Kawasaki KLR 650 Forum - Reply to Topic
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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  Topic Review (Newest First)
04-05-2010 05:11 PM
tomatocity Paper,

Will do on the speeds.

My 2005 got a 16T when I added the 685 and they were meant to be. I ended up with a 16x42 and that is almost 1,000 RPMs less than stock. I can cruise 70 MPH at 4,000 RPMs at 50 MPG.

The 2003 is a 650 and surely it will not like the 16 as well as the 685. I did not have my GPS connected but with the 15 and 4,500 RPMs I would be 65 speedometer MPH. That should be somewhere around 61-62 MPH.

I should be out and about tomorrow and will let you know the MPH at 4,500 RPMs and if there is a performance loss.

Most likely I will install the 15 for the CAN/AK trip.
04-05-2010 05:00 PM
Paper If you could, inform us of the difference in RPM at the same speed with the stock 15 tooth and the 16 tooth unit??

I'm about 2K miles away from 20K and the need for new sprockets and chain. Because I occasionally ride off road, and still occasionally ride at Interstate speed, I'm thinking about just remaining at the stock ratio, but if it's not a huge step with the 16 tooth unit I might go that route.
04-05-2010 02:44 PM
tomatocity Thanks for ALL of the advice. I am guessing it was Mechanical Life Screwing With Me.

I had loosened and and partially removed the CS more than once. The chain alignment was good and the CS would drag as it was tightened. Today the weather was good so I checked the chain and the rear wheel alignment, all was good. Removed the CS and looked for debri and any sign of scraping, NONE. Reinstalled the CS and chain, tightened it...no drag...loosened it...no drag...tightened it again...no drag...torqued it...no drag. Bad, I did not find the problem. Good, there was a positive solution.

Thanks for the suggestions.
04-05-2010 12:49 PM
john37 I got one from DK and both sides were protruding equally. I hear a wide range of opinions on this, numbers in, flat side in, etc. But on one that I had the numbers were not on the flat side.

I use a chain alignment tool that works well. If I wheel the bike back and forth about ten feet I can get a good feel for how the chain is aligned, or not!
04-05-2010 10:24 AM
klr4evr I'm not entirely familiar with the PBI sprocket but can't see it being any different than others. If I remember correctly the flat side should be in toward the motor and you need a spacer washer to sit against the ridge.
04-05-2010 12:50 AM
tomatocity
Counter Sprocket

2003: Thought I would take the time to install the PBI 16T CS. The stock CS came off easy enough. Installed the new PBI 16T CS and snugged it. Then noticed the rear wheel turned sluggish. Removed the wheel and checked the spacers and alignment and all was OK. Decided to remove the CS so I loosened it. Surprisingly the rear wheel rotated easily. Snugged the CS again and the wheel turned sluggishly. Arghhh!

The KLR is a 2003 with 3300 miles. The counter sprocket is a PBI and I installed it with the numbers and ridge in.

I have not had this problem with my 2005 which should be the same as the 2003.

Have any of you had this problem or something similar? Looking for a solution! Thanks.

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