6-42 2007 Buell Lightning: Drive/Transmission
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INSTALLATION: MAIN DRIVE GEAR
Main Drive Gear
1. See Figure 6-76. Lubricate both main drive gear needle
bearing assemblies and the mating surface of the main-
shaft with HARLEY-DAVIDSON SPECIAL PURPOSE
GREASE (Part No. 99857-97).
2. See Figure 6-67. Install new o-ring (5) into groove in
main drive gear. Lubricate o-ring with GENUINE HAR-
LEY-DAVIDSON FORMULA+ TRANSMISSION AND
PRIMARY CHAINCASE LUBRICANT (Part No. 99851-
05).
NOTE
See Figure 6-67. Make sure to install new o-ring (5) onto
main drive gear before installing main drive gear into crank-
case.
3. See Figure 6-75. Insert 8 IN. BOLT (Part No. HD-35316-
4A) (1) through WASHER (Part No. HD-35316-7) (2) and
main drive gear (3). From inside of case insert bolt with
washer and main drive gear through inner race of main
drive gear bearing.
4. At outside of case, place INSTALLER CUP (Part No. HD-
35316-12) (4), NICE BEARING (5), FLAT WASHER (6)
and NUT (7) over end of bolt. Tighten nut until main drive
gear bottoms against main drive gear bearing.
5. Remove MAIN DRIVE GEAR REMOVER AND
INSTALLER set.
6. See Figure 6-67. Tap in new oil seal (6) at threaded end
of main drive gear to a depth of 0.060-0.030 in. (1.524-
0.762 mm).
Figure 6-76. Lubricating Main Drive Gear Needle Bearings
10744
Figure 6-77. Installing Main Drive Gear (Typical)
6
1
4
5
2
3
11509
1. 8 in. bolt (Part No. HD-35316-4A)
2. Washer (Part No. HD-35316-7)
3. Main drive gear
4. Installer cup (Part No. HD-35316-12)
5. Nice bearing
6. Flat washer
7. Nut
7
11510
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