| PART NUMBER | TOOL NAME |
| HD-49096 | OIL LINE REMOVER, 3/8 INCH |
| FASTENER | TORQUE VALUE | |
| Return oil manifold screw: XR 1200X | 84-108 in·lbs | 9.5-12.2 Nm |
Removal
1. Disconnect and remove battery. See 1.22 BATTERY MAINTENANCE.
2. Remove exhaust system. See 4.14 EXHAUST SYSTEM: XR 1200X.
3. Drain oil tank. See 1.6 ENGINE OIL AND FILTER.
4. Remove oil drain hose from sleeve in rear engine crankcase.
5. Remove battery positive (+) cable from starter motor. See 6.10 STARTER.
6. See Figure 3-29. From right side of motorcycle, remove fastener (1) securing oil manifold.
7. See Figure 3-28. Disconnect oil return hose (2) from oil tank.
Figure 3-28. Rear cylinder oil line: 1. Rear cylinder head oil line; 2. Return oil hose to tank
8. Remove rear cylinder head oil line (1) from quick connect fitting using OIL LINE REMOVER, 3/8 INCH (Part No. HD-49096) while sliding return oil manifold back off from rigid oil lines and remove assembly from engine.
Installation
1. Install new O-rings in manifold assembly and apply a light film of oil to them.
2. Start return oil manifold on rigid lines and install rear cylinder head oil line in quick connect fitting. Verify that it is securely held by the retainer clip.
3. See Figure 3-29. Slide oil manifold onto rigid lines and secure with screw (1). Tighten to 84-108 in·lbs (9.5-12.2 Nm).
Figure 3-29. Return oil manifold fastener
4. Connect oil return hose to oil tank. Secure with clamp.
5. Install and connect oil tank drain hose. Install and secure plug in drain hose.
6. Connect battery positive (+) cable to starter. See 6.10 STARTER.
7. Install battery. See 1.22 BATTERY MAINTENANCE.
8. Fill the oil tank. See 1.6 ENGINE OIL AND FILTER.