How Do You Remove the Sprocket Nut? | ANSWERS

Q. I have a Kawasaki Versys 650 and just bought new aftermarket sprockets and a chain for it. The old pieces were worn out, and, besides, I wanted to raise the overall gearing so I'd stop looking for seventh gear on the highway. After I managed to get the original countershaft sprocket off, I noticed that it has a rubber doughnut bonded to the inner and outer faces. The replacement sprocket is just, well, a sprocket.

Will I somehow damage my bike by using a different kind of sprocket? Also, my buddy and I had a bear of a time getting the sprocket nut off. Any suggestions on how to make that easier?

Arthur Sellers
Slidell, LA

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A. "Just a sprocket" will work fine. The rubber doughnut on the OE sprocket is there for noise reasons. If you've ever rolled down a steep hill with the engine not running, you know a drive chain can be pretty noisy. Anything the manufacturer can do to reduce the clatter is considered.

By far, the best way to remove the countershaft sprocket is with a large impact gun. A ½-inch-drive gun with a sturdy socket should do the trick. And while it’s proper to use sockets designed for impact guns, the occasional use of a standard, six-point socket probably won’t cause you trouble. Be sure to wear your safety glasses.

Okay, so you don’t have the pneumatic tools. Start by hitting the threads with penetrating oil an hour or two before you begin. Use a punch to flatten the locking ring against the face of the sprocket. You can reuse this locking ring as long as there is enough unbent material to cover a new flat on the nut. Grab the longest breaker bar you have, insert a piece of wood between a wheel spoke and the top of the swingarm (we used a plastic mallet handle with the SV example above), have a friend stand on the rear brake, and give it a go. The torque spec is around 90 pound-feet, so it’ll be very tight coming off—you might need to use an old fork leg or other extender for more leverage. Borrow a high-range torque wrench when it comes time to install the new sprocket and nut.