Finishing the Transfer Case

Install the transfer case drain bolt. Use 13 ft-lbs.

Reconnect the right-side, chrome, oil delivery tubes from the oil tank to the engine case. Be sure all the O-rings are in place prior to installation. Use 7.2 ft-lbs of torque for the M6 (smaller) bolts. Use 17 ft-lbs for the two M8 (larger) bolts that go on the cover's left edge.

Slip in the circular oil screen into the hole near the bottom of the skinny (aka gear) cover. See photo in the Installing the Transfer Case in the Bike section above.

Now install the dowel pins for the transfer-case chrome cover. Note: There is no paper gasket for the chrome transfer case cover. Be sure the large O-ring seal is in the chrome cover. Then install the cover using 7.2 ft-lbs of torque.

Remove the transfer case oil fill plug and sight plug from the side of the chrome cover you just installed. Fill the case with hypoid gear oil, per the service manual.

Reinstall the sight plug and fill plug. Use only 5.8 ft-lbs on the sight plug. 5.8 ft-lbs equals 69.6 in-lbs.

Now reconnect the wiring bracket which is in the right side-cover area. Then reinstall and tighten the little bolt holding the bracket. See service manual for details.

Finally, you can reinstall the oil fill tube (aka dip-stick tube) into the top of the oil tank, near the battery. The mounting bracket only takes one bolt, but be sure you get the battery ground strap on the bolt before you install it. See overhead photo below. Torque the bolt to 7.2 ft-lbs.

To access related articles, refer back to the Complete Engine Tear Down, Orientation article in this series to see which additional articles best address your situation.

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DISCLAIMER: This information and procedure is provided as a courtesy and is for informational purposes only.  Neither the publishers nor the authors accept any responsibility for the accuracy, applicability, or suitability of this procedure.  You assume all risks associated with the use of this information.  NEITHER THE PUBLISHERs NOR THE AUTHORs SHALL IN ANY EVENT BE LIABLE FOR ANY DIRECT, INDIRECT, PUNITIVE, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, OF ANY NATURE ARISING OUT OF OR IN ANY WAY CONNECTED WITH THE USE OR MISUSE OF THIS INFORMATION OR LACK OF INFORMATION.  Any type of modification or service work on your motorcycle should always be performed by a professional mechanic. If performed incorrectly, this procedure may endanger the safety of you and others on your motorcycle and possibly invalidate your manufacturer’s warranty.

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