2006 Buell Lightning: Drive/Transmission 6-49
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INSTALLING RIGHT CRANKCASE
1. See Figure 6-91. Install the flywheel assembly into the
left crankcase half using CRANKSHAFT GUIDE TOOL
Part No. HD-42326.
NOTE
The Gear Detent Assembly Aid is used to move the gear
detent lever clear of the shifter drum for assembly purposes.
2. See Figure 6-92. Retract detent assembly in right case
half and install GEAR DETENT ASSEMBLY AID (Part
No. B-45520) until it has bottomed in right case half.
3. Place Transmission in the 1st gear position.
4. Lubricate main drive gear needle bearing assemblies,
the mating surface of the mainshaft and countershaft
with HARLEY-DAVIDSON SPECIAL PURPOSE
GREASE (Part No. 99857-97).
5. See Figure 6-93. Assemble crankcase halves together.
a. Apply a thin coat of GRAY HIGH-PERFORMANCE
SEALANT (Part No. 99650-02) to crankcase joint
faces.
b. Apply several drops of LOCTITE 262 (red) to last
few threads.
c. See Figure 6-94. Tighten 5/16-in. fasteners to 15-19
ft-lbs (20.3-25 Nm).
d. Remove GEAR DETENT ASSEMBLY AID and
install neutral indicator switch and washer. Tighten
to 60-84 in-lbs (6.7-9.5 Nm).See Figure 6-93.
Assemble crankcase halves together.
Figure 6-91. Installing Flywheel Assembly Using Crank-
shaft Guide Tool (Part No. HD-42326)
Figure 6-92. Using Gear Detent Assembly Aid
(Part No. B-45520)
8622
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1. Detent assembly
2. Detent assembly aid
1
2
Figure 6-93. Crankcase Halves
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