Service manual for dummies......

i have changed a number of trans sprockets...it wasnt that hard....but i dont have your manual or bike to see what it would entail.....i will check around to see what makes it so difficult......

One thing that may help is to take it step by step, then at the point where you say "huh???" post that portion here and we can walk you through to the next step.

I'm also going to copy this thread over to the Tech Talk section. There may be a good chance that someone browsing through there would know exactly how to help.

I'm going to move this thread over to the Tech area where I'm sure you'll get plenty of help. Curious to hear what size pulley you decided on.

ok....i have a stack of manuals and i had 2 on your bike, genuine hd and clymers....i dont see a big problem doing what ya want to do....ya want to do it???
chuck

First question is why, is there something wrong with the pulley? If you just want to change final drive ratio you can do that in the primary by changing the comp sprocket and clutch basket outer shell.

If you want to change that sprocket you have to pull the whole primary

Floorboard and rear mount need to be dropped
shift lever removed
Drain Primary
Remove outer primary cover
Remove comp nut (Use a breaker bar and you'll need a locking tool from Jims to lock the sprockets)
Loosen and remove adjuster
remove clutch plate cover
loosen center adju nut back off and remove C clip, slide out
Remove nut, reverse thread
Pull off comp nut and clutch basket as one assembly
Remove bolts and locking tabs for rear primary
bent starter jackshaft locking tab back
remove bolt, hold large gear with plyers to keep from rotating
Slide out jackshaft, spring, gears etc keep in order so you can put it back together correctly.
Remove starter bolts (back them off completely but you don't have to remove starter)
Remove primary cover

Now you can get to the trans pulley, you'll need a puller to get it off as well and maybe a locking tool

To reassemble be sure to get outside primary cover gasket, new locking tabs for inner primary bolts, new inner primary to motor o ring, fluids, reassemble the whole thing in reverse.

Done this so many times its not funny on a buds 113 LOL chasing leaks and all ,we got it down pat.

I use an electric battery drill to remove the allen bolts around the primary, no reason to sit there for an 1/2 hour unbolting the darn thing.

Clean the bolts up good, Loctite blue for the outer cover, many use antisieze on the inner primary bolts.

Torque to spec.

Oh and while you're at it get a new seal for the starter shaft and the trans mainshaft no reason not to replace them unless you like leaks.

If you have a HiPo motor remove the main bearing in the inner primary and seal, as well as the race on the trans shaft and replace the bearing with Zippers High Per bearing kit, it eliminates the race from walking on the main shaft and penetrating the seals.