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[Keith]

I beat the bushes too, and found no ready made sprockets to fit 520 chain. Almost all motorcycles use a spline rather than a straight bore and keyed shaft (2017 Zero's do too). 530 chain will work with the ansi #50 sprockets that are standard, but requires a custom rear, my quote for that was $126, 530 will not fit the chain guide very well and you need to move the motor by about 0.125 to clear the swingarm. All possible but machining a sprocket seems to be the best solution.

[odedmaz]

Thanks Ray & Keith!
So, I'll look into machining it.
What are the exact specs I need to provide the machinist with, to get a quote?

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[rayivers]

Courtesy of the nightmare Photobucket has become:



Ray

[odedmaz]

Wouldn't a 11T / 65T be more appropriate? How will the diagram change if I go with the 11T sprocket?
Any diagram of the rear sprocket?

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[Keith]

Here is a link to a drawing of the 11T I bought. Ray's drawing would apply to this as well, but this shows the width as 1.0. https://www.mcmaster.com/#2500t654/

[rayivers]

Wouldn't a 11T / 65T be more appropriate?

An 11T sprocket will last longer, produce less RW torque, and reduce sprocket/swingarm clearance to @ .028" / .7mm.  10T ? 11T ? - it's up to you.

How will the diagram change if I go with the 11T sprocket?

Post machining, my 11T sprocket's overall width is .884" from an initial width of 1.00" (as Keith noted), both .012" wider than my 10T diagram dimensions.

Any diagram of the rear sprocket?

The OEM Zero 65T sprocket?  Not that I know of.  This one 's mounting specs are correct:



Ray

[Keith]

This is the Sprocket Specialists spec for a custom rear

65T, 530 chain, 981 pattern (for the '03 - '07 KTM 85 SX), 132mm diameter M8 4-bolt circle, 110mm center hole dia., taper head bolt, countersunk bolt holes @90 degrees taper head, aircraft grade 7075 T6 aluminum standard brushed finish.

[odedmaz]

Thanks for your help.
Did some info gathering and it seems that it won't be easy locating the specially made sprockets. Too bad Zero are using their own specific dimensions for many of the bike's parts...

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[MrDude_1]

This is the Sprocket Specialists spec for a custom rear

65T, 530 chain, 981 pattern (for the '03 - '07 KTM 85 SX), 132mm diameter M8 4-bolt circle, 110mm center hole dia., taper head bolt, countersunk bolt holes @90 degrees taper head, aircraft grade 7075 T6 aluminum standard brushed finish.

This is great info. You should put it in the zero manual

[odedmaz]

Ordered the front Martin 11T sprocket (ebay) & rear 65T sprocket from sprocketspecialists.com.
Now I need to sort out a chain guide and a chain (108 links??)

[Keith]

Ordered the front Martin 11T sprocket (ebay) & rear 65T sprocket from sprocketspecialists.com.
Now I need to sort out a chain guide and a chain (108 links??)

520 or 530 chain? See my reply 19 for a good deal on a KTM 520 narrow O-ring. You'll need to cut to length, just grind off the pins on the link you don't need, pry off the side plate. If 530 a standard chain will probably fit, a 530 O-ring will be much too wide for the stock guide.

[odedmaz]

Ordered the front Martin 11T sprocket (ebay) & rear 65T sprocket from sprocketspecialists.com.
Now I need to sort out a chain guide and a chain (108 links??)

520 or 530 chain? See my reply 19 for a good deal on a KTM 520 narrow O-ring. You'll need to cut to length, just grind off the pins on the link you don't need, pry off the side plate. If 530 a standard chain will probably fit, a 530 O-ring will be much too wide for the stock guide.

Plan to use a 520 chain (thinking about it, a 428 chain would probably be enough, and easier to mount... Maybe next time).

I'll purchase the chain locally. More worried about the chain guide which I do not have. Perhaps a universal chain guide can be made to fit?

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[Keith]

428 is a different pitch, that won't work with the Martin sprockets. I don't know any universal guide that would fit. The 65T is larger than most so it needs a longer guide.

[rayivers]

I don't know any universal guide that would fit.

+1.  If an adaptor was made up that basically moved the stock swingarm guide mounts down about 30mm or so with different bolt spacing and oversized holes for adjustment, a whole lot of OEM & aftermarket guides would work.  I just went with the Zero parts - I have the p/n's if you need them.

Ray

[odedmaz]

That would be a problem.
Please let me know the PN of the chain guide, although I am pretty sure, it can only be bought as part of the chain kit.

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