2007 Buell Lightning: Drive/Transmission 6-3
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PRIMARY COVER 6.2
REMOVAL
1. Remove seat. See 2.44 SEAT.
11WARNING1WARNING
To prevent accidental vehicle start-up, which could
cause death or serious injury, disconnect negative (-)
battery cable before proceeding. (00048a)
2. Disconnect negative battery cable from battery.
3. Remove chin fairing. See 2.37 CHIN FAIRING.
4. See Figure 6-1. Place a drain pan under the engine/pri-
mary area. Remove drain plug (4) and drain lubricant
from primary drive.
5. Remove engine shift lever assembly (1) and rubber
washer. Do not scratch primary cover.
6. Remove flange bolt (5) from primary cover.
NOTE
It is recommended that the shifter shaft seal be replaced
whenever the primary cover is removed.
7. Add free play to clutch cable. See ADJUSTMENT under
1.8 CLUTCH.
8. See Figure 6-1. Loosen locknut (7). Turn chain adjuster
screw (6) counterclockwise to remove tension on primary
chain.
9. Remove three TORX screws with washers and clutch
inspection cover.
10. See Figure 6-1. Remove clutch inspection cover (3).
11. See Figure 6-2. Remove the outer ramp and hook (1)
from the cable end (3) and coupling (2). Remove cable
end from slot in coupling. See 6.3 CLUTCH RELEASE
MECHANISM.
12. Remove screws which secure primary cover. Remove
cover and gasket.
13. Discard gasket.
14. Remove and discard shifter lever oil seal.
15. Clean all parts in a non-volatile cleaning solution or sol-
vent.
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 determine air
flow rates. (00061a)
16. Blow parts dry with low pressure compressed air.
Figure 6-1. Removing Primary Cover
1. Engine shift lever
2. Primary cover
3. Clutch inspection cover
4. Drain plug
5. Flange head bolt
6. Chain adjuster screw
7. Locknut
8. Shift linkage assembly
3
2
4
7
6
1
8806
5
8
Figure 6-2. Clutch Release Mechanism
1. Outer ramp and hook
2. Coupling
3. Cable end
1
23
8413
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