Buell 2006LIGHTNING MODELS, Service Manual, Page: 512 / 638

6-14 2006 Buell Lightning: Drive/Transmission
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ASSEMBLY AND INSTALLATION
1. Submerge and soak all friction and steel plates in FOR-
MULA+ TRANSMISSION AND PRIMARY CHAINCASE
LUBRICANT for at least five minutes.
2. See Figure 6-19. Install the narrow friction plate on the
clutch hub engaging tabs on plate with slots in clutch
shell.
3. See Figure 6-20. Install damper spring seat (5) on clutch
hub so that it seats inboard of narrow friction plate (4).
4. Install damper spring (1) on clutch hub with the concave
side up (facing opposite damper spring seat).
5. Install a steel plate and then a friction plate on the clutch
hub. Install six remaining sets in the same manner, alter-
nating between steel plates and friction plates.
6. Place pressure plate, diaphragm spring, adjusting screw
assembly with
new retaining ring and spring seat onto
clutch pack.
a. See Figure 6-21. Align square openings of pressure
plate and diaphragm spring so that the assembly
can be installed over prongs on clutch hub.
b. Position spring seat with its larger outer diameter
side toward diaphragm spring.
NOTE
See Figure 6-14. Turn compressing tool handle only the
amount required to install spring seat and snap ring. Exces-
sive compression of diaphragm spring could damage clutch
pressure plate.
c. See Figure 6-22. Install SPRING COMPRESSING
TOOL (Part No. HD-38515-A) onto clutch hub
against diaphragm spring.
d. Place a wrench on the clutch spring forcing screw
flats to prevent the forcing screw from turning.
e. Turn compressing tool handle clockwise until dia-
phragm spring compresses just enough to install
new retaining ring into the groove in clutch hub
prongs.
f. With retaining ring fully seated in groove of clutch
hub, carefully loosen and remove compression tool.
NOTE
When the compressing tool is removed, the diaphragm spring
will move outward forcing the spring seat up into the inside of
the retaining ring. The spring seat provides an operating sur-
face for the diaphragm spring at the same time preventing the
retaining ring from coming out during operation.
Figure 6-19. Friction Plates
Narrow Plate
Regular Plate
b1063x6x
Figure 6-20. Clutch Pack Stack-Up (Cut-Away View)
Figure 6-21. Spring Seat Installation
b1059x6x
1. Damper spring
2. Clutch hub
3. Steel plate
4. Narrow friction plate
5. Damper spring seat
6. Clutch shell
4
2
5
1
6
3
5
6253
1
2
1. Diaphragm spring (pressure plate below)
2. Prongs on clutch hub
3. Retaining ring
4. Adjusting screw assembly
5. Spring seat
4
3