Question about 2003 Buell Lightning XB9S

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IS the gear and motor all in one,have to take the gear box out.

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Yes, the only way to get to the transmission is to remove the motor and split the cases.

Posted on May 17, 2011


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I've tried a home made fix to this problem which is working so far. It's a bit of work, so proceed with caution. The problem at least with mine was the back of the gear/motor assembly box. There is a back side of a gear that projects out of the gear box and into a slot in the ice tray. It seems to be made of cheap plastic that broke from all the twisting of the tray. Mine left a couple of prongs still on the gear from the break, which I was able to JB Weld and shape back into a tight fit with the ice tray slot.

To start, push the black button that projects down, holding the gear box in place while at the same time pulling the gear box towards you. The ice tray will fall at this point.

Now the gear box is just hanging by the power cables. The only way that I found to get the box out was to take out the four screws in the corners of the gear box, (careful, there are loose gears in there that can come out) and pull the motor, and circuit board out by their cables. If you did this without any gears falling out, put the clear plastic cover back on so that they stay in place.

If the gears fell out, like mine did, it's not to difficult to figure out how they go back in.

Now if you have enough of the gear protruding out the back to add the JB Weld to, than do that and shape it to fit the slot of the ice tray. I had to let it dry, then sand it to the right fit. Hope this holds for a while. I couldn't order just the gear, and the motor/gear box is $70.

Once shaped, make sure that the gear is rotated in position to let the "Ice tray full" arm drop down. Then take of the clear cover, put the circuit board and motor back into place, then put the cover back on. Put the rear of the ice tray into the hole in the back of the freezer, the put the motor box back into place the way you removed it sliding the new prong into the ice tray slot and cross your fingers.

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