Remove front sprocket - 2008 BMW F 800 GS

TIMING CHAIN, REPLACE Caution: With the timing chain removed, avoid turning the camshaft or crankshaft. If movement is required, exercise extreme caution to avoid valve damage caused by piston contact. 1. Disconnect and isolate battery ground cable. 2. Drain coolant into suitable container. 3. Remove accessory drive belt. 4. Remove front cover as follows: a. Remove coolant reservoir or surge tank. b. Attach engine support tool Nos. J-28467-360 and J-28467-400, or equivalents, onto alternator stud-ended bolt. c. Remove front cover upper mounting screws. d. Remove engine mount and bracket adapter. Discard adapter bolts. e. Raise and support vehicle with jack stands. f. Remove righthand front wheel and tire assembly, then the righthand splash shield. g. Hold balancer in position using harmonic balancer GM tool No. J-38122, or equivalent, remove mounting bolt and balancer using puller GM tool No. J-24420-C, or equivalent. h. Remove front cover lower mounting bolt. i. Lower vehicle. j. Remove front cover and gaskets. 5. Rotate crankshaft in clockwise direction until camshaft sprocket timing dowel pin holes line up with timing chain housing holes, Fig. 1. 6. Remove timing chain guides. 7. Raise and support vehicle with jack stands. 8. Ensure timing chain slack is above tensioner, then remove tensioner, Fig. 2. 9. Disconnect timing chain from tensioner shoe grooves and remove shoe using suitable screwdriver under timing chain while pulling shoe outward. 10. If removing tensioner shoe is difficult, proceed as follows: a. Lower vehicle. b. Hold intake camshaft sprocket in position with camshaft sprocket wrench GM tool No. J-39579, or equivalent. c. Remove sprocket bolt and washer. d. Remove washer and install bolt into camshaft by hand. e. Position suitable three-jaw puller into intake camshaft sprocket relief holes and remove sprocket. Do not pry on camshaft sprocket as damage to sprocket or timing chain housing may result. 11. Remove mounting bolts and tensioner. Caution: Tensioner is spring loaded. 12. Mark timing chain and crankshaft sprocket for installation. 13. Remove timing chain. 14. Apply adhesive sealant compound GM part No. 12345493, or equivalent, on camshaft sprocket bolt. 15. Hold camshaft sprocket in position with camshaft sprocket GM tool No. J-39579, or equivalent, then tighten mounting bolt and washer. 16. Position camshafts using camshaft sprocket timing alignment pin tools No. J-36800, or equivalent, through camshaft sprockets' into timing chain housing holes, Fig. 1. 17. If camshafts are out of position and must be rotated more than 1/8 turn, proceed as follows: a. Rotate crankshaft clockwise to 90° off TDC. b. Position camshafts and install dowels. c. Rotate crankshaft counterclockwise back to TDC. Caution: Rotating crankshaft clockwise to TDC will damage valves and pistons. 18. Place timing chain over exhaust camshaft sprocket, coolant pump or idler sprocket and crankshaft sprocket. 19. Remove intake camshaft timing pin and attach camshaft sprocket GM tool No. J-39579, or equivalent. 20. Rotate intake camshaft sprocket counterclockwise with tool until timing chain can be installed over sprocket. 21. Release tool. Timing chain tension between camshaft sprockets should tighten. 22. Timing pin should easily fit through intake camshaft sprocket timing hole into timing chain housing timing hole. If timing pin does not fit easily, repeat procedure. 23. With timing pins installed, raise and support vehicle with jack stands. 24. With timing chain slack between intake camshaft sprocket and crankshaft sprocket, timing marks on crankshaft and engine block should be aligned. If crankshaft timing marks are not aligned, move timing chain one tooth forward or rearward to remove slack, then align marks. 25. Load tensioner to zero position by forming keeper out of heavy gauge wire. 26. Apply slight force on tensioner blade to compress plunger. 27. Insert small screwdriver into reset access hole and pry ratchet pawl away from ratchet teeth while forcing plunger completely in hole. 28. Install keeper between access hole and blade. 29. Install tensioner to chain housing and inspect plunger installation again. Ensure long end is toward crankshaft. 30. Lower vehicle enough to remove alignment dowel pins. 31. Rotate crankshaft two revolutions clockwise. 32. Align crankshaft keyway with cylinder block alignment mark and insert timing pins through camshaft sprockets into timing chain housing timing holes. 33. Timing pins should slide easily through timing holes. If timing pins cannot be easily inserted, repeat procedure to properly time engine. 34. Install timing chain guides and front cover. Torque front cover bolts to 108 inch lbs. 35. Torque engine mount bracket adapter bolts to 81 ft. lbs., then tighten an additional 90° turn. 36. Install accessory drive belt. 37. Inspect cooling system and fill to proper level with recommended coolant, as required. 38. Fill engine crankcase to proper level with recommended engine oil. 39. Connect battery ground cable. 40. Start engine and confirm proper operation, and ensure there are no leaks. 41. Clear DTC(s) using a suitably programmed scan tool. 42. These engines do not require a specified bleed procedure. After filling cooling system, run engine to operating temperature with radiator/pressure cap off. Air will then be automatically bled through opening. Hope that helps.

To replace the front sprocket follow the chain to the cover on the left side and remove it, loosen the chain tensioners on the rear axle, slide rear wheel all the way forward and remove chain. Then remove the bolt in the center of the front sprocket, change sprocket and reverse process for assembly. That is the process but if you are going to change the front sprocket you should change both sprockets and chain, as the chain stretches and will cause premature wear of the new sprockets. Complete sets can be found on Ebay for little money, maybe they are not the best but as long as you do not abuse them they will do until you get the money for a good set.

Remove the gearbox sprocket cover, this may mean undoing the gear lever, First put the bike in gear. This will lock the sprocket so you can undo the securing nut, you will also need to loosen the rear axle to allow the chain to be taken off the sprocket. Then remove the sprocket, refit is the same process in reverse. I would suggest you change the complete set (front & rear sprockets and the chain) that way you only have to take it to bits once. And it will also mean the chain lasts longer as the wear will be the same at both ends.

Here you go This will help you

I assume you're talking about the front belt drive sprocket. First, disconnect the negative side of the battery. If you haven't already done so, you must drain the primary and remove the outer primary cover. Then you must take the engine compensator nut off and the nut that holds the primary chain adjuster. Remove the circlip and pull the clutch adjuster plate out of the center of the clutch. The mainshaft nut in the hole in the center of the clutch. The nut has LEFT-HANDED THREADS on it. Remove the engine compensator sprocket, primary chain, and clutch assembly all together. Then remove the small bolt that holds the jackshaft in and remove it and the coupling. Remove the starter. Then, take the bolts out and remove the inner primary cover. Now, you can see the front belt drive sprocket. You must take the large nut off the sprocket. It too has LEFT-HANDED THREADS. You need a special deep socket and a sprocket locking tool to get the sprocket off and retorque the nut when you put it back on. This is a major job requiring a fair amount of disassembly of the bike. If you're going to change the belt, the rear wheel and swingarm must come out as well. I would high recommend that you purchase a service manual to help with this project.

Good Luck
Steve

Timing is not resettable by the user, as the computer controls this based on knock or no knock conditions which will advance or ****** ignition timing for optimum performance.

The valve timing is something that is set when installing the timing chain:

2.5L, 2.8L and 3.1L Engines Fig. 4: Timing chain and sprocket removal - 2.5L engine
Fig. 5: Timing chain and sprocket removal - 1996 3.1L engine shown
Fig. 6: You must use a suitable puller to remove the crankshaft sprocket

1. Disconnect the negative battery cable.
2. Remove the timing chain front cover assembly, as outlined earlier in this section.
3. Rotate the crankshaft until the timing marks on the crankshaft sprocket and camshaft sprocket locator hole are aligned to the marks on the engine block or timing chain dampener. This is the No. 1 piston at TDC (No. 4 firing position).
4. Unfasten the camshaft sprocket retaining bolt/screw, then remove the camshaft sprocket and the timing chain. NOTE: If the camshaft sprocket does not come off easily, a light blow on the lower edge of the sprocket with a rubber mallet should loosen the sprocket.
   
5. Remove the crankshaft sprocket using tool J 23444-A or equivalent puller.
6. If necessary, remove the timing chain dampener retaining bolts, then remove the dampener. To install:
   
7. Install the crankshaft sprocket using tool J 38612 until it the sprocket is fully seated on the flange of the crankshaft nose. Apply a coat of Molykote® or equivalent, to the sprocket thrust surface.
8. Hold the camshaft sprocket with the chain hanging down, and align the marks on the camshaft and crankshaft sprockets.
9. If removed, install the timing chain damper to the engine block.
10. Align the dowel in the camshaft with the dowel hole in the camshaft sprocket. Install the camshaft sprocket and chain, use the camshaft sprocket bolts to draw the sprocket on to the camshaft. Tighten the sprocket bolts to 18 ft. lbs. (25 Nm).
11. Lubricate the timing chain with engine oil.
12. Install the front cover assembly, as outlined earlier in this section.
13. Connect the negative battery cable.

Your sportster is actually pretty easy to change the front sprocket on. On the right side of the bike, you'll see the rear brake master cylinder. The master cylinder must come off as well as the plate that the master cylinder sits on. To get this off, you'll have ot remove the brake pedal and the exhaust system.

Once you get the plate off, you'll need some special tools to remove and replace the front sprocket. You'll need a special socket to remove the large nut holding the sprocket on and a special device made to hold the sprocket so you can get the nut off and then back on with the proper torque.

In addition to changing the front sprocket, you'll also have to change the final drive belt to match the size of the rear sprocket and front sprocket combination.

Good Luck
Steve

5.0L and 5.7L Engines To Remove:

1. Remove the crankshaft balancer.
2. Drain the cooling system.
3. Remove the water pump.
4. Drain the engine oil.
5. Remove all engine oil pan fasteners except two nuts at rear of engine.
6. Separate the engine oil pan from the front cover.
7. Disconnect the crankshaft position (CKP) sensor wire.
   
   
8. Remove engine front cover.
   
   
9. Pry the oil seal from the front cover.
10. Inspect the front cover seal area and crankshaft balancer seal area for damage.
    
    
11. Rotate the crankshaft until the timing marks on the crankshaft and the camshaft sprockets are aligned.
12. Remove the crankshaft position sensor reluctor ring.
    
    NOTE: Free play on the slack side of the camshaft timing chain must measure less than 0.43 inch (11Mm) or timing chain and sprockets must be replaced.
    
13. Remove the camshaft sprocket bolts.
14. Remove the camshaft sprocket.
15. Remove the camshaft timing chain. NOTE: Do not turn the crankshaft assembly after the timing chain has been removed in order to prevent damage to the piston assemblies or the valves.
    
    
    
16. Remove the crankshaft sprocket using J 5825-A.
17. Remove the crankshaft balancer woodruff keys (if required).

To Install:

1. Install the crankshaft balancer woodruff keys into the crankshaft.
2. Align the crankshaft sprocket keyway with the crankshaft balancer woodruff key. WARNING
   Wear eye protection when installing crankshaft sprocket.
   
   
   
3. Use J 5590 to install crankshaft sprocket.
4. Install the camshaft sprocket and camshaft timing chain.
   
   
5. Ensure that the crankshaft sprocket alignment mark is in the 12 o'clock position and the camshaft sprocket alignment mark is at the 6 o'clock position.
6. Install the camshaft sprocket bolts and tighten the camshaft sprocket bolts;
   • Torque to: 18 ft. lbs. (25 Nm)
7. Install the crankshaft position sensor reluctor ring until completely seated against crankshaft sprocket. NOTE: The composite type engine front cover and seal must not be reused. Always install a new engine cover with a new seal.
   
8. Install new engine front cover and bolts.
   • Torque bolts to: 106 in. lbs. (12 Nm)
9. Clean sealer from corners of oil pan gasket where it meets the engine front cover.
   
   
10. Apply a 0.196 in (5 mm) bead of adhesive, GM P/N 12346141 or equivalent, 1.0 in (25 mm) long to the engine front cover to engine block junction.
11. Install oil pan bolts.
    • Torque bolts to: 106 in. lbs. (12 Nm)
12. Tighten oil pan nuts.
    • Torque bolts to: 18 ft. lbs. (25 Nm)
13. Connect the crankshaft position sensor wire.
14. Install the water pump.
15. Install the crankshaft balancer.
16. Fill the engine to the proper level with oil.
17. Fill the engine to the proper level with coolant.
18. Test drive the vehicle to confirm the repairs.

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Item Part Number Description 1 — 40 Timing Chain/Belt Teeth 2 6256 Camshaft Sprocket , Front 3 — 43 Timing Chain/Belt Teeth 4 6306 Crankshaft Sprocket 5 6268 Timing Chain/Belt 6 6256 Camshaft Sprocket , Rear
Removal

1. Drain the cooling system. Refer to Section 03-03 for the procedure.
   

1. Disconnect the battery ground cable (14301) .
   

1. Remove the generator drive belt, water pump and power steering pump drive belt, and the A/C compressor drive belt (if equipped). Refer to Section 03-05 for the removal procedure.
   

1. If equipped, remove the three A/C compressor drive belt idler pulley bolts and the A/C compressor drive belt idler pulley.
   

1. Remove the upper radiator hose bracket bolt.
   

1. Loosen the two upper radiator hose clamps and remove the radiator hose bracket bolt. Remove the upper radiator hose (8260) and the upper radiator hose bracket from the vehicle.
   

1. Remove the water bypass hose (8597) from between the thermostat housing and the water hose connection (8592) .
   

1. Remove the main wiring harness from the upper engine front cover (6019) .
   

1. Remove the eight upper engine front cover bolts and the upper engine front cover .
   

1. Raise and support the vehicle.
   

1. Remove the RH front wheel and tire assembly.
   

1. Remove the four RH outer engine and transmission splash shield bolts and two screws and remove the RH outer engine and transmission splash shield (6775) .
   

1. Use Strap Wrench 303-D055 (D85L-6000-A) or equivalent to hold the water pump pulley (8509) while removing the four water pump pulley bolts.
   

1. Remove the water pump pulley from the water pump (8501) .
   

1. Remove the crankshaft pulley (6312) . Refer to the procedure in this section.
   

1. Remove the five lower engine front cover bolts and the lower engine front cover .
   
2. Ensure that the timing marks between the crankshaft sprocket (6306) and the oil pump housing line up.
   
3. NOTE: The directional arrow is necessary to ensure that the timing chain/belt (6268) can be reinstalled in the same direction.
   
4. Loosen the timing chain/belt tensioner nut.
   
5. Remove the timing chain/belt .
   
   
6. Installation
   NOTE: Ensure that the timing marks on the camshaft sprockets (6256) and the seal plate are properly aligned. Ensure that the timing marks on the crankshaft sprocket and the oil pump housing are still aligned. NOTE: A new timing chain/belt has three white timing marks that indicate the correct timing positions of the camshafts (6250) and the crankshaft (6303) . These marks will help ensure that the engine (6007) is timed properly. When the engine is properly timed each white timing mark on the timing chain/belt will be aligned with the corresponding camshaft and crankshaft timing mark on the sprocket. Because the white timing marks are not evenly spaced you will need to refer to the following illustration for proper timing chain/belt placement. There should be 40 timing belt teeth between the timing marks of the front and rear camshaft sprockets and 43 teeth between the timing mark on the front camshaft sprocket and the timing mark on the crankshaft sprocket .
   
   NOTE: Verify that the camshaft timing marks are aligned with the timing marks on the seal plate, and that the crankshaft sprocket timing mark is aligned with the timing mark on the oil pump (6600) .
   
   Install the timing chain/belt starting at the crankshaft sprocket and moving around to the camshaft sprocket following a counterclockwise path. Do not allow any slack in the timing chain/belt between the timing sprockets. After all of the timing marks are matched up with the timing chain/belt installed, slip the timing chain/belt onto the timing chain/belt tensioner .
   
   
   
   
   
   

Get a new seal before taking the sprocket off. Remove the sprocket cover plate. You will see two small bolts holding a lock plate on the sprocket. Remove the bolts, lock plate and sprocket. Clean the sprocket shaft so the new seal is not damaged when installing. Now just pry out the old seal any way you can with a screwdriver and small hammer. Install the new seal flush with the casing.