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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If your wireless motor will not turn left or right that means the gears are bad.I had that problem so I opend gear box and found out the gear on motor was loose.I tried to contact the company to get the gear but they will not sell it to me.The company will only send me to a dealer which they will charge me 95 dollars to look at it and I have to pay for a new gear box.The ger box is 220 so add the 1 hour drive time there and 1 hour drive back plus the 95 dollars fee.Thats a load of you know what!!!!So with all that said,I had to improvise and used jb weld to the gear hole then set it in the shaft of the motor overnight.this fixed the problem for 6 dollars.If you must buy a new gear box do not buy from dealer for 220.Buy at boats.net for 170.Hope that this tip will help you fix the your problem.

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you have to disassemble the tool completely. Remove chuck, remove battery, remove all screws holding body parts together, remove one side of body. Now you can see motor and gear box. Pull out both of them and twist gearbox a bit (just few degrees or millimeters) if it goes, then just pull gear away from the motor. Be carefull, some gear parts may drop of, so hold gearbox down and motor up. Juraj

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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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