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 |