Honda XJR650L - XR650L over 50 mods - countershaft sprocket fix

This is my fix on the achilles heel of the XR650L countershaft sprocket spline wear. I use the Fritzco sprocket and a few custom machined and heat treated collars, etc. to stop the premature wear on the poor design of the countershaft sprocket retention system. Everything fits with about .002" maximum clearance. The sprockets do not rock or twist. I replaced the countershaft with a new one from the XR600R when I installed the XR600R kick starter and also the 2nd and 5th gear mod among others. I probably have 60 mods now on this bike. Every one is a vast improvement over stock.


I ran out of memory before I could explain how to properly adjust the drive chain on any bike. I lay across the rear section of the seat to slightly compress the rear enough to get the countershaft, the swingarm pivot and the rear axle inline. This is as tight as the chain will ever get. I then adjust the chain to give me about an inch of play in the chain when all three points are inline. Doesn't matter sprocket size or bike. Try it.