Buell S1 Lightning 1996 Manual page 238

2. See Figure 6-29. Place spacer (26) over mainshaft and
position next to bearing (28). Position split bearing (7)
into machined seat next to spacer (26). Locate mainshaft
4th gear (25), which can be identified by the two radial
grooves at one side. Slide gear (25) onto shaft with radial
grooves facing door. Position gear over bearing next to
spacer (26).
3. Install thrust washer (6) and retaining ring (5) next to
gear (25). It will be necessary to push the retaining ring
into final position with a screwdriver.
4. Slide mainshaft 1st gear (24) onto mainshaft with the
locking dogs facing gear (25).
5. See Figure 6-30. Install retaining ring (5). Position retain-
ing ring in the second ring groove from the end with inter-
nal threads. Install thrust washer (6) next to retaining
ring. Install split bearing (7) in seat next to washer (6).
6. Locate countershaft first gear (8). Gear (8) has a ring
groove at one side of the gear. Install gear (8) over split
bearing (7).
7. Install thrust washer (6) and retaining ring (5) next to
gear (8).
8. Locate countershaft 4th gear (4). This gear is splined and
has a single radial groove at one side. Position gear next
to retaining ring (5). Place beveled washer (3) over end
of shaft with beveled side away from gear (4).
9. See Figure 6-31. Stand countershaft assembly on press
with small end (end with threaded hole) upward. Place
access cover and mainshaft assembly on top of counter-
shaft with bearing (1) in access cover over end of coun-
tershaft. Place a socket or section of pipe on inner race
of bearing (1). Hold assembly straight, making sure gear
teeth on countershaft are engaged with gear teeth on
mainshaft, and press bearing onto shaft until beveled
spacer bottoms against bearing.
6-24
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xlh0633
Figure 6-29.
xlh0634
Figure 6-30.
xlh0635
Press
Mandrel
Blocks
Figure 6-31.
2 grooves
1 groove