1. Run motorcycle until engine is at 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)
2. See Figure 1. Drain lubricant into suitable container.
3. Clean drain plug. If plug has accumulated a lot of debris, inspect the condition of chaincase components.
4. Install new O-ring on drain plug.
5. Install drain plug into primary chaincase cover. Tighten to 19–28.5 N·m (14–21 ft-lbs).
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
6. Disconnect negative battery cable.
7. See Figure 2. Remove screws with captive washers (3) and clutch inspection cover (2).
8. 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)
9. Place motorcycle in an upright position to fill primary chaincase.
10. 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
ITEM
CAPACITY
Primary chaincase lubricant
0.95 L (32 fl oz)
Figure 1. Removal/Installation of Chaincase Drain Plug
1Seal
2Clutch inspection cover
3Screw with captive washer (5)
Figure 2. Clutch Cover
11. 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. Press each of the nubs on seal into the groove.
c. Secure inspection cover 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).
12. Connect battery negative cable. Tighten to 6.8–8.1 N·m (60–72 in-lbs).
Figure 3. Clutch Cover Torque Sequence