Buell 2007 FIREBOLT Service Manual page 533

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COUNTERSHAFT ASSEMBLY
11 1
WARNING
Wear safety glasses or goggles when removing or install-
ing retaining rings. Retaining rings can slip from the pli-
ers and could be propelled with enough force to cause
serious eye injury. (00312a)
NOTES
Use correct retaining ring pliers and correct tips. Verify
that tips are not excessively worn or damaged.
During assembly, the split bearings and the internal
bores of the gears must be lubricated with Harley-David-
son FORMULA+ TRANSMISSION AND PRIMARY
CHAINCASE LUBRICANT prior to assembly. Leaving
these parts dry could accelerate wear at start-up.
1. See Figure 6-65. Install new split bearing (3) in 1st gear
position on mainshaft.
2. Install 1st gear (4) and thrust washer (5).
x0600a6x
2
1
1. Countershaft 5th gear
2. Countershaft
3. Split bearing
4. Countershaft 1st gear
5. Thrust washer
6. Retaining ring
7. Dog ring
*
Countershaft 5th gear is integral to the shaft.
Figure 6-65. Transmission Countershaft Assembly Once Removed from Left Crankcase/Disassembly
6-36 2007 Buell Firebolt: Drive/Transmission
WARNING
5
6
3 4
7
*
8. Countershaft 4th gear
9. Retaining ring
10. Thrust washer
11. Split bearing
12. Countershaft 3rd gear
13. Thrust washer
14. Retaining ring
3. Using RETAINING RING PLIERS (Part No. J-5586-A),
expand and install new retaining ring (6).
4. Install dog ring (7) onto 4th gear (8). Now install dog ring
and gear assembly onto countershaft.
5. Expand and install new retaining ring (9).
6. Install thrust washer (10).
7. Install new split bearing (11) in 3rd gear position on
mainshaft.
8. Install 3rd gear (12) and thrust washer (13).
9. Expand and install new retaining ring (14).
10. Install dog ring (15). Make sure to install with dog ring
facing same direction as when it was removed.
11. Install spacer (16).
12. Install new split bearing (17) in 2nd gear position on
shaft.
13. Install 2nd gear (18) and spacer (19).
At this point both mainshaft and countershaft sub-assemblies
are ready to be pressed into the left crankcase half.
10
13
9 14
11
8 12
15. Dog ring
16. Spacer
17. Split bearing
18. Countershaft 2nd gear
19. Spacer
NOTE
Left Crankcase
15
17 19
16
18