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Discussion Starter · #1 ·
I thought on here at one time I saw a thread on the terminal and replacement of the CCT? I have a 2005 with about 70k on the odometer with the original CCT in it. I have the replacement green dot one and both gaskets but can’t really find a good video or thread on how to do it or the tools needed. Can anyone help me out especially with the tools and tricks of the job or dangers of the job?
Thanks.


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He caught that just in time, playing with fire.... I like the short video.

My suggestions... zip tie chain at crankshaft end down lower, use broken off/short 8mm from below to get one of the bolts out, while all the bolts are out, Dremel or hacksaw a slot in the bolt heads, insert screwdriver in frame hole to spin the bolts in, saves a lot of time with wrenches.
If you're careful upon removal of the timing cover, you can salvage the gasket, I've only ever replaced one on all the times I've had them apart, yes be aware of the dowels, put it back in place immediately if it comes out with the timing cover.
Be careful not to pinch the ignition pickup wire when putting the cover back on, especially at top corner, or bike could run like crap.
 

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The hacksaw or dremel idea is genius!! I'm waiting on the gasket now, so I will be doing mine today or tomorrow. I'll let ya know how it goes for sure.
 

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H use broken off/short 8mm from below to get one of the bolts out, while all the bolts are out, Dremel or hacksaw a slot in the bolt heads, insert screwdriver in frame hole to spin the bolts in, saves a lot of time with wrenches.
Here's the shorty wrench I used on my '05 a few years ago...plus a short hose to get the bolt started (if I recall correctly... been a few years).
Regards,
Mr. BR
 

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Why didn't I think of the hose, lol... not bad at all !!
 
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Discussion Starter · #7 ·
Thanks I'll definately zip tie that off, I'm struggling getting the bolts out, I'm a little short on the precise tools needed thats definatley a tight fit area. I bought a spanner set but they're too thick and won't fit over the bolts. Thanks everyone, Onward keep trying........
 

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Please tell me why I forgot all about the frickin hose idea!!! Worse actually, I went to a buddy's house 2 blocks down to use his vise and grinder to cut screwdriver notches in the new bolts. Guess what I used to not damage the new threads while in the vice.......a hose of course. But still did not use one to re-thread or start the new bolts!!! I'm messing around with small zip ties around the nut of the bolt, WOW do I feel like a complete idiot right now!! That job should of taken me a hour tops but it went way longer than that. How much longer I will take to my grave.

Good news is the Green dot CCT is in, fluids flushed except brake as I am waiting for new tires to get mounted. (I'll have them tomorrow.) Nothing leaks and she is running wonderfull.
 
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