2006 Buell Lightning: Drive/Transmission 6-35
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TRANSMISSION ASSEMBLY 6.10
GENERAL
MAINSHAFT ASSEMBLY
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)
NOTES
● Use correct retaining ring pliers and correct tips. Verify
that tips are not excessively worn or damaged.
● During assembly, the split bearings and the internal
bores of the gears must be lubricated with Harley-David-
son FORMULA+ TRANSMISSION AND PRIMARY
CHAINCASE LUBRICANT prior to assembly. Leaving
these parts dry could accelerate wear at start-up.
1. See Figure 6-64. Install new split bearing (5) in 4th gear
position on mainshaft.
2. Install 4th gear (4) and thrust washer (3).
3. Using RETAINING RING PLIERS (Part No. J-5586),
expand and install new retaining ring (2).
4. Install 1st gear (1).
PART NO. SPECIALTY TOOL
J-5586 Retaining ring pliers
Figure 6-64. Transmission Mainshaft Assembly/Reassembly
x0599a6x
Left Crankcase
1. Mainshaft 1st gear
2. Retaining ring
3. Thrust washer
4. Mainshaft 4th gear
5. Split bearing
6. Mainshaft
7. Mainshaft 3rd gear
*
8. Mainshaft 2nd gear*
5
8
7
4
3
1
6
2
* Mainshaft 2nd and 3rd gears are integral to the shaft.
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