do you guys have any tips on how to get the bottom allen bolt out of the front sprocket cover? i went to take it off and it looks like a b*tch to get it out. the shifter linkage is liek int he way.. and i cant get the allen wrench in.. HELP!!!

 

I removed the foot peg and while still connected to the shifter linkage I move it out of the way and then it was very easy.

 

Another way to do it is to get a ball end socket wrench and put it in with the longer part of the wrench going into the bolt (so that you are turning with the short end as the handle). Then get a pair of channel locks, crescent wrench, etc. and use that to turn the short end with enough leverage to get the bolt out.

Works for me and I don't have to remove the foot peg, although I've done it that way too.

 

While were on the subject of difficult bolts/parts to remove....how do you guys get the shifter to come off of the shift shaft. I loosened the 10mm bolt, and even put a flat blade screwdriver in the back of the shifter to try to loosen the death grip on the spline, but to no avail. [img]i/expressions/face-icon-small-disgusted.gif[/img] How do you guys remove it? Thanks, sorry for jumping in. [img]i/expressions/face-icon-small-smile.gif[/img]

 

For the sprocket cover I used an allen wrench with the ball on the end like slappie said.
You have to take the bolt all the way out of the shifter, then it should slide off.

 

The way I have my linkage adjusted, there is no way to get the bottom bolt out of the cover without removing the footpeg.

FlynBryan,

You have to remove the clamp bolt all the way to remove the linkage from the shift shaft. If it is not coming loose, try putting your screwdriver between the two ends of the clamp of the linkage (the gap created from removing the bolt) and pry it open a little. This should break loose any rust or debris and the linkage should slide right off the shift shaft.

~HoundDog

 

Like everyone has said, you do have to take the bolt all the way out. The reason is that the shaft has a channel milled out of it so that if the bolt loosens, the shifter can't fall off unless the bolt comes all the way out. Because of this, even if you have the bolt threaded out all the way, but still in the hole, the shifter won't come out.

And like Hound Dog said, if it is clamping the splines too hard, with the bolt out you could try to put the screwdriver into the slot and pry it a little.

Easy as pie!