I'm going to be changing the pinion gear on my 04 xl. The manual calls for a tool that locks the pinion gear to the case, to remove the pinion gear nut. I'm not too thrilled about buying 2 tools to make this swap (seems that you need to have the tool that matches the teeth on the gear, hence two tools). Is their another way to lock the crank well enough to make the swap? How about putting the tranny in gear and standing on the brake? I'm not really all that cheap, I just hate to buy specialized tools that i'm probably only going to use once.

I'm going to be changing the pinion gear on my 04 xl. The manual calls for a tool that locks the pinion gear to the case, to remove the pinion gear nut. I'm not too thrilled about buying 2 tools to make this swap (seems that you need to have the tool that matches the teeth on the gear, hence two tools). Is their another way to lock the crank well enough to make the swap? How about putting the tranny in gear and standing on the brake? I'm not really all that cheap, I just hate to buy specialized tools that i'm probably only going to use once.

1/2 inch impact gun:doh
:tour

Hehe got that. That will get it off. I'm more concerned about having my torque somewhat correct when putting it back. Good point tho..... it does bring me back to needing just the one tool.

Thats easy also, just make a flat bar to go between the two sprockets to lock them and you can use your torque wrench:doh
:tour

Is their another way to lock the crank well enough to make the swap? How about putting the tranny in gear and standing on the brake?
I don't think that's going to work. Not that I've done it, but that's what my experience in taking crankshaft pulleys off car engines tells me. Put it in gear, stand on the brake, chock the wheels; it never works. Used to have to take the sump off and jamb something in to stop the crankshaft turning. I guess the equivalent is this special tool.

Trouble is, you can stand on the brake all you want, but you're braking the wheel, not the crank. There's just too much flex in the tyre and give in the drivetrain. It ain't gonna work. If it was me I'd pass up on all that hassle and just buy the damn tool! :)

If you remove the primary cover you can lock the crankshaft by using a locking tool between the clutch basket and crank sprocket.

If you remove the primary cover you can lock the crankshaft by using a locking tool between the clutch basket and crank sprocket.
I think that's the tool he's talking about.

They actually do make a tool that bolts in the gearcase cover bolt holes and holds the pinion gear it's self.

The impact gun will take it off. you would only need the tool for the sprocket you are putting back on. btw. don't forget the locktite, red and lots of it.

simple trick for removing and installing:
- screw out spark plugs
- find out, which cylinder is on compression stroke (valves closed)
- take a 4 or 5 mm (1/4") nylon rope like used for mountaneering 3 to 4 m long (3 to 4 yards)
- insert as much rope as possible through the spark plug whole, but let end stick out :D
-->now the crank won´t turn over tdc, depending on wich side of tdc you are, you can get the screw off or on.
- after that: pull rope out the spark plug whole

this always worked fine for me, no special tools required exept a short (cheap) piece of rope and you don´t have to pull the primary cover....
and: you can use a torque wrench.

hope you understand, what i mean ;)

Isn't the pinion shaft/gear the one that drives the cams???

Yes it is and you do not want to hit that with an impact wrench. This is the pinion side of the flywheel you are hitting with the impact.

Yes, it is. Funnilly enough, the '05 manual doesn't mention needing a locking tool when taking the nut off. It just says: 'remove nut'. The section on installing the pinion gear says to use the crankshaft locking tool HD-43984.