Primary Cover - Buell 2009 XB Series Service Manual

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PRIMARY COVER

REMOVAL
1. Remove seat.
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
2. Disconnect negative battery cable from battery.
3. Remove chin fairing. See
4. See Figure 5-1. Place a drain pan under the
engine/primary area. Remove drain plug (4) and drain
lubricant from primary drive.
5. Remove engine shift lever assembly (1) and rubber
washer. Use care not to scratch primary cover.
6. Remove flange head bolt (5).
7. For Ulysses only, remove shifter bracket fasteners (10)
and shifter bracket (9) from primary cover.
NOTE
It is recommended that the shifter shaft seal be replaced
whenever the primary cover is removed.
8. Add free play to clutch cable. See
MISSION/PRIMARY FLUID,
9. See Figure 5-1. Loosen locknut (7). Turn chain adjuster
screw (6) counterclockwise to remove tension on primary
chain.
10. See Figure 5-1. Remove clutch inspection cover (3).
11. See Figure 5-2. Remove the outer ramp and hook (1) from
the cable end (3) and coupling (2). Remove cable end
from slot in coupling. See
MECHANISM.
12. See Figure 5-1. Remove screws which secure primary
cover (2). Remove cover and gasket.
13. Discard gasket.
14. See Figure 5-3. Remove and discard shifter lever oil seal
(19).
15. Clean all parts in a non-volatile cleaning solution or
solvent.
Compressed air can pierce the skin and flying debris from
compressed air could cause serious eye injury. Wear
safety glasses when working with compressed air. Never
use your hand to check for air leaks or to determine air
flow rates. (00061a)
5-4 2009 XB Service: Drive/Transmission
2.50 CHIN FAIRING.
1.9 CLUTCH/TRANS-
Adjustment.
5.4 CLUTCH RELEASE
16. Blow parts dry with low pressure compressed air.
sm00351
1
8
9
7
6
1. Engine shift lever
2. Primary cover
3. Clutch inspection cover
4. Drain plug
5. Flange head bolt
6. Chain adjuster screw
7. Locknut
8. Shift linkage assembly
9. Bracket, shifter (Ulysses only)
10. Fasteners, shifter bracket (Ulysses only)
Figure 5-1. Removing Primary Cover (Ulysses Shown)
sm00268
3
1. Outer ramp and hook
2. Coupling
3. Cable end
Figure 5-2. Clutch Release Mechanism (Typical)
5.3
2
3
10
5
4
1
2