ZR-7/s Oil and Filter Change/Lube Job

List of items and tools needed:

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
11.

Oil Filter Oil (4 Quarts) 6 x 12 piece of aluminum foil Latex/Rubber Gloves (Keeps the hands clean) Couple of clean rags Some type of drain pan (needs to hold at least 4-quarts) Grease Gun with 12 to 18 flexible hose Some good quality Moly-Grease for the Grease Gun 3/8 Ratchet 17 mm socket
Torque Wrench

Instructions/Procedures:
1. Take a short ride to the convenience store for that six-pack of beverage youll need afterwards! This short trip also ensures the bike has been warmed up. 2. Put the bike on the center stand in a clean well lit area you plan on working in. 3. Go put your six-pack in the ice chest, no drinking while playing with tools! Get all of your tools and items together and have them handy. By now your exhaust should have cooled down enough to work around. 4. Remove the oil filler cap. DO NOT LOSE THE CAP! Either leave it on the opening or put it someplace secure.

5. Use the aluminum foil to cover the exhaust pipe near the drain bolt and filter bolt. This makes it easier to keep the exhaust pipe clean, I hate that burnt oil smell. 6. Place your drain pan underneath both drain bolts.

7. Remove the drain bolt first. Remember, Righty-tighty, Leftyloosey. Be careful, as the oil make be a little hot coming out. DO NOT LOSE THE DRAIN BOLT! You need this part! Set it aside in a secure place.

8. After the old oil has drained, remove the filter bolt. Youll notice that once you start to loosen the bolt, the whole filter plate will turn with the bolt. At this point, you can just spin it by hand till it drops. Turn the filter assembly over and let the oil drain out.

9. Gently remove the filter from the bolt using a turning motion. Do not lose the spring that will fall out. Leave the bolt and base plate together. Set these parts aside in a secure place. 10. Clean and wipe down all of the loose parts with a clean lint free rag. I use fresh oil to coat all of the parts before reassembly. Check your O-rings for any nicks or cuts, and replace if needed. I have yet to replace the original ones, just be careful when wiping them down.

Reassembly:
1. Slip the cup like part over the filter/base plate assembly. Then slip the spring over the bolt. Now gently spin the new filter onto the bolt. Be careful not to pop out the rubber grommets on the filter.

2. Take the reassembled filter assembly and put it back in place under the engine. Be careful not to cross thread the bolt and DO NOT OVER TIGHTEN! (Filter Bolt Torque: 20 N-m { 2.0 kg-m, 14 ft-lb}) If you do not have a torque wrench, finger tighten the filter assembly and just barely tighten up with a wrench or ratchet/socket.

3. Replace the drain bolt, make sure you check the crush washer for damage and lightly coat the bolt/washer with oil. Once again, do not over tighten. (Drain Bolt Torque: 29 N-m { 3.0 kg-m, 22 ft-lb}) Finger tight and just notch it up a bit with the ratchet/socket if you dont have a torque wrench.

4. Remove drain pan and aluminum foil. Nows a good time to hit the three zerk fittings on the rear suspension with the grease gun.

Go to the muffler side of the bike and hit the zerk fitting on the swingarm with the grease gun as well.

Wipe off any excess oil and grease from the bottom of the bike. 5. Add three quarts of oil at the filler opening on the right side of the engine. Close up the filler cap and let the oil settle for a good 15minutes. Fire up the bike for about 5-minutes, shut it down and let the oil settle. Look for leaks under the crankcase and check you level window. DO NOT OVERFILL! You want the oil to be right in the middle of the marks. I find that if the level is closer to the top fill line, you end up with oil in the air filter box from blow back.

There you have it people! Now, get out and ride or stay home and work on that six-pack! DISCLAIMER: I am not a professional mechanic, nor claim to be. I am not responsible for any problems resulting from this tutorial. Basically, if you screw it up, dont blame me! Between the official Owners Manual and a Service Manual, you will find everything you heart desires. I have just tried to put things together so a simple person like myself can do this without spending a fortune at the shop. Remember, this motor is mostly made up of alloys and aluminum. DONT OVER TORQUE THE FRIGGIN BOLTS!