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.
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.
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!
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.
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.
Tom, that there’s the good stuff. Works great on my 2A items and a host of chores around the shop.
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