Honda XR650L – a better countershaft sprocket
Like all motorcycles, the Honda XR650L has some known weak points. One of which is the countershaft / front sprocket contact area. There are issues with the OEM sprocket that XRL owners have been using workarounds to solve since Big Red first started rolling off Honda’s assembly line in the 1990s. Luckily, the aftermarket has a recently come up with a solution – a better mousetrap, if you will. For current XRL owners, or those thinking about becoming an owner, this article could save you some money and aggravation.
Sirs;
I’m the proud owner of a 06 BRP. I too have experienced the countershaft/sprocket/keeper problem.
I’m of the mind that the retainer is the base of the problem. I see in the picture in the original post that the teeth on the retainer is missing the teeth. That I think starts the failure. Then the damage caused by the movement between shaft and sprocket is expensive. Replacing the retainer as a service note would be prudent at 10k miles. I incurred the complete release of the sprocket from the shaft at 17k miles. The motor was in perfect condition so splitting it was out of the question!
Lucky for me I know a TIG welder(me) and decided to rebuild the spline. Not for all to do but I did. Patience and skill saved the day. I also headed your recommendation and purchase the upgraded sprocket and the BRP is back on the road!