16 Tooth front sprocket

Hey everyone, just wanted to post a little more gearing information for those that might think about changing their sprockets to make a difference in their ride.

I primarily use my 250 as a mode of transportation to and from work. And that's 40 miles one way, all of which are on the highway. So for me, the stock gearing absolutely sucked. So I went the cheaper route first, and swapped the front 14 tooth for a 15 tooth. That made a nice difference. Especially since the internal gear ratios for first gear are so low, it would let this bike pull a small truck.

But always being on the highway screaming at 9000 RPM's... it was killing my fuel economy. So the 15 tooth was nice. I would reccomend it to anyone. I went from 55MPG up to 60MPG with this $13 mod. Well worth the money.

Then I wanted a little more, so I started on the rear. I went from a 45 tooth to a 43. That was a little better for me. Would let me cruise @ 65-70 mph at just over 7500 rpm, and fuel economy went from 60MPG to now averaging about 64-65mpg pretty consistently.

Then my parts guy, Joey, called me and told me that he could get me a 16 tooth front sprocket if I wanted it. I said sure, why not?

About 10 days later, it showed up in the mail.

So I decided to put it on. Which is where the challenges came up. Because that sprocket is SO BIG, that the countershaft cover wouldn't go back on once I had it all bolted on. So I had to take it off, and grind part of the cover away, in order to let the sprocket turn w/o grinding on the cover. (what I mean by grind some of it away, is where the chain came into contact with it when it was bolted back on. Not CUT part of it off per se.) So I just ground down a 2 inch line around the inside of it. You can't see it when it's bolted back on.
Not like it was difficult or anything, just took some time with a dremel and a cutting tool.

(MAKE SURE YOU WEAR SAFETY GLASSES, BECAUSE YOU WILL HAVE ALUMINUM FLAKES SHOOTING EVERYWHERE!!!!!)

It took me several attempts at doing some grinding, then putting it back on to check clearances. But after the 4th or 5th time, I finally got it right, and the wheel would spin w/o the chain hitting anything.

So then it was time to ride.
Now, remember, I'm running +2 on the front, and -2 on the rear: that's a HUGE change.

First gear wasn't that different, again, because it's geared so low internally. But when you click from second to third... and so on.... HOLY SH!T what a difference. It's like my ZX6. You can pull each gear for a really long time.

So I left it that way for a few days. On any type of hill.... I fould myself having to click down a gear to keep my speed up. Then another gear..... and another gear.

It was just TOO tall for the little motor to pull w/ any type of authority.

So I pulled the back wheel off, and put the stock rear on, which left me with a 16T front, and a 45T rear.

And after having that on for the better part of 2 weeks, I am happy to post, that I am running a consistent 65MPG on the highway, and rolling @ 70mpg at between 6500 and 7000 RPM.

For me, this is the perfect gearing. It will pull myself with my girl on the back from a light w/o a hitch, and cruise up most gradual hills w/ not so much as a grunt.

Now mind you, I've also done the $36 exhaust mod, and shimmed the needles 0.010, removed the snorkle, and re-sync'd the carbs. So it ran pretty good before the gearing was done. But now....
I'd reccomend the 15T to anyone. And for anyone that does any touring, or long distance rides... you'd be happy with the 16T if you wanted.

Since nobody else seems to be able to get any sprockets for the 250, my parts guy's name is Joey, like I mentioned before. He can be reached @ 800-596-6199. Tell him Todd from Florida told you to call, (he's in Ohio) and he'll give you more information than you'll know what to do with... besides being able to get you anyting that you want. Including the VENTURA rear seat bags that nobody in Florida can seem to get either.

Anyhow... I hope everyone finds some use out of my gearing experimentation. And I'll try and answer any questions that come up.