Front Sprocket - Got the nut and washer off but... - 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 15 Old 03-11-2020, 03:55 PM Thread Starter
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Front Sprocket - Got the nut and washer off but...

I was hoping to replace the stock 15t with a 16t.

Removed the nut and locking washer. The front sprocket should just slide off.

But I cannot pull it off!

Any ideas?
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post #2 of 15 Old 03-11-2020, 05:38 PM
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Have wrenched and ridden KLRs for over a decade and never had that problem but I do have a bearing puller which I would probably put on it if it was being stubborn.
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post #3 of 15 Old 03-11-2020, 09:14 PM
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Spray the splines with penetrating oil tonight. Tomorrow put the bike in 1st gear and yank it forward and backwards for a couple minutes.
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pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #4 of 15 Old 03-12-2020, 11:15 PM Thread Starter
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Thanks for the feedback! I found some 3-jaw gear pullers on Amazon that might work.
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post #5 of 15 Old 03-12-2020, 11:20 PM Thread Starter
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Quote:
Originally Posted by pdwestman View Post
Spray the splines with penetrating oil tonight. Tomorrow put the bike in 1st gear and yank it forward and backwards for a couple minutes.
Thanks for the tip. I tried this but still no go. Used PB Blaster for the penetrating oil. I'm gonna stick with the 15t for awhile. In the meantime will search for a tool to pull the sprocket off. Thanks again.
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post #6 of 15 Old 03-13-2020, 01:08 AM
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You probably will like that 16 T. I even had a 17 T on mine once when I was going for super long mpg.
In the absence of a gear puller, you might try tapping it in several different spots with a metal drift. Don’t blast it hard or you might damage the transmission bearings but some judicious tappings around the perimeter of it might break loose whatever is holding it.
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post #7 of 15 Old 03-13-2020, 09:41 AM
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Quote:
Originally Posted by vegasbill View Post
Thanks for the tip. I tried this but still no go. Used PB Blaster for the penetrating oil. I'm gonna stick with the 15t for awhile. In the meantime will search for a tool to pull the sprocket off. Thanks again.
Quote:
Originally Posted by TLHBill View Post
You probably will like that 16 T. I even had a 17 T on mine once when I was going for super long mpg.
In the absence of a gear puller, you might try tapping it in several different spots with a metal drift. Donít blast it hard or you might damage the transmission bearings but some judicious tappings around the perimeter of it might break loose whatever is holding it.
Here is another thought.

Leave the sprocket nut a Third of a Turn Loose from finger tight, and bend the locking tab to keep it from turning. Ride it an hour or a day. That should work it loose.

The thread pitch is probably 1.5mm per turn, so third of a turn would only be .020inch of clearance. That should keep the splines on the tab washer still engaged.
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pdwestman
Modify at "YOUR OWN RISK"!

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post #8 of 15 Old 03-13-2020, 12:13 PM
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eagle mike front sprocket nut will eliminate the bend over washer, just sayin

https://www.eaglemike.com/Prevailing-torque-nut-PTN.htm
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post #9 of 15 Old 03-16-2020, 03:53 PM
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the best
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post #10 of 15 Old 03-18-2020, 05:59 PM
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sprocket

Quote:
Originally Posted by vegasbill View Post
I was hoping to replace the stock 15t with a 16t.

Removed the nut and locking washer. The front sprocket should just slide off.

But I cannot pull it off!

Any ideas?
Spray some WD 40, wait an hour, hit it with a rubber hammer, then pry it off with a big honkin' flat-head screw driver.
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