Cleaning And Inspection; Countershaft Disassembly - Buell XB 2010 Service Manual

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Cleaning and Inspection

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)
1. Clean all parts 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.

COUNTERSHAFT DISASSEMBLY

PART NUMBER
J-5586-A RETAINING RING PLIERS
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.
Wear safety glasses or goggles when removing or
installing retaining rings. Retaining rings can slip from the
pliers and could be propelled with enough force to cause
serious eye injury. (00312a)
5-36 2010 XB Service: Drive/Transmission
TOOL NAME
1. See Figure 5-62. 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).
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
bearing (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
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)
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.