1. Run motorcycle until engine is warmed up to normal operating temperature.
NOTICE
When draining or adding lubricant, do not allow dirt, debris or other contaminants to enter the engine. (00198a)
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)
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
2. Disconnect negative battery cable. See Maintenance and Lubrication → Battery Access.
3. See Figure 1. Remove magnetic drain plug at bottom of primary chaincase. Drain lubricant into suitable container.
NOTE
Dispose of lubricant in accordance with local regulations.
4. Clean drain plug. If plug has accumulated a lot of debris, inspect the condition of chaincase components.
5. Install new O-ring on drain plug.
6. Install drain plug back into primary chaincase cover. Tighten plug to 19–28.5 N·m (14–21 ft-lbs).
7. See Figure 2. Remove five TORX screws with captive washers (3) to detach clutch inspection cover (2) from primary chaincase cover.
8. Remove the 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)
9. Refer to Specifications → Specifications → Capacities. Pour the specified amount of GENUINE Harley-Davidson FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT (Part No. 99851-05 quart) in through the clutch inspection cover opening.
Figure 1. Removing Chaincase Drain Plug
1Seal
2Clutch inspection cover
3Screws with captive washer
Figure 2. Clutch Cover
10. Install clutch inspection cover and new seal as follows:
a. Thoroughly wipe all lubricant from cover mounting surface and groove in chaincase.
b. See Figure 2. Position new seal (1) in groove in clutch inspection cover and press each of the nubs on seal into the groove. The nubs will retain seal in position.
c. See Figure 3. Insert screw (with captive washer) through clutch inspection cover and carefully thread it into the top cover screw hole.
d. Start the remaining four screws (with captive washers).
e. Alternately tighten screws to 9.5–12.2 N·m (84–108 in-lbs) following torque sequence shown in Figure 3.
11. Connect battery negative cable. Tighten to 6.8–7.9 N·m (60–70 in-lbs).
Figure 3. Clutch Cover Torque Sequence