sprockets
Hi everyone, on the weekend i fitted a bigger (55t) rear sprocket off a suzuki onto my tomahawk kx. To do this you will need..
A sprocket off a suzuki tf125 tf185 ts125, ts185 or similar. Look at this site.
JT Sprockets: Catalogue
A welder (optional)
A drill
A set of drill bits
A steel ring roughly 7mm high and at least 40 mm across and about 1mm thick
An angle grinder or hacksaw
Patience
This mod doesnt take as long as you think...
First, lay the old sprocket over the suzuki one, till the holes dont meet up and the centre hole is even all the way round. (photos and diagrams tomorrow)
Put a few light welds around to keep both sprockets in place (or you can clamp them)
Find a drill bit large enough so if fits snugly into the old sprockets holes.
Drill out the 4 holes.
Put the sprocket onto the wheel with bolts in (if they fit. If not, file them with a chainsaw file to make sure they fit nicely and the sprocket is still centered)
If youve done this right then you should have an even space between the small ridges in the hub and the centre sprocket hole. You should cut the ring now, in one place and stretch it so it fits into the gap I just mentioned. It should fit nicely, if not try it with some other pieces of pipe etc.
Weld into place. While your at it, you should replace the stock bolts with higher tensile ones. Go to a bolt place or machining shop. The size is 10 x m1.5, which is 10 mm wide with 1.5 mm between threads. Make sure the shank on them is as wide as the thread. like this...
______
|___|
|___|
|___|
<__>
<__>
The > parts, on the tips, should be as wide a the | parts. This stops the bolts wearing like the stock ones because the thread is too easy to wear away. Im looking a putting a 520 sprocket set on as well...
An end note, the hummer/kx sprockets for the front measure, on the spline, 17mm across at the narrowest, 20mm at the widest, which makes the splines 1.5mm deep, and the splines are 4mm wide, with the holes 34mm between the centres. If you need help with the mods, please feel free to contact or reply to this message. Thanks, Ben.