Buell 2004 XB9S, Service Manual

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2004 Buell Lightning: Engine 3-103
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8. See Figure 3-153. Use SPROCKET SHAFT SEAL
INSTALLER (Part No. B-45676) to install sprocket shaft
seal.
a. Center seal/spacer driver over seal, so that the
sleeve (smaller OD) seats between seal wall and
garter spring.
b. Sparingly apply graphite lubricant to threads of pilot
shaft to ensure smooth operation.
c. Slide sleeve over pilot until sleeve contacts the oil
seal. Install handle on top of sleeve.
d. Rotate handle clockwise until tool bottoms on crank-
case lip. Remove tool from sprocket shaft.
e. Install new retaining ring in groove in left crankcase
next to oil seal.
9. See Figure 3-148. Install thrust washer (4) from the out-
side against the left main bearing.
10. Install new spacer (1) in seal ID. With the thin (lipped)
side facing outward, center seal/spacer assembly over
bearing bore.
CAUTION
Do not remove the spacer after installation or the new
seal will have to be discarded and the procedure
repeated.
11. See Figure 3-154. Install cylinder studs.
a. Pack clean towels into crankcase opening.
b. Place a steel ball into a head screw.
c. The cylinder studs have a shoulder at the lower end.
Place the end of the stud without the shoulder into
the head screw.
d. Install the stud in the crankcase with the shoulder
end down. Use an air gun to drive the stud until the
shoulder reaches the crankcase.
e. Remove air gun. Use a torque wrench to tighten
stud to 10-20 ft-lbs (14-27 Nm).
12. Install piston and cylinder. See 3.7 CYLINDER AND PIS-
TON .
13. Install oil pump. See 3.13 OIL PUMP .
14. Install cam gears, gearcase cover, lifter guides and lift-
ers. See 3.16 GEARCASE COVER AND CAM GEARS .
15. Install cylinder head. See 3.6 CYLINDER HEAD .
16. Install starter. See 5.7 STARTER .
17. Install shift linkage.
18. Install all primary drive components. This includes
engine sprocket, primary chain, complete clutch assem-
bly, engine sprocket nut and mainshaft nut. See
6.4
CLUTCH .
19. Install primary cover. See 6.2 PRIMARY COVER .
NOTE
Be sure to refill transmission to proper level with fresh lubri-
cant. See
1.11 PRIMARY CHAIN .
20. See 3.6 CYLINDER HEAD and perform the applicable
steps.
21. To reinstall engine in frame see 3.5 ENGINE INSTALLA-
TION .
Figure 3-153. Sprocket Shaft Seal/Spacer Installer
(Part No. HD-42579 and B-45676)
8761
Figure 3-154. Cylinder Studs
1
4
1. Head Screw with ball inside
2. Cylinder stud
3. Shoulder on cylinder stud
4. Air gun
2
3
8799