Buell 2003XB9S Service Manual page 498

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COUNTERSHAFT ASSEMBLY
11 1
WARNING
Always wear proper eye protection when removing re-
taining rings. Use the correct retaining ring pliers. Verify
that the tips of the pliers are not damaged or excessively
worn. Slippage could propel the ring with enough force
to cause death or serious injury.
CAUTION
During assembly, the split bearings and the internal
bores of the gears must be lubricated with SPORT-
TRANS FLUID prior to assembly. Leaving these parts dry
could accelerate wear at start-up.
1. See Figure 6-67. Install new retaining ring (1) and thrust
washer (2) onto countershaft in the second ring groove
from the end with internal threads.
2. Install split bearing (4) onto countershaft.
3. Locate countershaft 1st gear (3), identified by one radial
groove at one side, and slide gear onto shaft. Position
gear over bearing (4).
b1020x6x
13 12 11 10
1. Retaining ring
2. Thrust washer
3. Countershaft 1st
4. Split bearing
5. Thrust washer
6. Retaining ring
WARNING
9 8 7
7. Countershaft 3rd
8. Retaining ring
9. Thrust washer
10. Split bearing
11. Countershaft 2nd
12. Countershaft 5th
Figure 6-67. Transmission Countershaft Assembly/Reassembly
4. Install thrust washer (5) and new retaining ring (6) next
to countershaft 1st gear (3).
5. Install countershaft 3rd gear (7) on countershaft with fork
groove facing away from countershaft 1st gear (3).
6. Install new retaining ring (8) on countershaft. Position
new retaining ring in the second ring groove from the
end. Install thrust washer (9) next to retaining ring (8).
Install split bearing (10) in seat next to washer (9).
5. Install countershaft 2nd gear (11) with the locking dogs
facing countershaft 3rd gear (7).
6. Install countershaft 5th gear (12) on countershaft.
7. Install new retaining ring (13) on countershaft.
8. Locate countershaft 4th gear (14). This flat, shoulder less
gear is splined and has a single radial groove at one
side. Position gear next to retaining ring (6) on counter-
shaft. Place beveled spacer (15) over end of shaft with
beveled side away from countershaft 4th gear (14).
NOTE
At this point both mainshaft and countershaft sub-assemblies
are ready to be pressed into the left crankcase half.
16
2 3
1
13. Retaining ring
14. Countershaft 4th
15. Beveled spacer
16. Countershaft
2003 Buell XB9S: Drive/Transmission
Left Crankcase
4 5 6 14 15
6-39