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Xplorer 400 drive sprocket

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Old Oct 17, 2007 | 02:25 PM
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sdort's Avatar
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Default Xplorer 400 drive sprocket

'98 non-concentric drive. Drive sprocket for rear wheels has been on it's way out for a while. I got the old one out no problem because it was so worn, but the new one doesn't clear the thrust bushing on the swingarm. Am I correct in thinking I have to remove the plastic chain guide from the swing arm to get to the nut on the swingarm bolt? This seems to be the only way to get that thrust washer out of the way to slide the new sprocket on. PITA because the chain guide is riveted on and it's nearly impossible to get a drill in there to drill the rivets out. Am I missing an easier way?
Thanks!
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Old Oct 17, 2007 | 02:38 PM
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94harley's Avatar
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Default Xplorer 400 drive sprocket

Take a chisel and shear them off in betweeen the plastic chain guard and the swingarm to gain accesss to the swingarm nut. Tap the rivet half into the swingarm. Loosen the nut and move the bushing, replace the sprocket, and reassemble.
 
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Old Oct 17, 2007 | 05:23 PM
  #3  
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Default Xplorer 400 drive sprocket

Thanks for the tip on chiseling the rivets rather than drilling. I had really hoped there was an easier way, but it's done now. The original chain and sprockets lasted nearly 10 years without the best maintenance by the p.o. so I'm hoping if I take care of these, I won't be doing this again.
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