location: Indiana/ Michigan line at the Lake
Posts: 1,585
Not having an impact wrench I used what was available.

I only have the silver non impact socket anyhoo and gave it a shot
of WD-40. Tapped the breaker bar lightly but firmly with a brass
mallet (2-3 lb). Took a few minutes but broke loose nicely n' came
right off. Yes on being in neutral and jamming the sprocket to take the
force just to be safe. (I didn't hit it that hard.) The book states to
hold the rear brake. I wuz just checking it to make sure that the threads
are not left handed. They aren't. Lefty loosey.

I need to snatch up an air wrench n' sockets at the pawn shop.
Pretty dumb not to have one with three cars, a bike, and an air compressor
all on homesite.
Cheeeeeeeeeeeeeeeeeaperthanyourboss

This is my son, with whom I am well pleased." ----God
CheapBassTurd is offline  
post #5 of 9 Old 01-27-2015, 07:53 PM Thread Starter
2nd Gear
 
NH Thumper's Avatar
 
Join Date: Jun 2011
Location: Ashland, NH
Posts: 285
Got it off! Thanks for the help fellas.
WD-40 and the impact gun. It still took some effort. Next time should be easier.
NH Thumper is offline  
post #6 of 9 Old 02-05-2015, 07:37 PM
4th Gear
 
GoMotor's Avatar
 
Join Date: May 2014
Location: Texas
Posts: 1,233
I regularly change sprockets while on the road/trail and I don't want to give up the room for a 12 volt impact wrench in my road kit. So, I use a prevailing torque lock nut from Eaglemike.com. It requires a 30mm wrench or a 30mm 1/2" drive socket and breaker bar which I also don't want to give up space for.

My solution was to get a cheap 30mm socket and cut 3/8" off the open end. I welded a short bolt with a 17mm hex head to the side of the cut piece with the head 3/8" above the edge of the socket for clearance.

Now I can use the 1/4" drive ratchet and 17mm socket already in my road kit to change the front sprocket without the need for impacts or breaker bars and the short socket takes very little space.
GoMotor is offline  
post #7 of 9 Old 02-06-2015, 06:17 PM
5th Gear
 
Join Date: Jan 2011
Posts: 4,285
[QUOTE=GoMotor;382577My solution was to get a cheap 30mm socket and cut 3/8" off the open end. I welded a short bolt with a 17mm hex head to the side of the cut piece with the head 3/8" above the edge of the socket for clearance.

[/QUOTE]Think I got it, GoMotor!

Yet . . . an IMAGE would be nice!

If you don't have the capability to post pictures, let's exchange e-mail addresses by PM; you can e-mail me an image file and I'll post it for you.
Damocles is offline  
post #8 of 9 Old 02-06-2015, 07:10 PM
4th Gear
 
GoMotor's Avatar
 
Join Date: May 2014
Location: Texas
Posts: 1,233
The photo shows the "crow foot socket" with my 1/4" ratchet and 17mm socket on the side bolt. The visible bolt has a 14mm head and is brazed on. I didn't like the brazing and welded on a bolt with a 17mm head that sits just a little higher for improved clearance to the crown on the locknut.
Attached Images
File Type: jpg DSCN0116.jpg (496.3 KB, 40 views)
GoMotor is offline  
post #9 of 9 Old 02-06-2015, 08:22 PM
5th Gear
 
Join Date: Jan 2011
Posts: 4,285
Quote:
Originally Posted by GoMotor View Post
The photo shows the "crow foot socket" with my 1/4" ratchet and 17mm socket on the side bolt. The visible bolt has a 14mm head and is brazed on. I didn't like the brazing and welded on a bolt with a 17mm head that sits just a little higher for improved clearance to the crown on the locknut.
'Way cool!

Crowfoots (crowfeet?) FOREVER!

Thanks, GoMotor.
Damocles is offline  
Sponsored Links
Advertisement
 
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Kawasaki KLR 650 Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Front Sprocket Removal LittleSteve 2008+ KLR650 Wrenching & Mod Questions 21 06-04-2012 07:37 PM
KLR Front Sprocket Removal for Crank Split? cawoodm 1987 to 2007 Wrenching & Mods 2 08-07-2011 11:00 AM
front wheel removal klarkekent 1987 to 2007 Wrenching & Mods 10 08-25-2010 10:21 AM
Front sprocket removal - help! DantesDame 1987 to 2007 Wrenching & Mods 18 04-14-2010 10:05 PM
2009 Front wheel removal SteelB12 2008+ KLR650 Wrenching & Mod Questions 4 07-20-2009 10:49 AM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome