Wilsons Sandbox

> Barry Pedersen wrote: > > I was greatly dismayed recently when I pulled the countershaft > sprocket off of my A9 for the first time. I bought it last August. A > few weeks ago, I decided that the chain was ready for replacement > (9700 mi). I replaced the chain and sprockets as set, but when I > pulled off the countershaft sprocket, I could see that it had worn > down the teeth (splines) on the countershaft. Comparing the area > where the sprocket rides to the end of the shaft revealed obvious > wear. The teeth on my retainer were also seriously mangled. > > If you haven't recently inspected the condition of your countershaft > with the sprocket off, I strongly advise doing so at your earliest > convenience. Once the teeth on the countershaft are rounded off, your > bike becomes just a noisy paperweight, and the engine must be removed > and split to replace the countershaft. > > Anyway, the culprit was play in the fit of the sprocket on the > countershaft. If you have a pre-'96 KLR650, your countershaft > sprocket is held on by a retainer fastened to the sprocket with two > bolts. If your bike is like mine was, this set up allows the > countershaft sprocket to move from side to side on the shaft during > operation causing excess wear. > > Fortunately, there is a fix available. Sagebrush Machine Shop has > shim sets available ($10), that you can install behind your > countershaft sprocket (between the sprocket and engine) to remove the > play. They come in sets because after market countershaft sprockets > aren't necessarily the same width as the stocker. So, if you get a > set, keep all of them in case you swap your Kawasaki c/s sprocket for > one of these. > > Also available from Sagebrush are upgraded retainers (also $10). The > stock retainer is designed so that no matter how it's slid onto the > countershaft, once it's rotated to line up the bolt holes, its teeth > will somewhat overlap the splines on the countershaft. The retainer > rides in a groove going around the countershaft, and it keeps the > sprocket on because it's teeth won't line up between the countershaft > splines once its bolted to the sprocket. This may be hard to > visualize, but it's quite obvious once you're looking at it. The > problem with the stock retainer is that its teeth only partially > overlap the countershaft splines. I think this contributes to the > play problem. > > The Sagebrush retainer is a little thicker and is cut so that its > teeth fully overlap the countershaft splines once its correctly > installed. CAUTION! If it's incorrectly installed, there is zero > overlap, and the c/s sprocket can slide off. This tends to ruin your > day. > > I have the shims and upgraded retainer on my A9 now, and there is no > side-to-side play in my countershaft sprocket. It's much sturdier > than before. If you find you have play in your setup, definitely give > Sagebrush a call and talk to Dave Jakeman about the upgrade. He's > very helpful, and he's available eves and weekends. > > Sagebrush Machine Shop > 49 S 400, PO Box 339 > Milford, Utah 84751-0039. > (435)387-5575. > > There's no email address, but he has a page on the DSN website. > http://www.geocities.com/~klrdsn/page92.html > ---------------------------------------------------------------------- > > ---------------------------------------------------------------------- > Visit the KLR650 archives at > http://www.listquest.com/lq/search.html?ln=klr650 > Support Dual Sport News... dsneditor@... > Let's keep this list SPAM free! > > Visit our site at http://www.egroups.com/group/DSN_klr650 > To unsubscribe from this group, send an email to: > DSN_klr650-unsubscribe@egroups.com

Anyway, the culprit was play in the fit of the sprocket on the countershaft.  If you have a pre-'96 KLR650, your countershaft sprocket is held on by a retainer fastened to the sprocket with two bolts.  If your bike is like mine was, this set up allows the countershaft sprocket to move from side to side on the shaft during operation causing excess wear. 

>From: David Kleber >To: Barry Pedersen >CC: DSN_klr650@egroups.com >Subject: Re: [DSN_klr650] Countershaft protection for older KLRs >Date: Tue, 23 May 2000 22:55:22 -0400 > >Excellent post, Barry. > >I just dropped a chain during a ride on a trail neer my house a few >weeks ago. Upon inspection of my countershaft after the long push home, >I discovered a badly worn retainer...the teeth were all chewed up and >the front sprocket was sliding freely on the countershaft. I don't know >whether the wear on the retainer caused the chain break or if the chain >break caused the wear on the retainer. When the chain broke, it took a >significant shaving of aluminum off the case and I would imagine that >when it wedged between the sproket and the case, it must have put quite >a bit of preasure on the retainer. > >One thing for sure is that I DO NOT like the design of that retainer. >I'm not sure why they would have designed that thing the way they did. >I'll be checking into the Sagebrush retainer - thanks for the tip. > >-Dave >http://www.city-net.com/~davekle/ >KLR 650 A7 > > > Barry Pedersen wrote: > > > > I was greatly dismayed recently when I pulled the countershaft > > sprocket off of my A9 for the first time. I bought it last August. A > > few weeks ago, I decided that the chain was ready for replacement > > (9700 mi). I replaced the chain and sprockets as set, but when I > > pulled off the countershaft sprocket, I could see that it had worn > > down the teeth (splines) on the countershaft. Comparing the area > > where the sprocket rides to the end of the shaft revealed obvious > > wear. The teeth on my retainer were also seriously mangled. > > > > If you haven't recently inspected the condition of your countershaft > > with the sprocket off, I strongly advise doing so at your earliest > > convenience. Once the teeth on the countershaft are rounded off, your > > bike becomes just a noisy paperweight, and the engine must be removed > > and split to replace the countershaft. > > > > Anyway, the culprit was play in the fit of the sprocket on the > > countershaft. If you have a pre-'96 KLR650, your countershaft > > sprocket is held on by a retainer fastened to the sprocket with two > > bolts. If your bike is like mine was, this set up allows the > > countershaft sprocket to move from side to side on the shaft during > > operation causing excess wear. > > > > Fortunately, there is a fix available. Sagebrush Machine Shop has > > shim sets available ($10), that you can install behind your > > countershaft sprocket (between the sprocket and engine) to remove the > > play. They come in sets because after market countershaft sprockets > > aren't necessarily the same width as the stocker. So, if you get a > > set, keep all of them in case you swap your Kawasaki c/s sprocket for > > one of these. > > > > Also available from Sagebrush are upgraded retainers (also $10). The > > stock retainer is designed so that no matter how it's slid onto the > > countershaft, once it's rotated to line up the bolt holes, its teeth > > will somewhat overlap the splines on the countershaft. The retainer > > rides in a groove going around the countershaft, and it keeps the > > sprocket on because it's teeth won't line up between the countershaft > > splines once its bolted to the sprocket. This may be hard to > > visualize, but it's quite obvious once you're looking at it. The > > problem with the stock retainer is that its teeth only partially > > overlap the countershaft splines. I think this contributes to the > > play problem. > > > > The Sagebrush retainer is a little thicker and is cut so that its > > teeth fully overlap the countershaft splines once its correctly > > installed. CAUTION! If it's incorrectly installed, there is zero > > overlap, and the c/s sprocket can slide off. This tends to ruin your > > day. > > > > I have the shims and upgraded retainer on my A9 now, and there is no > > side-to-side play in my countershaft sprocket. It's much sturdier > > than before. If you find you have play in your setup, definitely give > > Sagebrush a call and talk to Dave Jakeman about the upgrade. He's > > very helpful, and he's available eves and weekends. > > > > Sagebrush Machine Shop > > 49 S 400, PO Box 339 > > Milford, Utah 84751-0039. > > (435)387-5575. > > > > There's no email address, but he has a page on the DSN website. > > http://www.geocities.com/~klrdsn/page92.html > > ---------------------------------------------------------------------- > > > > ---------------------------------------------------------------------- > > Visit the KLR650 archives at > > http://www.listquest.com/lq/search.html?ln=klr650 > > Support Dual Sport News... dsneditor@... > > Let's keep this list SPAM free! > > > > Visit our site at http://www.egroups.com/group/DSN_klr650 > > To unsubscribe from this group, send an email to: > > DSN_klr650-unsubscribe@egroups.com

>From: Tom Myers >To: DSN_klr650@egroups.com >Subject: Re: [DSN_klr650] Countershaft protection for older KLRs >Date: Wed, 24 May 2000 11:15:59 -0700

>>Anyway, the culprit was play in the fit of the sprocket on the >>countershaft. If you have a pre-'96 KLR650, your countershaft >>sprocket is held on by a retainer fastened to the sprocket with two >>bolts. If your bike is like mine was, this set up allows the >>countershaft sprocket to move from side to side on the shaft during >>operation causing excess wear.

>I've been told this looseness is intentional to increase the life of >the drivetrain. Hondas have 'loose' countershaft sprockets too. >Anyone know the "truth"? > >Tom >

>+------------------------------------+ >| CycoActive Products tel (206) 323-2349 >| 701 34th Ave fax (206) 325-6016 >| Seattle, WA 98122 USA >| webpage: http://www.cycoactive.com >| e-mail: TomMyers@... >+------------------------------------+

> > This is all good info but I think you're missing the root cause of the > problem, and that is the effect of drive chain tension. Trust me I know. The > only way you are going to break a chain and at the same time exhibit damage > to the drive shaft and countersprocket retainer is if the chain is too > tight. They have the same problem on the TransAlp list, with thier bikes. > Jake jakeman has the right idea in correcting a problem solved with the > shims and it's always good to source parts locally than having to send to > Japan for them. > Dave- what kind of chain did you break? Endless or master link type? Brand?

> Conall always keeps his chain loose. > > >From: David Kleber > >To: Barry Pedersen > >CC: DSN_klr650@egroups.com > >Subject: Re: [DSN_klr650] Countershaft protection for older KLRs > >Date: Tue, 23 May 2000 22:55:22 -0400 > > > >Excellent post, Barry. > > > >I just dropped a chain during a ride on a trail neer my house a few > >weeks ago. Upon inspection of my countershaft after the long push home, > >I discovered a badly worn retainer...the teeth were all chewed up and > >the front sprocket was sliding freely on the countershaft. I don't know > >whether the wear on the retainer caused the chain break or if the chain > >break caused the wear on the retainer. When the chain broke, it took a > >significant shaving of aluminum off the case and I would imagine that > >when it wedged between the sproket and the case, it must have put quite > >a bit of preasure on the retainer. > > > >One thing for sure is that I DO NOT like the design of that retainer. > >I'm not sure why they would have designed that thing the way they did. > >I'll be checking into the Sagebrush retainer - thanks for the tip. > > > >-Dave > >http://www.city-net.com/~davekle/ > >KLR 650 A7 > > > > > Barry Pedersen wrote: > > > > > > I was greatly dismayed recently when I pulled the countershaft > > > sprocket off of my A9 for the first time. I bought it last August. A > > > few weeks ago, I decided that the chain was ready for replacement > > > (9700 mi). I replaced the chain and sprockets as set, but when I > > > pulled off the countershaft sprocket, I could see that it had worn > > > down the teeth (splines) on the countershaft. Comparing the area > > > where the sprocket rides to the end of the shaft revealed obvious > > > wear. The teeth on my retainer were also seriously mangled. > > > > > > If you haven't recently inspected the condition of your countershaft > > > with the sprocket off, I strongly advise doing so at your earliest > > > convenience. Once the teeth on the countershaft are rounded off, your > > > bike becomes just a noisy paperweight, and the engine must be removed > > > and split to replace the countershaft. > > > > > > Anyway, the culprit was play in the fit of the sprocket on the > > > countershaft. If you have a pre-'96 KLR650, your countershaft > > > sprocket is held on by a retainer fastened to the sprocket with two > > > bolts. If your bike is like mine was, this set up allows the > > > countershaft sprocket to move from side to side on the shaft during > > > operation causing excess wear. > > > > > > Fortunately, there is a fix available. Sagebrush Machine Shop has > > > shim sets available ($10), that you can install behind your > > > countershaft sprocket (between the sprocket and engine) to remove the > > > play. They come in sets because after market countershaft sprockets > > > aren't necessarily the same width as the stocker. So, if you get a > > > set, keep all of them in case you swap your Kawasaki c/s sprocket for > > > one of these. > > > > > > Also available from Sagebrush are upgraded retainers (also $10). The > > > stock retainer is designed so that no matter how it's slid onto the > > > countershaft, once it's rotated to line up the bolt holes, its teeth > > > will somewhat overlap the splines on the countershaft. The retainer > > > rides in a groove going around the countershaft, and it keeps the > > > sprocket on because it's teeth won't line up between the countershaft > > > splines once its bolted to the sprocket. This may be hard to > > > visualize, but it's quite obvious once you're looking at it. The > > > problem with the stock retainer is that its teeth only partially > > > overlap the countershaft splines. I think this contributes to the > > > play problem. > > > > > > The Sagebrush retainer is a little thicker and is cut so that its > > > teeth fully overlap the countershaft splines once its correctly > > > installed. CAUTION! If it's incorrectly installed, there is zero > > > overlap, and the c/s sprocket can slide off. This tends to ruin your > > > day. > > > > > > I have the shims and upgraded retainer on my A9 now, and there is no > > > side-to-side play in my countershaft sprocket. It's much sturdier > > > than before. If you find you have play in your setup, definitely give > > > Sagebrush a call and talk to Dave Jakeman about the upgrade. He's > > > very helpful, and he's available eves and weekends. > > > > > > Sagebrush Machine Shop > > > 49 S 400, PO Box 339 > > > Milford, Utah 84751-0039. > > > (435)387-5575. > > > > > > There's no email address, but he has a page on the DSN website. > > > http://www.geocities.com/~klrdsn/page92.html > > > ---------------------------------------------------------------------- > > > > > > ---------------------------------------------------------------------- > > > Visit the KLR650 archives at > > > http://www.listquest.com/lq/search.html?ln=klr650 > > > Support Dual Sport News... dsneditor@... > > > Let's keep this list SPAM free! > > > > > > Visit our site at http://www.egroups.com/group/DSN_klr650 > > > To unsubscribe from this group, send an email to: > > > DSN_klr650-unsubscribe@egroups.com > > ________________________________________________________________________ > Get Your Private, Free E-mail from MSN Hotmail at http://www.hotmail.com

  Anyway, the culprit was play in the fit of the sprocket on the countershaft.  If you have a pre-'96 KLR650, your countershaft sprocket is held on by a retainer fastened to the sprocket with two bolts.  If your bike is like mine was, this set up allows the countershaft sprocket to move from side to side on the shaft during operation causing excess wear.