6-48 2007 Buell Lightning: Drive/Transmission
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SHIFTER FORKS AND DRUM
ASSEMBLY
NOTES
● See Figure 6-89. Shifter design allows for one common
part number for both countershaft shifter forks. As the
transmission runs, each shifter fork develops a certain
wear pattern with its mating parts. For this reason, it is
important that each shifter fork be reinstalled in its origi-
nal location.
● Always lubricate the shaft bore in each shifting fork with
GENUINE HARLEY-DAVIDSON FORMULA+ TRANS-
MISSION AND PRIMARY CHAINCASE LUBRICANT
(Part No. 99851-05) before assembly.
1. Place 2nd/3rd gear shifter fork onto dog ring between
countershaft 2nd and 3rd gears.
2. Install shifter drum into left case half with previously
scribed line at 12 o’clock position. This will place shifter
drum in neutral position.
NOTE
See Figure 6-90. Install shifter fork shafts in the left case half
by lightly tapping on the end of the shaft with a brass or hard
plastic hammer until shaft is seated in bore.
3. Place 1st gear shifter fork onto dog ring between coun-
tershaft 1st and 4th gear gears. Install shifter fork shaft
through two installed shifter forks and into left crankcase
half.
4. Install 4th/5th gear shifter fork onto sliding gear with dogs
located on mainshaft. Install remaining shifter fork shaft
through last installed shifter fork and into left crankcase
half.
NOTE
See Figure 6-90. Install shifter fork shafts in the left case half
by lightly tapping on the end with a brass hammer until
seated in bore.
Figure 6-89. Shifter Forks, Drum and Shafts
11495
Countershaft
Mainshaft
Left
12-3
4-5
Right
Figure 6-90. Installing Shift Fork Shafts
8623
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