Section D8 - Countershaft (Gearbox Final Drive) Sprocket

Changing the countershaft sprocket.

1) Remove the outer and inner primary chaincase, clutch and primary transmission as in Section C14 to get to the sprocket.

2) Remove the set screw and lockplate.

3) You have to keep the sprocket from turning while removing the nut. If the tranny is in the frame, use the rear brake to keep it from turning. If out of the bike, then wrap a length of chain around the sprocket and clamp the ends in a vise. 

4) Nut is LEFT HANDED. Remove both nut and sprocket. (1 1/2" ATF).

5) Before replacing the sprocket make sure the sprocket spacer (Part No 040131) is in place.

6) Place the new sprocket, make sure it's all the way home.

7) If you trashed the lockplate, get a new one.

8) Fit and tighten the left-hand nut while keeping the sprocket from turning using the brake. Use Locktite Blue on the nut.

9) Secure the lockplate with the locating screw. The screw hole is normal to the dished portion of the sprocket, so it goes in at a funny angle. Again some more Locktite Blue. 

NOTE: The nut has a flat side and a chamfered side. Chamfered side in, flat side out - NOT AS SHOWN HERE!!! Oops. (Thanks Bill)

10) Replace the outer and inner primary chaincase, clutch and primary transmission as in Section C34. Reconnect the rear chain.