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redrider you're kidding right? Repairing the transmission requires a complete engine disassembly, down to splitting the engine case. The tools needed to replace the dogs alone are hundreds $$$.

I...

That'll work. The factory manual suggests using propane and a crushed piece of tubing.

Swweeeet sticker! My sentiments exactly.

Torca clamp. This is the clamp that mates the muffler with the exhaust pipes.

I tried to order some oil lines for the Buell. Milwaukee said they have no idea when they will ever be available. A...

I had a total transmission failure on an 03 XB9S. There was a lot of metal in the primary: slivery chunks, not just slivers. The problem was the seal on the transmission shaft on the left side of the...

What about the other side of the bike?

And I believe the cam cover screws are 304 stainless, too.

Update on the reassemble:

I managed to remove the shell needle bearing (part #28 in the diagram) using a large socket and a shop press. Wasn't at all hard, really. Go slow and watch that you're...

I think I'm giving up on this one. I'm going to try and take it to the stealer to fix it because:

1) I can't remove the inner race from the old clutch hub to put it on the new one with the thrust...

I used thread sealant with teflon. Bad idea?

So by cupped (beveled) you mean the larger diameter should face AWAY from the bike?

Should it be like this:

outside
/ \
transmission

Or like this:

jimjeans, thanks for the info!

You're suggesting replacing both the dampner spring and seat? I don't understand, however, what you mean by "beveled side out" since the cross section of the part...

I'm reassembling my clutch and have a couple of questions.

1) I think I have a couple of parts missing. I'd like some help confirming this.

2) I don't know what way the dampner seat or spring...

The reason I ask is I'm in the middle of a complete engine rebuild on a 2003 XB9S that only had 8600 miles because of an early tranny death.

I was shocked at how much wear the rear cyl had...

gtp3800 do you notice a general heat reduction with this setup?

samiam901, on that same note, I bought a replacement boot for an XL harley (it's the same part) in case mine wears out from adjusting too much. It's like $10.

But if you look at the stout splined...

upthemaiden, change your tranny fluid but often.

I am using that case. You're right, it's not perfect but it's all I got.

Really the pre 06 Buells have an inferior design around the transmission. The shaft seal is in the middle of the tranny,...

Here's the story. My tranny started sounding like a cement mixer. Tore the engine down to this:
...

Ask someone with a firebolt, maybe? They might have their shifter up there, who knows.

My factory manual for my 03 states them clearly. I just talked to St. Paul Harley Davidson TODAY who apparently no longer have an 03 parts line (gulp) but in their 04 parts line it's the exact...

These bolts are not what you can get at the hardware store guys. They are a GR8 bolt that have a special washer with a seal embedded in them. If you have an older XB (like 2003-4) those were...

St. Paul Harley Davidson has diagnosed the problem as "complete internal transmission failure". They reccommend rebuilding it. They want $3600 to do it.

I bought the bike as a "repairable" so I'm...

I have the exact symptoms here in Minneapolis on an '03 Buell Lightning. St. Paul Harley looked at the bike and essentially said that there is a total tranny meltdown going on and they want $3600 to...

I've ridden both. Love both of them but I own a Lightning. Like the way the bolt's headlights are sorted better but I don't like the way the rear subframe is done. Take the rear body panels off the...