Buell 2007 ULYSSES Service Manual page 539

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COUNTERSHAFT DISASSEMBLY
NOTES
Countershaft 5th gear is integral to the shaft.
Once the transmission assembly has been pressed out
of the left crankcase half, the mainshaft and countershaft
assemblies can be serviced separately.
All thrust washers are one common part number. This
transmission requires no shimming.
Use correct retaining ring pliers with correct tips. Verify
that tips are not excessively worn or damaged.
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)
1. See Figure 6-63. Remove spacer (19) and 2nd gear (18)
from the end of the of the countershaft (2). Remove and
discard split bearing (17).
2. Remove spacer (16).
NOTE
When removing the dog ring (15), it is important to mark the
direction of the ring on the shaft as parts establish wear pat-
terns.
3. Remove dog ring (15).
x0600a6x
2
1
1. Countershaft 5th gear
2. Countershaft
3. Split bearing
4. Countershaft 1st gear
5. Thrust washer
6. Retaining ring
7. Dog ring
*
Countershaft 5th gear is integral to the shaft.
Figure 6-63. Transmission Countershaft Assembly Once Removed from Left Crankcase/Disassembly
6-34 2007 Buell Ulysses: Drive/Transmission
WARNING
5
6
3 4
7
*
8. Countershaft 4th gear
9. Retaining ring
10. Thrust washer
11. Split bearing
12. Countershaft 3rd gear
13. Thrust washer
14. Retaining ring
4. Using RETAINING RING PLIERS (Part No. J-5586-A),
expand and remove retaining ring (14). Discard retaining
ring.
5. Remove thrust washer (13), 3rd gear (12), and split bear-
ing (11). Discard bearing.
6. Remove thrust washer (10).
7. Expand, remove and discard retaining ring (9).
8. Remove 4th gear (8) and dog ring (7).
9. Expand, remove and discard retaining ring (6).
10. Remove thrust washer (5), 1st gear (4) and split bearing
(3). Discard bearing.
Cleaning And Inspection
11 1
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 deter-
mine air flow rates. (00061a)
1. Clean all parts (except bearings) in cleaning solvent and
blow dry with compressed air.
2. Check gear teeth for damage. If gears are pitted, scored,
rounded, cracked or chipped, they should be replaced.
3. Inspect the engaging dogs on the gears. Replace the
gears if dogs are rounded, cracked, battered, chipped or
dimpled.
10 13
9 14
11
12
8
15. Dog ring
16. Spacer
17. Split bearing
18. Countershaft 2nd gear
19. Spacer
WARNING WARNING
Left Crankcase
15
17 19
16 18