| FASTENER | TORQUE VALUE | |
| Primary chain adjuster locknut | 20-25 ft·lbs | 27.1-33.9 Nm |
| Primary chain inspection cover | 90-120 in·lbs | 10.2-13.6 Nm |
Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding.
1. Remove main fuse.
2. See Figure 1-19. Remove the primary chain inspection cover (1).
Figure 1-19. Primary Chain Inspection Cover and Adjuster: 1. Inspection cover; 2. Locknut; 3. Adjuster screw
Note. Rotate the engine to measure free play at several chain positions.
3. See Figure 1-20. Through the inspection opening, measure chain free play at the tightest position.
Figure 1-20. Primary Chain Free Play
Note. Factory Setting: The factory sets initial cold engine free play to 1/4-3/8 in (6.35-9.53 mm). With the engine cold, measure free play on a primary chain that has never been adjusted:
- Less than 1/4 in (6.35 mm): Adjust to specification.
- Between 1/4 in (6.35 mm) and 3/8 in (9.53 mm): Do NOT adjust.
Notice: Do not adjust the primary chain tighter than specified. Running chain too tight will result in excessive wear.
4. If the measurement is not in specification, adjust the primary chain. Refer to Table 1-10.
- a. See Figure 1-19. Loosen the locknut (2).
- b. With a hex key, turn the adjuster screw (3) clockwise to reduce free play or counterclockwise to increase free play.
- c. When free play is within specification, hold the adjuster screw with a hex key and tighten the locknut to 20-25 ft·lbs (27.1-33.9 Nm).
5. If the primary chain cannot be adjusted to specification, replace the chain. See 5.4 PRIMARY DRIVE AND CLUTCH: XL MODELS or 5.5 PRIMARY DRIVE AND CLUTCH: XR 1200X.
6. Install a new gasket and the primary chain inspection cover. Tighten to 90-120 in·lbs (10.2-13.6 Nm).
7. Install main fuse.
Table 1-10. Primary Chain Free Play Specifications
| ENGINE | in | mm |
| Cold | 3/8-1/2 | 9.5-12.7 |
| Hot | 1/4-3/8 | 6.3-9.5 |