- 1). Park the motorcycle on firm, level ground. Have a helper hold the bike upright and level.
- 2). Loosen and remove the five inspection cover retaining screws with a T27 Torx driver.
- 3). Remove the inspection cover and o-ring. Use caution: do not allow debris to enter the primary chaincase through the open inspection hole.
- 4). Slide the rubber protector boot off of the clutch-cable adjuster located near the middle of the clutch cable. Take care to not damage the boot during this operation.
- 5). Hold the cable-adjuster body with a 1/2-inch open-end wrench, and loosen the jam-nut with a 9/16-inch open-end wrench.
- 6). Move the jam-nut away from the adjuster barrel and loosen the adjuster to create a large amount of free play in the clutch cable.
- 7). Loosen the clutch-adjuster locknut located in the center of the clutch pack with an open-end wrench.
- 8). Tighten the clutch-adjuster screw lightly with an Allen wrench then back the adjuster screw off one half to one full turn.
- 9). Hold the adjuster screw firmly in its position with the Allen wrench, and tighten the adjuster locknut to 72 to 120 pound-inches of torque with a pound-inch torque wrench and a crow's foot.
- 10
Squeeze and release the clutch lever to the limit of its maximum travel three times to ensure the clutch release mechanism is seated. - 11
Rotate the clutch-cable adjuster barrel to extend the adjuster and remove the slack from the clutch cable. - 12
Lightly pull the clutch-cable ferrule located at the end of the clutch cable where it enters the lever bracket. Loosen the clutch-cable adjuster barrel until there is 1/16- to 1/8-inch gap between the clutch-cable ferrule and the lever bracket. - 13
Prevent the adjuster barrel from rotating with a 1/2-inch open-end wrench while tightening the clutch adjuster locknut with a 9/16-inch open-end wrench. - 14
Slide the clutch-cable adjuster's protector boot back into position over the clutch-cable adjuster. - 15
Remove the used inspection cover o-ring from the cover plate and inspect the o-ring for damage or wear. Replace if necessary. - 16
Remove any primary chaincase lubricant from the inspection cover plate with a clean shop rag and install the o-ring. Ensure the o-ring nubs contact the ring groove walls. - 17
Position the clutch's inspection cover plate over the inspection hole and install the five retainer screws. Tighten the retainer screws to 84 to 108 pound-inches of torque with a pound-inch torque wrench and a T27 Torx driver using a cross-pattern starting at the screw at the 12 o'clock position. Tighten the 12 o'clock screw, then the 7 o'clock screw, the 2 o'clock screw, the 10 o'clock screw and, lastly, the 5 o'clock screw. - 18
Start the motorcycle. Engage and disengage the clutch to ensure proper operation before riding the motorcycle.
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