[dsn_klr650] countershaft sprocket questions

[David Kleber]

Attachments : RE: [DSN_klr650] countershaft sprocket questions Kevin,   It sounds like your KLR's previous owner was doing some creative engineering.   On the countershaft, you should see a grove cut the whole way around across the slines on the shaft.  The sprocket goes on first, over the slines past this grove, then another retainer plate goes on.  The retainer slides over the splines and seats against the sproket.  At the point where it is against the sproket is where the grove is that is cut around the counter shaft.  You then rotate the retainer in the grove, where there are no splines, so that the two holes line up with the threaded holes in the sproket.  At the point where the holes line up, the notches on the retainer should be completely offset against the splines on the countershaft and this is what prevents the sproket from moving on the countershaft.   The problem with the Kaw retainer is that it isn't thick enough which allows for side to side play on the sproket.  And the notches on mine were only slightly offset against the groves on countershaft.  Jake's machined retainer is thicker and made of better stainless steel and the groves completely overlap instead of just catching the edges of the splines on the countershaft like the Kaw retainer does.   Here's a pic I scanned from my base manual.   I think this sproket set up was changed after '96, but someone might be able to correct me if I'm wrong.   -Dave http://www.city-net.com/~davekle/ klr650 A8  

----- Original Message ----- [b]From:[/b] MSeiler@racal-pelagos.com [b]To:[/b] davekle@city-net.com ; MSeiler@racal-pelagos.com ; DSN_klr650@egroups.com ; dan_iss@yahoo.com [b]Sent:[/b] Wednesday, September 06, 2000 5:12 PM [b]Subject:[/b] RE: [DSN_klr650] countershaft sprocket questions I'm a little unclear what you mean, David. Do you mean that I'm supposed to have a plate that bolts to the countershaft sprocket- as in the one that Dan referred to? If so, I don't have that item. All I've got is an E-clip. There was a lot of other shoddy work done by previous owner on the bike, and I'm thinking he had a few left over parts that got round-filed when he did a sprocket replacement on this bike. Would also appreciate a response on the Sagebrush Machine Shop address and or phone number, as the archives give me oh, about 3,465,324 responses. BTW, am I the only one out here that finds the archives on this list pretty much close to useless? Kev -----Original Message----- From: David Kleber ----- Original Message ----- From: dan shaw dan_iss@yahoo.com> > hmmmm.... my 89 klr has a plate that bolts on the the > sprocket that fits in the groove on the shaft. it is > able to move lateraly about 1/16 of an inch or so > thoough.... > > dan That is the complete assembly.  But the Kaw retainer is junk.  It is made of soft steel and the overlap isn't much over the grooves on the countershaft and they are too thin so you get the play.  You need to contact Jake Jakeman at Sagebrush machine shop in Utah.  He makes a better stainless steel retainer which is thicker and overlaps much better over the grooves.  He also includes a washer shim set which goes between the sproket and the countershaft.  When you get the right combination of shims, the sproket is on VERY tight. I don't have Jake's number handy (maybe someone else on the list does).  You could check the archives for his number. I forget what he charges for the retainer and the shims.  Whatever it was it was worth it. -Dave Pittsburgh, PA http://www.city-net.com/~davekle/ klr650 A8 > --- "Seiler, Kevin" mseiler@racal-pelagos.com> wrote: > > Hi all > > > > Upon investigating the countershaft sprocket on my > > A3, some things seem > > amiss. The only thing securing the sprocket to the > > countershaft is an E clip > > in a groove. That is there are only three pieces > > there- sprocket, shaft and > > E clip. The sprocket is free to move side to side on > > the splines. Should > > there be some sort of shim or spacer arrangement to > > hold the sprocket in > > place laterally? Anyone got a web address for > > someone I might get the needed > > parts from? > > > > Kev > > > > > > > __________________________________________________