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Discussion Starter #1 (Edited)
EURO GEARS - Started Install Yesterday!

I thought I would Start A New Thread On My Install Of The Euro Gears!

So I started the " Installation " Yesterday and WOW !
Very first thing I started with was the Speed Sensor Bolt removal and re-Installation !

I figured I would start with that ..
Because if I could not remove the washer needed to make the speedometer
work then I would not do the rest of it! LOL
( I Was NOT going to remove all the electronics, battery, ECU, Shock and Plastic Ect )
Just to remove ONE Bolt !!! No Way !!!

HERE WE GO ! PART ONE! ( Will Update As I Go ! )

1. Remove Bolt For Speed Sensor - 4-5 Hours !
Well this took better part of a day ! With Beer Breaks, Swearing, Talking to other MC People.

A. Make a 5MM Hex Wrench that will fit in the VERY SMALL Area you have to work with!
I cut down a cheap 5mm but this didn't work!
Because of the angle the bolt! Also because of the 5mm wrench was very short!
And Because of MY BIG FINGERS ! There was NO WAY to get the wrench to turn!

B. Had a 5mm BIT that fit ! ( 3/4 Inch Long Maybe )
Because of the angle the bolt! Also because of the 5mm BIT was kinda long!
And Because of MY BIG FINGERS ! There was NO WAY to get a wrench on the BIT to turn it !
OR The BIT would Fall OUT of the bolt every time you tried !!

C. MAKE a 5mm BIT that was 3/8 Long ! Out of the 5mm Wrench ! ( HAS TO BE 3/8 in LONG ! )
Because of the angle the bolt and Because of MY BIG FINGERS !
There was NO WAY to get a wrench on the BIT to turn it !
OR The BIT would Fall OUT of the bolt every time you tried !

D. Take Home made 3/8 inch Bit and Duct Tape it to 5mm Mini Closed End Wrench!

YOU HAVE TO USE A MINI CLOSED END WRENCH !
BECAUSE THERE IS NO ROOM BETWEEN THE PLASTIC AND THE BOLT !!!!!!!!!!


Like: http://www.fasttech.com/product/1451309-h5511-10-pieces-of-metal-combination-wrench

By doing this I was able to get the Mini 5mm BIT I made to "stay on" the Mini wrench! and NOT fall Off !
I THOUGHT AFTER DOING THIS MAYBE IT WOULD BE BETTER TO GLUE IT ON!
But the DUCT TAPE Was Working !


BUT ! There was Still NO ROOM to get a grip on the wrench to turn it !!!

SO .. I had to "BEND" The Mini Wrench a little to make room for my fingers! ( See Pic )


I had to use a large flat head screw driver to " HOLD " the Mini BIT and Wrench
On to the BOLT Wile Turning the Wrench ! So it would Not " POP OUT " Wile Turning it !


FINALLY ! I was able to turn the bolt !!

TO MY DISMAY !
It had LOCTITE on the bolt!
Also You Could Only Turn The Bolt 1/4 to 1/8 Turn ? Maybe At A time !!
Because of the LOCTITE I was UNABLE To Use A Long Needle Nose Pliers! To Turn The Bolt!


So after all that !

I had to turn the bolt 1/4 to 1/8 Turn and remove the wrench!
replace the wrench on the bolt turn it 1/4 to 1/8 then remove the wrench.
replace the wrench on the bolt turn it 1/4 to 1/8 then remove the wrench.
99% OF THE TIME USING A NEEDLE NOSE PLIERS TO REMOVE THE WRENCH!
ECT ECT ECT ECT ECT 100's of times ! OMG OMG OMG !!!!!!!!!!!!!!!!!!!!!!!


TO TOP IT ALL OFF THEY USED A HUGE LONG BOLT !!!!!

Soooo .. after 100's of turns of the bolt it was too long to get the wrench back on it !!
And it was still not off !


Soooo ... I ended up taking a big screw driver and "bending the Plastic"
and removing / scraping some of the heat shield on the plastic to make room!


FINALLY ! I was able to remove the bolt !! And Get The WASHER Out !

WOW ! OK THEN I THOUGHT TO MY SELF!
WHY THE HELL AM I DOING THIS TO MYSELF! THIS CAN NOT BE WORTH IT!
AND HOW THE HELL AM I GOING TO GET IT BACK IN !


Ok now I got this far there no turning back now !

PART TWO - REINSTALL BOLT FOR SPEED SENSOR.

OK I CAN MAKE THIS PART KINDA SHORT ! LOL :eek:

I Found a bolt that was 1/2 to 3/4 in sorter then the Original !!!
Still a 5mm Hex head. ( Figured it would be easier to install ) And Was!

I but the bolt into the sensor and was able to use my wrench "start" the Bolt into the threads.

Then I used the Screw Driver to "HOLD" the Mini 3/8 in 5mm BIT into the BOLT
And used an OPEN END MINI WRENCH that I made longer by taping a Allen wrench on it !

And was able to screw the Bolt all the way in !
Quicker this time because the bolt was shorter !
And Because the Wrench was an OPEN END this time!
There was NO need to keep removing the Bit and Wrench every time!


I think if you Super Glued the 3/8 in long Home Made Hex BIT into the BOLT!
This would have been MUCH easier to reinstall ! No Screw Driver Needed !


Also After doing this ..
I think if I had MADE the longer wrench and used it for removal
Like I did for re-install it may have gone a little quicker !

I hope this write-up helps anyone considering doing this!
To NEVER DO THIS ! LOL And PAY Someone to do it ! LOL


PARTS NEEDED >

1. Home Made : 5mm 3/8 in Long hex Bit.
2. Mini 5mm Closed End Wrench
3. Mini 5mm Open End Wrench - Make Longer !!!
4. RAG TO STUFF AREA AROUND BOLT TO CATCH 5mm BIT !!!
( Can not Stress How Important #4 Is !!! )
5. Duct Tape
6. A Lot of Time and Patience !!


Ok .. So that was the Longest Write up on removing a Single Bolt !!
Ever in the history of man kind!


PART 3 - Removing stuff to get Mufflers off !

A. Remove Right Side Floorboard - Simple ! LOL Remove "C" Clip And Bolt.
B. Remove Floorboard Bracket - Two Bolts - Done!
C. Remove leather Bags to get a bolts for muffler.
D. Remove Bolts at Engine for muffler! - Again NO ROOM ! FFS ! OMG !
E. Figure a way to get at the freaking bolts off for the muffler!'
F. Use 1/4 Socket and a 1/4 swivel extension to remove bolt by radiator!
G. DROP BOLT INTO ENGINE - CAN NOT FIND ! OMG ! SCREW THIS I QUIT !


QUIT FOR THE DAY !!
 

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wocka, wocka, wocka
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ww, you need to take a time out and go get a :beer: go do something else and not think about this project..
many of us have done this w/o near the frustration that you are putting yourself thru..

1st.. when you was jus a pup kid you lerned to do test by answering all the ez questions first. often embedded in those questions where the answers to the more.. challenging ones.. so you got some free miles by using good judgement. and you were scored by the total number of answers, not by the difficulty, so it makes sense to knock out the ez stuff first.
also, that gets you into yor "zen" state where you are at one with the machine and not manhandling or butchering the beast..

you need to come back to this project with a fresh new 'tood. you n yor girl are gonna get along and have some fun getting down to her "nasties"...

ther are so many previous threads on this subject, you should have picked up a few pointers..
first, loose the rt floor board is all needed to clear the pipe.
2nd, if you do any wrenchin on this bike, the front exhaust bolt is a work around. the radiator shroud comes off with 4 skrews, or in time you will learn how to use that 1/4" universal. hell you could just take out the top rite one and pull the shroud forward enuff to get a direct shot at that capscrew..
I get mine off no problem. yes Iv dropped more than one bolt, nut or cap in/on/around this and every other bike. I have flashlights and magnets to fish them out.
GENTLY undress her. she will yield w/o a fuss if you dont beat her. Learn what makes her special and do her rite.. Its a world of diff.. this bike is cake to work on. poncho
 

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Hang on, Hold the phone, i just read this elsewhere, lol.

Oh well ya can't get too much of a good thing, keep the info comin

Ando





Sent from the bottom of the Earth via a Tapatalk clone........……Motorcycle.com.
 

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wocka, wocka, wocka
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Grinder?

ww,, looks as though you got the speedo sensor out and then put it back in w/o the spacer.? which is the correct thing to do as part of this project..
most fellas save this item for last.
now that you've got the sensor in further(minus that washer/spacer) into the motor cavity, it is now within striking distance of the original 50t final drive gear.

Do NOT rotate your Rear Wheel as this gear will grind the sensor..

that is why it is left to be the LAST thing to do as the new final gear is 48t and smaller diameter to accomadate this sensor new position.. poncho
 

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I used a little piece of an allen wrench and a teeny little open end 5mm wrench (it came in a pack of "ignition wrenches"), much like you're describing. After a LOT of contorting and finagling to make each 1-flat turn I got it out far enough where it looked like I could get a small dykes (hee hee) in and cut the washer out. It worked. If you try it, just remember to account for every little piece of every little thing. You don't want those kinds of spare parts in your motor.

And like Ponch said, I did it last.
 

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So a follow up today was the first day since i change my gears out that I have rode the bike to work. Lets say its so smooth and much easier to cruise at highway speeds that i was just i my own world totally missed the 55mph speed drop and got to meet the state trooper. said i was doing 75. luckily he liked the bike and gave a ticket only for speeding above post speed limit.
 

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Discussion Starter #7
PART 4 - Removing Mufflers - And Everything Else !

Well Tuesday I started the Un-Install and install again
Took me from about 11 am till 9 pm ! With Breaks and Store Runs!

I was able to get the after market mufflers off using a 1/4 Socket and a 1/4 swivel extension
and a closed end wrench that I bent to make fit!

I Broke / sheered one of the bolts that hold the back of the mufflers on the bike !
I was able to drill it out and used a buddies tap and die set to make a new bolt hole.

After doing that .. Everything else came off fairly easy!

I got the Fuel Tank off .. again fairly easy!
Then started on all the stuff needed to get at the tranny covers.

Drained The Oil Just used the TWO Main Plugs.
I did NOT Drain The Coolant. I Left The Re-Fill Cap ON.
And Removed the BOTTOM Hose that went to the Water Pump.
Not Much Came out. Maybe a 1/2 quart or so.

Removed Water lines .. Oil Lines .. Brake Line Ect.

Then Started On the OUT SIDE Cover. Came Off Nice! With the Gasket In-tacked!
Then The Inner Cover. Came Off Nice! With the Gasket In-tacked!

I Removed The Inner Case VERY SLOWLY !
SO NOT TO LOSE THE TINY " PIN " For the Shit Sensor !

At this point ...
I Realized that I had a HUGE AMOUNT Of room to remove the Washer For SPEED SENSOR !
You can get at The Speed Sensor MUCH Easier With All That Stuff Out Of The Way!

Sooo .. Anyone That Wants to do this .. Keep this in Mind !
Its A Great Time To Do This Step ! ( BANGS HEAD ON DESK! )
No Write Up I Saw Ever Tells You this !!!

--------------------------------------------------------

Then it was time to remove the two Gears.

The Two NUTS need a 36mm Socket I did not have one.
So I called around and found AUTOZONE Rents Tools For Free!

I went and got the 36mm Socket and a BIG Breaker Bar From them
And Used The " Nickel " Trick to remove the Gears!

They were on there really TIGHT!
That Poor Nickel Was FLAT! When I got Done! LOL

PART 5 - RE-INSTALL - And Everything Else !

Anyway ... I Got them off ! And Installed The New Gears !

Went and got a few washers from my local hardware store ..
To fix or eliminate a tiny bit of play between the gear and the nut.
The " Slop " People talk about. And This Worked Great !

OK .. Time to Clean both transmission covers and re-Install!

From Here I just Installed the New Gaskets and transmission covers
And Did everything in reverse! LOL

Everything went back together Just fine !

I refilled the radiator with new fluid, Didn't take Much.
And Re-Filled the Oil Using the Old Oil .. Will change out later.

I figured that a small amount of coolant and Stuff got into the bike during
dis-assembly .. So I used the OLD Oil to " Clean " What's In there and Will
Change the Oil After a few Runs.

Did a " TEST " Run In the garage and the SPEEDO WORKS

Anyway ... ITS ALL BACK TOGETHER ! AND SO FAR NO LEAKS !
( Totally bummed that I can not Ride her now ! )

I hope this helps anyone thinking about doing this MOD
I will let you guys know how she rides if and when winter ends!
 

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wocka, wocka, wocka
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so... like,, er wen is the road test? we need some feedbak how this mod is working for you.?
 

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Latchin' on this old(er) thread cus is the most recent I could find on the subject, Just got Cooter's tool sent to 2K# and it should be already on his hands.
Here are a few tips from my gear install.
  • Like Warlock said, leave the Speed sensor screw for the right time, once you get stuff out of the way it is much easier. Cooter's tool is a "of course, how else would you do this" kind of thing, got the washer out and the bolt back in it's place in about 15 minutes.
  • In a thread I read (I think it was Ponch) it indicated that you can easily do this with the bike on the side stand and that you did not have to eve drain the oil, side stand part was right, having the rear wheel on the ground helps a lot when loosing up those big nuts that hold the gears but after taking off the first cover I could see that taking off the second one without draining the oil was NOT possible, will have to ask Ponch how he did it or if he was only messing with my head.
  • I had trouble finding the drain bolt for coolant and just disconnected one of the hoses, like you would imagine, just as the last drops of coolant were dripping I found the drain bolt right there where it should be, be sure to do this the right way, less mess and A LOT easier.
  • keep track of the order of the bolts that hold the covers together, some of them are not the same length. Do not advice to do this the usual "put them in their place so you keep track where they belong " deal cus you might bend them them in the following steps. NO!!! I did not bend any bolts, but I could see how easy it would have been to bend one.
  • Be mindful of the little pin, if your bike is leaning over and you take your covers off carefully, it wont pop out and it will stay where it belongs.
  • Putting a Penny between the gears really helps to loose up those big nuts, the idea is to use a penny cus is a softer metal than a nickle or a quater, you might not mind scratching the gears you taking out but you do not want to damage the ones your putting in.
  • When re-assembling, be careful to cross tighten the cover bolts, you want your covers to seat evenly so no leaks will creep up and have you disassemble all over again.
  • +1 on putting the oil you drained out back in, just don,t forget to change it after a few short rides. You don't want to have that dust and stuff on your engine for long.
  • Enjoy the hell out of those longer legs, usable first gear and overall smoother shifting, the beast feels just right with these gears.
Hope this helps any guys trying out this mod, for me is kick ass.
 
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