17t Wont come off... WTF?

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by Scary Mc, Mar 5, 2008.

  1. Scary Mc

    Scary Mc hellgrammite

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    Is there a trick to getting the sprocket off the counter shaft? I've got everthing removed and out of the way but the sprocket won't budge.

    I've tapped it with the 32mm socket and a hammer to unseat it, tried to gently pry it off, etc.
    What am I doing wrong?:ear

    30 minute job my ass!:lol3
    #1
  2. MookieBlaylock

    MookieBlaylock Long timer

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    time to put a 45 on the back and call it a day :D
    #2
  3. cpmodem

    cpmodem Orange Caveman

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    Sounds like it may be rusted on the shaft :eek1
    #3
  4. Scary Mc

    Scary Mc hellgrammite

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    It's only got a 112 miles on it and I can't see any rust.
    #4
  5. cpmodem

    cpmodem Orange Caveman

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    Something is totally fooked up then. The sprocket on my 03 slides on and off by hand without any effort. Maybe the Trolls in Mattighofen pounded the pooch and bugger'd the splines. Looks like your gonna have to, I hate to say this:cry take it to the stealer and go through the warranty :topes
    Sorry :baldy
    #5
  6. Scary Mc

    Scary Mc hellgrammite

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    The Dealer, ugh. The spines look to be properly alligned on the shaft... anything is possible I suppose...
    I've got a blow dryer strategically zip-tied and heating the assmbly up, we'll see what happens in a few minutes.
    #6
  7. scorpion

    scorpion Two arm bandit

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    Try to get a gear puller around it if there's room.

    Otherwise maybe a slide hammer with a "L" shaped grabber on the end
    may bugger up the gear though

    good luck
    #7
  8. ABYSS

    ABYSS KTM

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    I had this happen on a WR 450 once I put the chain back on the front and then put the bike in neutral. Next I had a friend push and pull the chain to rotate it back and forth while I got a large socket and dead blow hammer tapped the sprocket while it was moving. After about three hits it slid right off. i just ended up being real dry in the center and was stuck.
    #8
  9. Head2Wind

    Head2Wind MotorcycleMayhem

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    mmm maybe a larger hammer? :D

    seriously, really silly question here but you did remove the nut on the end of the shaft right? Then also the retainer washer that folds against one of the nut flats?

    If you have removed both of these items and it still doesn't want to come of easily, maybe a light pry out with a bar and a soft blow to the shaft will pop it loose. If you don't have a soft blow hammer, thread the nut back on but not tight against the sprocket then with a 2x4 or some other piece of wood do the same procedure..... pry out the sprocket and tap the shaft in.

    You don't want to damage the end of the shaft/threads or the internals of the transmission so don't strike the end of the shaft with extreme force even though you my want to right now...
    #9
  10. Scary Mc

    Scary Mc hellgrammite

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    Yup, the nut and washer are off.

    -Blowdryer method: Nope

    -Beating sprocket with socket and big f'ing hammer: Nope

    -Prybar method migth work if I could get one in there: Nope



    I'm off to buy a slide hammer....
    #10
  11. Rabid Dog

    Rabid Dog Been here awhile

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    Scorpion is right - Gear Puller is how I got mine off.
    #11
  12. auslander

    auslander Meh

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    After I bent that washer down, it slid out really easily.
    #12
  13. Scary Mc

    Scary Mc hellgrammite

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    Luckily Napa is four blocks away from home! Napa had a very small gear puller, $15, that worked perfectly.
    The sprocket is off, finally. The inside of the sprocket is coated with some sort or white thread locker like material. This is what was keeping it from coming off.
    Anyone else has this stuff on their 17t sprocket?

    I'm off to put the 16t on now, with a nice helping of anti-sieze!:lol3
    #13
  14. auslander

    auslander Meh

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    Goofy. No, mine ('07 990, bought in october last year) didn't have anything on the sprocket.
    #14
  15. emelgee

    emelgee Been here awhile

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    Get hold of a gear puller, or if it's a new bike take it back to the dealer and let them sort it.
    [​IMG]
    #15
  16. Scary Mc

    Scary Mc hellgrammite

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    Brilliant! I'll run down to Napa and buy one right away....


    (read the rest of the thread) :lol3
    #16
  17. marin ktm

    marin ktm Been here awhile

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    Did you have to remove the clutch slave cylinder? Can it leak fluid if you do?
    #17
  18. MR4WD

    MR4WD Adventurer

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    Yes and no in that order.
    #18
  19. Scary Mc

    Scary Mc hellgrammite

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    I did, zip-tied it onto the frame so it'd be out of the way. It won't leak fluid unless you fuck up. So don't fuck up. :deal:evil

    The whole thing would have been a peice of cake if not for the whole PITA off removing the sprocket...
    #19
  20. Garry

    Garry Old and In The Way

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    It's still a PITA job compared every other bike I've worked on. Having to remove the shift lever, various guide things, clutch slave cylinder and barely enough slack in the chain to remove the sprocket. I was expecting to just:

    1) Remove sprocket cover (4 or 5 bolts)
    2) Unbend washer
    3) Loosen sprocket nut
    4) Loosen rear axle and slide forward (chain slack)
    5) Remove sprocket
    #20