Buell 2004 XB9S, Service Manual

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6-50 2004 Buell Lightning: Drive/Transmission
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INSTALLATION
1. See Figure 6-93. Install transmission sprocket (4) with
secondary drive belt onto main drive gear (5).
2. Place transmission in neutral.
3. Apply a few drops of LOCTITE 262 (red) to the left-hand
threads of transmission sprocket nut (3) and lightly coat
the washer-faced side with clean H-D 20W50 engine oil.
Wipe off any excess oil.
4. Position nut with washer-faced side facing transmission
sprocket. Turn the nut
counterclockwise to install it onto
main drive gear.
NOTE
The drive on 2004 Lightning models is a 14mm belt. Use the
P3/Blast SPROCKET HOLDING TOOL with the spacer and
fastener from the 2003 Firebolt SPROCKET LOCKING TOOL
to hold the sprocket.
5. See Figure 6-94. Install SPROCKET HOLDING TOOL
(Part No. B-43982) as shown.
6. Using MAINSHAFT LOCKNUT WRENCH (Part No. HD-
94660-37B) and a torque wrench, tighten sprocket nut to
50 ft-lbs (67.8 Nm) INITIAL TORQUE ONLY.
7. See Figure 6-95. Scribe a line on the transmission
sprocket nut and continue the line on the transmission
sprocket as shown.
8. Tighten the transmission sprocket nut an additional 30°-
40°.
CAUTION
Maximum allowable tightening of sprocket nut is 45° of
counterclockwise rotation, after initially tightening to 50
ft-lbs. Do not loosen sprocket nut while attempting to
align the screw holes. If you cannot align lockplate and
sprocket screw holes, nut may be additionally tightened
45° as specified above. Tightening too much or too little
may cause the nut to come loose during vehicle opera-
tion.If you cannot align lockplate and sprocket screw
holes, nut may be additionally tightened until screw
holes align.
9. See Figure 6-93. Install lockplate over nut so that two of
lockplate’s four drilled holes (diagonally opposite) align
with sprocket’s two tapped holes.
NOTE
The lockplate has four screw holes and can be turned to
either side, so you should be able to find a position without
having to additionally tighten the nut. If you cannot align the
screw holes properly, the nut may be additionally TIGHT-
ENED until the screw holes line up,
but do not exceed 45°.
NEVER LOOSEN nut to align the screw holes.
10. See Figure 6-93. Install two socket head screws through
aligned holes of lockplate and into tapped holes of
sprocket. Tighten to 90-110
in-lbs (10.2-12.4 Nm).
NOTE
The original equipment socket head screws (1) have thread-
locking compound applied to them. Since this compound
remains effective for about three removal/installation cycles,
the original screws may be reused up to three times. After the
third removal/installation cycle, replace both screws with
new
screws identical to the original.
11. Center rear wheel in the swingarm at the same time slid-
ing the drive belt onto the rear sprocket.
12. With wheel centered in swingarm, lower bike to align
swingarm and wheel hub.
13. Apply ANTI-SEIZE LUBRICANT to hole in right side of
swingarm where rear axle slides through.
Figure 6-94. Transmission Sprocket Tightening
Figure 6-95. Aligning Transmission Sprocket
1. Sprocket holding tool (Part No. B-43982)
2. Mainshaft locknut wrench
(Part No. HD-94660-37B)
8632
2
1
45°
30°
a0163x6x
1. Transmission sprocket nut
2. Transmission sprocket
3. Line scribed on nut and sprocket
3
2
1