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Discussion Starter #1
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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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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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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Discussion Starter #5
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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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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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.
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.
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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sprocket

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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Wheel puller. Wait for it to arrive. It was necessary on mine , too. Fortunately I had one and it took about 30 seconds.
 

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I just changed my front sprocket and had the exact same issue. I was beating myself up trying to figure this out, then I found a compression sleeve remover I bought from home depot and that worked great! It's a little tricky keeping the two sides from slipping off, but worked well enough. You just have to make sure the little round attachment is on the end so the end doesn't go through the bike (if that makes sense). It was super cheap and seemed to be made for that exact purpose. Hope this helps!

Husky Compression Sleeve and Faucet Puller

https://www.homedepot.com/p/Husky-Compression-Sleeve-and-Faucet-Puller-63876/304543091

P.s. I also am in Vegas! Let me know if you would like to ride. And that 16 tooth sprocket is amazing!
 

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50/50 mix of acetone and ATF makes some fantastic penetrating fluid. I believe it works better than most commercial dedicated "penetrating" oils
 
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Good old "Ed's Red".
 
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50/50 mix of acetone and ATF makes some fantastic penetrating fluid. I believe it works better than most commercial dedicated "penetrating" oils
I use ATF and Acetone, it has worked a treat on heavy machinery parts that I have been having difficulty removing. I have had to use an application of high temperature as well on a few occasions.
 

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Discussion Starter #16
Follow-up:

Success in removing the front sprocket! I tried some of the posted suggestions, but no luck.

Wound up using a 3" gear puller purchased from Amazon to remove the sprocket. Still took some effort to get it off. I feel like I'm the only KLR owner that had this issue.

But I love the new 16t sprocket! With the 15t, revs were about 5200 at 75mph. With the 16t, it's a less buzzy 4800 (approximate) at 75.
 
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