1. Run motorcycle until engine is at normal operating temperature. Turn off engine.
WARNING
Be sure that no lubricants or fluids get on tires, wheels or brakes when changing fluid. Traction can be adversely affected, which could result in loss of control of the motorcycle and death or serious injury. (00047d)
NOTICE
When draining or adding lubricant, do not allow dirt, debris or other contaminants to enter the engine. (00198a)
2. See Figure 1. Drain primary chaincase.
3. Clean drain plug. If plug has accumulated excessive debris, inspect the condition of chaincase components.
4. Install new O-ring on drain plug.
5. Install drain plug. Tighten to 19–28.5 N·m (14–21 ft-lbs).
Figure 1. Removal/Installation of Chaincase Drain Plug
6. See Figure 2. Remove screws with captive washers (3) and clutch inspection cover (2).
7. Remove seal (1). Wipe oil from groove in chaincase cover and mounting surface.
NOTICE
Do not overfill the primary chaincase with lubricant. Overfilling can cause rough clutch engagement, incomplete disengagement, clutch drag and/or difficulty in finding neutral at engine idle. (00199b)
8. Stand motorcycle upright (not leaning on jiffy stand) on a level surface.
9. Pour specified amount of FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT through clutch inspection cover opening. Refer to Table 1.
Table 1. Primary Chaincase Lubricant Refill Capacity
CONDITION
CAPACITY
fl oz
L
Wet
34
1.0
Dry *
38
1.1
* Quantity after complete disassembly.
10. Install clutch inspection cover and new seal:
a. Thoroughly wipe all lubricant from cover mounting surface and groove in chaincase cover.
b. See Figure 2. Position new seal (1) in groove in clutch inspection cover (2). Press each of the nubs on seal into the groove.
c. Secure clutch inspection cover (2) with screws with captive washers (3).
d. See Figure 3. Tighten in sequence shown to 9.5–12.2 N·m (84–108 in-lbs).
1Seal
2Clutch inspection cover
3Screw and captive washer (5)
Figure 2. Clutch Cover (Typical)
Figure 3. Clutch Cover Torque Sequence