DIY 3 Hole Oil Change
Article by Mark Trotta
For many Harley Big-Twin models, the factory service manual recommends changing engine oil and filter, primary chaincase oil, and transmission fluid every 5,000 miles. This is commonly known as a three hole oil change.
This article explains how to drain and refill all three, how to remove and install the oil filter, and also includes torque specs and what special tools are needed. Procedures are basically the same for all Evo and Twin-Cam Big-Twins.
Getting Started
After taking a ride to get the engine warmed up, I have my 2005 Road King parked just outside the garage. While the motor cools off, I step inside the house for something to eat.
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Working outdoors has several advantages--fresh air, direct sunlight (the best light to work in), and a lot more room than my crowded garage!
To avoid spilling oil on the concrete driveway, I've put some down some cardboard and a 3' x 4' metal drip tray under the drain pan.
Drain Plug Locations
Looking underneath the engine, you'll see two drain plugs. The one facing down and furthest to the rear is the transmission drain plug.
The engine oil drain plug is the one furthest to the left on the engine case. It faces forward and it's in-line with the rear cylinder.
I'll start by draining the engine oil, but it doesn't matter what order they get done in.
A 5/8" socket on a 3/8-drive ratchet removes either plug.
When sitting on the jiffy stand, the bike is at an angle, which actually helps drain the oil. Give it time to completely drain. There's really no need to straddle the bike and rock it back and forth.
Magnetic Drain Plug
It is normal and Ok to have a small amount of metal shavings on a magnetic drain plug. But if you find metal shavings in your old oil in the drain pan, you may have issues.
The O-ring on the drain plug measures 7/16" I.D x 9/16" O.D, and I replace it every 2nd or 3rd oil change. You can buy cheap ones, but James Gasket #11105 O-Rings are top quality and made in USA, and I don't mind spending the extra two dollars.
TIP: The service manual recommends adding a little oil on the O-ring before installing.
Drain Plug Torque
Recommended drain plug torque is 14-21 Foot/Pounds. Engine cases are aluminum and can strip easily. By using a torque wrench, you won't have to worry about possible over-tightening and damaging the threads (and getting into a potential nightmare).
The problem with a standard torque wrench is that they're too long to fit under the engine. Having an inch-pounds torque wrench set at 200-240 Inch/Pounds solves that problem.
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Oil Filter Removal
On my 2005 FLHRI, the oil filter can be removed with a 76mm 14 flute cap wrench, which is a common automotive size.
Cap wrench (also called a cup wrench), 3/8-drive ratchet, and 6" extension.
I have yet to buy that special funnel that slides under the oil filter that pro-shops and dealers use.
Without it, some oil will drip down on and around the module, so have the drain pan positioned and ready.
After the old filter is off, I'll let it drip for a minute, then spray the area with brake parts cleaner and wipe dry with a shop towel.
The rubber gasket of the new filter should be lightly coated with oil, then threaded on by hand until it's snug, then tightened by hand 1/2 turn past O-ring contact (but we all go a little more).
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Oil Filter Specs - Absolute vs Nominal
Absolute rating - indicates the filter's ability to capture 99.9% of particles of a certain size or larger.
Nominal rating - indicates a capture efficiency at a lower particle size, with 50% being a common example.
Harley-Davidson branded filters are rated at nominal value, which is 50% of the 5 or 10 micron sized particles that it can catch.
Aftermarket companies, such as Amsoil and Wix, are Absolute rated, 30 microns at 99% flow.
Absolute-rated is a more realistic way of measuring filtration efficiency.
I'll run a Harley-Davidson 63798-99A, which is chrome and rated at 5 microns NOMINAL, or a Wix 57148 (NAPA 7148), which is rated at 30 microns at 99%.
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Oil Viscosity
The factory manual states: "Use the proper grade of oil for the lowest temperature expected before the next oil change".
Recommended Oil
There's lots of good brands out there. For Harley Big-Twins, Amsoil 20W50 (MCVQT) is always top-rated. All of their products are synthetic.
Engine oil capacity on my 2005 FLHRI is 3.5 quarts.
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Transmission Oil Change
Changing the transmission oil is just a drain and refill, and replace O-rings if needed.
As previously mentioned, the transmission drain plug is the one that faces down and is furthest to the rear. It can be removed with a 5/8" socket. O-ring size (7/16" ID x 9/16" OD) is the same as the engine drain plug. Recommended torque is 14-21 Foot/Pounds (200-240 Inch/Pounds).
The transmission dipstick on Harley Big Twins is located on the right side of the transmission behind the rear cylinder.
A 3/8" Allen key is needed to remove it.
Dipstick O-ring size is 7/8" O.D. x 11/16" I.D. James Gasket #11178 replaces OEM 11178. All their products are made in USA.
My '05 Road King takes 20-24 ounces of trans fluid. Check FSM for your year and model.
I'm refilling with Amsoil SVG (full synthetic) which replaces H-D 99892-84 (semi synthetic).
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Primary Oil Change
Moving over to the left side of the bike.
The Motor Company calls it a clutch inspection cover, but most everyone else calls it a derby cover.
You'll need a T27 Torx bit to remove the five cover bolts and a T30 Torx bit to remove the drain plug.
The drain plug location is directly below center and part of the primary cover.
Remove plug and allow oil to completely drain.
Inspect derby cover gasket. Clean or replace as needed.
New James Gasket on left, old H-D gasket on right.
Inspect O-ring on drain plug and replace if needed (5/6" ID x 7/16" OD). Recommended torque is 36-60 Inch/Pounds.
My 2005 FLHRI takes 32 ounces (one full quart) of primary oil.
Amsoil primary fluid MCF 75/90 replaces H-D part 99887-84 (one quart).
I'm sure there's better ways to refill than this--but I didn't spill any!
Derby cover bolts torque to just 36-60 Inch/Pounds.
When done, start the bike and let the engine idle for a minute or two. Look underneath for leaks.
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Notes and Misc
Along with changing engine oil and filter, primary fluid and transmission fluid, it is also recommended to clean/replace the air filter every 5,000 miles.
If you can see through the air filter while holding it up to sunlight, it's Ok for re-use.
Even though not due, I'll check primary chain play at this time. The four inspection cover bolts are removed with a T27 Torx bit.
Oil change in a box? Sounds convenient, but I haven't tried it yet. Maybe next time.
Always use oil designed for air-cooled engines.
Engine Oil Dipstick Level
Checking oil level when warm is the recommended and more accurate way.
When the engine is cold (like on pre-ride checks), it will read lower than when hot, so don't add any if it reads a little low.
No oil was spilled on the driveway today.
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Conclusion
Every time you work on your own bike, you gain a little confidence in your skills and learn a little more about how everything works together.
Ready for the next ride!
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Articles of Interest:
2005 Harley Road King Review by Owner
AGM Motorcycle Battery Review
Motorcycle Gear For Senior Riders
