Buell 2004 XB9S, Service Manual

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2004 Buell Lightning: Drive/Transmission 6-3
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PRIMARY COVER 6.2
REMOVAL
1. Remove seat. See 2.41 SEAT .
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WARNING
1
WARNING
To protect against shock and accidental start-up of vehi-
cle, disconnect the negative battery cable before pro-
ceeding. Inadequate safety precautions could result in
death or serious injury.
2. Disconnect negative battery cable from battery.
3. Remove chin fairing. See 2.34 CHIN FAIRING .
4. See Figure 6-1. Place a drain pan under the engine/pri-
mary area. Remove drain plug (4) and drain lubricant
from primary drive.
5. Remove shifter lever assembly and rubber washer. Do
not scratch primary cover.
NOTE
It is recommended that the shifter shaft seal be replaced
whenever the primary cover is removed.
6. Add free play to clutch cable. See ADJUSTMENT under
1.9 CLUTCH.
7. See Figure 6-1. Loosen locknut (6). Turn chain adjuster
screw (5) counterclockwise to remove tension on primary
chain.
8. Remove three TORX screws with washers and clutch
inspection cover.
9. See Figure 6-1. Remove clutch inspection cover (3).
10. See Figure 6-2. Remove the outer ramp and hook (1)
from the cable end (3) and coupling (2). Remove cable
end from slot in coupling. See
6.3 CLUTCH RELEASE
MECHANISM
11. Remove screws which secure primary cover. Remove
cover and gasket.
12. Discard gasket.
13. Remove and discard shifter lever oil seal.
14. Clean all parts in a non-volatile cleaning solution or sol-
vent.
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WARNING
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WARNING
Low pressure compressed air can blow debris into your
face and eyes. Always wear eye protection or a face shield
when using pressurized air. Failure to take adequate
safety precautions could result in death or serious injury.
15. Blow parts dry with low pressure compressed air.
Figure 6-1. Removing Primary Cover
1. Shifter linkage
2. Primary cover
3. Clutch inspection cover
4. Drain plug
5. Chain adjuster screw
6. Locknut
3
2
4
6
5
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8806
Figure 6-2. Clutch Release Mechanism
1. Outer ramp and hook
2. Coupling
3. Cable end
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