Motorycle Speedo Gear Relocation Tutorial

Tutorials > Miscellaneous > Speedo Gear Relocation

Speedo Gear Relocation

Description

This modification is basically used to regain meter usage when front end conversion is done and speedometer/odometer assembly cannot be reinstalled on front axle.

Details

michigan_313

Tutorial by:

September 25, 2008

Created:

520

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5/5 stars (1 vote)

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Installation Vehicle:

1989 CBR600F

Parts and Cost:

44800-MR7-003 - Speedometer box assembly - $70
44830-KR5-000 - Speedometer cable - $13
93700-05020-0G - Screw, oval (5x20) - few cents
96600-06012-07 - 6mm hex bolt - few cents, need 2

Introduction:
This is a conversion to regain use of speedomter/odometer reading by taking meter reading from counter sprocket gear. This modification is basically used to regain meter usage when front end conversion is done and speedometer/odometer assembly cannot be reinstalled on front axle. This document assumes that front suspension or rim has been changed and stock speedo gear can no longer be used.

Warning Note:
Improper installation of odometer gear assembly and cable to instrument cluster could cause improper readings and/or potential issues with both. I have tried to document this process as best as possible with all caveats and workarounds. I do not take responsibility for any mistakes or problems caused by this modification to said persons motorcycle. If you are not sure about something in this document, ASK! and I will try to clarify with revision. If there is a better process to this, please add as this will be greatly appreciated by members of this community. This modification took several long hours but with this document should take about 3 if all parts and tools are available.

Reasoning:
I wanted to be able to have the use of the speedometer and odometer after the front suspension swap. I did not feel like going through a instrument cluster swap from analog dial to digital (my electrical skills not as good as my mechanical), and did not feel like looking at electronic solutions to adapt to my bike from other later model years that do not use mechical means. Thus, I looked at other older model bikes to see how I could adapt a mechinical solution to my motorcycle. After many months, I took one look at my VFR and there was the solution staring me right in the face. Not to say that all the effort I put into researching a solution was a waste, but I could've really saved myself a lot a time and a few headaches.

Cable and Gear assembly removal:

Remove leftside bodywork, front fairing can be left in place but windscreen will need to be removed.
Unbolt instrument cluster. 3 bolts.
Uscrew speedo cable from instrument cluster and remove completely from bike.

Sprocket cover removal:

Unbolt and remove gear shift lever from gear shift shaft. 1 bolt.
Unscrew bolts from sprocket cover. 4 bolts.
Remove cover. be careful of dirt and grease buildup on inside of cover. i recommend lining the work area underneath the bike with a painters drop cloth or newspaper. clean out inside of cover.

Sprocket cover modification:

Since the cover is not symmetrical, you will have to find the center of the sprocket bolt and determine where to drill the hole in the cover. use a pair of calipers to determine where center would be by taking readings from cover bolts to center of sprocket bolt. mark on paper any two points that intersect. mark cover accordingly with distance recorded on paper.
Secure the cover before drilling. use a small bit to make a hole and see if close to sprocket bolt center. if not, drill another accordingly. when center is found, use larger bit to drill hole. i used a unibit. hole diameter should be approximately 21mm.
When finished drilling, mount cover back on and see if bolt is completely visible.

Sprocket bolt modification:

Remove sprocket bolt or if not able to remove, mod can be done on bike.
Top of bolt will need to be removed.
Cut top pin off and reinstall bolt.
Reinstall cover.
Take speedo gear and put into hole. Make sure that it sits flush on cover and not lopsided. If it sits lopsided, hole in cover may have to be drilled wider or offset. do whatever is necessary for the gear to sit flush and the unit to run smoothly. If it feels like it is missing, the joint may not be sitting on the sprocket bolt correctly.

Speedo cable install:

Route cable (oem cable can possibly be used with new assembly) as straight as possible and avoid any kinks or hard turns as this will cause the cable to bind up and run tight. i ran mine between the engine and frame rail, and up behind the headlight. be sure to avoid any tangles with electrical connections to pods on clip-ons. be sure that steering is not impeded by routing of cable and cable function is not impeded by steering.
At the speedo gear end, attach cable to assembly. be sure that cable is bottomed out in the assembly. look through the screw hole to see opposite side of screw hole is visible.
Put speedo gear back into cover hole.
Now rotate assembly till cable is straight or not binding on or against anything.
Take marker and mark holes on sprocket cover.
Remove speedo gear and sprocket cover.

Sprocket cover modification, Part II:

Drill holes for speedo gear mounting screws. remember not to drill larger than the tap used to thread the holes.
Use tap to thread holes.
Be sure to completely clean all newly threaded holes and remove any tapped metal from cover.
Install speedo gear onto cover and check for bolt fitment and hole clearance.

Final installation:

A rear stand is recommended to prop the rear tire to facilitate quick rotation of the countershaft sprocket to check cable and gear function. This will be much easier than having to move the bike forwards and backwards.
Reinstall sprocket cover.
Install speedo gear. make sure that joint sits over sprocket bolt.
Install cable into speedo gear.
***caveat symptom: sprocket cover is slightly rounded and is not a completely flat surface.
***workaround: do not tighten bolts completely or else the mounting wings on the gear assembly may bend and break off. this unit is made of cast aluminum and is very brittle. use thin lock washers to make up spacing over cover and then speedo assembly can be tighted. use loctite and do not overtighten as threads may strip since cover is made of aluminum.
Install cable into instrument cluster.
Screw back down instrument cluster.
Rotate rear wheel to make sure cable is not kinked or binding at any location. if so, you will need to reroute.
Reinstall gear shift lever and holding bolt.
Reinstall windscreen and bodywork.
Take bike for spin and check odometer reading and speedo reading.
Done!