Buell 2004 XB9S, Service Manual

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3-90 2004 Buell Lightning: Engine
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CRANKCASE 3.17
GENERAL
When rod bearings, pinion shaft bearing, or sprocket shaft
bearing are in need of repair, the engine must be removed
from the chassis; see
3.4 STRIPPING MOTORCYCLE FOR
ENGINE SERVICE in this section. It is recommended proce-
dure to check and make repairs to cylinder heads, cylinders,
gear case and transmission at the same time (perform entire
engine overhaul).
CAUTION
Laying engine on primary side will damage clutch cable
end fitting. If fitting is damaged, clutch cable must be
replaced.
DISASSEMBLY
Crankcase Halves
1. Remove cylinder heads. See 3.6 CYLINDER HEAD .
CAUTION
After removing cylinders, install plastic or rubber hose
over cylinder studs. Lifting or moving crankcase by
grasping studs will cause cylinder stud damage.
2. Remove cylinders and pistons. See 3.6 CYLINDER
HEAD.
3. Remove oil pump. See 3.13 OIL PUMP .
4. Remove gearcase components. See 3.16 GEARCASE
COVER AND CAM GEARS .
5. Remove primary cover and primary drive/clutch compo-
nents. See
6.2 PRIMARY COVER .
6. Remove starter motor. See 5.7 STARTER.
7. See Figure 3-131. Remove rear isolator assembly by
removing the forward two fasteners first and then the two
rear fasteners (re-install with new fasteners).
8. See Figure 3-132. Remove screws securing crankcase
halves together.
9. Tap crankcase with plastic mallet to loosen and separate
the halves.
Figure 3-131. Rear Isolator Assembly
8723