Buell S1 Lightning 1996 Manual page 240

REMOVAL
1. Remove transmission. See
REMOVAL on page 6-16.
2. See Figure 6-35. From inside case tap out seal (3) at end
of mainshaft 5th gear (1). Discard seal (3).
3. See Figure 6-36. Use MAIN DRIVE GEAR REMOVER
AND INSTALLER (Part No. HD-35316-A)
PLATE (Part No. HD-35316-91). Take support bracket (1)
and insert pins, at one side, into holes which are now
exposed under access cover.
4. See Figure 6-37. Insert bolt (2) through support bracket
(1) and 5th gear (3).
CAUTION
When removing the main drive gear, the gear is pressed
out against the resistance of the bearing inner race. With-
out any support at the inner race, the bearing is
destroyed. Whenever the main drive gear is removed the
main drive gear bearing will also have to be replaced.
5. At outside of case, place driver (4) and thrust washer (5)
over end of bolt (2). Install and tighten nut (6) until 5th
gear (3) is free.
xlh0639
For inner bearing
0.315-0.285 in.
(8.001-7.239 mm)
For outer bearing
For seal
0.06-0.03 in.
(1.5-0.7 mm)
1. Main drive gear
2. Needle bearing
Figure 6-35. Main Drive Gear Assembly
6-26
MAIN DRIVE GEAR
TRANSMISSION CASE,
with CROSS
0.080 in.
(2.03 mm)
3. Seal
www.PlanDeGraissage.org
3563
Figure 6-36. Support Bracket Mounting
xlh0641
1. Support bracket 4.
2. Bolt 5.
3. 5th gear 6.
Figure 6-37. Removing Main Drive Gear
Cross Plate (Part
No. HD-35316-91)
Driver
Thrust washer
Nut