| PART NUMBER | TOOL NAME |
| HD-49096 | OIL LINE REMOVER, 3/8 INCH |
| FASTENER | TORQUE VALUE | |
| Oil line quick connect fitting, cylinder head return: XR 1200X | 108-156 in·lbs | 12.2-17.6 Nm |
| Oil line retainer, front, nut: XR 1200X | 84-108 in·lbs | 9.5-12.2 Nm |
| Oil rigid line retainer, rear, screw: XR 1200X | 84-108 in·lbs | 9.5-12.2 Nm |
Removal
1. Remove return oil manifold. See 3.12 PRECISION COOLING SYSTEM: XR 1200X, Return Oil Manifold.
2. See Figure 3-30. Remove fastener (1) and raise retainer until alignment pin (2) is clear of bore in crankcase. Roll retainer out from beneath rigid oil lines to remove.
Figure 3-30. Rigid oil line retainer: 1. Fastener; 2. Alignment pin (hidden)
3. See Figure 3-31. Remove nut (1) and washer.
Figure 3-31. Cylinder head oil lines: 1. Locknut; 2. Front oil line; 3. Rear oil line
4. Separate front oil line (2) from cylinder head using OIL LINE REMOVER, 3/8 INCH (Part No. HD-49096).
5. Separate rear oil line (3) from cylinder head using OIL LINE REMOVER, 3/8 INC (Part No. HD-49096).
6. If front oil line needs to be completely removed, remove starter. See 6.10 STARTER.
7. If necessary, remove quick connect fitting from cylinder head.
Installation
Note. Used O-rings can leak. Always install new O-rings when performing repairs.
1. If removed from cylinder head, install quick connect fittings with new O-rings. Tighten to 108-156 in·lbs (12.2-17.6 Nm).
2. Install new internal O-rings in quick connect fittings.
3. If removed, place front cylinder head oil line on engine and install electric starter. See 6.10 STARTER.
Note. Apply a light film of oil to the end of the line before inserting it into the fitting.
4. See Figure 3-31. Connect front oil line (2) to cylinder head. Verify that it is securely held by the retainer clip.
5. Secure front line to crankcase with locknut (1) and washer. Tighten to 84-108 in·lbs (9.5-12.2 Nm).
6. Install retainer.
- a. See Figure 3-30. Roll retainer under rigid lines at rear of crankcase.
- b. Orient alignment pin to bore in case.
- c. Verify that the flanges on lines are on the manifold side of the retainer.
- d. Secure with fastener (1).
- e. Tighten to 84-108 in·lbs (9.5-12.2 Nm).
7. Install return oil manifold. See 3.12 PRECISION COOLING SYSTEM: XR 1200X, Return Oil Manifold.
8. See Figure 3-31. Connect rear oil line (3) to cylinder head. Verify that it is securely held by the retainer clip.