So it's getting harder and harder to shift from 1st to 2nd gear on my 1999 1200 with 52K miles on it. The shifter pawl and clutch are adjusted correctly, so I'm fixin' to pull the trans to check the shift drum and shifting forks. According to my FSM, first step in that process is to remove the nut from the front drive belt sprocket. I took my trusty vernier caliper and measured the nut. It appears to be a 1-7/8", but before I make a trip to Sears and drop $20 on a socket I just want to check and see if anyone knows for sure if that's the right size.
Also, any words of wisdom about pulling/inspecting/repairing and re-installing the trans would be greatly appreciated. Thanks!
1. Use a 4" brass door hinge to lock the primary drive (wedge it between the teeth on the engine sprocket and clutch basket).
2. The clutch centre nut is Left Hand Thread.
3. You do not have to disassemble your clutch to remove the primary drive. Remove the circlip that holds the clutch actuating mechanism in place to reveal the clutch centre nut. Remove this, and you can take the clutch off as a complete unit.
4. You shouldn't need a puller to remove the engine sprocket. It may seem tight, but this will probably just be due to the attraction of the alternator rotor magnets to the stator. A sharp tug on the sprocket with both hands should move it enough that you can then remove the sprocket, chain and clutch together.
5. I'm not at home to check right now, but 1-7/8" sounds familiar for the engine sprocket nut.
6. Replace both the circlip you removed to access the clutch centre nut, and the domed washer under the clutch centre nut (note which way it is domed as you remove it).