Changing front sprocket
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  1. #1
    Senior Member Omega Man's Avatar
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    I had ordered the case gasket in anticipation of changing the front sprocket and then I read in one of the recent posts about 2 seals that should be changed. I ordered the 2 seals and it looks like from the parts breakdown that there is a bearing and seal on both sides of the sprocket-have I got it right? If so is it much trouble to get the seals out? Hopefully not and all will be well when I open it up. The local dealer has limited parts so every time I need a part it's "next Tuesday" TIA OM
    "It's more fun going fast on a slow bike than going slow on a fast bike" UK

    1994 TW200, 2009 F800GS loaded,

  2. #2
    Senior Member joedirt1970's Avatar
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    I found the link...here



    https://tw200forum.com/index.php?/top...h__1#entry1328





    I was lucky and the shop I go to has the ability to cut/make any gasket known to man. If I remember correctly, there is only one gasket on the sprocket side.

    The most important thing is to make sure you don't pinch the wires when you tighten down the case. I am not sure where it is, but there are one if not many topic/discussions about this.
    Hidden Content [/IMG]It's not why, but why not. Do it for the right reason now, versus the wrong reason later.
    Born on a Honda Z50, '78 YZ 80, '79 Husky WR 250

    2008 TDub--Jimbo Shield, Lizard Oil Cooler, Blaster Shock, YZ Hybrid Forks, Supermoto front fender, ATV Bars, Acerbis Brake Cover, 1460 Pelican Case, Cycle Rack, Power Core, Gold Chain.

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  3. #3
    Senior Member elime's Avatar
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    I am for changing the drive shaft seals and the shift shaft seal the first time you replace the front sprocket, especially on an older bike. Later on if you change the front sprocket again you can make the judgement if it is needed again.



    The other thing in that area that can start leaking is the neutral switch. On my second TW I changed everything else but the switch and guess what started leaking soon after I got it back together? I am waiting for the new switch to arrive at the dealers so I can put it back together.



    You can flip / pry out the old seals with a thin screw driver. You can install the new seals using a socket of the same diameter on the shift shaft and outer drive shaft. For the inner seal I used a plastic tube from my shop vac. Not the best thing to use and I had to be very careful but it did work. A correct sized pipe would have been better.



    As for the gasket, I too bought a new one but have used the same old gasket 5 or 6 times now. As long as it doesn't rip it is re useable. It usually sticks to either the cover or engine case. I grease the other side when I put it back together so it hopefully won't stick there and will come apart easily the next time I take it apart and I can re use it again. So far it has worked.




    All in all it isn't hard. Take your time, watch the wires, and don't panic. One last thing is you most likely will need an impact wrench to loosen the screws. Visit you local Harbor Freight and get a cheap one.
    Long live the internal combustion engine!

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  5. #4
    Senior Member Omega Man's Avatar
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    Thanks guys, that link from the past helped. Looks like I'll have to get the shifter seal also-hope I can get it in the order for Tuesday. I'm going to do the chain, sprockets, seals and an oil change all at once. Btw I figured out how to drill the carb plug out while on the bike. I don't know if there is interest in that process or not. OM
    "It's more fun going fast on a slow bike than going slow on a fast bike" UK

    1994 TW200, 2009 F800GS loaded,

  6. #5
    Banned qwerty's Avatar
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    Quote Originally Posted by Omega Man View Post
    . I'm going to do the chain, sprockets, seals and an oil change all at once.


    Smart move.



    Quote Originally Posted by Omega Man View Post
    Btw I figured out how to drill the carb plug out while on the bike. I don't know if there is interest in that process or not. OM
    Loosen the clamps on the boots, remove the cables and fuel line, and rotate the carb in the boots.




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