Buell 2004 XB9S, Service Manual

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6-38 2004 Buell Lightning: Drive/Transmission
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MAIN DRIVE GEAR 6.11
REMOVAL
1. Split crankcases in half. See 6.8 CASE DISASSEMBLY
FOR TRANSMISSION REMOVAL.
2. Remove transmission as an assembly. See 6.9 TRANS-
MISSION DISASSEMBLY .
3. See Figure 6-67. From inside case tap out seal at end of
mainshaft 5th gear. Discard seal.
4. See Figure 6-68. Place cross plate on crankcase as
shown.
5. See Figure 6-69. Assemble MAIN DRIVE GEAR
REMOVER AND INSTALLER (Part No. HD-35316-A)
with CROSS PLATE (Part No. B-45847).
6. Insert bolt (2) through cross plate (1) and 5th gear (3).
CAUTION
When removing the main drive gear, the gear is pressed
out against the resistance of the bearing inner race.
Without any support at the inner race, the bearing is
destroyed. Whenever the main drive gear is removed the
main drive gear bearing will also have to be replaced.
7. At outside of case, place driver (4) and thrust washer (5)
over end of bolt (2). Install and tighten nut (6) until 5th
gear (3) is free.
Figure 6-67. Main Drive Gear Assembly
Figure 6-68. Bearing Remover Cross Plate Mounting
(Part No. B-45847)
1. Main drive gear
2. Needle bearing (2)
3. Seal
b1069x6x
2
3
1
8681
Figure 6-69. Removing Main Drive Gear
1. Cross plate
2. Bolt
3. 5th gear
4. Driver
5. Thrust washer
6. Nut
a0121x6x