"How to" instructions for this mod
At the request of Roaddog in another thread, I'll post up the how to on this mod.
0) Before starting determine whether you are going to use a new sprocket nut or reuse the existing. I reused the existing. A new one will require a trip to your dealer.
-There are 2 steps that require a second person.
-No special tools where used. Ratchet and sockets, allen keys, torque wrench, screwdriver, hammer, wrenches.
1) Place bike on a rear stand and remove the main chain guard.
2) Remove the drive sprocket cover (item 4 from the picture)
3) Tricky part - The drive sprocket nut (item 5) has a small lip that has about 1/8" deformed into the channel that is cut in the spline shaft. You need to use a small flat head screwdriver (or similar) to start to straighten it out. This will allow you to loosen it with less force. I didn't try to remove the nut before doing this, so I don't know if you can just take it off. You will need someone to press down firmly on the rear brake lever while you remove the nut. Remove the nut (5).
4) Loosen the rear axle nut.
5) Loosen both locknuts on each side of the swing arm and back them off.
6) Push the rear wheel assembly forward as far as it will go. This will create slack in the chain to remove it from the rear sprocket.
7) Remove chain from rear sprocket. Let it hang there.
8) Remove the Shift arm from its spline (3) and rotate the shift rod back towards the rear of the bike (need to do this to get clearance). Make sure you mark the location of the shift arem on the spline so you can put it back in the same place.
9) Remove the washer (6) and sprocket (7), with the chain.
10) Take the chain off the sprocket and put it on the new sprocket, before you attempt to put the new sprocket on the spline shaft. Make sure you orient it correctly. With the Driven sprocket, only one side has chamfers to allow easy alignment with the spline shaft.
11) Tricky part - You will need to work with the chain position to allow the new sprocket to slide onto the spline shaft.
12) Tricky part - the chain placed on the larger diameter sprocket (+1 tooth) creates a slight interference with the plastic chain guard that sits a couple inches above the spline shaft. You will need to force the chain under the chain guard. I tapped mine on with a rubber mallet.
13) Place the chain over the rear sprocket and rotate it onto the rear sprocket. Test the installation by hand to ensure it rotates freely.
14) Reassemble all the bits.
15) Set your chain tension.
16) Take a slow test ride to check out your install. Stop and check the chain for alignment and tension, to make sure nothing moved.
At the request of Roaddog in another thread, I'll post up the how to on this mod.
0) Before starting determine whether you are going to use a new sprocket nut or reuse the existing. I reused the existing. A new one will require a trip to your dealer.
-There are 2 steps that require a second person.
-No special tools where used. Ratchet and sockets, allen keys, torque wrench, screwdriver, hammer, wrenches.
1) Place bike on a rear stand and remove the main chain guard.
2) Remove the drive sprocket cover (item 4 from the picture)
3) Tricky part - The drive sprocket nut (item 5) has a small lip that has about 1/8" deformed into the channel that is cut in the spline shaft. You need to use a small flat head screwdriver (or similar) to start to straighten it out. This will allow you to loosen it with less force. I didn't try to remove the nut before doing this, so I don't know if you can just take it off. You will need someone to press down firmly on the rear brake lever while you remove the nut. Remove the nut (5).
4) Loosen the rear axle nut.
5) Loosen both locknuts on each side of the swing arm and back them off.
6) Push the rear wheel assembly forward as far as it will go. This will create slack in the chain to remove it from the rear sprocket.
7) Remove chain from rear sprocket. Let it hang there.
8) Remove the Shift arm from its spline (3) and rotate the shift rod back towards the rear of the bike (need to do this to get clearance). Make sure you mark the location of the shift arem on the spline so you can put it back in the same place.
9) Remove the washer (6) and sprocket (7), with the chain.
10) Take the chain off the sprocket and put it on the new sprocket, before you attempt to put the new sprocket on the spline shaft. Make sure you orient it correctly. With the Driven sprocket, only one side has chamfers to allow easy alignment with the spline shaft.
11) Tricky part - You will need to work with the chain position to allow the new sprocket to slide onto the spline shaft.
12) Tricky part - the chain placed on the larger diameter sprocket (+1 tooth) creates a slight interference with the plastic chain guard that sits a couple inches above the spline shaft. You will need to force the chain under the chain guard. I tapped mine on with a rubber mallet.
13) Place the chain over the rear sprocket and rotate it onto the rear sprocket. Test the installation by hand to ensure it rotates freely.
14) Reassemble all the bits.
15) Set your chain tension.
16) Take a slow test ride to check out your install. Stop and check the chain for alignment and tension, to make sure nothing moved.
