- 1). Remove the primary chain case drain plug on the bottom of the chain case under the clutch cover with an Allen socket and a socket wrench. Drain the primary chain case fluid into a pan.
- 2). Inspect the magnetic end of the drain plug for bits of metal. Dredge the drained primary chain case fluid with a magnetic probe. Inspect the probe for bits of metal.
- 3). Remove the five clutch cover screws with an Allen or Torx socket (depending on the year and model of your bike) and a socket wrench. Remove the round clutch cover and gasket. Discard the gasket.
- 4). Remove all four screws in the oval inspection cover with an Allen or Torx socket and a socket wrench. Remove the cover and gasket. Discard the gasket.
- 5). Remove all 12 primary chain case cover screws with an Allen or Torx socket and a socket wrench. Remove the primary chain case cover.
- 6). Remove and discard the primary chain case cover gasket and both primary chain case tower gaskets inside the primary.
- 7). Inspect the compensating sprocket, the clutch, the chain and the chain tensioner for obvious defects or wear.
- 8). Heat the compensating sprocket nut with a heat gun to loosen the nut. Remove the compensating sprocket nut with a hex socket and a breaker bar.
- 9). Remove the spacer, sprocket cover, sliding cam and compensating sprocket. Clean and inspect all components for wear. Replace or repair as needed.
- 10
Inspect the shaft extension for wear before beginning reassembly. Clean the threads on the engine sprocket shaft and the internal threads in the sprocket nut with Loctite 7649 cleaner/primer or equivalent. - 11
Apply thread locker to the threads on the engine sprocket shaft. Apply engine oil to the underside of the sprocket nut. - 12
Replace the compensating sprocket, sliding cam, sprocket cover and spacer. Hand tighten the sprocket nut. - 13
Tighten the sprocket nut to 75 foot-pounds of torque with a hex socket and a torque wrench. - 14
Install two new tower gaskets and a new primary chain case cover gasket. Replace the primary chain case cover. - 15
Tighten the primary cover screws to 120 inch-pounds of torque with a Torx or Allen socket and a torque wrench in the exact tightening sequence described in the service manual for your motorcycle. - 16
Replace the inspection cover with a new inspection cover gasket. Coat the threads of the of the primary drain plug with Teflon paste and replace the drain plug - 17
Pour primary chain case lubricant into the primary chain case until the lubricant just touches the bottom of the clutch. Replace the clutch cover with a new clutch cover gasket. - 18
Check for leaks. Road test the motorcycle.
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