sprocket question - 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.

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post #1 of 16 Old 03-08-2017, 11:30 AM Thread Starter
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sprocket question

Just to make sure does the wider lip on the front sprocket face the outside of the bike or in ? thanks
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post #2 of 16 Old 03-08-2017, 02:33 PM
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Originally Posted by thomasj70 View Post
Just to make sure does the wider lip on the front sprocket face the outside of the bike or in ? thanks
I'll assume KLR650. The big wide flat lip faces OUT.

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post #3 of 16 Old 03-08-2017, 08:44 PM Thread Starter
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Yes , Its KLR 650 . I just wanted to make sure. I put it on that way (flat lip out) and its making a scrubbing noise. I thought it might be the plastic cover which it was scrubbing a little so I trimmed it where it was marking but its still making a noise. I can hear it when in low gear. I'll look closer. thanks for your help friend !
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post #4 of 16 Old 03-08-2017, 10:10 PM
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Guesswork, I grant you.

I bought a KLR-specific Olympia sprocket-and-chain set.

I figured, if the sprocket has a BOSS, it's there for a purpose.

Thus, I put the boss, the thicker part of the sprocket, against the engine side of the countershaft.

The EFFECT of this installation configuration remains: Moves the sprocket teeth OUTBOARD of the engine, in contrast to inboard, as would the reverse installation.

Have I done wrong, pdwestman?

The confiruation has lasted a number of thousands of miles, so far, without obvious damage or compromise; I'll be CRUSHED if I've been living in error this long!

(I hope the word picture above of the installation configuration is clear; my, a picture or accurate sketch would be so USEFUL at times like this!)

Last edited by Damocles; 03-08-2017 at 10:21 PM.
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post #5 of 16 Old 03-08-2017, 10:30 PM
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Thus, I put the boss, the thicker part of the sprocket, against the engine side of the countershaft.

Have I done wrong, pdwestman?

The confiruation has lasted a number of thousands of miles, so far, without obvious damage or compromise; I'll be CRUSHED if I've been living in error this long! [/QUOTE]

I guess at a lot of stuff too. If I am wrong, Murphy will tell me.

Older KLRs a grove in the splines near the end of the output shaft. The sprocket was held on by a notched tab with two wings. The notches fit over the shaft and the tab was rotated half a spline to lock the sprocket in place. A bolt screwed through a hole in each wing into the sprocket.

Since no destructions come with the sprocket, I assume the two holes in the boss are for the bolts on older KLRs, so I put the boss on the outside.
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post #6 of 16 Old 03-09-2017, 05:13 AM
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Originally Posted by GoMotor View Post
Since no destructions come with the sprocket, I assume the two holes in the boss are for the bolts on older KLRs, so I put the boss on the outside.
Makes sense!

As I ride on, with my hopelessly mis-aligned sprocket, awaiting whatever doom this malfeasance portends!

If I develop enough ambition to REVERSE the sprocket, I shall have stolen some additional mileage of service life from the component, equalizing somewhat wear from the changed driving- and driven-sides of the sprocket teeth . . .

A minor silver lining to an otherwise gloomy foul-up . . .
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post #7 of 16 Old 03-09-2017, 10:02 AM
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Hmmmm; what year KLR, what brand sprocket and how many teeth?

Short answer: probably boss out.....though I lay my original sprocket beside my new one and double check the height to make sure I get it right. As GoMotor said, earlier KLR's had the 2 bolt/plate retention system and there were some changes to the splines early on: basically 1987 - 1989 used a different spline, 1990-1995 used the later splines but the two bolt retention plate and 1996 and up use the nut and washer. Old info but still relevant; KLR650 FAQ

Eaglemike sells sprocket washers/shims for pre-'96 bikes; http://www.eaglemike.com/countershaf...m-kit-cssk.htm I keep a set of these shims on hand just in case.

I use Sunstar countershaft sprockets; part numbers 34914, 34915 and 34916 (last two digits are the number of teeth). These work for 1990 to present and the thick part faces out. no shims required.


Dave
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post #8 of 16 Old 03-09-2017, 11:25 AM
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For what it's worth, here's what the service manual says.
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File Type: jpg sprocket.jpg (131.8 KB, 20 views)
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post #9 of 16 Old 03-09-2017, 12:41 PM
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The same service manual that suggest Only 2.2 US quarts of engine oil!

If your master link tips don't go "click, click------------ click, click" as it passes by your LH lower subframe mounting bolt nut, I guess one could install the later Gen1 and all GEN2 front sprockets on either way.

I just know which way was the original way, the reasons why and still the preferred/correct way, imho.

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post #10 of 16 Old 03-09-2017, 12:47 PM
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Quote:
Originally Posted by thomasj70 View Post
Yes , Its KLR 650 . I just wanted to make sure. I put it on that way (flat lip out) and its making a scrubbing noise. I thought it might be the plastic cover which it was scrubbing a little so I trimmed it where it was marking but its still making a noise. I can hear it when in low gear. I'll look closer. thanks for your help friend !
Thomas,
Is your drive chain Loose Enough, that when you lift the bottom run UP it can just touch the rear tip of the rubber slider Under the swingarm?
If not, it needs to be loosened!

And how many miles are on this chain?

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 83,000+ miles & counting

Last edited by pdwestman; 03-09-2017 at 12:51 PM.
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