buell s1 lightning '97 マニュアル

 

Verify that all parts have been properly installed, as described
earlier in this section under 

, and 

.

1.

Carefully insert transmission into case opening. Position
the assembly so that the mainshaft enters fifth gear, and
so that the countershaft and drum shifter shaft enter their
respective bearings.

2.

See 

 Apply a few drops of LOCTITE

THREADLOCKER 242 (blue) to the threads of the five
access door mounting bolts (7). Insert the bolts with
washers (8) through holes in access door, and thread
into tapped holes in right transmission case. Tighten
bolts to 13-17 ft-lbs (18-23 Nm).

3.

Lift pawl (5) over drum pins, and place shifter shaft
assembly (6) on studs at transmission case. Loosely
install a washer (11) and locknut (3) on each stud.

4.

Attach the loop of spring (1) over and into groove in post (2).

5.

Place detent plate (9) over drum pins. Rotate plate until
blind holes in plate align with pins in end of drum shaft.
Install 

 

 retaining ring (10) using 

Verify that retaining ring is fully engaged with drum
groove.

6.

 Place transmission in third gear. Place

a No. 32 drill bit (0.116 in. dia.) through hole in detent
plate (3), and between pawl (2) and drive pin at end of
shifter drum shaft. Push down top of crank (4) to remove
all clearance between pawl and drill bit; this will correctly
align pawl to shift drum pins (do not push down with too
great a force, as this might cause the shifter drum to
rotate). With bit in place, tighten shifter shaft assembly
bottom nut (1) first to 90-110 

 

 (10.2-12.4 Nm).

Then, tighten shifter shaft assembly top nut (1) to the
same torque. 

 

7.

See 

 

 quad ring (17) over

threaded end of fifth gear (21), and position next to the
gear taper. Install spacer (16) over threaded end of fifth
gear with chamfered end toward quad ring. Slide spacer
up against bearing (19).

8.

Coat lips of seal (15) with SPORT-TRANS FLUID. Posi-
tion seal over spacer (16) with lips of seal toward case.
Gently tap seal into bore of case until the outside of seal
is flush with outer edge of bore. It is acceptable to recess
seal to about 0.030 in. (0.76 mm) below outer edge of
bore; seal recession will be limited by seal bottoming
against retaining ring (18).

9.

See 

 Install transmission sprocket (2) with

secondary drive belt onto main drive gear shaft (1).

10. Place transmission in neutral. Apply a few drops of LOC-

TITE THREADLOCKER 262 (red) to the 

 

 of transmission sprocket nut (3). Position nut

with washer-faced side facing transmission sprocket. 

11. Increase belt deflection by loosing rear axle and moving

rear wheel forward. Turn the nut 

 

 to

install it onto main drive gear shaft. 

a. Use 

Tighten nut to 50 ft-lbs (68 Nm) INITIAL torque,
ONLY.

b. See 

 Scribe a line on the transmission

sprocket nut and continue the line on the transmis-
sion sprocket as shown.

c.  Tighten the transmission sprocket nut an additional

30

 

°

 

-40

 

°

 

.

d. See 

 Install lockplate (4) over nut (3) so

that two of lockplate’s four drilled holes (diagonally
opposite) align with sprocket’s (2) two tapped holes.

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