MODIFICATIONS: 48t to 44t Rear Sprocket

One of the complaints of my riding buddies with KLRs and VSTROMs is my lack of range on the ATK (~100 miles / tank), but another has been my comfort for running the 494 Rotax at 70 mph on the highway for any lengthy period of time (>20 minutes). I know this thing can go fast (I might have seen 95 mph before I cut back), but I just never liked the feel of running at such high RPMs for a long period of time (not only on the motor, but also on my ass). In looking at things I could do to improve my situation it looked like changing gear ratios might be the easiest and cheapest way to make 70 more comfortable.

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As it was I was running 16t countershaft with a 48t rear sprocket. That equates to a exactly a 3:1 ratio. A 17t up front with a 48t in the rear would equate to a 2.82:1 ratio. A 16t countershaft with a 44t rear would be 2.75:1 ratio. A 17t countershaft with a 44 t rear would be a 2.58:1 ratio.

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I decided to just go with the 44t rear sprocket to see how that affected low end torque before jumping to the 17t countershaft. From silly internet research and ZERO math I have come to understand that for every tooth increase in the front is worth 3 teeth in the rear. The 44t with my current setup would put me right at 2.75:1 ratio... That I can live with. Plus Lee told me not to mess around with a 17t, and that these bikes can do 90 all day wide open with stock gearing and why go any faster than that?

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Artsy comparison of the 44t to the 48t

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I will need to remove a link out of the chain since this pushed the rear axle all the way to the back of the drop out, but I am liking the speed in 5th at half throttle. I have not noticed any real change in the lower gears, torque in the corners persists despite the ratio change.

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Probably won't be going to 12 o'clock any time soon, but look at that rear sprocket!!!

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COSTS:

Rear 44t Talon Sprocket $59.99 + $15 Shipping = $74.99

REPAIRS: Rear and Countershaft Sprocket Change

Like any good story begins, I was out on a 100 mile Taco run on a Sunday morning last year minding my own business.

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I started feeling some slippage in the hind end and the horrific sound of aluminum being eaten away.

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Fewer teeth than a Eureka Tweeker, and that chain doesn't looks so hot either.

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A quick call to Lee at ATK and I had a nice bright and shiny, yet slightly orange 48t in my mailbox. He was very in kind in telling me that I had my chain WAAAYYY too tight and the three finger rule is one to abide by and the only thing that could shred a 7075 aluminum sprocket is over tightening the chain. He was right.

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Got a gold Regina D.I.D. 520x120 to "match" the talons

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That Loctite was exactly that!

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My countershaft

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The countershaft I wish I had.

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After trying to source the countershaft part locally I finally came to my senses and called down to Ron Woods shop and got a replacement 16t within a couple of days.

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Of course trying to make sure it is "shouldered" and the splines are correct. Looks decent.

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A few different shades of anodized gold FTW!

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Took the opportunity while the bike was on the stand to take a look at the CRF brake pads....not so good.

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Some EBCs popped in and I'll be doing stoppies in no time.

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PART #s

Rear 48t Talon Sprocket 090034 From ATK

Regina D.I.D. 520X120 340582 From Amazon

Rotax 16t Countershaft Sprocket From Ron Woods

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COSTS

Rear 48t Talon Sprocket $59.99 + $15 Shipping = $74.99

Regina D.I.D. 520 x 120 $88.44 Free shipping

Rotax 16t Countershaft Sprocket $34.99 + $16.60 Shipping + $2.80 tax = $54.39

Total: $217.82