Chain & Sprocket Replacement Checklist With Procedures and Tips
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Thread: Chain & Sprocket Replacement Checklist With Procedures and Tips

  1. #1
    Senior Member TopPredator's Avatar
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    Chain & Sprocket Replacement Checklist With Procedures and Tips

    I have been looking around on our Forum and it seems there are bits and pieces on this topic in many Threads. Replacing a chain has opened up a can of worms for me. I know everyone has there own favorite products but when it comes to my TW I would like to use good quality components. When I start this project I want to have everything I need with procedures. Here's what I have so far and I have put Question marks where I need assistance

    Checklist
    Chain DID O Ring 428 ?
    (2) Master Links one for spare
    Sprockets? What company makes a descent product?
    Rear Sprocket Bolt Kit. Do I need it?
    Left Side cover Gasket
    Counter Shaft Oil Seal Kit ? I have 5000 miles on my TW Do I need it?
    Oil and Filter
    Loctite What Type do you use on Motorcycles?
    Permatex for one side of the gasket
    Chain Break ? inexpensive and works

    Have I missed anything?

    I seem to remember a gear ratio program that calculated gears. I have a F-14 R-45. Is it really that big of a deal to change my front sprocket to a 15 tooth? I love my gear ratio. I was told 15-47 was the same I just want to make sure.
    Torque Specifactions on all bolts. I do have a shop manual and I can look these up later unless someone has them on hand.
    Your input on products and tips would be greatly appreciated. Thanks
    Rick
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    If I’m ever on LIFE SUPPORT, UNPLUG ME. Then plug me back in... See if that works. Hidden Content

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    TW 1988 Black Widow.
    1994 Harley FXR

    Rick

  2. #2
    Senior Member RockyTFS's Avatar
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    DID O or X-ring 428 yes
    Master links (2) yes
    JT Sprockets
    Use the same bolts and tabs....once.
    If your gasket is less that one year old you may re-use it if not torn.
    My seals are fine at 10,000 miles
    Clean the oil filter but unless the oil needs changing don't....Lie the bike on its side for the sprocket change...no oil will be lost.
    I have never used Locktite for this type of service. Neither have I used Permatex on the left side case...no leaks in 7,000 miles, but my gaskets came off perfectly clean. Still, can't hurt.

    Chain breaker: Motion Pro Chain Breaker - Motorcycle Superstore
    Gearing Commander: Gearing Commander: Motorcycle Speed and Drive Train Calculator (Online and Stand alone)

    There are TWO critical items when removing/replacing the left case and changing the front sprocket: Make SURE the locating dowels go back where they came from and don't fall out into the case...use heavy grease. Make SURE the stator wires do not get pinched. Because the magnets tend to force the stator and housing to stick, you need to exert force SIDEWAYS BUT NOT MUCH INWARDS to get the outer case to line up. NEVER force it inwards.....Once you have the dowels located the case will go in the rest of the way smoothly. Inspect the stator wires and the little plug just above the sprocket with a mirror and a flashlight after threading a few bolts but before tightening them to be sure they are seated right and not crushed.

    It's really pretty easy.
    Rocky
    2018 TW200
    2014 BMW R1200GS LC

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    Senior Member TopPredator's Avatar
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    A picture is worth a 1000 words. You guys can visualize what your explaining in this repair. If we can give this Thread a visual it would help us newbie's who have never worked on motorcycles. Things like dowel pins dropping inside the case, pinching wires and getting the left cover to seat without pushing down all cause me anxiety. The tip using grease to hold the dowel pins in place is huge in my mind. I visualize myself carefully removing the case and the dowel pins go flyin. Not know how many there are and where they go back is a problem for me. Thanks
    rick
    Last edited by TopPredator; 05-11-2015 at 09:21 AM.
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    If I’m ever on LIFE SUPPORT, UNPLUG ME. Then plug me back in... See if that works. Hidden Content

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    TW 1988 Black Widow.
    1994 Harley FXR

    Rick

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    Senior Member plumbstraight's Avatar
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    When talking about greasing the dowels to keep them in place, just a dab on the dowel sides. don't put it in the hole as it can keep the dowel from fully seating in the hole. When tightening excess grease will have to get by way of the gasket.
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  6. #5
    Senior Member RockyTFS's Avatar
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    Quote Originally Posted by TopPredator View Post
    A picture is worth a 1000 words. .....
    rick
    Damn, I know there are pictures in here somewhere....I just can't find them.

    On other thing that I would recommend the first time you do this is to cut a piece of cardboard approximately the same shape as the cover, hold it up to the engine and use a pen to poke holes about where the various bolts are. Then place your bolts in those holes as you remove them....they are NOT all the same and this way you won't run the risk of putting the wrong bolt back in the wrong hole. Also, USE A TORQUE WRENCH when putting it all back together. The value is 7 Nm or 61 inch/lbs. Tighten the bolts on opposite sides in a couple of sequences just like you would lug nuts on your car.

    Getting the wires seated is not difficult, there is a plug that is part of them that seats in the engine case....just press it back in place and look one last time just before you fully seat the case cover.
    Last edited by RockyTFS; 05-12-2015 at 04:48 PM.
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    Rocky
    2018 TW200
    2014 BMW R1200GS LC

  7. #6
    Senior Member Motoad's Avatar
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    No replacements here. Brand new. But, I am curious. Made the chain adjustment on my 600 mile service. It was quite loose but clicking the cams one notch almost brought it to too tight. I have changed out the OEM rear sprocket for a plus two tooth job. Could this be the reason for the adjustment difference?

  8. #7
    Senior Member RockyTFS's Avatar
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    Yeah, makes sense to me....a larger sprocket will tighten the chain more for the same movement of the axle. If you still have the OEM chain, no worries, it will stretch in a week.
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    Rocky
    2018 TW200
    2014 BMW R1200GS LC

  9. #8
    Senior Member Tiny-Wheel-200's Avatar
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    dont forget to clean around the case beforehand and have a shop vac handy to suck grit out of the stator wire area. very important.

  10. #9
    Senior Member TopPredator's Avatar
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    I'm getting more confident with each post. You guys Rock!!!
    mudbug, plumbstraight and TWilight like this.
    If I’m ever on LIFE SUPPORT, UNPLUG ME. Then plug me back in... See if that works. Hidden Content

    TW 2006 Ruth
    TW 1988 Black Widow.
    1994 Harley FXR

    Rick

  11. #10
    GTG
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    Senior Member GTG's Avatar
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    There are some pictures here https://tw200forum.com/forum/technica...pictorial.html
    I've studied that thread to death, as this is my next (first) big project.
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