How To:Sprocket Replacement and Upgrade

[ben2go]

89-93 GS500E 15 Tooth Steel JTS Sprocket Part Number JTF 565.15 $14.95 shipped to my door.

www.kinneycycles.com



Tools
1/4 inch Rachet
3 inch extension
8mm and 10mm sockets
Snap Ring Pliars-These are cheap at places such as Harbor Frieght.
Gloves-optional
You will also need the tools to adjust your chain when you are finished.That's been cover on here before.



First start by removing the shift pedal.One 10mm bolt and it needs to be completely removed for the shifter to slide off.
Make a note or mark so you know what position to reinstall it in.






Next remove the five 8mm side cover bolts.Make note of where they came out.There are three different lengths of bolts used.
DO NOT REMOVE THE CLUTCH CABLE THAT ENTERS THE TOP OF THE SIDE COVER UNLESS YOU ARE PLANNING TO ADJUST IT.Don't remove the
small cover with the JIS screws.Please note that Japanese bike use JIS screws and not Phillips.JIS screw drivers can be
purchased for a few dollars online.





Pull the cover off and hang it off the the side.I used an old clothes hangar.String or twine will do.



I installed a new chain recently, so it was fairly clean and flexible.Do not worry about loosening the chain,unless it's
really tight.


Now grab those snap ring pliars,open the snap ring,and slide it off the output shaft.You shouldn't have to force it.
Becareful not to damage it.It will be reused.





The sprocket should slide right off of the output shaft.


Hold the chain above the sprocket,let the chain droop,roll the sprocket down, and off the chain.Install the new sprocket into
the chain in the reverse order.
 


The new sprocket should slide right back on the out put shaft.If you have troble,make sure the back wheel is off the ground
and the transmission is in neutral.



Reinstall the snap ring onto the out put shaft.There is no certain way for it to go on.Just make sure it seats into the
groove on the output shaft.



If you have trouble seating the snap ring,give it a little push with the snap ring pliars.



Reinstall the side cover and shifter.Hopefully you remember which bolts go where and what position the shifter was in.
Check and adjust the chain as needed.I went from a 16t sprocket to a 15t sprocket.My set up required 3.5 turns on the
adjusters.However,I am running a 4.5 inch wide Bandit 600 rear wheel with a 160-60-17 rear tire,so my adjustment is a little
tighter than a stock set up, to keep the chain from rubbing the wheel.

Now that everything is back together,go for a ride to warm up the chain and sprockets,then give the chain a fresh coat
of lube.Fresh lube will help protect the new sprocket from rapid wear.Lubes have been discussed here so I won't go into it.

If you ever need to replace a sprocket again,it shouldn't take more than 20 minutes.

My other right ups can be found on my build thread. This one will be added there also. http://gstwins.com/gsboard/index.php?topic=57042.0

[Kms254]

Good writeup, I spent another 20 min or so cleaning the crud behind the sprocket cover and on the engine itself. It might not be necessary but I figured it was good to do while I was there. I just used some CRC Carb cleaner.

[lucky4034]

AWESOME!!  Upgrade write-ups like these are invaluable to the mechanically inept. 

IMHO this is the only thing this site is missing!  There should be a stock pile of 'how to' write ups done by the community... (to help noobs like me)

Something like this Ninja 250 site --> http://www.google.com/url?sa=t&source=web&cd=4&ved=0CD4QFjAD&url=http%3A%2F%2Ffaq.ninja250.org%2Fwiki%2FNinja250_Howto&ei=On2PTuXVFaOIsgKYrrGtAQ&usg=AFQjCNGzoT7SPE58a2P9Egf8mkzbAHvCEw

[weedahoe]

certainly i nice write up. right now my bike is in 100 pcs and replacing parts as needed so this helps

[ben2go]

Thanks guys.

I use kerosene and a tooth brush to clean inside the cover and case.It wasn't bad this time so I left it alone.

AWESOME!!  Upgrade write-ups like these are invaluable to the mechanically inept. 

IMHO this is the only thing this site is missing!  There should be a stock pile of 'how to' write ups done by the community... (to help noobs like me)

Something like this Ninja 250 site --> http://www.google.com/url?sa=t&source=web&cd=4&ved=0CD4QFjAD&url=http%3A%2F%2Ffaq.ninja250.org%2Fwiki%2FNinja250_Howto&ei=On2PTuXVFaOIsgKYrrGtAQ&usg=AFQjCNGzoT7SPE58a2P9Egf8mkzbAHvCEw

The FAQ has most of the write ups.My write ups are on my build page.The link is posted above.

[Suzuki Stevo]

Good how to, the only thing I would have done different, would be to add some grease to the splines, probably wouldn't add any life to anything? 

[ben2go]

Good how to, the only thing I would have done different, would be to add some grease to the splines, probably wouldn't add any life to anything? 

So far I've had no problems with keeping the splines dry.It would help with rust.

[sledge]

Good how to, the only thing I would have done different, would be to add some grease to the splines, probably wouldn't add any life to anything? 

So far I've had no problems with keeping the splines dry.It would help with rust.

That red dust is a by product of corrosion fretting, microscopic particles of metal wearing away from the contact surfaces between the male and female splines and rusting due to moisture in the atmosphere.

Google the subject and you will find out why you SHOULD grease the splines and what will ultimately happen if you dont.

Oh go on then.......I will do it. Note the list of characteristics....esp #5

http://www.epi-eng.com/mechanical_engineering_basics/fretting_corrosion.htm