I have an '04 XL883C that was converted to a 1200. I wanted to change the drive sprocket to reduce the RPMs at highway speeds. So I bought a sprocket on eBay.

I got my 29T sprocket today and pulled off the sprocket cover to see what size bolt holds it in place. I measured 1.905". What size is this exactly??

It's a bit too small to be 1 - 15/16" (1.9375") and too big to be a 1 - 7/8" ( 1.875").

Is it metric?? 1.905" = 48.387mm

What size do I need?? I don't have a larger boxend wrench. Do I need one or is there something else I can use??

Thanks

 

I have a 2004 1200R and I went to the 28T counter, I bought the 3/4 drive 12 point 1 7/8" socket at Sears to make the swap. Remember, it's a right hand thread so things are backwards.

 

I assume you meant LEFT hand thread. Righty tighty

 

Righty Loosey lefty tighty on this one......

 

Went out and picked up a 1 7/8" socket today - expensive sucker at $26!! Removed the rear muffler, and took the cover off. Removed the smaller hex screws and the lock, then tried to turn the nut (clockwise) with the socket to loosen it. Won't move.

This bike had been stored outside by the first owner and there was a lot of oxidization on the aluminum parts. I've also found a bit of rust, including quite a bit on the aforementioned nut.

I sprayed a little bit of WD40 between the nut and threads, and a little between the nut and pulley face. I then placed a rag at the bottom to capture any excess. Don't want any on the belt!!

Gave it about an hour and tried again. No good. Fired up a small propane torch and heated the nut a little bit and tried again. Nothing. I then just sprayed some more WD on the nut and closed up the shed for the night. I'll let it soak for a while.

I have the bike on a lift and it's a bit difficult holding the pulley still. I'm engaging the rear brake to prevent the pulley from turning, while attempting to loosen the nut. I think I'm gonna lower the rear wheel to the ground and let the weight do the work for me.

For as quickly as I progressed, I thought I'd be done in about an hour. Guess I was wrong!!

 

WD40 is really not the best penetrating oil around. You might want to pickup a can of PB Blaster.

 

If you are trying to do this operation by hand, good luck. The nut comes off real easy with a 1/2 inch impact gun. Clockwise off and counterclockwise on.

 

Torx T25 control housing screws
T27 clutch inspection cover
control clamps
T40 front brake disk
front wheel hub plate
T45 rear brake disk mounting bolts
fork bracket pinch screws
Allen 6 or 7 mm fork damper tube screw
5/32 sissy bar mounting screws
primary chain inspection cover screws
3/16 primary cover screws
rocker box cover screws
gearcase cover
sprocket cover
sissy bar side plate mounting screws
1/4 front fender bolts
handlebar clamp bolts
eyebrow bolts
coil bracket bolt
left footpeg mount screws
rear master cylinder mounting screws
belt guard mounting screw
primary adjuster screw
5/16 upper engine mounts
front axle pinch bolt
3/8 timing plug
Hex Head 5/16 heat shield worm drive clamps
brake line mounting clips
horn mounting bracket screws
3/8 voltage regulator mounting screws
7/16 coil mounting screws
battery strap nut
brake pedal adjustment screw
10mm horn mounting nut
battery terminal screw
throttle cable adjustment jam nut
1/2 front fender bolt nuts
enricher bracket
front directional signal mounts
mirror mount
coil bracket bolt
brake pedal adjustment screw locknut
9/16 lower front engine mounts
front axle pinch bolt
upper shock mounting bolt
belt tension adjuster screws
upper front engine mount screws
rear engine mount bolts
5/8 front directional swivel nut
spark plugs
11/16 lower front engine mount flange nuts
3/4 front axle nut
lower shock mounting bolt
headlight mounting bolt
7/8 primary chain adjuster screw locknut
15/16 rear axle nut
stem bolt
1 3/8 fork tube cap
Twelve Point 3/8 caliper banjo bolts
rear master cylinder banjo bolt
7/16 front master cylinder banjo bolt
1/2 head screws
Phillips #1 headlight clamp ring
directional signal lens screws
taillight lens screws
#3 ignition module cover screws
#4 air cleaner cover screws

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I used a big breaker bar when I did mine. It isn't easy getting it off, but the breaker bar , along with some PB Blaster did the trick.

 

Just a thought but you folks don't have an air compressor and impact tools? If not, they're a great investment.