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 |
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| Remove Coil Cover Disconnect Accessory Plug(s) |
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| 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 |
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| Lift up Rear of Tank, Pull Back and Lift Tank off Bike |
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| Remove Radiator Over Flow Tank | ||
| Disconnect Radiator Tank Over Flow Hose at Radiator Cap |
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| 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 |
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| 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 |
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| 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) |
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| 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 |
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| 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) |
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| Drive Shaft Should Remain Connected to the Transmission Out Put Shaft |
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| 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 |
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| 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) |
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| Side Stand and Center Stand Will Come Off With the Mount |
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| 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 |
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| Reassemble | ||
| Important to Replace Clutch Arm and Side Stand Arm First. Clearance Problem Otherwise. |
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| Be Sure the Rubber Boot on the Clutch Arm is Firmly Mounted and Secured |
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| 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 |
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| 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 |
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| Be Sure to Apply Antisieze Paste to the Swing Arm Plugs |
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| 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 |
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| 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 |
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| Connect Brake Arm Retaining Spring | ||
| Connect Speedometer Sensor, ABS Unit, Rear Brake Switch, ABS Sensor and Gear Indicator Wires |
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| The Battery Plate Should be Installed at this Time to Hold the ABS Mount in Place |
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| 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 |
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| Be Sure to Use the Correct Muffler Clamp on the Correct Header Pipe |
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| 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 |
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| 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 |
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| 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 |
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| Connect Any Accessories | ||
| Replace Gas Tank | ||
| Lift Tank onto Bike and Push Rear of Tank into Retaining Mounts |
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| 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 |