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REF: Tools - 101

Gearcase / Cam Cover Tools

Pinion Gear Nut

90 and Prior Models (4 Speed)

Built Pinion Gear / Removal / Installation Tools 1)

91 and Up Models (5 Speed)

For turning the engine over using the pinion gear nut

You can use a 15/16“ wrench or deep well socket to turn the engine over using the pinion gear nut. 2)
93-Present Pinion Gear Nut (7916A) 3)

To remove or install the pinion gear nut
You'll need to lock the pinion gear from moving while turning the nut.

  • It's very important to hold the crank on the pinion side with an appropriate pinion locking tool whenever you take the pinion nut off or put it on.If you hold the crank still from the primary side (or by putting the bike in gear and holding the brake), the twisting torque applied to the pinion nut gets transmitted through the crank, from one side to the other. The crank pin is not designed to resist much twisting force. You'll risk scissoring the crankshaft (knocking the crank out of true), which requires a full tear-down to fix. 4) So this is one of those situations where it's best to use the proper tool. 5)
The Grindlock Pinion Shaft Locking Tool engages for the full depth of the pinion gear for max. strength. 6)
Due to a change in the pinion gear in 2000, there are 2 different versions of this tool:
1. (91-99) year models & 2. (2000 to present) year models 7)
Grindlock Tool
(designed by XLFORUM member, “Grind”). 8) 9)

Cam / Gearcase Cover Removal

Alternatives

You can use an old points plate with a 1/2”X13 nut welded in the center to ease the cover off. Mount the plate inside the cover as you would normally and insert a 1/2“X13x3” headless bolt in the center. Turn it in until the cover comes loose. This way the #2 cam stays in place so they don't all fall out when you remove the cover.

Cam Cover Removal Tool 10)


2) , 6)
photos by Hippysmack
3)
photo by Hippysmack
8)
photo (L) by Hippysmack
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