Taller gearing for the freeway 17/38 sprocket ratio change

[Triangles]

I have installed a 17/38 = 2.24 sprocket setup. I bought a '90 ninja 500 "damper - hub." The ninja 500 has a 38t rear sprocket option. I am using an EN500A rear wheel on my EN500C. There are some fitment issues discussed below with the EN500C rear wheel that could be overcome to make it work with the EN500C wheel.

Here are some pictures showing the Vulcan 500 LTD hub (EN500C) next to the '90 Ninja 500 hub:


All the pertinent dimensions were the same. One minor difference is that the four metal tangs (what the rubber pushes on) on the ninja hub were about 1.5mm shorter. However there is one major problem when it comes to using the EN500C wheel. The rubber dampers shown in the picture above are from the Vulcan 500 LTD. As you can see from the picture below and of the rubber damper above there is a "finger" on the damper that goes down into the recess on the Vulcan 500 LTD hub. As this recess is not on the Ninja 500 hub I would have to either cut off the "finger" and not be able to go back or simply get the rubber dampers for a Ninja 500 (dampers from EN500A also work).


This little spacer from the Vulcan 500's rear hub fits in the ninja rear hub bearing The same.


With all that background investigation out of the way, I installed the dampers:


installed Ninja 500 hub on EN500A wheel and installed on bike.


I did the math and have a spreadsheet here. My new 5th gear is actually slightly taller than stock 6th. So far I've only ridden about 60 miles 80% freeway 20% city and absolutely love it! 6th is now a freeway only gear (mostly used it at about 50mph +). It will be interesting to see if this affects fuel economy too.

[Triangles]

I used the following chain and sprockets from my local shop:

I've used JT sprockets before and was happy so I specifically searched for them. I'm sure there are other manufacturers out there that make good sprockets too. I just stuck with something that worked for me before.
38T Rear sprocket for a ninja 500 '87-'93 scroll down to part# 249380
17T Front sprocket for '96-09 EN500C scroll down to part# 248502
108 link EK 520 SRX x-ring chain. I don't have a link as I don't know exactly which one I got. I ordered the gold colored chain and they were on back order so I subbed in a black chain.

Edit 07/04/2023
So my chain and sprockets have finally wore out. It looks like JT sprockets offers a 37 T rear sprocket Part# JTR1490.37 now that fits the EN500C This might be a solution instead of having to go the Ninja rear hub route that I went for the 38T rear sprocket.

So I figured after over 18k miles it was time for a new chain and sprockets. I looked up things from my local shop. I'll provide links because they have good prices even if you have to pay shipping:
The front sprocket is now available with the rubber cushion just like the OEM sprocket. 17 tooth front sprocket JT part# JTF512.17RB Dist #: 269367. The 38 Tooth Ninja rear sprocket is JT sprockets part# JTR486.38 Dist #: 249380
I've been happy with my 108 link EK 520SRX x-ring chain that I will replace it with the current production EK 520SRX2 x-ring chain.

After looking this up I went and measured my chain stretch and was pleasantly surprised I have maybe 1mm of chain stretch over the 20 link measurement. If the info I found is correct a new chain should measure 317.5mm over 20 links (21 pins center to center). Mine measured 318ish maybe 319mm. Guess I am good for another year or so. the sprockets show wear but don't look too bad.

[burkbuilds]

Hey cool, I was never able to find a 38 tooth that I knew would fit our bikes. Thanks for sharing. Now that I'm not traveling 400-500 miles per week mostly on the highway, I actually decided to go back to the stock rear sprocket and keep the 17 tooth front sprocket. I probably haven't put 300 highway miles on my bike in the last six months. I just did that last weekend, so I haven't really ridden enough to feel much of a difference. I'll be curious to see if my in town mileage will go up or down or stay the same though.