1. | Ride motorcycle until engine is warmed up to normal operating temperature. | |
2. | Position motorcycle straight up. | |
WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) | ||
3. | Remove main fuse. See Maintenance and Lubrication → Fuses. | |
4. | XL models with mid-mount controls: See Figure 3. Remove screws and detach the rider footrest support bracket from the left side of the vehicle. | |
5. | See Figure 1. Remove screws with washers from clutch inspection cover. Remove clutch inspection cover from primary cover. NOTE The filler access is the clutch inspection cover. | |
6. | See Figure 2. Verify that lubricant level is even with bottom of clutch diaphragm spring. NOTE Add only enough of FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT through clutch inspection cover opening until the lubricant reaches the bottom of clutch diaphragm spring. | |
7. | Install the clutch inspection cover. a. Install new quad ring. b. Verify that quad ring is fully seated in groove of primary cover. c. Install clutch inspection cover and secure with six screws. d. Tighten in a crosswise pattern to 10.2–13.6 N·m (90–120 in-lbs). | |
8. | If the left footrest assembly was removed, install support bracket with two screws. Tighten screws to 61–67.8 N·m (45–50 ft-lbs). | |
9. | Install main fuse. | |
10. | Start engine. Check for any lubricant leaks. | |
11. | Turn engine off. |
1 | Clutch inspection cover |
2 | Drain plug |
3 | Primary chain inspection cover |
1 | Clutch diaphragm spring |
2 | Clutch adjusting screw |
3 | Quad ring |
4 | Primary cover |
5 | Chaincase lubricant level |
1. | Ride motorcycle until engine is warmed up to normal operating temperature. | |
2. | When the engine reaches normal operating temperature, turn the engine off and position motorcycle on jiffy stand. This will allow the chaincase lubricant to drain out of transmission. | |
WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) | ||
3. | Remove main fuse. See Maintenance and Lubrication → Fuses. | |
4. | See Figure 1. Position a suitable container under transmission drain plug (2). | |
5. | The drain plug is located under the clutch, on the underside of the primary cover. Remove drain plug and drain lubricant. | |
6. | Position the motorcycle STRAIGHT UP and LEVEL. This allows additional fluid to be drained from clutch compartment. NOTE Dispose of lubricant in accordance with local regulations. | |
NOTICE Do not over-tighten filler or drain plug. Doing so could result in a lubricant leak. (00200b) | ||
7. | Clean the magnetic drain plug. Replace the O-ring if it is damaged. | |
8. | Apply LOCTITE 565 PIPE SEALANT WITH TEFLON and install drain plug. Tighten to 19–40.7 N·m (14–30 ft-lbs). | |
9. | XL models with mid-mount controls: See Figure 3. Remove screws and detach the rider footrest support bracket from the left side of the vehicle. | |
10. | See Figure 1. Remove screws with washers from clutch inspection cover. Remove clutch inspection cover from primary cover. NOTE The filler access is the clutch inspection cover. | |
11. | See Figure 2. Add 0.95 L (1.00 qt) of FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT (Part No. 98851-05 qt) through clutch inspection cover opening until the lubricant reaches the bottom of clutch diaphragm spring. | |
12. | Install the clutch inspection cover. a. Install new quad ring. b. Verify that quad ring is fully seated in groove of primary cover. c. Install clutch inspection cover and secure with six screws. d. Tighten in a crosswise pattern to 10.2–13.6 N·m (90–120 in-lbs). | |
13. | If the left footrest assembly was removed, install support bracket with two screws. Tighten screws to 61–67.8 N·m (45–50 ft-lbs). | |
14. | Install main fuse. | |
15. | Start engine. Check for any lubricant leaks. | |
16. | Turn engine off. |
1 | Support bracket |
2 | Screws (2) |