6-34 2005 Buell Firebolt: Drive/Transmission
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MAINSHAFT DISASSEMBLY
NOTES
●
Once the transmission assembly has been pressed out
of the left crankcase half, the mainshaft and countershaft
assemblies can be serviced separately.
●
All thrust washers are one common part number. There
is no shimming required with this transmission.
11WARNING1WARNING
Wear safety glasses or goggles when removing or install-
ing retaining rings. Retaining rings can slip from the pli-
ers and could be propelled with enough force to cause
serious eye injury. (00312a)
1. See Figure 6-65. Remove spacer (1), mainshaft 4th gear
(3), split bearing (2) and thrust washer (4) from the
threaded end of the mainshaft.
2. On the mainshaft, between mainshaft 1st gear (6) and
mainshaft 3rd gear (10), use RETAINING RING PLIERS
(Part No. J-5586) to expand retaining ring (7) and move
next to mainshaft 1st gear along with thrust washer (8).
a. Move mainshaft 3rd gear (10) as far as possible
toward mainshaft 1st gear (6).
b. Expand retaining ring (12) at opposite side of main
shaft 3rd gear (10) and slide off end of mainshaft
with thrust washer (11).
c. Remove mainshaft 3rd gear (10) and its split bearing
(9).
3. Slide thrust washer (8) off end of mainshaft.
4. Expand retaining ring (7), which is next to mainshaft 1st
gear (6), and slide off end of shaft.
5. Remove mainshaft 1st gear (6).
6. Expand retaining ring (5) and remove.
Cleaning And Inspection
11WARNING1WARNING
Never use compressed air to “spin-dry” bearings. Spin-
ning bearings with compressed air can also cause a
bearing to fly apart, which could result in death or seri-
ous injury.
11WARNING1WARNING
Compressed air can pierce the skin and flying debris
from compressed air could cause serious eye injury.
Wear safety glasses when working with compressed air.
Never use your hand to check for air leaks or to deter-
mine air flow rates. (00061a)
1. Clean all parts (except bearings) in cleaning solvent and
blow dry with compressed air.
2. Check gear teeth for damage. If gears are pitted, scored,
rounded, cracked or chipped, they should be replaced.
3. Inspect the engaging dogs on the gears. Replace the
gears if dogs are rounded, cracked, battered, chipped or
dimpled.
7. Discard all retaining rings that were removed.
Figure 6-65. Transmission Mainshaft Assembly Once Removed from Left Crankcase/Disassembly
1. Spacer
2. Split bearing
3. Mainshaft 4th
4. Thrust washer
5. Retaining ring
6. Mainshaft 1st
7. Retaining ring
8. Thrust washer
9. Split bearing
10. Mainshaft 3rd
11. Thrust washer
12. Retaining ring
13. Mainshaft
5
7
8
9
11
12
10 6
b1019x6x
4 3
2 1
Left Crankcase
13
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