| PART NUMBER | TOOL NAME |
| HD-46503 | OIL LINE REMOVER, 1/2 INCH |
| HD-49096 | OIL LINE REMOVER, 3/8 INCH |
| FASTENER | TORQUE VALUE | |
| Oil pump quick connect fitting: XR 1200X | 108-156 in·lbs | 12.2-17.6 Nm |
| Oil rigid line retainer, rear, screw: XR 1200X | 90-120 in·lbs | 10.2-13.6 Nm |
Removal
1. Remove return oil manifold. See 3.12 PRECISION COOLING SYSTEM: XR 1200X, Return Oil Manifold.
2. Remove retainer.
- a. See Figure 3-34. Remove fastener (1).
- b. Raise retainer until alignment pin (2) is clear of bore in crankcase.
- c. Roll retainer out from beneath rigid oil lines.
Figure 3-34. Rigid oil line retainer: 1. Fastener; 2. Alignment pin (hidden)
3. See Figure 3-35. Remove return oil line (1) from gearcase cover using OIL LINE REMOVER, 3/8 INCH (Part # HD-49096).
Figure 3-35. Oil pump lines: 1. Oil pump return line; 2. Oil pump feed line; 3. Vent hose; 4. Oil cooler line, to cooler; 5. Oil cooler line, from cooler
4. If removing the return oil line, remove starter. See 6.10 STARTER.
5. Remove feed oil line (2) from gearcase cover using OIL LINE REMOVER, 1/2 INCH (Part # HD-46503).
6. Disconnect vent hose (3) from fitting on oil pump.
7. See Figure 3-36. Remove locknut (1) and washer. Remove oil cooler line retainer (2) from lines.
Figure 3-36. Oil cooler line retainer: 1. Fastener; 2. Line retainer (partially hidden)
8. See Figure 3-35. Release each oil cooler line (4, 5) from bottom of gearcase cover using OIL LINE REMOVER, 1/2 INCH (Part # HD-46503).
9. If necessary, remove quick connect fittings.
Installation
Note. Used O-rings can leak. Always install new O-rings when performing repairs.
1. If removed, install quick connect fittings with new O-rings. Tighten to 108-156 in·lbs (12.2-17.6 Nm).
2. Install new O-rings in quick connect fittings.
Note. Apply a light film of oil to the end of each line before inserting it into the fitting.
3. See Figure 3-35. Connect oil cooler lines (4, 5) to lower gearcase cover. Verify each is securely held by the retainer clip.
4. See Figure 3-36. Install oil cooler line retainer (2) and tighten fastener (1) securely.
5. See Figure 3-35. If removed, place return line (1) on engine and install starter. See 6.10 STARTER.
6. Connect vent (3), feed oil (2) and return oil (1) lines to oil pump body and cam support. Verify each is securely held by the retainer clip.
7. Remove retainer.
- a. See Figure 3-34. Roll retainer under rigid lines at rear of crankcase.
- b. Orient alignment pin (2) to bore in case.
- c. Verify flanges on lines are on the manifold side of the retainer.
- d. Secure with screw (1).
- e. Tighten to 90-120 in·lbs (10.2-13.6 Nm).
8. Install return oil manifold. See 3.12 PRECISION COOLING SYSTEM: XR 1200X, Return Oil Manifold.
9. Fill oil tank. See 1.6 ENGINE OIL AND FILTER.