I just finished installing the Moose XR650R front sprocket as recommended by spud on the awesome 650L front sprocket/spline wear issue thread. Any new owners reading this its an absolute MUST DO mod......I'll explain why in a sec.

I cannot believe that honda would install that narrow little sprocket with all that slop on the front countershaft........in 11,800 miles I had significant wear on the splines, in twice that distance running the stock style sprocket I would have had SERIOUS damage, and most likey would have had to replace the countershaft, which is a huge job labor and expense wise. This set-up is beyond ridiculous, and I'll be calling Honda tomorrow to give them my feedback

For those that don't know the stock front sprocket on the XR650L is a narrow thin sprocket that fits very loosely on the front countershaft, using only a small part of the available splines, and over very little time the front sprocket can chew up and destroy the front countershaft splines. The XR650R front sprocket is 3 times as wide as the stock 650L sprocket, and fits completely over the whole shaft, using ALL the splines and fitting perfectly tight like a normal front sprocket should And it uses the exact same size chain, so its a complete bolt on affair.
The moose sprocket is the one you need to get, just like spud said. I had to grease the splines, then mark the shaft and bolt holes in the sprocket to make sure and keep the same fit if I removed the sprocket, then I tapped the sprocket on lightly with a socket and rubber mallet, wiggled it back off some, tapped it on again, wiggled it off some, and repeated that till I could get the clip to fit and bolt up. it didn't take long at all, the sprocket will come off no prob, and the clip holds the sprocket in tight as a rock, just like it should have been from the factory

You do have to be very careful and line the sprocket clip up perfectly, theres no room for error with the bolt holes, but with a little patience and finesse its not a problem. That was the only difficult part of the install actually. And be sure and get the bolts tight with some blue or red locktite and you're good to go

I caught this in time and this will be a permanent, long lasting fix for this problem as long as you always use Moose XR650R (any year) front sprockets. Now the front sprocket set-up will last as long as the rest of the bike, which can be a VERY long time   

Edited by Sierra Thumper, 22 August 2012 - 12:30 AM.

Just machined my 650r jt front sprocket down a little at work today. 2200 miles and mine has really bad slack but no visible wear. I'll be installing mine today along with a new set of Shinko 705's. The sprocket is definately a must do, it should come of the assy. line with the 650r sprocket.

Ross just so you know, Spud tried most of the diff brand 650R front sprockets, and the Moose is the thinnest, and fits the 650L shaft perfectly without any maching required. Its pretty much a slide on affair like the stocker. The others like the JT will work, but you do have to take a little metal off the back to get them to fit.
And remember, the 650R sprocket goes on with the flat side out, the opposite way it fits on the 650R.

I'm glad you caught it early .........why Honda designed it this way, and has left it the same for so many years boggles my mind
As soon as I saw the problem, I knew something had to be done, but having the answer already figured out and here waiting for me was beyond awesome

Edited by Sierra Thumper, 23 August 2012 - 02:02 AM.

I quickly figured that out the first time I tried putting it on. Nothing a few minutes of being chucked up in a lathe didn't take care of though!

I used a Renthal sprocket. It only took a couple of light passes with a Dremel on the backside chamfer to fit perfectly. Slid right on, no tapping with a hammer either.

rossp, on 22 August 2012 - 11:30 AM, said:

paul246, on 25 August 2012 - 02:13 PM, said:

I'm glad you guys got that issue handled....I hope more guys see this and prevent themselves headaches down the road. Its also def something to keep in mind when looking at used xrl's.
Besides this issue I think the xrl is an amazing dualsport tho imo

Hi,

where did you buy your sprocket and how much did you pay for it?

I'm glad you are enjoying your XR650R C/S sprocket, ST.   It appears to me PBI manufactures the XR650R C/S sprocket for Moose Racing.  I always recommend the PBI/Moose Racing, XR650R C/S sprockets because they are thinner than some others, and also have a deeper chamfer.  After riding a few thousand miles with your PBI/Moose Racing sprocket, you will be able to remove and install subsequent, new, PBI/Moose Racing C/S sprockets easily, by hand.

Spud

Edited by SpudRider, 28 August 2012 - 10:59 PM.

Hummm ? I did the kick start on my 650L so I have A 600 output shaft Is their a better sprocket for it ?

DocS, on 26 August 2012 - 12:55 PM, said:

You can buy the sprocket right here from this site for a good price Its about 20 bucks before shipping I believe...but money VERY well spent

SpudRider, on 28 August 2012 - 10:59 PM, said:

Spud thanks again for sharing your hard earned info to help your fellow riders.....guys like you make these forums great
I haven't got to ride the bike yet with the moose sprocket, but the fit is awesome, nice and tight and using all the splines like a front sprocket should......I'm so glad I found this site and caught the problem early

winginit, on 29 August 2012 - 10:49 AM, said:

I'm not familiar with the xr600, but if the sprocket uses all the splines on the front shaft and fits tight with no side to side wobble you're prolly good

Currently in the process of this mod. For those who have been running the  xr650r cs sprock, did the stock chain hold up well after the conversion or is a new chain going to save me grief? Doing the 13&14tooth and keeping the stock 45. Thanks brian.

Backnj18, on 31 August 2012 - 02:03 AM, said:

I've just installed a brand new chain with the moose xrr sprocket....both bikes run the same exact size chain if thats what you're wondering. The xrr front sprocket is a beefier sprocket in every way over the stock xrl sprocket......makes the xrl sprocket look pathetic honestly. And the chain runs in almost the exact same position as the stock sprocket.

Spuds been running this set-up for thousands of miles with pictures and the combo looks perfect

I wouldn't put a brand new xrr front sprocket on a wore out chain and rear sprocket, but if your chain will barely pull away from the back of the rear sprocket, and the rear sprocket still has square teeth with a tight fit to the chain you'll be fine.

If the XR600R countershaft has the high spline count,,13 splines i believe..........then the XR650R front sprocket will fit........

If the XR600R is an early model with only 5 splines then no.........

B

Edited by brianhare, 31 August 2012 - 07:14 AM.

When I rebuilt the trans on 600 I went from 5 spline to 13 spline... New honda countershaft, new renthal 650r sprocket.  Gave it a few healthy taps on the bench and pre assembled it a few times, the clip goes on by lightly tapping it around-no material removed.  Very good fit and finish on the renthal.

Another vote for the renthal... I remember the price being good as well.

Thanks siera thumper! My stock is in great shape. Just wanted to know what my future holds for me. Yours and every one else's help is very much appreciated.

Backnj18, on 31 August 2012 - 04:37 PM, said:

Hummm ? when I did the kick start on my L I used the shaft from an 88 xr 600 5 spline   .Looking at OEM part mumbers it dosent tell the splin count Dose anyone have a good part mumber for the 13 spline shaft from a xr600  ? It looks like I'll have the trans apart soon I just bought a trans on ebay in Germany from a 98 nx650 for 2 ed gear and 5 th overdrive thanks

winginit, on 04 September 2012 - 08:59 AM, said:

I wouldn't be in a rush to switch from the 5-spline, XR600R countershaft.  ThumpNRed has the 5-spline countershaft, and it is working well for him.

Spud

Edited by SpudRider, 04 September 2012 - 09:22 AM.

SpudRider, on 04 September 2012 - 09:22 AM, said:

The splines are a little ruff looking ,if I dont change it now while I have it apart Iam sure I"ll be kicking myself latter

So if I get a counter shaft from a 2000 xr 600r would you say it would be a safe bet that it is the 13 spline