Spline Lube Checklist

By Deryle Mehrten
July 2000

TASK SUBTASK Completed
Remove Body Parts    
  Take off Tank Bag  
  Take off Rear Trunk  
  Remove Side Covers  
  Take off Taillight Fender  
  Remove Rear Fender  
  Remove Belly Pan  
  Remove Hard Bag Mounts
Left Side Holds Muffler
 
  Remove Coil Cover
Disconnect Accessory Plug(s)
 
  Remove Alternator Cover (Right side)  
  Take off Left Lower Fairing Panel  
     
Take Seat Off    
  Remove Seat Stay Arm Clip  
  Remove Rear and Side Stay Clips  
     
Remove Under-seat Tray    
  Remove Brain  
  Remove Brain Box Left Side Cover  
  Remove Retaining Pin on Right Side  
  Slide Brain Out  
  Disconnect Brain Master Socket  
  Put Brain in Safe Place  
  Disconnect Any Accessories  
  Remove Tray (Check for Rubber Mounts)  
     
Remove Battery    
  Unbolt Battery Clamp  
  Disconnect Battery  
  Negative Terminal From Engine Case  
  Positive Connections at Battery  
  Pull Over Flow Tube From Transmission  
  Remove Battery  
  Unbolt and Remove Battery Plate  
     
Remove Gas Tank    
  Pull Tank Clips  
  Disconnect Fuel Line/Fuel Return Line  
  Disconnect Fuel Pump/Gas Gauge
Electric Lines
 
  Lift up Rear of Tank, Pull Back
and Lift Tank off Bike
 
     
Remove Radiator Over Flow Tank    
  Disconnect Radiator Tank Over Flow Hose
at Radiator Cap
 
  Pull Radiator Over Flow Tank From Frame  
     
Remove Rear Wheel    
     
Disconnect Electrical Lines    
  Unplug Rear Brake Switch Line  
  Unplug Speedometer Drive Line  
  Unplug Gear Indicator Switch Line  
  Unplug ABS Sensor Line  
  Unplug Right ABS Unit Line  
  Left ABS Unit Does Not Need
to be Disconnected
 
     
Take off Footpeg Mounts And Rear Brake Caliper    
  Remove Left Mount:  
  Unbolt Left ABS Unit From ABS Bracket  
  Unbolt ABS Unit From Engine  
  Suspend Left ABS Unit From Frame  
  Unbolt Footpeg Mount and Remove  
  Remove Right Mount:  
  Unbolt Rear Brake Caliper  
  Unbolt ABS Unit from Engine  
  Unbolt Footpeg Mount  
  Take Off as a Complete Unit:  
  ABS Unit, ABS Bracket,
Rear Caliper, Master Cylinder, Reservoir
and Footpeg Mount
 
  Be sure to Locate and Remove Brake Arm  
  Retaining Spring  
     
Remove Muffler    
  Take Off Muffler Cover  
  Loosen Headpipe Clamps  
  Remove Muffler by Vigorous Shaking
While Pulling Back
(Note Which Clamp Came off Which Pipe)
 
     
Remove Clutch Arm    
  Disconnect Clutch Cable  
  Disconnect Side Stand Retractor Arm  
  Loosen Rubber Boot Clamp  
  Drive out Clutch Arm Pin  
  Drive First From Left Side - Far Enough
to Remove Side Stand Arm and Spring
 
  Drive Out Pin From Right Side all the Way  
  Remove Boot From Trans & Arm  
  Examine Boot for Any Rips or Tears  
  Replace if Any Rips or Tears  
  Clean and Grease Both Arms  
     
Remove Rear Drive    
  Block Up Swing Arm or Suspend From Frame  
  Unbolt Shock Absorber  
  Unbolt Rear Drive and Remove  
  Lube Rear Drive Splines  
     
Remove Swing Arm    
  Remove Retaining Screws on Right Side  
  Pull Right Side Plug  
  Loosen Left Side Lock Nut  
  Unscrew Left Side Plug  
  Pull Back on Swing Arm
(Rubber Boot Should Come Off Transmission)
 
  Drive Shaft Should Remain Connected to
the Transmission Out Put Shaft
 
  Examine Boot for any Rips or Tears  
  Replace if any Rips or Tears  
  Remove Drive Shaft  
  Pull Back Vigorously to Disconnect
the Snap Ring Holding Swing Arm to
Transmission Output Shaft
 
  Lube Drive Shaft Splines - Both Ends  
     
Remove Electric Starter    
  Remove the Two Retaining Bolts  
  Pull Back to Remove  
  Examine Rubber O-ring for Damage  
  Replace O-ring if Worn  
     
Block and Brace Bike    
  Rope From Ceiling or Use Saw Horses  
  Place Blocks Under Motor  
  Block Front Tire to Prevent Rolling Forward  
     
Remove Side and Center Stand Mount    
  Remove Four Stand Mount Bolts
(Bolts May Require Replacing)
 
  Side Stand and Center Stand Will Come
Off With the Mount
 
     
Remove Transmission    
  Place Blocks or Rolling Jack Under Trans  
  Remove Transmission Bolts  
  Slide Transmission Back  
  Lube Clutch Spline  
  Lube Transmission In-put and Out-put Splines  
  Slide Transmission Back into Place  
  To Align Splines Put Transmission into
5th Gear and Turn the Transmission Out-put
Spline to Align the Splines
 
     
Reassemble    
  Important to Replace Clutch Arm and Side
Stand Arm First. Clearance Problem
Otherwise.
 
  Be Sure the Rubber Boot on the Clutch Arm
is Firmly Mounted and Secured
 
  Connect Clutch Cable  
  Bolt on Side Stand and Center Stand Mount  
  The Bike Can be Lowered from the Roof or
Taken off the Saw Horses if Desired
 
  Connect Side Stand Retractor Arm  
  Connect Drive Shaft to Transmission  
  Besure the Drive Shaft "Snaps" into Place  
  Put on Swing Arm  
  Slide Swing Arm Over Drive Shaft  
  Be Sure the Boot Snaps Over the
Transmission Lip
 
  Be Sure to Apply Antisieze Paste to
the Swing Arm Plugs
 
  Insert Right Plug and Bolt into Place  
  Screw in Left Side Plug  
  Torque Left Side Plug to Spec  
  Torque Lock Nut to Spec  
  Put on Rear Drive and Rear Shock  
  Recommend Applying RV Sealant to
Rear Drive and Swing Arm Faces
 
  Replace Right Foot Peg Mount  
  The ABS Unit, ABS Bracket, Rear Caliper,
Master Cylinder, Brake Fluid Reservoir
and Footpeg Mount go on as a Unit
 
  Connect Brake Arm Retaining Spring  
  Connect Speedometer Sensor, ABS Unit,
Rear Brake Switch, ABS Sensor
and Gear Indicator Wires
 
  The Battery Plate Should be Installed at this
Time to Hold the ABS Mount in Place
 
  Bolt Right ABS Unit to Engine  
  Push Battery Over Flow Tube Through Trans  
  Replace Left Foot Peg Mount  
  The Muffler Should be Replaced at the
Same Time
 
  Be Sure to Use the Correct Muffler
Clamp on the Correct Header Pipe
 
  Install Left Hard Bag Mount to Hold Muffler  
  Bolt Left ABS Unit to ABS Mount and Engine  
  Install Battery  
  Be Sure Ignition and Any Accessories
are Off or Disconnected
 
  Set the Battery into the Battery Tray  
  Connect Negative Wire(s) to Frame  
  Connect Positive Wire(s) to Battery  
  Connect Battery Over Flow Hose to Battery  
  Replace Radiator Over Flow Tank  
  Connect Rubber Tube to Radiator Cap Mount  
  Slide Radiator Over Flow Tank into Place  
  Install Battery/Over Flow Tank Retaining Plate
Mount Under Seat Tray
 
  Push Under Seat Tray into Place  
  Insure All Rubber Mounts are in Place  
  Connect Brain to Wiring Harness  
  Slide Brain into Under Seat Tray  
  Push the Retaining Pin In and Push on the
Left Cover
 
  Connect Any Accessories  
  Replace Gas Tank  
  Lift Tank onto Bike and Push Rear of Tank
into Retaining Mounts
 
  Put on Tank Retaining Clips  
  Connect Fuel Pump/Fuel Gauge Wire  
  Connect Fuel Line and Fuel Over Flow Line  
  Install Seat  
  Mount Rear Tire  
  Replace All Body Parts  

 

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Last Update: 05 October 2007