Buell XB 2008 Series Service Manual page 16

TABLE OF CONTENTS
Wiring Diagrams..........................................................5-2
Removal.............................................................................5-2
Disassembly, Inspection, and Repair..................................5-2
Assembly............................................................................5-6
Installation..........................................................................5-7
5.3 STARTER SOLENOID
Replacement......................................................................5-9
Disassembly................................................................5-9
Assembly.....................................................................5-9
DRIVE/TRANSMISSION
6.1 SPECIFICATIONS
General...............................................................................6-1
6.2 PRIMARY COVER
Removal.............................................................................6-2
Primary Chain Adjuster Replacement................................6-3
Installation..........................................................................6-4
6.3 CLUTCH RELEASE MECHANISM
Disassembly.......................................................................6-6
Cleaning and Inspection.....................................................6-6
Assembly............................................................................6-7
6.4 CLUTCH
General...............................................................................6-8
Removal...........................................................................6-10
Clutch Pack Cleaning and Inspection...............................6-11
Adjusting Screw Disassembly/Assembly..........................6-11
Assembly and Installation.................................................6-12
6.5 PRIMARY CHAIN
General.............................................................................6-15
Removal...........................................................................6-15
Clutch Shell/Hub Inspection.............................................6-16
Clutch Shell Bearing Replacement...................................6-17
Installation........................................................................6-18
6.6 DRIVE BELT AND IDLER PULLEY
General.............................................................................6-21
Drive Belt Removal...........................................................6-22
Drive Belt Installation........................................................6-22
Idler Pulley Removal.........................................................6-23
Idler Pulley Installation......................................................6-23
6.7 TRANSMISSION
General.............................................................................6-25
6.8 CASE DISASSEMBLY FOR
TRANSMISSION REMOVAL
General.............................................................................6-26
Right Crankcase Removal................................................6-26
6.9 TRANSMISSION DISASSEMBLY
Transmission Removal From Left Crankcase...................6-29
Mainshaft/Countershaft....................................................6-33
Mainshaft Disassembly.....................................................6-33
Cleaning and Inspection............................................6-34
X TABLE OF CONTENTS
Countershaft Disassembly................................................6-34
Cleaning and Inspection............................................6-34
6.10 TRANSMISSION ASSEMBLY
Mainshaft Assembly.........................................................6-36
Countershaft Assembly....................................................6-36
6.11 MAIN DRIVE GEAR AND BEARING
General.............................................................................6-38
Removal...........................................................................6-38
Main Drive Gear Bearing...........................................6-39
Disassembly.....................................................................6-40
Assembly..........................................................................6-40
Installation........................................................................6-41
Main Drive Gear Ball Bearing....................................6-41
Main Drive Gear........................................................6-42
Main Drive Gear Seal................................................6-43
6.12 TRANSMISSION RIGHT CASE
BEARINGS
Removal...........................................................................6-45
Countershaft Needle Bearing....................................6-45
Shifter Drum Bushing................................................6-45
Installation........................................................................6-45
Countershaft Needle Bearing....................................6-45
Shifter Drum Bushing................................................6-45
6.13 TRANSMISSION LEFT CASE
BEARINGS
Removal...........................................................................6-47
Mainshaft and Countershaft Bearings.......................6-47
Shift Drum Bearing....................................................6-47
Installation........................................................................6-47
Mainshaft and Countershaft Bearings.......................6-47
Shift Drum Bushing...................................................6-47
6.14 TRANSMISSION INSTALLATION
Installation........................................................................6-48
Shifter Forks and Drum Assembly....................................6-49
Installing Right Crankcase................................................6-50
6.15 SHIFTER SHAFT
Installation........................................................................6-52
6.16 TRANSMISSION SPROCKET
Removal...........................................................................6-54
Installation........................................................................6-55
ELECTRICAL
7.1 SPECIFICATIONS
General...............................................................................7-1
7.2 IGNITION SYSTEM
General...............................................................................7-3
Troubleshooting..................................................................7-3
7.3 IGNITION/HEADLAMP KEY SWITCH
General...............................................................................7-5