NOTE
Always install a new gasket between primary cover and housing. Not replacing this gasket may cause primary chaincase leaks.
1. Verify that all debris is washed from the inside ribs of the cover.
2. See Figure 5-2. Install new cover gasket (1).
3. See Figure 5-1. Apply a drop of LOCTITE 243 MEDIUM STRENGTH THREADLOCKER AND SEALANT (blue) to each cover fastener. Install nine short (1) and four long (2) fasteners in positions shown. Snug fasteners.
4. See Figure 5-3. Tighten primary cover fasteners to 12-13 ft-lbs (16.3-17.6 Nm) in the sequence shown.
Do not overfill the primary chaincase with lubricant. Overfilling can cause rough clutch engagement, incomplete disengagement, clutch drag and/or difficulty in finding neutral at engine idle. (00199b)
5. Place motorcycle in an upright position and fill primary chaincase. See 1.10 PRIMARY CHAINCASE LUBRICANT, Changing Primary Chaincase Lubricant.
6. Install heel shift lever. Align marks made during disassembly.
7. Install pinch screw. Tighten to 18-22 ft-lbs (24.4-29.8 Nm).
8. Install jiffy stand, rider footboard and interlock sensor if equipped. See 2.53 JIFFY STAND, Jiffy Stand Bracket and 2.52 FOOTBOARDS AND FOOTRESTS.
9. Install passenger left footboard. See 2.52 FOOTBOARDS AND FOOTRESTS.
10. Verify shift lever operation.
11. Connect negative battery cable.
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