.....after this.... 8 mm (cut and welded spare gears)









metzeler 16' 180/60 Marathon is already fitted.

2 questions; what will you do the next time you need to change the rear sprocket and how is the front sprocket mounted on the drive shaft ?!

Hello G.
I have already read before your against opinion about this "welding" and I was thinking follow.
- Every how many kilometers will need replacement for gears?
- After how many years these kms will be covered?
All above calculated,but flat tire moment not calculated.
Also me I have stock new tires (2004 production) but this is not solution any more.
The cost is not worth for our baby to feel free from this cancer until.........
Merry Christmas to all.

I will be back with more detail photos.

Hello stylianos62.
Can you please post here a working drawings of rear and front crowns?

I figure I'll revive this old thread and see what everyone has done about their front sprocket. Has anyone been able to move their front sprocket out toward the end of the shaft to help with clearance for the 180/60-16, yet? If so, how did you do it?

I just finished off my front and rear tires on the Paso and am needing to replace them. I already picked up a 130/70-16 front tire (Dunlop D208) and was hesitant to purchase a rear tire, so I picked up a used Dunlop D250 from a local dealer for free to check clearances with.....and the chain hits the D250, too. I know how I want to shim the rear sprocket out (have a buddy make a spacer with his plasma cutter), but I cannot think of a good way to shim out the front sprocket. The front sprocket already has a built-in offset into it, and by testing out a spare from another bike, it appears that the front sprocket is heat treated completely, so I can't simply machine a deeper recession into it for the retainer.

So, has anyone successfully moved their front sprocket out further to compensate for shimming the rear sprocket?

Terry, there are 2 possibilities:





I`m currently going for the second, had the teeth removed from an old sprocket and the threadholes of a new sprocket drilled through (5mm). The sprocket teeth were cut off with an angle grinder, the lathe did the rest.
I just need a shim ring of ca. 1-1.5mm now to fill the gap between retainer ring and rear side of outer sprocket to eliminate clearance (green in the pic above) and then find out how to get to the offset I need.



G.

Well, I have mounted a used Dunlop D205 that I picked up for free and put it on the bike. The chain definitely hits the tire and the tire hits the chain guard...

Tire hitting the chain guard...



Chain hitting the tire...



So, I removed the chain and looked at the OEM sprocket on the shaft and there simply isn't much shaft available beyond the sprocket and appears to be about 3.5 mm. I removed the sprocket and looked at it as a mounting adapter for another sprocket as Gerhard suggested. It looks a bit positive. This is the overall height of the OEM Paso 750 sprocket (approximately 12 mm)...



I had two 520 sprockets that are different than the Paso's laying around, so I figured I'd check these out. I stacked the Paso sprocket with the retainer on top of it and then a sprocket from a 748 to get this...



The combination is 26 mm tall, so this would be the same as a 14 mm offset from the original Paso sprocket location (26 mm minus the stock 12 mm). Then, I placed a front sprocket from a 2001 Monster 900ie that has a shoulder on both sides of the sprocket and got this...



This results in a total height of 22 mm, or an offset of 10 mm. I liked this smaller offset and wanted to look at what it would be like on the Paso, so I placed the OEM sprocket on the shaft, put the retainer in place, and then slid the Monster's sprocket in place....



I don't like the idea of having that much of the sprocket unsupported as it may put too much strain on the sprocket bolts and if they stretch any, there is a risk of damaging the splines on the output shaft. I'm thinking of going with this arrangement, but will have a shaft extension machined so I can bolt it to the end of the shaft and give the sprocket more support. If I do not spline the extension, I will have it made with the OD just a little smaller than the smallest ID of the sprocket spline teeth. Ideally, I'd like to duplicate the splines and figure out a way to bolt and pin (to avoid rotation) the extension in place.

I was curious about the sprocket cover, and even without grinding any of the second sprocket, there is plenty of clearance to reinstall the sprocket cover without the chain or sprocket hitting it. I also looked at the swingarm protector, and it looks like if the two tabs on either side of the swingarm are cut off the sides that hold it in place, a spacer can be installed where it bolts to the swingarm with the chain guard to shift it over. This way, the swingarm protector can continue to be used correctly.

Here is a picture of the alignment without moving the swingarm protector over...




I'm hoping to get a few things machined over the next week or two and hope to have the Paso back up and on the road very soon...

man, what bs did I measure that time?! Option 2 is 11mm offset. That corresponds about with what you have measured.