Transfer Case

[dna9656]

Anyone know why the transfer case would be low on gear lube? Who has changed or added gear lube to the transfer case? Is anybody AWARE there is a transfer case (at all) that needs periodic maintenance? If it leaks does it leak on to the ground or into the engine?

[Shores]

I think the recommended service is every 16000 miles. I've done it twice and it's a piece of cake. The drain is on the bottom, the filler is the large plug and the weep hole is a small button head. Fill the large hole with 70 / 90 gear oil until it runs out the small weep hole when the bike is level. Never heard of it leaking. Maybe it was on your pills by the previous owner. Do not fill it up to the top of the large hole.

[Father Pobasturd]

That's too much. The weep hole is below that. Stand the bike up straight and take out the weep hole screw and let oil come out till it stops. You may want to remove the filler plug while doing this so it'll come out faster.

[Duke]

What Farther Pobasturd said, "that's to much". You will be way overfilled with oil and will leak out the breather. The only place I've heard of oil leaking is; when the pulley becomes loose, it will leak out behind the pulley.

[dna9656]

You're right Father!

Section 3, pg. 3-2: Transfer case oil, Check for leakage. Replace oil at initial 1,000 km and thereafter every 24,000km or

24 months (whichever comes first).


On pg 3-25

1. Stand the motorcycle on a level surface. Place the motorcycle on a suitable stand. Make sure the motorcycle is upright.

2. Remove: (the) checking bolt # 1 (that's the "drain" bolt).

3. Check: transfer gear oil level. The transfer gear oil level should be up to the brim (bottom) of # 1 hole. Below the brim;

Add the recommended transfer gear to the proper level.

4. Install (the) checking bolt, (tighten to) 8 Nm (0.8 m/kg


On pg. 3.26 tells how to change the gear lube.

CHANGING THE TRANSFER GEAR OIL

1. Place a container under the transfer gear oil drain bolt.

2. Remove: straight plug # 1 (and) transfer gear oil drain bolt # 2.

3. Drain (the) transfer gear oil (completely from the transfer gear case).

4. Check: (the) transfer gear oil drain bolt gasket (if it's damaged) replace (it).

5. Install (the) transfer gear oil drain bolt, (tighten to) 18 Nm (1.8 m/kg)

6. Fill (the) transfer gear case (with the specified amount of the recommended transfer gear oil) (Quantity,Total amount:0.4 L)

7 Install (the) straight plug.

8. Check (the) transfer gear oil level. Refer to “CHECKING THE TRANSFER GEAR OIL LEVEL”.

So, the idea is to just keep the chain lubed, the rest will get lubed by the spray from the chain (I suppose)

I haven't ridden/started my bike since I (overfilled) changed the transfer case lube because the ^%#%^*&%^%$#$ Main Switch (due tomorrow) is broken!

[Shores]

BTY, join the local Western Washington Riders meetup group as well as the Kitsap Riders Meetup group. We ride frequently.

[dna9656]

Where do they meet please?

[LUV4RS]

Anyone know why the transfer case would be low on gear lube? Who has changed or added gear lube to the transfer case? Is anybody AWARE there is a transfer case (at all) that needs periodic maintenance? If it leaks does it leak on to the ground or into the engine?

Drop a couple bucks and order the Clymer manual. Includes maintenance schedule along with fluid specs, toque specs, and easy to follow step by step procedures with pics to follow. Between the information/knowledge in this site, the Clymer and a few YouTube videos you’ll have a much better understanding of your bike.

[Shores]

Where do they meet please?

Just search for Western Washington Riders motorcycle Meetup and you will find the site. You can join for free. Rides are posted frequently that you can sign up for. They meet in different locations and at different times depending on the ride.

[Bikerron]

s anybody AWARE there is a transfer case (at all) that needs periodic maintenance?

Ha! You’d be surprised at the number of RS riders that would blush at that question after finding the case practically bone dry and the chain stretched and jumping teeth!



(Not mine)

[Jclevesque]

Never got how it can change that color??

[Jclevesque]

How could it of started?

[Bikerron]

Condensation will do it. Probably from total lack of servicing the thing along with a loose pulley and maybe even drove through high water. Who knows?

I had a case cover leak from high water and trapped enough water inside to destroy a stator back in the ‘80’s.

[dna9656]

Hot oil based products leave that sort of color, overheating is not required to leave that stain.

[Shores]

Is anybody AWARE there is a transfer case (at all) that needs periodic maintenance.

On this site that's about as common of knowledge as that the bike has two tires. This site is well over a decade old and pretty much everything that can be done has been done to the road star and posted here somewhere or on the old site. Additionally, most people own service manuals. You won't find a more knowledgeable group of folks than on this site.

[dna9656]

I have the service manual at https://data2.manualslib.com/pdf6/12...cdf081c9e48950 and there is no word on removing/installing the ignition main switch that I can find. Doing a search on how to remove and replace the switch a link on how to do it leads to this forum but the page is no longer there.

[LUV4RS]

On this site that's about as common of knowledge as that the bike has two tires. This site is well over a decade old and pretty much everything that can be done has been done to the road star and posted here somewhere or on the old site. Additionally, most people own service manuals. You won't find a more knowledgeable group of folks than on this site.

Knew my bike only had two tires when I first found this site but not a whole lot more. Got myself a paper manual to thumb through knowing that I’d want to upgrade my suspension immediately. Between advise on this site, the manual and some pretty awesome YouTube vids (talking bout you Darrel...Sorry, I know you’re on here, I just can’t remember your screen name) you’ll learn a lot.

[RobD]

To those that have gone into their transfer case, was the gear oil the only thing you need to drain or should you drain the engine oil as well. I'm kinda thinking its only the gear oil, but don't want any messy surprises. Can't seem to find anything about this. thanks

[Shores]

To those that have gone into their transfer case, was the gear oil the only thing you need to drain or should you drain the engine oil as well. I'm kinda thinking its only the gear oil, but don't want any messy surprises. Can't seem to find anything about this. thanks

They are two different compartments and two different oils so there's no need to change them at the same time. The transfer case recommendation is very 16,000 and most folks change their engine oil about every 3 to 4,000 mi.