HOW TO- Sparks Advance Key Installation
OK Guys,
A few have asked for these, so here's my pics for the Sparks key install.
You will not need to drain the oil, if you put the left side tires up on about 6" boards. (this will also make it eaiser to work on).
Also you will not need to use an Impact gun/wrench providing you have a Large Adjustable Wrench, (24" is good), a Medium Adjustable Wrench, (18" is good), a Long Breaker bar, (24" is good), and a good Torque Wrench.
Remember to have your replacement side cover gasket BEFORE you start. it is Honda part number, 11395-KCY-671
(note- captions for pics will be BELOW the pic)
so lets get going here....
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8275.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8275.jpg" border="0" alt="Photobucket"></a>
Sparks Timing Advance Key with Flywheel Puller Bolt
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8274.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8274.jpg" border="0" alt="Photobucket"></a>
with your bike lifted up about 6" on the left side, you will not need to drain the oil, and it makes it eaiser to remove the starter cover bolts, and the Left Side Cover bolts.
(yes you need to remove the starter cover, gear, and spacer )
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8277.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8277.jpg" border="0" alt="Photobucket"></a>
remove the neutral switch wire. (it just pulls straight off)
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8279.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8279.jpg" border="0" alt="Photobucket"></a>
Remove the Shifter Lever, Side Case bolts, and Starter Cover bolts
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8280.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8280.jpg" border="0" alt="Photobucket"></a>
Gently remove Started Cover, Gear, Spacer, and Shaft.
(If you are gentle, and with a little luck, the gasket should be ok)
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8281.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8281.jpg" border="0" alt="Photobucket"></a>
Now GENTLY Tap the Side Cover Case with a Soft Blow Mallet to break the seal, and pull the Side Cover STRAIGHT back.
Remember that there is a o-ring seal around the starter shaft housing, and you must remove the Side Case straight without trying to wiggle it too much.
Now remove any gasket material from the Side Case.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8282.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8282.jpg" border="0" alt="Photobucket"></a>
Now place a Large Adjustable Wrench on the 2 flats of the flywheel. Make sure to get the wrench as tight as possible on the flats to prevent it from slipping off.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8283.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8283.jpg" border="0" alt="Photobucket"></a>
If you use a 24" Adjustable Wrench, it will conviently reach, and rest on the front spindle, allowing for a solid contact surface
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8284.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8284.jpg" border="0" alt="Photobucket"></a>
Next place socket and LONG breaker bar on the Flywheel bolt, and you can easily remove the bolt, without the need for a Impact gun, and chancing damage to the bolt or Crankshaft.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8285.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8285.jpg" border="0" alt="Photobucket"></a>
Remove bolt and washer
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8287.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8287.jpg" border="0" alt="Photobucket"></a>
put the puller bolt into the Flywheel.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8288.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8288.jpg" border="0" alt="Photobucket"></a>
Swap sides with the Large Adjustable Wrench, and remember to get it as snug as possible on the Flywheel.
Find a convienent point for the handle of the Wrench to rest.
(my spot was on the nerf bar), yours may be the footpeg.
Now use you Medium Adjustable Wrench on the Puller bolt, and carefully TIGHTEN the bolt, into the Flywheel, until it pops loose.
(sorry I dont have a pic of this, but I only have two hands, and was doing this all alone)
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8289.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8289.jpg" border="0" alt="Photobucket"></a>
Flywheel removed.
Now clean off any gasket material from the Engine case.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8290.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8290.jpg" border="0" alt="Photobucket"></a>
Using a small screwdriver, and tap hammer, remove the stock Woodruff key.
take your time and dont damage the keyslot.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8292.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8292.jpg" border="0" alt="Photobucket"></a>
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8294.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8294.jpg" border="0" alt="Photobucket"></a>
these 2 pics show the difference between the Stock key, and the Sparks Advance key.
(this is how far you will be turning the Flywheel to the left).
This applies to the "single notch" type keys only.
Note- if you recieved one of the keys that is the "offset type", you will not need to hold the Flywheel to the left when tightening the flywheel back on.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8295.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8295.jpg" border="0" alt="Photobucket"></a>
Now install the Sparks Advance key into the slot, with the red side facing AWAY from the Engine.
Make sure to get it COMPLETLY seated into the slot so that the "notch" is COMPLETLY flush with the surface of the Crankshaft.
This is eaisly accomplished using a small, flat tipped, drift punch, and small tap hammer.
(Be careful not to damage the edge of the key, OR the edge of the keyslot)
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8298.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8298.jpg" border="0" alt="Photobucket"></a>
Now carefully replace the Flywheel, aligning the Flywheel keyway, with the Sparks Advance key.
Rotate the Flywheel forward to touch the backside of the Sparks key, and slide the Flywheel onto the Crankshaft until it stops.
next, replace the stock Flywheel bolt finger tight.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8288.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8288.jpg" border="0" alt="Photobucket"></a>
Put the Large Adjustable Wrench back onto the flats of the Flywheel, and find a solid place to rest the wrench handle.
Using a Torque Wrence set to 94 ft/lbs, tighten the Flywheel bolt.
(this method will insure that you a keeping the Flywheel "turned to the left").
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8298.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8298.jpg" border="0" alt="Photobucket"></a>
install new Side Case gasket.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8297.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8297.jpg" border="0" alt="Photobucket"></a>
Honda Side Case gasket part number
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8299.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8299.jpg" border="0" alt="Photobucket"></a>
Re-install Side Cover, being careful to slide it over the O-Ring Seal on the Starter Shaft Housing.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8309.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8309.jpg" border="0" alt="Photobucket"></a>
replace the Side Case bolts,(and 1 nut), back in their original positions, finger tight.
(If you use a piece of cardboard before you started, and draw a picture of the sidecase and bolt positions,... then it is easy to insure they all go back in their original positions).
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8302.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8302.jpg" border="0" alt="Photobucket"></a>
OK, Now we are going to re-install the Starter gears.
I tried to put the gear shaft first, then slide the gear on.
This did not work too well due to the Starter Gear meshes with the Starter Shaft FIRST, and makes it a little difficult to get the Starter Gear to mesh with the Flywheel gear....
SOooo,...
To make it a little eaiser, do it this way.
Put the Starter Ge ar in FIRST. this will make it much eaiser to get the Starter Gear meshed with BOTH the Starter Shaft, AND the Flywheel Gear together.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8303.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8303.jpg" border="0" alt="Photobucket"></a>
Starter Gear in, and meshed with both the Starter Shaft, and the Flywheel Gear.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8304.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8304.jpg" border="0" alt="Photobucket"></a>
Next, Slide the Shaft through the Starter Gear , and into the Side Case Cover.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8305.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8305.jpg" border="0" alt="Photobucket"></a>
Shaft in place.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8306.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8306.jpg" border="0" alt="Photobucket"></a>
Next, Place Shaft Spacer onto Shaft.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8307.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8307.jpg" border="0" alt="Photobucket"></a>
Spacer in place on Shaft.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8308.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8308.jpg" border="0" alt="Photobucket"></a>
And now replace Starter Cover.
<a href="http://s111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/?action=view¤t=IMG_8274.jpg" target="_blank"><img src="http://i111.photobucket.com/albums/n148/tri5ron/Sparks%20advance%20key%20installation/IMG_8274.jpg" border="0" alt="Photobucket"></a>
Now replace remaining bolts, Neutral Wire Clip, 1 Case nut.
Tighten all bolts, and 1 nut to 7 ft/lbs ., Replace Neutral Switch Wire to it's connector,
Reinstall Shifter lever, (re-align the dots on the Shifter Lever, and the shaft).
Now, turn key, push Starter button, get your Helmet, (I don't think I need to tell ya how to put that on...LOL!), give the throttle a couple of quick snaps,
and start Bangin' some gears!
(Little tip here, You might want to sit/lean a little more forward than usual for your first Launch !)
