Transmission Assembly - Buell 2007 LIGHTNING Service Manual

HOME

TRANSMISSION ASSEMBLY

GENERAL
PART NO.
J-5586-A Retaining ring pliers
MAINSHAFT 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)
x0599a6x
1. Mainshaft 1st gear
2. Retaining ring
3. Thrust washer
4. Mainshaft 4th gear
*
Mainshaft 2nd and 3rd gears are integral to the shaft.
SPECIALTY TOOL
WARNING
1
5
3
2
4
Figure 6-64. Transmission Mainshaft Assembly/Reassembly
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
CHAINCASE LUBRICANT prior to assembly. Leaving
these parts dry could accelerate wear at start-up.
1. See Figure 6-64. Install new split bearing (5) in 4th gear
position on mainshaft.
2. Install 4th gear (4) and thrust washer (3).
3. Using RETAINING RING PLIERS (Part No. J-5586-A),
expand and install new retaining ring (2).
4. Install 1st gear (1).
6
8
7
5. Split bearing
6. Mainshaft
*
7. Mainshaft 3rd gear
*
8. Mainshaft 2nd gear
2007 Buell Lightning: Drive/Transmission
6.10
AND PRIMARY
Left Crankcase
6-35