buell s1 lightning '97 Manuale

4.

Remove three shift fork pins (5). A small magnet is useful
in freeing the fork pins (5).

5.

Slide shifter drum (7) away from access door, through
shifter forks. The neutral switch pin prevents removal in
the other direction.

6.

Remove shift forks (1, 2 and 3).

1.

 Clean all parts except bearings (19, 20)

with solvent.

2.

Inspect bearings (19, 20) and shifter drum ends. If ends
of shifter drum are pitted or grooved, replace the shifter
drum and bearings. If replacing bearings, see 

.

3.

Inspect shifter drum (7) for cracks or wear. Replace if
necessary.

1.

 for shifter fork identification. See 

 Lubricate the shaft bore in fork (1) with SPORT-

TRANS FLUID. Place 3rd and 5th gear shifter fork (1) in
the fork groove of mainshaft 2nd gear. Be sure the flat
side of fork is facing the access cover.

2.

Lubricate the shaft bore in fork (2) with SPORT-TRANS
FLUID. Place 1st and 2nd gear shifter fork (2) in the fork
groove of countershaft 3rd gear. Be sure the flat side of
fork is facing away from the access door.

3.

Lubricate the shaft bore in fork (3) with SPORT-TRANS
FLUID. Place 4th gear shifter fork (3) in the fork groove of
mainshaft 1st gear. Be sure the flat side of fork is facing
away from the access door.

4.

See 

 Position the shifter drum shaft so that

the neutral indicator switch activator pin (6) is upward.
The shaft is then in the neutral position. Insert the pin
end of drum shaft (7) through the hubs of shifter forks (1,
2 and 3) and through the bearing in access cover.

5.

Align the hole through the top of each shifter fork with the
appropriate cam groove in the shifter drum. Lubricate
pins (5) with SPORT-TRANS FLUID. Drop pins (5)
through the holes in shifter forks. With a small screw-
driver press on the pins while manipulating the forks back
and forth until the pin seats in the drum groove. Secure
pins in place with new cotter pins (4).

1

NOTE

 Detent plate (2) and bowed snap ring (1) are

not installed at this time. These parts are installed during
transmission installation after the final shifter pawl adjustment
is made. See 

.

6.

At the inside of the access door, place the shifter drum
plate (7) in the groove of the drum shaft. See inset 

 Take care to correctly align the drum plates (7) and

(8) with the pin pressed in the drum plate. Take detent
screw (3) and insert it through detent arm (5), access
door, shift drum plate (7), drum reinforcement plate (8),
and washer (9). Thread nut (10) on detent screw and
tighten to 13-17 ft-lbs (18-23 Nm).

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