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I have not rode as much as I wanted last year do to having two major Knee Surgeries, but I have now have about 500 miles on the new tranny and I LOVE IT, It is perfect wide ratio that Kawasaki should have put in the bike.
Just think of what ever gearing you have in your bike now , with this gear set it is like you went up one tooth in the front , for a better top speed but still have the lower first like if you went down one in the front. it is that nice.
the counter shaft is the same as the older KLX250/300's as it is a 6 spline with a clip retainer so easy on the trail sprocket swap, I carry one tooth smaller just in case I need the lower gearing for a tight steep single track I may encounter.
I'm moving along well with my Sherpa transmission swap. It's been a winter project in the basement. I'm getting closer to firing up the engine for the first time. Sherpa transmission I bought on eBay. It took awhile to find one as the only one I saw came up from a motorcycle salvage business.
Transmission swapped into the left side of the engine cases. The right side case requires the bearing for the output shaft to be replaced.
This is the old bearing removed, it gets replaced with Kawasaki part number 92045-1291. The Sherpa transmission has a 17mm ID bearing vs the klx transmission is 20mm. Old bearing removed.
New bearing installed
I installed a Bill Blue 351 kit to complete the transmission swap.
Swapped the engine into a klr250 frame for testing, should be ready for first start in the next few days.
The super sherpa as far as I know was only available in the US from 2000-2004 and then again from 2009-2010. Any of those years will work. I actually just bought a bottom end Sherpa engine locally for my next 351 klx big bore/ Sherpa transmission swap.
Got another year on my transmission build swap.
It is SO Good, this is the best dual sport mod for the KLX IMO, well that with the addition of the Ohlins and the Bill Blue 351kit
Be careful running a 15 tooth counter sprocket. I did for about 1,000 miles and I had a bit of wear against the cases wear the chain was rubbing into the aluminum. I swapped back to the 14 tooth with a 39 tooth rear since I have a 351 big bore and it's able to pull that gearing.
What is 14-39 like offroad?
I have a 330cc kit with 14-42 but seem to have lost some top end freedom with the addition of the race cams that came with the kit.
Can the chain length remain the same going to 39 on rear or it needs cutting?
