Buell X1 2002 Service Manual page 388

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2. See Figure 6-45. Place spacer (26) over mainshaft and
position next to bearing (28). Position split bearing (7)
into machined seat next to spacer (26). Locate mainshaft
4th gear (25), which can be identified by the two radial
grooves at one side. Slide gear (25) onto shaft with radial
grooves facing door. Position gear over bearing next to
spacer (26).
3. Install thrust washer (6) and retaining ring (5) next to
gear (25). It will be necessary to push the retaining ring
into final position with a screwdriver.
4. Slide mainshaft 1st gear (24) onto mainshaft with the
locking dogs facing gear (25). The shifter fork groove
must face the access door.
5. See Figure 6-46. Install retaining ring (5) on counter-
shaft. Position retaining ring in the second ring groove
from the end with internal threads. Install thrust washer
(6) next to retaining ring. Install split bearing (7) in seat
next to washer (6).
6. Locate countershaft first gear (8). Gear (8) has a radial
groove at one side of the gear. Install gear (8) over split
bearing (7) with radial groove facing access door.
7. Install thrust washer (6) and retaining ring (5) next to
gear (8).
8. Locate countershaft 4th gear (4). This flat, shoulderless
gear is splined and has a single radial groove at one
side. Position gear next to retaining ring (5). Place bev-
eled washer (3) over end of shaft with beveled side away
from gear (4).
9. See Figure 6-47. Stand countershaft assembly on press
with beveled washer upward. Place access cover and
mainshaft assembly on top of countershaft with bearing
(1) in access cover over end of countershaft. Place a
socket or section of pipe on inner race of bearing (1).
Hold assembly straight, making sure gear teeth on coun-
tershaft are engaged with gear teeth on mainshaft, and
press bearing onto shaft until beveled spacer bottoms
against bearing.
NOTE
When correctly installed, countershaft 4th gear should have
zero end play.
6-28
xlh0633
Figure 6-45.
xlh0634
Figure 6-46.
xlh0635
Press
Mandrel
Blocks
Figure 6-47.
2002 Buell X1: Drive/Transmission
2 Grooves
1 Groove