To change the sprockets on a 1999 Kawasaki KLR 250, you'll need to follow these steps:
Gather the necessary tools: You'll need a socket wrench set, a rear wheel stand or a bike lift, a chain breaker tool, and a new front and rear sprocket.
Lift the rear wheel: Use a rear wheel stand or a bike lift to elevate the rear wheel off the ground. This will allow you to rotate the wheel freely and remove the rear sprocket.
Remove the chain: Use a chain breaker tool to break the chain. This tool will push out one of the chain pins, allowing you to separate the chain.
Remove the rear sprocket: Unscrew the bolts that secure the rear sprocket to the rear wheel. Once the bolts are removed, the rear sprocket should slide off the wheel hub.
Install the new rear sprocket: Place the new rear sprocket onto the wheel hub and align the bolt holes. Screw in the bolts and tighten them securely.
Adjust the chain tension: With the new rear sprocket installed, you'll need to adjust the chain tension. Follow the manufacturer's guidelines for your specific motorcycle model to ensure proper chain tension.
Remove the front sprocket cover: Use a socket wrench to remove the bolts securing the front sprocket cover. Once the bolts are removed, you'll have access to the front sprocket.
Remove the front sprocket: Use a socket wrench to unscrew the bolt that holds the front sprocket in place. Once the bolt is removed, the front sprocket should slide off the output shaft.
Install the new front sprocket: Slide the new front sprocket onto the output shaft and secure it with the bolt. Tighten the bolt securely.
Reinstall the front sprocket cover: Place the front sprocket cover back onto the bike and screw in the bolts to secure it in place.
Reinstall the chain: Use the chain breaker tool to reattach the chain. Align the ends of the chain and insert a new chain pin to connect them. Use the chain breaker tool to push the pin back into place.
Once you've completed the sprocket replacement, your gearing will depend on the number of teeth on the new sprockets you've installed. For higher gearing to achieve better performance on the freeway, you'll want to decrease the number of teeth on the front sprocket or increase the number of teeth on the rear sprocket. However, it's important to note that changing the sprocket sizes may require adjustments to the chain length and may affect the overall performance and drivability of your motorcycle.
To gear it for 65 MPH on the freeway, you would generally want to increase the number of teeth on the rear sprocket or decrease the number of teeth on the front sprocket. This change will result in higher gearing, allowing the engine to turn at a lower RPM while maintaining the desired speed.
It's difficult to determine the exact sprocket sizes without knowing the available options for your specific motorcycle model. I would recommend consulting with a knowledgeable motorcycle mechanic or referring to a Kawasaki KLR 250 forum or community where owners may have shared their experiences with sprocket changes. They can provide more specific recommendations based on their personal experiences and preferences for freeway riding.