6-38 2007 Buell Lightning: Drive/Transmission
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REMOVAL
1. Split crankcases in half. See 6.8 CASE DISASSEMBLY
FOR TRANSMISSION REMOVAL.
2. Remove transmission as an assembly. See 6.9 TRANS-
MISSION DISASSEMBLY.
3. See Figure 6-67. From inside case tap out seal (3) at end
of mainshaft 5th gear. Discard seal.
4. Obtain MAIN DRIVE GEAR REMOVER AND
INSTALLER SET. See Figure 6-68. Place CROSS
PLATE on right crankcase as shown. Position cross plate
so that roll pins (2) fit into crankcase mating screw holes
and bolt hole in cross plate is centered over main drive
gear.
5. See Figure 6-69. Insert bolt (2) through cross plate (1)
and 5th gear (3).
NOTE
When removing the main drive gear, the gear is pressed out
against the resistance of the bearing inner race. Without any
support at the inner race, the bearing is destroyed. Whenever
the main drive gear is removed the main drive gear bearing
will also have to be replaced.
6. At outside of case, place WASHER (Part No. HD-35316-
7) (4), NICE BEARING (5), FLAT WASHER (6) and NUT
(7) over end of bolt. Tighten nut until main drive gear is
free.
Figure 6-67. Main Drive Gear Assembly
Figure 6-68. Bearing Remover Cross Plate Mounting
(Part No. B-45847)
1. Main drive gear
2. Needle bearing (2)
3. Seal
4. O-ring
5. Retaining ring
x0669x6x
2
3
1
4
5
8681
Figure 6-69. Removing Main Drive Gear Bearing (Typical)
6
3
4
5
2
1
1150
1. Cross plate (Part No. B-45847)
2. 8 in. bolt (Part No. HD-35316-4A)
3. Main drive gear
4. Washer (Part No. HD-35316-7)
5. Nice bearing
6. Washer
7. Nut
7
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