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)
2. Secure motorcycle upright (not leaning on jiffy stand) on a level surface.
3. See Figure 1. Drain primary chaincase.
4. Clean drain plug magnet. If plug has excessive debris, inspect the condition of chaincase components.
5. Install drain plug and new O-ring. Tighten.
Torque: 19–28.5 N·m (14–21 ft-lbs) Primary chaincase drain plug
Figure 1. Removal/Installation of Chaincase Drain Plug
6. See Figure 3. Remove screws (3) and clutch inspection cover (2).
7. Remove seal (1). Wipe oil from primary cover and groove in inspection cover.
NOTE
FLSB has seal installed on groove in primary cover.
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. Add lubricant.
a. Pour specified amount of FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT through clutch inspection cover opening. Refer to Table 1.
b. See Figure 2. Proper level is approximately at bottom of pressure plate OD.
Table 1. Primary Chaincase Lubricant
AMOUNT*
DRY FILL**
WET FILL***
Oz
L
Oz
L
Wide Primary
46
1.36
42
1.24
Narrow Primary
40
1.18
36
1.06
* Amount is approximate. Fill to bottom of pressure plate OD with vehicle upright.
** Cover was removed and installed.
*** Lubricant was drained through the drain plug only.
Figure 2. Primary Chaincase Lubricant Level
9. Install clutch inspection cover and new seal:
a. See Figure 3. Install new seal (1) in groove in cover.
b. Secure clutch inspection cover with screws with captive washers (3).
c. See Figure 4. Tighten in sequence shown.
Torque: 9.5–12.2 N·m (84–108 in-lbs) Clutch inspection cover screws (All except FLSB)
Torque: 2.8–3.9 N·m (25–35 in-lbs) Clutch inspection cover screws (FLSB)
1Seal
2Clutch inspection cover
3Screw and captive washer (5)
Figure 3. Clutch Cover (Typical)
Figure 4. Clutch Cover Tightening Sequence