Front sprocket

[Chubnut]

I have just fitted the new front sprocket with the rubber moulding inserted. It has a recess and the lock washer will not fit into the recess, will I still be OK without it if it is torqued correctly and thread lock put on ?

[vstroman]

I think I'd prefer to have the lock washer in place.

[Chubnut]

The only problem is I would have to try to force it into the recess which would make it dish shaped and probably not work as well, if at all if I don't shape it correctly. Will get a couple of new ones and see how it goes.

[Ianmc]

“I have just fitted the new front sprocket with the rubber moulding inserted. It has a recess and the lock washer will not fit into the recess, will I still be OK without it if it is torqued correctly and thread lock put on ?”

  The lock washer should have a spline that's fits over the output shaft and then after you have tightened the sprocket holding nut, you bend the lock-washer over one of the flats on the nut to make it extra secure in case for any reason it comes loose.I just cannot see why the lock-washer won’t fit.It did on my L2 and it is the same bike as you have.
   Unless it is the wrong sprocket.
   How about a picture of the sprocket and original lock-washer.

[Chubnut]

Cheers Ian, The recess is 5 mm deep

[kwackboy]

That's unusual ..  has the lock washer been changed at all ? It should fit . 🤔

Always use a lock washer ...

[TLPower]

Drop it round, I'll put a bit of weld on.

Just in case....

[Chubnut]

Have ordered 2 from Fowlers parts,  will just have to wait a day or so to finish it off. This way at least it might fit if the OD is bigger. Thanks for help

[kwackboy]

TL .. bodgery at his finest ... 

[Gert]

As long as the sprocket and washer splines cutouts match / slide onto that of the gearbox shaft, then all that is further needed, is a big hammer, a file and the sprocket lock nut.
1st flatten the washer if deformed.  An easy test. Place the washer on a hard flat surface. Place the lock nut on top of the washer. If you are able to rock the lock nut while pressing the nut to the washer surface, the washer is deformed.
2nd a file to trim the outer edge of the washer to allow for proper fit in the sprocket recess. Take care that there is sufficient material left to be able to fold onto the lock nut to allow for locking the sprocket nut in place.
When all else fails, the easy way out is to buy a new sprocket washer. Do remember to take the sprocket with to the dealer, to check for fit.

[rus998]

I had the same problem and found that the new sprocket had not gone on the shaft far enough even though I had used a socket to tap it home. Using the old nut and an air gun drove it home with little force then fitted a new washer & nut.