Star Ted wrote:
The transfer case is on the right side of the bike (sitting on the bike). It should be chrome. (It is on my '06). It has a BIG slotted plug, like a huge screw. Just below that is a 4mm screw. The big plug is a fill hole, and the 4mm is to check the level.(when filled to correct level, the oil will come out of this hole). The drain plug is a 12mm VERTICLE plug below the small plug. Lay down and you'll see it. I run Samson cannon pipes, and had to remove them in order to gain access to all the plugs. If you have to remove your pipes, don't forget to purchase new exhaust seals. The old ones will probably remain in the exhaust port when you remove the pipes. Just use a small flat tip screwdriver and pop them out. I just changed my transfer oil 2 days ago, and was surprised how easy it was. Oh, it holds .42 quarts (just under 1/2 qt). Probably wouldn't hurt if you put 1/2 qt in. I used AMSOIL 75-90 synthetic oil. You should contact a dealer and purchase an owner's manual. They are very helpful. Hope this info is of some help.
It is very easy to damage the fill plug if you use a screwdriver to remove it. I made a tool to remove the fill plug to avoid damaging the slot (which I did the first time I changed the oil).
Materials:
(1) 2" dia. fender washer
(2) 1 1/2" dia. fender washers
(1) 1/4" dia. X 5" long bolt
(2) 1/4" nuts
electrical tape
Assembly:
Put electrical tape around about 1/3 of the
OD of the 2" washer and flatten on faces of both sides of washer. The tape protects the plug slot.
Put (1) nut on bolt leaving about 1/2" to 3/4" of thread at end.
Sandwich the 2" washer between the (2) 1 1/2" washers.
Put washer stack on bolt.
Clamp washer stack with second nut.
Cost of parts is about $2 or less.
Assembly time is about 5 minutes.
Although you won't use this tool much it's nice to have it when you need it. Of course, you can also use just the 2" taped washer with a pair of channel-locks or vise grips but adding the (2) 1 1/2" washer really stiffens the 2" washer.
Favoured: 0
