Buell S1 Lightning Workshop Manual

Page 1

SECTION I–MAINTENANCE

SUBJECT PAGE NO.

1. Speciﬁcations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2. Side Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3. Fluid Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4. Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5. Rear Preload Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

6. Ignition Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

This section explains procedures unique to 1997 model S1 Lightnings. Any procedures not found in this supplement are covered in the 1996 S1 Lightning Service Manual (Part No. 99490-96Y).

Page 2

NOTES

Page 3

SPECIFICATIONS

DIMENSIONS IN. MM

IGNITION SYSTEM

Wheel base 55 1397 Overall length 79.5 2019 Overall width 30 762 Road clearance 5.2 132 Seat height 29.5 749

CAPACITIES U.S. LITERS

Fuel tank (including reserve) 4.0 gallons 15.14 Reserve 0.6 gallons 2.27 Oil tank 2.0 quarts 1.89 Transmission 1.0 quart 0.95

WEIGHT LBS. KG

S1 shipping weight 446 202 GVWR 820 372 GAWR - Front 340 154 GAWR - Rear 480 218

Spark plugs No. 6R12 Size 12 mm Gap 0.038-0.045 in. 0.97-1.14 mm

TRANSMISSION

Type Constant Mesh, Foot Shift Speeds 5 Forward

NUMBER OF SPROCKET TEETH

Engine 35 Clutch 56 Transmission 27 Rear wheel 61 Belt 128

TRANSMISSION GEAR RATIOS FINAL* OVERALL**

First (low) gear 2.69 9.717 Second gear 1.97 7.118 Third gear 1.43 5.180

NOTE

Gross Vehicle Weight Rating (GVWR) (maximum allowable loaded vehicle weight) and corresponding Gross Axle Weight Ratings (GAWR) are given on an information decal located on the front frame steering head.

ENGINE

Number of cylinders 2 Type 4-Cycle, 45 Degree V-Type Bore 3.498 in. 88.849 mm Stroke 3.8125 in. 96.838 mm Piston displacement 73.4 cu. in. 1203 cc Compression ratio 10.0 to 1 Horsepower @ RPM 91 @ 5800 Torque ft-lb @ RPM 87 @ 5200

Fourth gear 1.18 4.269 Fifth (high) gear 1.00 3.615

*Final gear ratios indicate number of mainshaft revolutions required to drive output sprocket one revolution. **Overall gear ratios indicate number of engine revolutions required to drive rear wheel one revolution.

PRESSURE

TIRE AND POSITION

Front-Dunlop Sportmax Radial II 120/70 ZR 17

Rear-Dunlop Sportmax Radial II 170/60 ZR 17

Do not inflate any tire beyond its maximum inflation pressure as specified on tire sidewall. Overinflation may cause tire to suddenly deflate leading to personal injury.

WARNING

FOR SOLO

RIDING

32 PSI

(2.2 bar)

36 PSI

(2.5 bar)

PRESSURE

AT GVWR

36 PSI

(2.5 bar)

38 PSI

(2.8 bar)

Page 4

SIDE VIEWS

5806

1. Right rear turn signal

2. Tail/stop lamp

3. Rear brake master cylinder/ reservoir

4. Air cleaner cover

5. Fuel filler cap

6. Front brake master cylinder

7. Front brake hand lever

8. Right front turn signal

9. Headlamp

10. Front brake caliper

11. Timer cover

8 9

1112131415

12. Rear shock absorber

13. Rear brake pedal

14. Rider footrest

15. Belt guard(s)

16. License plate light

5808

1. Rear axle adjuster nut

2. Rear sprocket and secondary drive belt

3. Ignition module

4. Fuse block and spare fuse

Figure 1. 1997 S1 Lightning, Right Side View

4 5

1011121314

5. Turn signal flasher

6. Remote idle adjuster

7. Front brake master cylinder

8. Front brake hand lever

9. Front brake caliper

10. Oil pump

11. Battery

12. Voltage regulator

13. Rider footrest

14. Passenger footrest

Figure 2. 1997 S1 Lightning, Right Side View (Body Removed)

Page 5

5807

3 6 7 8

1112131415

1. Left front turn signal

2. Headlamp

3. Clutch hand lever

4. Fuel filler cap

5. Horn

5809

6. Ignition/headlamp key switch

7. Fuel supply valve

8. Tail/stop lamp

9. Left rear turn signal

10. Rear brake caliper

Figure 3. 1997 S1 Lightning, Left Side View

2 31

6 84

5 9

11. Passenger footrest

12. Rider footrest

13. Gear shift lever

14. Exhaust muffler

15. Oil filter

1. Steering head lock

2. Instruments

3. Clutch hand lever

4. Ignition coil

5. Enrichener knob

6. Starter relay

7. Oil filler plug/dipstick

8. Oil tank

9. Rear brake caliper

10. Rear axle adjuster nut

Figure 4. 1997 S1 Lightning, Left Side View (Body Removed)

11121314

11. Oil tank drain hose

12. Gear shift lever

13. Exhaust muffler

14. Oil filter

15. Speedometer drive

Page 6

FLUID REQUIREMENTS

GENERAL

United States System

Unless otherwise speciﬁed,

in this Service Manual are expressed in United States (U.S.) units-of-measure

●

1 pint (U.S.) = 16 ﬂuid ounces (U.S.)

●

1 quart (U.S.) = 2 pints (U.S.) = 32 ﬂ. oz. (U.S.)

●

1 gallon (U.S.) = 4 quarts (U.S.) = 128 ﬂ. oz. (U.S.)

all ﬂuid volume measurements

. See below:

Metric System

Fluid volume measurements in this Service Manual include the metric system equivalents. In the metric system, 1 liter (L) = 1,000 milliliters (mL). Should you need to convert from U.S. units-of-measure to metric units-of-measure (or vice versa), refer to the following:

●

ﬂuid ounces (U.S.) x 29.574 = milliliters

●

pints (U.S.) x 0.473 = liters

●

quarts (U.S.) x 0.946 = liters gallons (U.S.) x 3.785 = liters

●

milliliters x 0.0338 = ﬂuid ounces (U.S.)

●

liters x 2.114 = pints (U.S.)

●

liters x 1.057 = quarts (U.S.) liters x 0.264 = gallons (U.S.)

●

STEERING HEAD BEARING GREASE

Use WHEEL BEARING GREASE (Part No. 99855-89).

BRAKE FLUID

FRONT FORK OIL

Use only WP FORK OIL, 5 WEIGHT.

FUEL

Use a good quality leaded or unleaded gasoline (91 pump octane or higher). Pump octane is the octane number usually shown on the gas pump.

ENGINE OIL

Use the proper grade of oil for the lowest temperature expected before the next oil change.

Table 1. Recommended Oil Grades

COLD

WEATHER

STARTS

BELOW

50° F

Excellent

Good

Poor

HARLEY-

DAVIDSON TYPE

H.D. Multi-Grade

H.D. Regular Heavy

H.D. Extra Heavy

VISCOSITY

SAE

10W40

SAE

20W50

SAE

HARLEY-

DAVIDSON

RATING

HD 240

LOWEST

AMBIENT

TEMP.

Below 40

(4°C)

Above 40

(4°C)

Above 60

(16°C)

Above 80

(27°C)

PRIMARY DRIVE/TRANSMISSION LUBRICANT

Use only SPORT-TRANS FLUID (Part No. 98854-96 quart size or Part No. 98855-96 gallon size).

WARNING D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID can cause eye irritation. In case of contact with eyes, ﬂush with plenty of water and get medical attention. KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN!

Use only D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID (Part No. 99902-77).

Page 7

CLUTCH

MODEL YEAR CHANGE

See Figure 5. All 1997 model year motorcycles use the new style clutch release ramp introduced on late 1996 vehicles. The clutch adjustment and lever freeplay procedures remain the same. The change was made to provide additional clearance between the coupler and the primary cover.

5671

New style Old style

Figure 5. Ramp Change

Page 8

REAR PRELOAD ADJUSTMENT

GENERAL

Rear suspension spring preload must be adjusted before any other adjustments can be attempted. This adjustment assures that the rear suspension has the proper amount of travel.

Spring preload is the most important suspension adjustment on the S1 Lightning. Improper preload will adversely affect both the handling and motorcycle ride. Correct preload setting will result in motorcycle handling that suits the rider’s size and weight.

ADJUSTMENT

You will need three people to carry out this adjustment.

1. Verify correct front and rear tire pressure. See SPECIFI-

CATIONS on page 3.

2. Remove all accessories from motorcycle including tank

bag and/or saddlebags.

3. Take the motorcycle off the side stand and bounce the

rear up and down a few times to be sure the suspension is free and not binding.

4. See Figure 6. Measure the distance from the center of the

rear axle nut to the rear turn signal mounting bolt rider/passenger/cargo/accessories on the motorcycle.

5. Install items removed in Step 2. Load all cargo.

6. Bounce a few times on the seat to be sure the suspen-

sion is free and not binding.

7. With the help of an assistant, take the same measure-

ment with the vehicle fully loaded (rider/passenger/luggage/cargo). The assistant should help balance the motorcycle so the rider can keep both feet on the footrests.

8. Subtract the second measurement from the ﬁrst. The dif-

ference, which is the squat, should be 0.25-0.75 in. (6.4-

19.1 mm). If it is not, you will have to adjust the spring preload.

CAUTION

Be sure to apply the same number of turns to each

●

preload adjusting nut to ensure that the drawing rings do not become misaligned. Misaligned drawing rings will cause the shock absorber spring to bind against the adjustment rods

Be sure the drawing rings are parallel within 1/64 in.

●

(0.4 mm). Misaligned drawing rings will cause the shock absorber spring to bind against the adjustment rods.

9. See Figure 7. Change the spring preload by adjusting

both preload adjusting nuts (1) (metric) behind the rear drawing ring (2).

a. Increase the preload by tightening the nuts. b. Decrease the preload by loosening the nuts.

without

b0269xox

Rear turn signal

mounting bolt

Rear axle nut

Figure 6. Checking Rear Preload

2 3

1. Preload adjusting nut (2) (metric)

2. Rear drawing ring

3. Adjustment rod (2) Figure 7. Adjusting Rear Preload

b0283x2x

Page 9

IGNITION TIMING

MODEL YEAR CHANGE

See Figure 8. All 1997 model year motorcycles have the remote idle adjuster introduced on late 1996 vehicles. Using this adjuster, it is no longer necessary to use the CARBURE-

TOR IDLE ADJUSTMENT TOOL (Part No. HD-33413) and

TIP (SNAP-ON Part No. TMP23A) to adjust engine idle speed.

NOTE The new idle adjuster changes Step 4 of IGNITION TIMING,

INSPECTION in Section 1 the 1996 manual.

See REMOTE IDLE ADJUSTER on page 21 for more infor- mation.

5853

Figure 8. Remote Idle Adjuster

Page 10

NOTES

Page 11

SECTION II–CHASSIS

SUBJECT PAGE NO.

1. Vehicle Identiﬁcation Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2. Front Wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3. Front Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4. Swingarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

This section explains procedures unique to 1997 model S1 Lightnings. Any procedures not found in this supplement are covered in the 1996 S1 Lightning Service Manual (Part No. 99490-96Y).

Page 12

NOTES

Page 13

VEHICLE IDENTIFICATION NUMBER

MODEL YEAR CHANGE

See Figure 9. A 17-digit serial number, or Vehicle Identiﬁca- tion Number (V.I.N.), is stamped on the right side of the steering head (ex., 4MZSS11J1V3200001). Also afﬁxed to the steering head at this location is an information decal bearing the V.I.N. code.

Manufacturer: Buell Motorcycle Company

Type Designation

Engine

Horsepower Code

4MZSS 11 J* V 32 00001

Varies - can be 0 thru 9 or X

11 = World 56 = California

Model Year - 1997

An abbreviated V.I.N. is stamped on the front left side of the crankcase.

NOTE Always give the V.I.N. or abbreviated V.I.N. when ordering parts or making inquiries about your Buell motorcycle.

Sequential Number

00001-20000 = World 20001-25000 = California

Sample V.I.N. as it appears on the steering head - 4MZSS11J1V3200001 Sample abbreviated V.I.N. as it appears on the left side crankcase- SS11V200001

Figure 9. Vehicle Identiﬁcation Number (V.I.N.)

Page 14

FRONT WHEEL

MODEL YEAR CHANGE

See Figure 10. All 1997 model year motorcycles have new fasteners on the front brake rotor/carrier assembly.

Separate the carrier from the rotor only when necessary. Use

new

clips when reassembling.

NOTE The new rotor/carrier assembly changes Step 4 of FRONT

WHEEL, REMOVAL and Step 2 of FRONT WHEEL, ASSEMBLY in the 1996 manual.

REMOVAL/INSTALLATION

1. See Figure 10. Remove and discard the clip (2).

2. Remove the wave washer (3).

3. Remove the drive pin (1). Repeat this procedure for the

other ﬁve fasteners to separate the carrier (4) from the rotor (5).

4. Assemble in reverse order. Use

new

clips upon assembly.

5874

1. Drive pin (6)

2. Clip (6)

3. Wave washer (6) Figure 10. 1997 Rotor to Carrier Fastener

4. Carrier

5. Rotor

Page 15

FRONT BRAKE CALIPER

TOOL INFORMATION

Use the BRAKE CALIPER PISTON REMOVER (Part No. B-

42079) to simplify front caliper piston removal.

NOTE The following instructions expand upon Step 9 of FRONT

BRAKE CALIPER, REMOVAL/DISASSEMBLY in the 1996

manual.

1. Attach caliper half to tool.

a. See Figure 11. Attach outside caliper half using two

screws.

b. See Figure 12. Attach inside caliper half using two

screws and two nuts.

WARNING

When using air pressure to remove pistons from caliper, pistons may be ejected with considerable force. Wear safety glasses and heavy gloves to prevent personal injury.

CAUTION Exercise care to avoid dropping piston on hard surface. Any damage requires piston replacement.

2. If removing pistons from outside caliper half, place a

gloved ﬁnger over the banjo bolt hole.

3. See Figure 13. Apply low pressure air to force the pistons

from the caliper bores.

b0265x2x

Banjo bolt hole

Figure 11. Outside Caliper Half

b0266x2x

Figure 12. Inside Caliper Half

b0297x2x

Figure 13. Using Air Pressure to Remove Pistons

Page 16

SWINGARM

MODEL YEAR CHANGE

All 1997 model year motorcycles use a revised swingarm pivot assembly. The modiﬁcations allow preload to be adjusted without using the PIVOT SHAFT BEARING

ADJUSTER (Part No. B-41175).

NOTE See Figure 14. The threaded rod (1) replaces a pivot shaft used on 1996 models. This new part changes the SWING-

ARM, ASSEMBLY and SWINGARM, INSTALLATION proce-

dures in the 1996 manual.

ASSEMBLY

1. See Figure 14. If necessary, draw

cups (5) into swingarm using BEARING INSTALLATION

BOLT (Part No. B-35316-5) and STEERING HEAD BEARING RACE INSTALLER (Part No. HD-39302).

NOTE Timkin roller bearing assemblies should be replaced as a unit. Do not intermix components. Mark all components so they may be correctly installed.

2. Coat bearing components with WHEEL BEARING

GREASE (Part No. HD-99855-89) and assemble.

3. Install a

4. Slide swingarm assembly into position.

See Figure 14. The left side bearing adjustment bolt (6) has additional internal threads.

5. Install both bearing adjustment bolts (2, 6) and the

threaded rod (1). Insert the rod from the air cleaner side of the motorcycle.

6. Tighten the left pinch screw on the swingarm mount

block. Do not tighten the right side pinch screw at this time.

new

swingarm seal (3) ﬂush to the swingarm.

NOTE

new

roller bearing

1. Threaded rod

2. Bearing adjustment bolt, right

3. Swingarm seal (2)

Figure 14. Swingarm

b0290a2x

Threads

4. Roller bearing (2)

5. Bearing cup (2)

6. Bearing adjustment bolt, left

b0294x2x

INSTALLATION

1. See Figure 15. Adjust swingarm preload by tightening the threaded rod. Preload should measure 3.5-5.5 lbs (1.6-2.5 kg).

2. Follow the remaining installation instructions in the 1996 manual.

Figure 15. Adjusting Preload

Page 17

SECTION III–ENGINE

All engine procedures in the 1996 S1 Lightning Service Manual (Part No. 99490-96Y) apply to 1997 models.

Page 18

NOTES

Page 19

SECTION IV–FUEL SYSTEM

SUBJECT P AGE NO .

1. Remote Idle Adjuster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2. Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

This section explains procedures unique to 1997 model S1 Lightnings. Any procedures not found in this supplement are covered in the 1996 S1 Lightning Service Manual (Part No. 99490-96Y).

Page 20

NOTES

Page 21

REMOTE IDLE ADJUSTER

GENERAL

See Figure 16. The remote idle adjuster allows idle adjust- ments without use of tools. Idle speeds are listed in Table 2.

REMOVAL

1. Remove seat and fuel tank. See FUEL TANK, REMOVAL in Section 4 of the 1996 manual.

2. Remove cable strap holding adjuster to frame.

3. See Figure 17. Unthread adjuster assembly from bracket (4). Remove spring (3) and washer (2).

NOTE If remote idle adjuster is permanently removed, install idle adjuster screw, spring and two washers. See the 1996 S1 LIGHTNING PARTS CATALOG (Part No. 99571-96Y).

INSTALLATION

1. See Figure 17. Thread remote adjuster (1), spring (3)

and washer (2) into bracket (4). Adjuster shaft (5) must touch stop plate (6).

2. See Figure 18. Secure adjuster to frame with a ﬁgure-8

cable strap. a. Wrap cable strap around inside of frame, then up

and through the slot. b. Contine cable strap over adjuster. c. Run cable strap through the other side of the slot.

Strap should be tight enough that the adjuster turns

easily.

b0291xox

Increase

idle speed

Decrease

idle speed

5900

Adjuster

Figure 16. Idle Speed Adjuster

WARNING After installing seat, pull upward on front of seat to be sure it is locked in position. If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control and personal injury.

3. Install fuel tank and seat. See FUEL TANK, INSTALLA-

TION in Section 4 of the 1996 manual.

4. Start vehicle and warm engine to normal operating tem-

perature.

5. See Figure 16. Set idle speed by turning adjuster. See

Table 2.

a. Turn clockwise to increase idle speed. a. Turn counterclockwise to decrease idle speed.

Table 2. Engine Idle Speed

MODEL REGULAR IDLE FAST IDLE

World Model 950-1050 RPM California 1150-1250 RPM

2000 RPM

1. Remote adjuster

2. Washer

3. Spring Figure 17. Removal/Installation

b0302x4x

Figure 18. Cable Strap

4. Bracket

5. Shaft

6. Stop plate

Page 22

AIR CLEANER

MODEL YEAR CHANGE

All 1997 model year motorcycles use a modiﬁed air cleaner assembly. The new design increases serviceability.

REMOVAL

CAUTION

Do not run engine without ﬁlter element in place. Debris could be drawn into the engine causing damage.

1. See Figure 19. Remove screw and nylon washer (1) on top of air cleaner cover.

2. Remove screw and lockn ut (2) at rear of air cleaner cov er .

3. See Figure 20. Remove cover (3) with attached ﬁlter box (2) and ﬁlter (1).

4. See Figure 21. Remove backplate hoses. a. Detach rear breather hose (4) from tee ﬁtting (3). b. Detach snorkel breather hose (2) at snorkel (1). c. Remove hoses (2, 5) and tee ﬁtting (3) from front

breather bolt (6).

d. On California models, slide fresh air hose from can-

ister through backplate.

5. See Figure 22. Remove two screws and snorkel plate.

6. Remove snorkel.

7. See Figure 23. Remove screw with spacer and gasket.

8. Remove backplate. a. See Figure 24. Remove two bolts (1), washers (2)

and nuts (3). b. Draw rear breather hose through backplate. c. Remove front breather bolt. Detach backplate from

motorcycle.

9. If necessary, remove air cleaner support ring. a. Detach breather hose from rear cylinder head

breather bolt. b. Loosen rear bolt. c. Slide air cleaner support ring upward and remove.

5705

1. Screw and nylon washer

2. Screw and locknut Figure 19. Air Cleaner Cover

5883

1. Filter

2. Filter box

Figure 20. Inside of Air Cleaner Cover

5881

3. Cover

4. Rear mount

NOTE

Air cleaner support ring ﬁts around breather bolts. Fitting on rear breather bolt may not clear the frame if bolt removal is attempted. Do not remove rear breather bolt unless absolutely necessary.

1. Snorkel

2. Snorkel breather

3. Tee ﬁtting

Figure 21. Breather Hoses

4. Rear head breather

5. Front head breather

6. Front breather bolt

Page 23

INSTALLATION

1. Install backplate. a. Apply HYLOMAR to threads of breather bolts. b. Install air cleaner support ring and backplate using

breather bolts. Tighten breather bolts to 10-15 ft-lbs (13.6-20.3 Nm).

5884

c. Attach rear breather hose to rear breather bolt. d. See Figure 24. Install two bolts (1), washers (2) and

nuts (3) through backplate into isolator mount.

2. See Figure 21. Install breather hoses. a. Slide rear breather hose through backplate. b. Attach front breather hose (5, with attached tee and

snorkel breather hose) to front breather bolt (6). c. Connect rear breather hose (4) to tee ﬁtting (3). d. On California models, insert fresh air hose from can-

ister through backplate.

3. See Figure 23. Apply LOCTITE THREADLOCKER 242 (blue) to screw. Install ring with screw through backplate. Tighten to 7-9 ft-lbs (9.5-12.2 Nm).

4. See Figure 22. Apply LOCTITE THREADLOCKER 242 (blue) to screws. Fasten snorkel tube with ring and two screws. Tighten to 6-8 ft-lbs (8.1-10.8 Nm).

5. Connect snorkel hose to snorkel tube.

6. See Figure 20. Check air cleaner ﬁlter. Place ﬁlter inside ﬁlter box. Place cover assembly over backplate.

1. Screw (2)

2. Snorkel plate Figure 22. Snorkel Ring

5897

3. Snorkel

1. Air cleaner spacer with gasket

2. Screw

Figure 23. Air Cleaner Spacer

7. See Figure 19. Install screw and washer into top well nut.

8. Install screw and locknut at rear mount. Tighten to 6-8 ftlbs (8.1-10.8 Nm).

5898

1. Bolt (2)

2. Washer (2)

3. Nut (2) Figure 24. Front Isolator Mount Attachment

4. Backplate

5. Isolator mount

Page 24

NOTES

Page 25

SECTION V–ELECTRIC ST ARTER

SUBJECT PAGE NO.

1. Starting System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

This section explains procedures unique to 1997 model S1 Lightnings. Any procedures not found in this supplement are covered in the 1996 S1 Lightning Service Manual (Part No. 99490-96Y).

Page 26

NOTES

Page 27

STARTING SYSTEM DIAGNOSIS

Perform V oltage Drop Tests

Between Battery and

“Relay” Terminal on

Solenoid. Less Than 1 Volt?

YES

Perform V oltage Drop

Tests from Battery

(Pos. +) to Starter “Motor”Terminal.

Crank Engine. Is

Voltage Greater than

1 Volt?

YES

Perform V oltage Drop Tests from

Battery (Pos. +)

to Starter Motor

“M” (Battery)

Terminal. Crank

Engine. Is

Volta ge Greater

than 1 Volt?

YES

Repair

Connection

Between

Battery and

Starter.

Repair or

Replace

Solenoid

(Contacts).

Relay terminal

Solenoid Clicks.

Backtrack to

Pinpoint Poor

Connections or

Relay Contact

Problems Using

Voltage Drop

Tests.

Perform V oltage

Drop Test

Between Battery

(Neg. -) and Starter

Studs or Bolts.

Is Volta ge Greater

than 1 Volt?

YES

Clean

Ground

Connections

● VISUAL ● VOLTAGE ● LOAD

— BATTERY TESTS —

Check Connections at Battery

and Starter Components.

Nothing Clicks.

Starter Relay.

Does Starter Motor Turn if

Jumped?

YES

Replace

Solenoid.

Check for Battery Voltage

at Relay T erminal 86 Fr om

Starter Button. Battery

Voltage Present?

YES

Check for

Ground at Relay

Terminal 85.

Ground Present?

INOPERATIVE

Relay

Clicks.

Test for Voltage at

Solenoid Terminal. Is

12V Present When

Starter Button is

Pressed?

YES

Test for Voltage to Relay. Is 12V

Present on

Relay Terminal

YES

Test Starter

Motor for

Opens, Shorts or Grounds.

Check for Battery Voltage from Starter

Button BK/R Wire. Battery Voltage

Present With Starter Button Pressed?

Test for Voltage

from Relay . Is 12V

Present on Relay

Terminal 87 When

Starter Button is

Pressed?

YES

Repair Open

on GN Wire

Between Relay

and Solenoid.

Continued on

Repair Open on

R/BK Wire Feeding

Terminal 30 on

Starter Relay.

Replace

Motor terminal

YES

Substitute

Good Relay

or Test Relay.

Battery terminal

Inspect Starter

Interlock

Circuit or

Correct Relay

Ground.

YES

Repair Wiring

From Starter

Button to Relay.

Check for Battery Voltage to

Starter Button W/BK Wire.

Battery Voltage Present?

YES

Replace

Starter Button.

Repair Wiring to

Starter Button.

Page 28

Continued from

RUN-ON

Disconnect Solenoid

“Relay” Terminal from Solenoid. Is 12V Present at GN Wire Terminal with

Starter Button NO

Pressed?

YES

Is 12V Present on Starter Relay Terminal 86 with Starter Button

T Pressed?

YES

Replace Starter

Button.

STARTER STALLS OR

STARTER SPINS, BUT

DOES NOT ENGAGE

Remove Starter.

Disassemble Drive Housing Assembly. Inspect for Damage

Replace

Solenoid.

Replace Starter

Relay.

to Armature Gear or

Idler Gear. Damage

Damaged Gear

SPINS TOO SLOWLY

Present?

YES

Replace

and Armature.

Starter Clutch

Failure. Replace

Starter Clutch.

Perform V oltage Drop

Tests from Battery (Pos. +)

to Starter “Motor” Terminal.

Crank Engine. Is V oltage Greater

than 1 Volt?

YES

Perform V oltage Drop

Tests from Battery (Pos. +)

to Starter “Battery” Terminal.

Crank Engine. Is V oltage Greater

than 1 Volt?

YES

Repair Connection

Between Battery

and Starter.

(Contacts).

NOTES

Remove starter motor and connect jumper wires as

described in Free Running Current Draw Test.

See T roub leshooting/Diagnostics- V oltage drops.

See Starter Current Draw Test.

See Free Running Current Draw Test.

See Starter Interlock Circuit Test

Repair or

Replace

Solenoid

Perform V oltage Drop Test

Between Battery

(Neg. -) and Starter Studs

or Bolts. Is Voltage Greater

than 1 Volt?

YES

Clean Ground

Connections.

Perform Starter Motor Current Draw Test (on

Vehicle).

Perform Starter Motor

Free Draw Bench Test. Are

Test Results in Range?

YES

Inspect Engine or

Primary Drive.

Test Starter

Motor

for Opens,

Shorts or Grounds.

Page 29

SECTION VI–DRIVE/TRANSMISSION

All drive/transmission procedures in the 1996 S1 Lightning Service Manual (Part No. 99490-96Y) apply to 1997 models.

Page 30

NOTES

Page 31

SECTION VII–ELECTRICAL

SUBJECT PAGE NO.

1. Handlebar Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2. Starter Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3. Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4. Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

This section explains procedures unique to 1997 model S1 Lightnings. Any procedures not found in this supplement are covered in the 1996 S1 Lightning Service Manual (Part No. 99490-96Y).

Page 32

NOTES

Page 33

HANDLEBAR SWITCHES

MODEL YEAR CHANGE

All 1997 model year motorcycles use new handlebar switches. The switches feature new icons, connectors and a different pin numbering sequence.

NOTE

All HANDLEBAR SWITCHES, REMOVAL and HANDLEBAR

SWITCHES, INSTALLATION procedures remain the same.

The new switch assemblies are interchangeable between 1996 and 1997 models if the corresponding connector on the wiring harness is changed.

See WIRING HARNESS on page 37 for more information.

Right Handlebar Switch

See Figure 25. The right handlebar switch [P1] contains:

Engine stop switch (ignition ON or OFF)

●

Electric starter switch

Left Handlebar Switch

See Figure 26. The left handlebar switch [P6] contains:

●

Passing lamp switch Headlamp dimmer switch (headlamp HIGH or LOW

●

beam)

●

Turn signal switch

●

Horn switch

b0279x7x

b0274x7x

Ignition ON

Ignition OFF

Electric starter

RIGHT HANDLEBAR SWITCH CONNECTOR

IGN POWER IGN MODULE FROM (2) TO STARTER

ACC POWER TO STOPLIGHT

BE W/R GN/BK Y/R

W/BK

2 1

BK/R

O/WO/W

R/YR/Y

BRAKE SWITCH

Figure 25. Right Handlebar Switch [P1]

LEFT HANDLEBAR SWITCH CONNECTOR

LT.B E

R/BE

1 2 3 4 5 6 7 8 9

Y/BK V/BN

O/W

TN/GN

W BN BK

GN BE

LOW BEAM LIGHT POWER HIGH BEAM

HORN FROM FLASHER LEFT TURN RIGHT TURN HORN POWER

FROM IGN RLY TO GROUND

CLUTCH SWITCH

Passing lamp

HIGH beam

LOW beam Turn signals

Horn

Figure 26. Left Handlebar Switch [P6]

Page 34

STARTER INTERLOCK SYSTEM

INSPECTION

The starter interlock system is designed to prevent unintended start-up and/or forward motion of the motorcycle with the vehicle’s side stand not retracted. Use the following two tests to check the system for proper operation.

The STARTER CIRCUIT and IGNITION CIRCUIT tests should be performed in one continuous operation. Conduct both tests one after the other in the sequence given without interruption

NOTE

Starter Circuit

Raise rear wheel off ﬂoor using REAR WHEEL SUPPORT STAND (Part No. B-41174). Remove GN wire from starter motor. Connect a test light or voltmeter to the vehicle in series.

a. Attach one end to starter wire terminal. b. Attach the other end to vehicle ground.

Set engine stop switch to RUN. Turn ignition switch to IGN. Place motorcycle in neutral. Press starter button on right handlebar.

Is current present? (Current is present if test light illuminates or if voltmeter shows 12 VDC ± 1.0 VDC.)

Check neutral switch and circuit. See NEUTRAL INDI-

YES

CATOR SWITCH in Section 7 of the 1996 manual.

Repeat entire interlock circuit test when ﬁnished.

Place motorcycle in ﬁrst gear. Press starter button on right handlebar.

Is current present?

Disengage clutch lever by pulling lever in fully. Press starter button on right handlebar.

Is current present?

YES

Release clutch lever. Press starter button on right handlebar.

Is current present?

Starter circuit operating properly.

a. Turn ignition switch to LOCK. b. Remove test light or voltmeter. c. Reattach starter motor wire.

YES

Check neutral switch. See NEUTRAL INDICATOR

SWITCH in Section 7 of the 1996 manual. Repeat

entire interlock circuit test when ﬁnished.

Check clutch switch. See STARTER INTERLOCK in Section 7 of the 1996 manual. Repeat entire interlock circuit test when ﬁnished.

Proceed to IGNITION CIRCUIT on page 35.

Page 35

Ignition Circuit

Remove W/BK wire from ignition coil. Connect a test light or voltmeter to the vehicle.

a. Attach one end to W/BK wire terminal. b. Attach the other end to vehicle ground.

Turn ignition switch to IGN. Set engine stop switch to RUN. Place motorcycle in neutral. Is current present?

YES

Place motorcycle in ﬁrst gear. Is current present?

Retract side stand. Is current present?

YES

Extend side stand. Pull-in clutch lever. Is current present?

YES

Check neutral switch and circuit. See NEUTRAL INDI-

CATOR SWITCH in Section 7 of the 1996 manual.

Repeat entire ignition portion of interlock circuit test when ﬁnished.

Check neutral switch. See NEUTRAL INDICATOR

SWITCH in Section 7 of the 1996 manual. Repeat

entire ignition portion of interlock circuit test when ﬁnished.

Check side stand switch. See STARTER INTERLOCK in Section 7 of the 1996 manual. Repeat entire ignition portion of interlock circuit test when ﬁnished.

Check clutch switch. See STARTER INTERLOCK in Section 7 of the 1996 manual. Repeat entire ignition portion of interlock circuit test when ﬁnished.

YES

Ignition circuit operating properly.

a. Turn ignition switch to LOCK. a. Set engine stop switch to OFF. b. Remove test light or voltmeter. c. Reconnect W/BK wire to ignition coil. d. Remove REAR WHEEL SUPPORT STAND.

Page 36

HORN

MODEL YEAR CHANGE

See Figure 27. All 1997 model year motorcycles have a new horn in a new location.

NOTE

For troubleshooting information, see HORN, TROUBLE-

SHOOTING in Section 7 in the 1996 manual.

REMOVAL

1. Remove seat and fuel tank. See FUEL T ANK, REMOVAL in Section 4 of the 1996 manual.

2. See Figure 28. Detach horn wires. a. Disconnect Y/BK power wire (5). b. Disconnect BK ground wire (6).

3. Remove bolt (1), lockwasher (2) and washer (3) to detach horn and bracket from frame.

INSTALLATION

1. See Figure 28. Attach horn assembly to frame using bolt (1), lockwasher (2) and washer (3).

2. Connect horn wires. a. Attach Y/BK power wire (5). b. Attach BK ground wire (6).

5882

Figure 27. Horn Location

5875

WARNING

After installing seat, pull upward on front of seat to be sure it is locked in position. If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control and personal injury.

3. Install fuel tank and seat. See FUEL TANK, INSTALLA-

TION in Section 4 of the 1996 manual.

1. Bolt

2. Lockwasher

3. Washer Figure 28. Horn Attachment

4. Adjuster

5. Power wire (Y/BK)

6. Ground wire (BK)

Page 37

WIRING HARNESS

MODEL YEAR CHANGE

The following changes were made to the wiring harness for 1997 model year motorcycles.

●

New connectors and a different pin numbering sequence for the right handlebar switch [P1] and the left handlebar switch [P6]. See HANDLEBAR SWITCHES on page 33.

●

Longer wires leading to the horn to accommodate the new mounting position.

Table 3. Electrical Connectors

CONNECTOR

NUMBER

[P1] 4-place connector right handlebar switch housing-ignition power, module and starter [P2] 2-place Amp Multilock front brake switch [P3] 12-place Amp Multilock instruments and indicator lamps [P4] 4-place Amp Multilock headlamp [P5] 2-place Amp Multilock clutch switch [P6] 8-place connector left handlebar switch housing-horn, turn signals, lights [P7] 2-place Deutsch vacuum-operated electric switch [P8] 4-place PED ignition/headlamp switch

[P9] 4-slot fuse block four 15 amp fuses-ignition, instruments, lights and accessories [P10] 8-place Deutsch ignition module [P11] 8-place Amp Multilock tail lamp and rear turn signals [P12] 4-place relay ignition relay [P13] 4-place relay starter relay [P14] 2-place Amp Multilock side stand switch

DESCRIPTION COMPONENT(S)

[P15] 2-place Amp Multilock license plate light [P16] 3-place Deutsch timer and pickup [P17] 2-place plug voltage regulator

Page 38

1997 BUELL WIRING DIAGRAM

 

6/10/96



LEFT TURN

RIGHT TURN

HIGH BEAM

OIL PRESSURE

SPEEDOMETER

TACHOMETER

NEUTRAL

GN/Y

W/GN

O/W

123456789101112

VBNW

GN/Y

P10

O/W

ELECTRONIC IGNITION

TIMER AND PICKUP

BK/W

GN/W

W/BK

R/W

V/W

12345678

BK/W

GN/W

W/BK

R/W

V/W

P16

/WGN

/WBK

R/W

/WV

FLASHER

VACUUM SWITCH



O/W

V/BN

HORN

/BYK

GN/Y



OIL PRESSURE

SWITCH



NEUTRAL SWITCH

R/Y

O/W

REAR

STOPLIGHT

SWITCH

 

TN/WBK

BK W

P14

SIDE STAND

SWITCH



RIGHT REAR TURN SIGNAL

1 2 3 4 5 6 7 8

P11

R/Y

O/W

BK BK

R/Y

V BK BK

1 2

P15

BE BE Y BK BK BK

LICENSE PLATE LIGHT



MAIN CHASSIS GROUND

R/Y

O/W

R/BK

TAIL LAMP

LEFT REAR TURN SIGNAL

BEBK

LT.BE

30A

MASTER CIRCUIT BREAKER

ABC

P17

/RGY

/BRK

/BR

VOLTAGE REGULATOR

STATOR

BATTERY

/BRK

/RGY

KEY SWITCH

LOCK

OFF

IGN

BK/R

R/BK

87A

TN/GN

STARTER RELAY

P13

BK/R

R/BK

TN/GN

VIEW FROM FUSE INSERTION SIDE

GY/O

O/W O/W

O O

R/BK

R/GY

INSTRUMENTS

15A

LIGHTS

15A

ACCESSORIES

15A

IGNITION

FUSE BLOCK

REAR PLUG

FRONT PLUG

COIL

W/BK

87A

GY/O

TN/W

IGNITION RELAY

GY/O

P12

S14 S15

TN/W

TN/GN

1 2

TN/GN

R/BE

CLUTCH SWITCH

LOW BEAM

HIGH BEAM

HORN

LIGHT POWER

LEFT TURN

FROM FLASHER

HORN POWER

RIGHT TURN

TO GROUND

FROM IGN RLY

3 4 5 6 7 8

O/W

V/BK

Y/BK

W BN BK

GN BE O

LT.BE

TN/GN

S11

S10

S12S13

BKBE

VLT.BE

2 3

O/W

POSITION LMP HIGH BEAM LOW BEAM LMP GROUND

HEADLAMP

LEFT FRONT

TURN SIGNAL

RIGHT FRONT TURN SIGNAL

BNR/BK

KBBE

W/BK W/BK BK/R

3 2

GN/BK

W/R

Y/R

BRAKE SWITCH

1 2

O/W

R/Y

TO STOPLIGHT

ACC POWER

IGN MODULE FROM (2) TO STARTER

IGN POWER

BN O/W

LT.BE LIGHT BLUE

CABLE COLOR

COLOR CODE:

BLUE

BLACK

BROWN

GREEN

GRAY

ORANGE

PINK

RED

TAN

VIOLET

WHITE

YELLOW

STRIPE COLOR

XX XX

PIN CONNECTOR SOCKET CONNECTOR

NO CONNECTION CONNECTION

DIODE

b0245a7x

Figure 29. 1997 Wiring Diagram

Page 39

FOREWORD

GENERAL

This Service Manual Supplement has been prepared with two purposes in mind. First, it will acquaint the user with the construction of the 1997 Buell S1 Lightning and assist in the performance of basic maintenance and repair. Secondly, it will introduce to the professional Buell Technician the latest ﬁeld-tested and factory-approved major repair methods. We sincerely believe that this Service Manual Supplement will make your association with Buell products more pleasant and proﬁtable.

HOW TO USE YOUR SERVICE MANUAL SUPPLEMENT

1. Check the TABLE OF CONTENTS following this FORWORD to ﬁnd the desired subject.

2. If the information you seek is not in this supplement, refer to the corresponding section in the Buell 1996 S1 Lightning Service Manual (Part No. 99490-96Y). Check the TABLE OF CONTENTS or INDEX to ﬁnd the desired subject.

3. Information is presented in a deﬁnite order as follows:

PREPARATION FOR SERVICE

WARNING

Gasoline is extremely ﬂammable and highly explosive. Always stop the engine when refueling or servicing the fuel system. Do not smoke or allow open ﬂame or sparks near the work site. Inadequate safety precautions may result in personal injury.

Good preparation is very important for efﬁcient service work. A clean work area at the start of each job will allow you to perform the repair as easily and quickly as possible, and will reduce the incidence of misplaced tools and parts. A motorcycle that is excessively dirty should be cleaned before work starts. Cleaning will occasionally uncover sources of trouble. Tools, instruments and any parts needed for the job should be gathered before work is started. Interrupting a job to locate tools or parts is an unnecessary distraction and causes needless delay.

SERVICE BULLETINS

In addition to the information presented in this Service Supplement, Buell Distribution Corporation will periodically issue Service Bulletins to Buell dealers. Service Bulletins cover interim engineering changes and supplementary information.

Speciﬁcations General/Model Y ear Change Adjustment/T esting Removal/Disassembly Cleaning, Inspection, and Repair Assembly/Installation

In ﬁgure legends, the number which follows the name of a part indicates the quantity necessary for one complete assembly.

NOTE

To avoid needless disassembly, carefully read all relative service information before repair work is started.

USE GENUINE REPLACEMENT PARTS

WARNING

When replacement parts are required, use only genuine Buell parts or parts with equivalent characteristics (which include type, strength and material). Failure to do so may result in product malfunction and possible injury to the operator and/or passenger.

To ensure satisfactory and lasting repairs, carefully follow the instructions and use only genuine Buell replacement parts. This is your assurance that the parts you are using will ﬁt right, operate properly and last longer.

Page 40

PRODUCT REFERENCES

WARNING

Follow the directions listed on all products. Carefully read all labels, warnings and cautions before use. Inadequate safety precautions may result in personal injury.

When reference is made in this Service Manual Supplement to a speciﬁc brand name product, tool or instrument, an equivalent product, tool or instrument may be substituted.

Kent-Moore Products

All tools mentioned in this supplement with an “HD”, “J” or “B” preface must be ordered through:

Kent-Moore SPX Corporation 29784 Little Mack Roseville, Michigan 48066-2298 Telephone: 1-800-345-2233

Sealing and Threadlocking Products

LOCTITE PRODUCTS

Some procedures call for the use of Loctite® products. If you have any questions regarding Loctite product usage or retailer/wholesaler locations, please call Loctite Corp. at 1800-323-5106.

All photographs and illustrations may not necessarily depict the most current model or component, but are based on the latest production information available at the time of publication.

Since product improvement is our continual goal, Buell reserves the right to change speciﬁcations, equipment or designs at any time without notice and without incurring obligation.

WARNINGS AND CAUTIONS

Statements in this supplement preceded by the word

“1WARNING” or “1CAUTION”

these items alert you to situations where the possibility of personal injury or vehicle damage exists, please take special notice of them.

WARNING

A “WARNING” indicates the potential for personal injury, whether to yourself or others.

CAUTION

A “CAUTION” indicates that vehicle damage can occur.

WARNING

●

Proper service and repair is important for the safe, reliable operation of all mechanical products. The service procedures recommended and described in this Service Manual are effective methods for performing service operations. Some of these service operations require the use of tools specially designed for the purpose. These special tools should be used when and as recommended. It is important to note that some warnings against the use of speciﬁc service methods, which could damage the motorcycle or render it unsafe, are stated in this Service Manual. However, please remember that these warnings are not all-inclusive.

●

Since Buell could not possibly know, evaluate or advise the service trade of all possible ways in which service might be performed, or of the possible hazardous consequences of each method, we have not undertaken any such broad evaluation. Accordingly, anyone who uses a service procedure or tool which is not recommended by Buell must ﬁrst thoroughly satisfy himself that neither his nor the operator’s safety will be jeopardized as a result.

●

Wear eye protection when using hammers, arbor or hydraulic presses, gear pullers, spring compressors, slide hammers and similar tools. Be especially cautious when using pulling, pressing or compressing equipment. The forces involved can cause parts to ﬂy outward with considerable force, possibly resulting in personal injury.

are very important. Since

Buell products are manufactured under one or more of the following patents: U.S. Patents – 2986161, 2987934, 2998809, 3116089, 3144531, 3144860, 3226994, 3229792, 3434887, 3559773, 3673359, 3709317, Des. 225 626.

ii.

Page 41

GENERAL

SERVICING A NEW MOTORCYCLE

WARNING

Always follow the listed service and maintenance recommendations, since they affect the safe operation of the motorcycle and the personal welfare of the rider. Failure to follow recommendations may cause personal injury.

Service operations to be performed before customer delivery are speciﬁed in the applicable model year PREDELIVERY AND SETUP MANUAL.

The performance of new motorcycle initial service is required to keep warranty in force and to ensure proper emissions systems operation.

After a new motorcycle has been driven its ﬁrst 500 miles, and again at 2500 mile intervals, a Buell dealer should perform the service operations listed in the REGULAR

MAINTENANCE INTERVALS chart on page 1-9.

SAFE OPERATING MAINTENANCE

A careful check of certain equipment is necessary after periods of storage, and frequently between regular service intervals, to determine if additional maintenance is required.

CAUTION

●

Do not attempt to retighten engine head bolts. Retightening can cause engine damage.

●

During the initial 500 mile (800 km) break-in period, use only 20W50 engine oil. Failure to use the recommended oil will result in improper break-in of the engine cylinders and piston rings.

Do not lubricate the enrichment cable on C.V.

●

carburetors. The cable requires friction to operate properly.

SHOP PRACTICES

Repair Notes

NOTE

●

General maintenance practices are given in this section.

●

Repair = Disassembly/Assembly.

●

Replace = Removal/Installation.

All special tools and torque values are noted at the point of use.

All required parts or materials can be found in the appropriate PARTS CATALOG.

Safety

Safety is always the most important consideration when performing any job. Be sure you have a complete understanding of the task to be performed. Use common sense. Use the proper tools. Protect yourself and bystanders with approved eye protection. Don’t just do the job – do the job safely.

Removing Parts

Always consider the weight of a part when lifting. Use a hoist whenever necessary. Do not lift heavy parts by hand. A hoist and adjustable lifting beam or sling are needed to remove some parts. The lengths of chains or cables from the hoist to the part should be equal and parallel and should be positioned directly over the center of the part. Be sure that no obstructions will interfere with the lifting operation. Never leave a part suspended in mid-air.

Always use blocking or proper stands to support the part that has been hoisted. If a part cannot be removed, verify that all bolts and attaching hardware have been removed. Check to see if any parts are in the way of the part being removed.

When removing hoses, wiring or tubes, always tag each par t to ensure proper installation.

Check:

1. Tires for abrasions, cuts and correct pressure.

2. Secondary drive belt for proper tension and condition.

3. Brakes, steering and throttle for responsiveness.

4. Brake ﬂuid level and condition. Hydraulic lines and ﬁttings for leaks. Also, check brake pads and rotors for wear.

5. Cables for fraying, crimping and free operation.

6. Engine oil and transmission ﬂuid levels.

7. Headlamp, passing lamp, tail lamp, brake lamp and turn signal operation.

Cleaning

If you intend to reuse parts, follow good shop practice and thoroughly clean the parts before assembly. Keep all dirt out of parts; the unit will perform better and last longer. Seals, ﬁlters and covers are used in this vehicle to keep out environmental dirt and dust. These items must be kept in good condition to ensure satisfactory operation.

Clean and inspect all parts as they are removed. Be sure all holes and passages are clean and open. After cleaning, cover all parts with clean lint-free cloth, paper or other material. Be sure the part is clean when it is installed.

Always clean around lines or cov ers before they are removed. Plug, tape or cap holes and openings to keep out dirt, dust and debris.

1-1

Page 42

Disassembly and Assembly

Bushings

Always assemble or disassemble one part at a time. Do not work on two assemblies simultaneously. Be sure to make all necessary adjustments. Recheck your work when ﬁnished. Be sure that everything is done.

Operate the vehicle to perform any ﬁnal check or adjustments. If all is correct, the vehicle is ready to go back to the customer.

REPAIR AND REPLACEMENT PROCEDURES

Hardware and Threaded Parts

Install helical thread inserts when inside threads in castings are stripped, damaged or not capable of withstanding speciﬁed torque.

Replace bolts, nuts, studs, washers, spacers and small common hardware if missing or in any way damaged. Clean up or repair minor thread damage with a suitable tap or die.

Replace all damaged or missing lubrication ﬁttings. Use Teﬂon pipe sealant on pipe ﬁtting threads.

Wiring, Hoses and Lines

Replace hoses, clamps, electrical wiring, electrical switches or fuel lines if they do not meet speciﬁcations.

Instruments and Gauges

Replace broken or defective instruments and gauges. Replace dials and glass that are so scratched or discolored that reading is difﬁcult.

Bearings

Anti-friction bearings must be handled in a special way. To keep out dirt and abrasives, cover the bearings as soon as they are removed from the package.

Wash bearings in a non-ﬂammable cleaning solution. Knock out packed lubricant inside by tapping the bearing against a wooden block. Wash bearings again. Cover bearings with clean material after setting them down to dry. Never use compressed air to dry bearings.

Coat bearings with clean oil. Wrap bearings in clean paper. Be sure that the chamfered side of the bearing always faces

the shoulder (when bearings installed against shoulders). Lubricate bearings and all metal contact surfaces before pressing into place. Only apply pressure on the part of the bearing that makes direct contact with the mating part.

Always use the proper tools and ﬁxtures for removing and installing bearings.

Bearings do not usually need to be removed. Only remove bearings if necessary.

Do not remove a bushing unless damaged, excessively worn or loose in its bore. Press out b ushings that must be replaced.

When pressing or driving bushings, be sure to apply pressure in line with the bushing bore. Use a bearing/bushing driver or a bar with a smooth, ﬂat end. Never use a hammer to drive bushings.

Inspect the bushing and the mated part for oil holes. Be sure all oil holes are properly aligned.

Gaskets

Always discard gaskets after removal. Replace with gaskets. Never use the same gasket twice. Be sure that gasket holes match up with holes in the mating part.

new

Lip T ype Seals

Lip seals are used to seal oil or grease and are usually installed with the sealing lip facing the contained lubricant. Seal orientation, however, may vary under different applications.

Seals should not be removed unless necessary. Only remove seals if required to gain access to other parts or if seal damage or wear dictates replacement.

Leaking oil or grease usually means that a seal is damaged. Replace leaking seals to prevent overheated bearings.

Always discard seals after removal. Do not use the same seal twice.

O-Rings (Preformed Packings)

Always discard O-rings after removal. Replace with rings. To prevent leaks, lubricate the O-rings before installation. Apply the same type of lubricant as that being sealed. Be sure that all gasket, O-ring and seal mating surfaces are thoroughly clean before installation.

new

O-

Gears

Always check gears for damaged or worn teeth. Lubricate mating surfaces before pressing gears on shafts.

Shafts

If a shaft does not come out easily, check that all nuts, bolts or retaining rings have been removed. Check to see if other parts are in the way before using force.

Shafts ﬁtted to tapered splines should be very tight. If shafts are not tight, disassemble and inspect tapered splines. Discard parts that are worn. Be sure tapered splines are clean, dry and free of burrs before putting them in place. Press mating parts together tightly.

Clean all rust from the machined surfaces of new parts.

1-2

Page 43

Part Replacement

Always replace worn or damaged parts with

new

parts.

●

Disconnect the air supply line to an air hammer before attaching a bit.

●

Never point an air tool at yourself or another person.

CLEANING

Part Protection

Before cleaning, protect rubber parts (such as hoses, boots and electrical insulation) from cleaning solutions. Use a grease-proof barrier material. Remove the rubber part if it cannot be properly protected.

Cleaning Process

Any cleaning method may be used as long as it does not result in parts damage. Thorough cleaning is necessary for proper parts inspection. Strip rusted paint areas to bare metal before repainting.

Rust or Corrosion Removal

Remove rust and corrosion with a wire brush, abrasive cloth, sand blasting, vapor blasting or rust remover. Use bufﬁng crocus cloth on highly polished parts that are rusted.

Bearings

Remove shields and seals from bearings before cleaning. Clean bearings with permanent shields and seals in solution.

Clean open bearings by soaking them in a petroleum cleaning solution. Never use a solution that contains chlorine.

Let bearings stand and dry. Do not dry using compressed air. Do not spin bearings while they are drying.

●

Protect bystanders with approved eye protection.

Wrenches

●

Never use an extension on a wrench handle.

●

If possible, always pull on a wrench handle and adjust your stance to prevent a fall if something lets go.

●

Never cock a wrench. Never use a hammer on any wrench other than a

●

STRIKING FACE wrench. Discard any wrench with broken or battered points.

●

Never use a pipe wrench to bend, raise or lift a pipe.

Pliers/cutters/prybars

Plastic- or vinyl-covered pliers handles are not intended

●

to act as insulation; don’t use on live electrical circuits. Don’t use pliers or cutters for cutting hardened wire

●

unless they were designed for that purpose. Always cut at right angles.

●

Don’t use any prybar as a chisel, punch or hammer.

Hammers

TOOL SAFETY

Air Tools

●

Always use approved eye protection equipment when performing any task using air-operated tools.

●

On all power tools, use only recommended accessories with proper capacity ratings.

Do not exceed air pressure ratings of any power tools.

●

Bits should be placed against work surface before air hammers are operated.

Never strike one hammer against a hardened object,

●

such as another hammer. Always grasp a hammer handle ﬁrmly, close to the end.

●

Strike the object with the full face of the hammer.

●

Never work with a hammer which has a loose head. Discard hammer if face is chipped or mushroomed.

●

Wear approved eye protection when using striking tools.

●

Protect bystanders with approved eye protection.

1-3

Page 44

Punches/chisels

Never use a punch or chisel with a chipped or

●

mushroomed end; dress mushroomed chisels and punches with a ﬁle.

●

Hold a chisel or a punch with a tool holder if possible. When using a chisel on a small piece, clamp the piece

●

ﬁrmly in a vise and chip toward the stationary jaw. Wear approved eye protection when using these tools.

●

Protect bystanders with approved eye protection.

Screwdrivers

Don’t use a screwdriver for prying, punching, chiseling,

●

scoring or scraping. Use the right type of screwdriver for the job; match the tip

●

to the fastener.

●

Don’t interchange POZIDRIV®, PHILLIPS® or REED AND PRINCE screwdrivers.

●

Screwdriver handles are not intended to act as insulation; don’t use on live electrical circuits.

●

Don’t use a screwdriver with rounded edges because it will slip – redress with a ﬁle.

Ratchets and Handles

●

Always support the ratchet head when using socket extensions, but do not put your hand on the head or you may interfere with the action of its reversing mechanism.

●

When breaking loose a fastener, apply a small amount of pressure as a test to be sure the ratchet’s gear wheel is engaged with the pawl.

Sockets

●

Never use hand sockets on power or impact wrenches. Select the right size socket for the job.

●

Never cock any wrench or socket.

●

Select only impact sockets for use with air or electric impact wrenches.

Replace sockets showing cracks or wear.

●

Keep sockets clean. Always use approved eye protection when using power

●

or impact sockets.

Storage Units

●

Don’t open more than one loaded drawer at a time. Close each drawer before opening up another.

Periodically clean and lubricate ratchet mechanisms with

●

a light grade oil. Do not replace parts individually; ratchets should be rebuilt with the entire contents of service kit.

●

Never hammer or put a pipe extension on a ratchet or handle for added leverage.

●

Close lids and lock drawers and doors before moving storage units.

Don’t pull on a tool cabinet; push it in front of you.

●

Set the brakes on the locking casters after the cabinet has been rolled to your work.

1-4

Page 45

1996 S1 LIGHTNING SPECIFICATIONS

DIMENSIONS IN. MM

IGNITION SYSTEM

Wheel base 55 1397 Overall length 79.5 2019 Overall width 30 762 Road clearance 5.2 132 Seat height 29.5 749

CAPACITIES U.S. LITERS

Fuel tank (including reserve) 4.0 gallons 15.14 Reserve 0.6 gallons 2.27 Oil tank 2.0 quarts 1.89 Transmission 1.0 quart 0.95

WEIGHT LBS. KG

S1 shipping weight 446 202 GVWR 820 372 GAWR - Front 340 154 GAWR - Rear 480 218

Spark plugs No. 6R12 Size 12 mm Gap 0.038-0.045 in. 0.97-1.14 mm

TRANSMISSION

Type Constant Mesh, Foot Shift Speeds 5 Forward

NUMBER OF SPROCKET TEETH

Engine 35 Clutch 56 Transmission 27 Rear wheel 61 Belt 128

TRANSMISSION GEAR RATIOS FINAL* OVERALL**

First (low) gear 2.69 9.717 Second gear 1.97 7.118 Third gear 1.43 5.180

NOTE

ENGINE

Fourth gear 1.18 4.269 Fifth (high) gear 1.00 3.615

PRESSURE

TIRE AND POSITION

Front-Dunlop Sportmax Radial II 120/70 ZR 17

Rear-Dunlop Sportmax Radial II 170/60 ZR 17

Do not inflate any tire beyond its maximum inflation pressure as specified on tire sidewall. Overinflation may cause tire to suddenly deflate leading to personal injury.

WARNING

FOR SOLO

RIDING

32 PSI

(2.2 bar)

36 PSI

(2.5 bar)

PRESSURE

AT GVWR

36 PSI

(2.5 bar)

38 PSI

(2.8 bar)

1-5

Page 46

SIDE VIEWS

5745

1. Right rear turn signal

2. Tail/brake lamp

3. Rear brake master cylinder and reservoir

4. Air cleaner cover

5. Fuel filler cap

6. Front brake master cylinder

7. Front brake hand lever

8. Right front turn signal

9. Headlamp

10. Front brake caliper

11. Timer cover

8 9

11121314

12. Rear shock absorber

13. Rear brake pedal

14. Belt guard(s)

15. License plate light

5746

1. Rear axle adjuster nut

2. Rear sprocket and secondary drive belt

3. Ignition module

4. Fuse block and spare fuse

Figure 1-1. 1996 S1 Lightning, Right Side View

4 5 6

1011121314

5. Turn signal flasher

6. Horn

7. Front brake master cylinder

8. Front brake hand lever

9. Front brake caliper

10. Oil pump

11. Battery

12. Voltage regulator

13. Rider footrest

14. Passenger footrest

1-6

Figure 1-2. 1996 S1 Lightning, Right Side View (Body Removed)

Page 47

5747

4 5 6 7 8

111213

1. Left front turn signal

2. Headlamp

3. Instruments

4. Clutch hand lever

5. Fuel filler cap

6. Ignition/headlamp key switch

7. Fuel supply valve

8. Tail/brake lamp

9. Left rear turn signal

10. Rear brake caliper

11. Gear shift lever

12. Exhaust muffler

13. Oil filter

5748

6 84

2 31

11121314

5 9

1. Steering head lock

2. Instruments

3. Clutch hand lever

4. Ignition coil

5. Enrichener knob

6. Starter relay

7. Oil filler plug/dipstick

8. Oil tank

9. Rear brake caliper

10. Rear axle adjuster nut

11. Oil tank drain hose

12. Gear shift lever

13. Exhaust muffler

14. Oil filter

15. Speedometer drive

Figure 1-3. 1996 S1 Lightning, Left Side View

Figure 1-4. 1996 S1 Lightning, Left Side View (Body Removed)

1-7

Page 48

FLUID REQUIREMENTS

GENERAL

United States System

Unless otherwise speciﬁed,

in this Service Manual are expressed in United States (U.S.) units-of-measure

1 pint (U.S.) = 16 ﬂuid ounces (U.S.)

●

1 quart (U.S.) = 2 pints (U.S.) = 32 ﬂ. oz. (U.S.)

●

1 gallon (U.S.) = 4 quarts (U.S.) = 128 ﬂ. oz. (U.S.)

●

all ﬂuid volume measurements

. See below:

Metric System

●

ﬂuid ounces (U.S.) x 29.574 = milliliters

●

pints (U.S.) x 0.473 = liters

●

quarts (U.S.) x 0.946 = liters

●

gallons (U.S.) x 3.785 = liters

●

milliliters x 0.0338 = ﬂuid ounces (U.S.) liters x 2.114 = pints (U.S.)

●

liters x 1.057 = quarts (U.S.)

●

liters x 0.264 = gallons (U.S.)

●

STEERING HEAD BEARING GREASE

Use WHEEL BEARING GREASE (Part No. 99855-89).

BRAKE FLUID

FRONT FORK OIL

Use only WP FORK OIL, 5 WEIGHT.

FUEL

Use a good quality leaded or unleaded gasoline (91 pump octane or higher). Pump octane is the octane number usually shown on the gas pump. See ENGINE in Section 3 for a detailed explanation of alternative fuels.

ENGINE OIL

Use the proper grade of oil for the lowest temperature expected before the next oil change.

Table 1-1. Recommended Oil Grades

COLD

WEATHER

STARTS

BELOW

50° F

Excellent

Good

Poor

HARLEY-

DAVIDSON TYPE

H.D. Multi-Grade

H.D. Regular Heavy

H.D. Extra Heavy

VISCOSITY

SAE

10W40

SAE

20W50

SAE

HARLEY-

DAVIDSON

RATING

HD 240

LOWEST

AMBIENT

TEMP.

Below 40

(4°C)

Above 40

(4°C)

Above 60

(16°C)

Above 80

(27°C)

WARNING

D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID can cause eye irritation. In case of contact with eyes, ﬂush with plenty of water and get medical attention. KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN!

Use only D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID (Part No. 99902-77).

PRIMARY DRIVE/TRANSMISSION LUBRICANT

Use only SPORT-TRANS FLUID (Part No. 98854-96 quart size or Part No. 98855-96 gallon size).

1-8

Page 49

Table 1-2. Regular Maintenance Intervals

n n u

SERVICE DATA

0 0

4 4 0 0 0

30-40 in-lbs (3.4-4.5 Nm)-hold cables when tightening

Checking oil level

Check with vehicle at operating temperature, engine off, motorcycle upright (not on side stand) on a level surface.

Oil level

Between upper and lower marks on dipstick (1/2 quart [0.47 liter] difference).

Oil capacity

2.0 quarts (1.9 liters)

D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID Front master cylinder level

Above LOW mark on sight glass or within 1/8 in. (3.2 mm) of molded boss when cover is removed.

Rear master cylinder level Between upper and lower marks on reservoir.

1/8 in. (3.2 mm) Pedal action should be smooth and not binding.

1/16 in. (1.6 mm)

Minimum front rotor thickness

0.17 in. (4.4 mm)

Minimum rear rotor thickness

0.19 in. (4.8 mm)

SERVICE OPERATIONS

AND SPECIAL TOOLS

i d e

8 0 0

Battery connections (page 1-13) I IIIIIIIIIIIII Torque

Engine oil (page 1-15)

OIL FILTER WRENCH (Part No. HD-41215)

Oil ﬁlter (page 1-16) Brake ﬂuid level and condition (page 1-17) I I I I I I I I Fluid type

Rear brake pedal height adjustment and freeplay (page 1-17)

Brake pads and rotors for wear (page 1-17) I IIIIIIIIIIIII Minimum brake pad thickness

Condition of rear brake caliper mounting pins and boots

IRIRIRIRIRIRIRRSee Recommended Oil Grades on page 1-15.

R R R R R R R R Hand tighten ﬁlter 1/2-3/4 turn after gasket contacts surface.

II I I I I I I Maximum freeplay

IL IL IL IL IL IL

1 2 0 0 0

1 6 0 0 0

2 0 0 0 0

0 0

2 4 0 0 0

5 0 0

3 6 0 0 0

5 0 0 0

4 0 0 0 0

1-9

Table Code: A - Adjust. I - Inspect, and if necessary, correct, adjust, clean or replace. L - Lubricate with speciﬁed lubricant.

R - Replace or change.

T - Tighten to proper torque.

X - Perform.

Page 50

1-10

n n u

SERVICE DATA

0 0

4 4 0 0 0

1.0 quart (0.95 liter) of SPORT-TRANS FLUID (Part No. 98854-96)

Fluid level Lubricant should reach bottom of clutch spring with motorcycle upright (not on side stand).

Drain plug torque

14-21 ft-lbs (19-28 Nm)

1/16-1/8 in. (1.6-3.2 mm)

Clutch inspection cover screw torque

7-9 ft-lbs (9-12 Nm)

7/8-1 in. (22.2-25.4 mm)

Rear axle nut torque

68-73 ft-lbs (89.5-98.9 Nm)

1/4-3/8 in. (6.4-9.5 mm)

Chain freeplay with cold engine

3/8-1/2 in. (9.5-12.7 mm)

Inspection screws torque

40-60 in-lbs (4.5-6.8 Nm)

3.5-5.5 ft-lbs (1.6-2.5 kg)

Lubricant

WHEEL BEARING GREASE (Part No. HD99855-89)

4 0 0 0

8 0 0 0

SERVICE OPERATIONS

AND SPECIAL TOOLS

i d e

8 0 0

Tire pressure and inspect tire for wear/damage IIIIIIIIIIIIII See Tire Pressures on page 1-18. Wheel bearings (page 1-18) I I I I Check for wear and corrosion. Replace in sets only. Primary chaincase/transmission lubricant (page 1-19)

REAR WHEEL SUPPORT STAND (Part No. B-41174)

Clutch adjustment (page 1-20)

Rear belt deﬂection (page 1-21)

BELT TENSION GAUGE (Part No. HD-35381)

Primary chain (page 1-22)

Rear shock absorber (page 1-24) Steering head bearing adjustment (page 1-25)

FRONT WHEEL SUPPORT STAND (Part No. B-41395)

& S1 ADAPTER (B-41686)

R IRIRIRIRIRIR Fluid type and amount

A A A A A A A Hand lever freeplay

IA I I I I I I Belt deﬂection with 10 lbs (4.5 kg) of upward force

I I I I I I I Chain freeplay with hot engine

I I I I I I I Check for bushing wear and loose mounting hardware. I I IL I IL I IL Force to pull front wheel to center

1 2 0 0 0

1 6 0 0 0

2 0 0 0 0

0 0

2 4 0 0 0

5 0 0

3 6 0 0 0

5 0 0 0

4 0 0 0 0

Table Code: A - Adjust. I - Inspect, and if necessary, correct, adjust, clean or replace. L - Lubricate with speciﬁed lubricant.

R - Replace or change.

T - Tighten to proper torque.

X - Perform.

Page 51

n n u

0 0 0

4 4 0 0 0

WP FORK OIL, 5 weight Fluid level

4.33 in. (110 mm) from top with fork fully compressed

No. 6R12 Spark plug gap

0.038-0.045 in. (0.96-1.14 mm) Lubricant

LOCTITE ANTI-SEIZE LUBRICANT Torque

11-18 ft-lbs (15-24 Nm)

DO NOT lubricate the enrichener cable.

2000 RPM

Regular idle-49 state models

950-1050 RPM

Regular idle-California models

1150-1250 RPM

SERVICE OPERATIONS

AND SPECIAL TOOLS

i d e

8 0 0

Front fork oil (page 1-26)

FRONT WHEEL SUPPORT STAND (Part No. B-41395)

& S1 ADAPTER (B-41686)

PRO-LEVEL OIL GAUGE (Part No. B-59000A)

Spark plugs (page 1-27)

Air cleaner ﬁlter (page 1-28) Throttle control grip sleeve, cables and speedometer cable (Section 2) I L L L L L L Check for damage and freeplay. Front brake hand lever, throttle control cables, clutch control cable and

hand lever (Section 2) Operation of throttle and enrichener controls (page 1-29)

Engine idle speed (page 1-30)

CARBURETOR IDLE ADJUSTMENT TOOL (Part No. HD-33413)

TIP (Snap-on Part No. TMP23A)

Ignition timing (page 1-30)

TIMING MARK VIEW PLUG (Part No. HD-96295-65D) INDUCTIVE TIMING LIGHT (Part No. HD-33813)

Vacuum-operated electric switch (V.O.E.S.) (page 1-32)

I R R R R R R Check more often in dusty conditions.

L L L L L L L Check for damage and freeplay.

IIIIIIIIIIIIII Controls must be smooth and not binding.

IIIIIIIIIIIIII Fast idle-all models

I R I R I R Spark plug type

I I I I I I Ignition timing set at regular engine idle speed (listed above).

I I I I I I

R R R Fluid type

2 0 0 0 0

0 0

2 4 0 0 0

5 0 0

3 6 0 0 0

5 0 0 0

4 0 0 0 0

SERVICE DATA

1-11

Table Code: A - Adjust. I - Inspect, and if necessary, correct, adjust, clean or replace. L - Lubricate with speciﬁed lubricant.

R - Replace or change.

T - Tighten to proper torque.

X - Perform.

Page 52

1-12

SERVICE OPERATIONS

AND SPECIAL TOOLS

i d e

8 0 0

Fuel supply valve, hoses and ﬁttings for leaks (Section 4) I IIIIIIIIIIII Fuel tank ﬁlter screen (Section 4) I I I I I I Swingarm pivot bolt (Section 2) I I I I I I Lubricant

Swingarm bearings (Section 2)

Oil and brake lines (Section 2 and 3) Side stand (Section 2) I L L L L L L Engine mounts (Section 3) I I I I I I I Operation of all electrical equipment and switches (Section 7) IIIIIIIIIIIIII All fasteners except engine head bolts T T T T T T T Road test XXXXXXXXXXXXXX

IIIIIIIIIIIIII Check for leaks and loose connections.

I IL I IL I IL Lubricant

1 2 0 0 0

1 6 0 0 0

2 0 0 0 0

0 0

2 4 0 0 0

5 0 0

3 6 0 0 0

5 0 0 0

4 0 0 0 0

n n u

SERVICE DATA

LOCTITE ANTI-SEIZE LUBRICANT

WHEEL BEARING GREASE (Part No. HD99855-89)

Table Code: A - Adjust. I - Inspect, and if necessary, correct, adjust, clean or replace. L - Lubricate with speciﬁed lubricant.

R - Replace or change.

T - Tighten to proper torque.

X - Perform.

Page 53

BATTERY

GENERAL

WARNING

Batteries contain sulfuric acid which can cause severe

●

burns. Avoid contact with skin, ey es or c lothing.

●

Batteries produce explosive hydrogen gas at all times, especially when being charged. Keep cigarettes, open ﬂame and sparks away from the battery at all times. Ventilate area when charging battery. Always protect hands and pr otect e y es with shield or goggles when working near a battery or acid. KEEP BATTERIES AND ACID OUT OF THE REACH OF CHILDREN!

The battery is below the seat in the center of the vehicle. The battery can be removed from the left side of the motorcycle without removing the tail section or fuel tank.

The battery requires no additional ﬂuid at any time. Check the battery:

At every scheduled service interval.

●

When storing or removing the motorcycle for the season.

●

CHARGING

The sealed, low maintenance battery has a very slow discharge rate. See Figure 1-6. If you suspect a battery problem, test as described below.

1. Remove battery from motorcycle. See BATTERY,

REMOVAL on page 1-14.

2. Test battery voltage using a multimeter.

3. If battery voltage is below 12.66 Volts, use a 1-100 Amp, 12 Volt charger on battery. See Table 1-3.

1DANGER - EXPLOSIVE GASES

Cigarettes, ﬂames or sparks could cause battery to explode resulting in personal injury. Always shield eyes and face from battery. Do not charge without proper instruction and training. Securely connect cables to the proper terminals.

POISON - CAUSES SEVERE BURNS

Contains sulfuric acid. Avoid contact with skin, eyes, and clothing. In event of accident, ﬂush with water and call a physician immediately.

KEEP OUT OF REACH OF CHILDREN

Figure 1-5. Battery Warnings

b0188xox

12.9

12.6

12.3

12.0

Open Circuit Volts

11.7

11.4 0

Figure 1-6. Open Circuit Voltage vs. State of Charge

20 40 60 80 100

State of Charge, %

(No Charge Last 24 Hours)

Table 1-3. Charging Rates

CHARGER

OUTPUT

CURRENT

RATE

1 Amp 32 hours 48 hours 96 hours 2-5 Amps 16 hours 24 hours 48 hours 6-10 Amps 8 hours 12 hours 24 hours

OPEN CIRCUIT VOLTAGE

12.00 to

12.66 V olts

11.40 to

11.99 V olts

Less than

11.40 V olts

1-13

Page 54

REMOVAL

WARNING

To avoid accidental start-up of vehicle and possible personal injury, disconnect the battery cables before proceeding. Always disconnect the negative cable ﬁrst. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion producing personal injury.

CAUTION

See Figure 1-8. Hold battery cable when loosening bat- tery terminal hardware. Failure to hold cable will cause battery damage.

1. Disconnect battery cables, negative cable ﬁrst.

2. Remove battery strap locknut using 7/16 in. ﬂex socket (SNAP-ON Part No. TMU141) and handle (SNAP-ON Part No. TM62B).

NOTE

On California models, detach carbon canister from bracket before removing battery.

3. Remove battery from left side.

5548

b0189x7x

Locknut

Battery positive

terminal (metric)

Battery negative terminal (metric)

Battery strap

Figure 1-7. Battery

Hold cable during removal/installation

Tighten to 30-40 in-lbs (3.4-4.5 Nm)

INSTALLATION

1. Clean cable connectors and battery terminals using a wire brush or sandpaper to remove any oxidation.

WARNING

Always connect positive battery cable ﬁrst. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion resulting in personal injury.

CAUTION

Connect cables to correct terminals of battery or serious damage to motorcycle electrical system will occur.

2. Connect positive cable to positive (+) battery terminal. Then, after positive cable has been connected to positive terminal, connect negative cable to negative (-) battery terminal.

CAUTION

See Figure 1-8. Hold battery cable when tightening bat- tery terminal hardware. Failure to hold cable will cause battery damage.

3. Tighten battery hardware to 30-40

4. Apply light coat of petroleum jelly or corrosion-retardant material to both terminals.

in-lbs

(3.4-4.5 Nm).

Figure 1-8. Checking Battery Terminals

NOTE

On California models, attach carbon canister to bracket after installing battery.

1-14

Page 55

ENGINE LUBRICATION SYSTEM

CHECKING ENGINE OIL LEVEL

Check engine oil level:

At least once every 500 miles (800 km).

●

At every service interval.

NOTE

If engine uses more oil than normal or if vehicle is operated under harsh conditions, check oil more frequently.

When checking or changing engine oil:

●

Warm vehicle to normal operating temperature.

●

Turn engine off.

●

Hold motorcycle upright (not leaning on side stand) on a level surface.

1. Remove seat.

2. See Figure 1-10. Remove ﬁller cap/dipstick from oil tank. Wipe dipstick clean.

3. Install ﬁller cap onto oil tank. Make sure cap is fully seated on tank.

CAUTION

Do not switch oil brands indiscriminately because some oils interact chemically when mixed. Use of inferior oils or non-detergent oils can damage the engine.

5582

Oil pressure

switch

Oil filter

Figure 1-9. Oil Filter and Mount

5545

Lower mark

Upper mark

Oil tank

4. Remove ﬁller cap again and check oil level on dipstick. Oil level should be between lower and upper dipstick

level marks. If oil level in tank is below lower mark of dipstick, add oil to tank. Install ﬁller cap/dipstick.

Recommended viscosity depends upon ambient temperature. See Table 1-4.

NOTE

Difference between upper and lower dipstick marks is

0.5 quart (0.47 liter).

WARNING

5. Install seat.

Figure 1-10. Checking Oil Tank Level

Table 1-4. Recommended Oil Grades

HARLEY-

DAVIDSON TYPE

H.D. Multi-Grade

H.D. Regular Heavy

H.D. Extra Heavy

VISCOSITY

SAE

10W40

SAE

20W50

SAE

HARLEY-

DAVIDSON

RATING

HD 240

LOWEST

AMBIENT

TEMP.

Below 40

(4°C)

Above 40

(4°C)

Above 60

(16°C)

Above 80

(27°C)

COLD

WEATHER

STARTS

BELOW

50° F

Excellent

Good

Poor

1-15

Page 56

CHANGING ENGINE OIL AND FIL TER

Change engine oil:

●

At the 500 mile (800 km) service interval. At every 5000 mile (8000 km) service interval thereafter.

●

When storing or removing the motorcycle for the season.

NOTE

The colder the weather, the shorter the recommended oil change interval. A vehicle used only for short runs in cold weather must have the engine oil drained more frequently.

5547

Drain hose

Clamp

Drain plug

1. Place a suitable container under the motorcycle.

2. See Figure 1-11. Compress clamp. Remove hose from drain plug by pulling hose forward. Direct hose to container and completely drain oil tank.

3. Install drain hose on drain plug. Tighten clamp.

4. Remove oil ﬁlter using OIL FILTER WRENCH (Part No.

HD-41215).

5. Clean ﬁlter gasket contact surface on crankcase . Surface should be smooth and free of any debris or old gasket material.

6. See Figure 1-12. Apply a thin ﬁlm of oil to gasket contact surface on crankcase mounting plate and to

7. Pour 4.0 ounces (0.12 liter) of clean oil into when changing oil.

8. Screw ﬁlter onto adapter until gasket contacts mounting plate surface. Apply another 1/2-3/4 turn by hand.

WARNING

Be sure no oil gets on tires when changing oil and filter. Traction will be adversely affected which may lead to a loss of control and personal injury.

9. Fill oil tank with an oil from Table 1-4. Oil tank capacity is

2.0 quarts (1.90 liters) plus the 4.0 ounces (0.12 liter) added in Step 7.

10. Install ﬁller cap onto oil tank. Make sure ﬁller cap is fully seated.

new

oil ﬁlter.

new

ﬁlter

b0138aox

Figure 1-11. Oil Tank Drain Line

Apply a thin film of oil to new filter gasket

and crankcase mounting plate.

Figure 1-12. Oil Filter

WARNING

11. Install seat.

12. Start engine. Verify that oil pressure signal light on dash panel turns off when engine speed is 1000 RPM or above.

13. Check for oil leaks at oil ﬁlter and drain hose.

14. Check oil level as described on page 1-15.

1-16

Page 57

BRAKES

GENERAL

WARNING

Brake ﬂuid can cause irritation of eyes and skin, and may be harmful if swallowed. If ﬂuid is swallowed, induce vomiting by administering two tablespoons of salt in a glass of warm water. Call a doctor. In case of contact with skin or eyes, ﬂush with plenty of water. Get medical attention for eyes. KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN.

Check brake ﬂuid level and condition:

●

At the 500 mile (800 km) service interval. At every 5000 mile (8000 km) service interval thereafter.

●

When storing or removing the motorcycle for the season.

●

Front brake hand lever and rear brake foot pedal must have a ﬁrm feel when brakes are applied. If not, bleed system as described.

BLEEDING BRAKES

NOTE Hydraulic brake ﬂuid bladder-type pressure equipment can be used to ﬁll brake master cylinder through the bleeder valve. Remove master cylinder reservoir cover so that system cannot pressurize. Do not use pressure bleeding equipment when the hydraulic system is sealed with master cylinder reservoir cover and gasket in place.

5565

Bleeder valve

Figure 1-13. Front Brake Caliper Bleeder Valve

5566

Protective

cap removed

Bleeder valve (metric)

1. Install end of a length of plastic tubing over caliper

bleeder valve; place other end in a clean container. Stand motorcycle upright.

a. Front brake caliper-Figure 1-13. b. Rear brake caliper-Figure 1-14.

2. Add D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID to

master cylinder reservoir. Do not reuse brake ﬂuid. a. Bring ﬂuid level to within 1/8 in. (3.2 mm) of molded

boss for front master cylinder reservoir .

b. Bring ﬂuid level between upper and lower marks for

rear master cylinder reservoir.

3. Depress and hold brake lever/pedal to build up hydraulic

pressure.

4. Open bleeder valve about 1/2-turn counterclockwise;

brake ﬂuid will ﬂow from bleeder valve and through tubing. When brake lever/pedal has moved 1/2-3/4 of its full range of travel, close bleeder valve (clockwise). Allow brake lever/pedal to return slowly to its released position.

5. Repeat Steps 2-4 until all air bubbles are purged.

6. Tighten bleeder valves.

a. Front bleeder valve to 4-6 ft-lbs (5.4-8.1 Nm). b. Rear bleeder valve to 6-9 ft-lbs (8.1-12.2 Nm).

7. Verify master cylinder ﬂuid level as described in Step 2.

8. Tighten master cylinder reservoir cover screws to 9-13

in-lbs

(1.0-1.5 Nm). Install cover on rear reservoir.

Figure 1-14. Rear Brake Caliper Bleeder Valve

PADS, ROTORS AND LINKAGE

Check brake pads and rotors for minimum thickness. See

Table 1-5. See Section 2 for replacement procedures.

At the 500 mile (800 km) service interval.

●

At every service interval thereafter.

●

Check rear brake pedal height and freeplay. See Table 1-5. See Section 2 for adjustment procedures.

Before every ride.

●

At the 500 mile (800 km) service interval.

●

At every 5000 mile (8000 km) service interval thereafter.

●

Table 1-5. Brake System Components

SPECIFICATION FRONT REAR

Minimum rotor thickness 0.17 in.

(4.4 mm) Minimum pad thickness 1/16 in. (1.6 mm) Hand lever/pedal freeplay 1/8 in. (3.2 mm) maximum

0.19 in.

(4.8 mm)

1-17

Page 58

TIRES AND WHEELS

TIRE INFLATION

WARNING

Do not inﬂate any tire beyond its maxim um inﬂation pressure as speciﬁed on tire sidewall. Overinﬂation may cause tire to suddenly deﬂate leading to personal injury.

Check tire pressure and tread:

●

Before every ride.

●

At the 500 (800 km) mile service interval.

●

At every scheduled service interval.

Check for proper front and rear tire pressures when tires are cold. Compare pressure against Table 1-6.

Table 1-6. Tire Pressures

TIRE AND POSITION

Front-Dunlop Sportmax Radial II 120/70 ZR 17

Rear-Dunlop Sportmax Radial II 170/60 ZR 17

PRESSURE

FOR SOLO

RIDING

32 PSI

(2.2 bar)

36 PSI

(2.5 bar)

PRESSURE

AT GVWR

36 PSI

(2.5 bar)

38 PSI

(2.8 bar)

WHEEL BEARINGS

Check wheel bearings:

Every time the wheel is removed.

●

At every 10,000 mile (16,000 km) service interval.

●

When storing or removing the motorcycle for the season.

●

Check wheel bearings and axle spacers for wear and corrosion. Excessive play or roughness indicates worn bearings. Replace bearings in sets only.

SPEEDOMETER CABLE

Check speedometer cable:

●

Inspect before every ride.

●

Lubricate at every 5000 mile (8000 km) service interval.

Examine speedometer cable housing (outer sheath) for kinks or other damage. Replace entire cable assembly if any damage is noted.

Lubricate inner cable with a good quality graphite grease. Wipe off excess grease.

1-18

Page 59

CLUTCH

TRANSMISSION FLUID

Check transmission ﬂuid:

Replace at the 500 mile (800 km) service interval.

●

Inspect level at e v ery 2500 mile (4000 km) service interval.

●

Replace at every 5000 mile (8000 km) service interval.

Primary chaincase lubricant capacity is approximately 1.0 quart (0.95 liter). For best results, drain lubricant while hot.

1. Raise rear of vehicle off the ﬂoor using REAR WHEEL

SUPPORT STAND (Part No. B-41174) to prevent chain-

case lubricant from draining out of clutch cover opening when reﬁlled.

2. Remove mufﬂer . See EXHAUST SYSTEM in Section 2.

3. See Figure 1-15. Position a suitable container under transmission lubricant drain plug. Remove drain plug and drain lubricant.

4. Remove foreign material from magnetic drain plug. Reinstall plug and tighten to 14-21 ft-lbs (19-28 Nm).

5. Remove four TORX screws with washers from clutch inspection cover. Remove clutch inspection cover from primary cover. Do not damage or dislodge Quad ring from primary cover.

5592

Torx screw with

washer (4)

Clutch inspection

b0190x6x

cover

Drain plug

Figure 1-15. Primary Cover

Clutch adjusting screw

Quad ring

Diaphragm spring

CAUTION

Do not overﬁll the primary chaincase with lubricant. Overﬁlling may cause rough clutch engagement and incomplete disengagement (or clutch drag).

6. Add SPORT-TRANS FLUID (Part No. 98854-96 quart size; Part No. 98855-96 gallon size) as required until lubricant is even with bottom of clutch diaphragm spring. See Figure 1-16.

7. Install clutch inspection cover using four TORX screws with washers. Tighten screws in a crosswise pattern to 79 ft-lbs (9-12 Nm).

8. Install mufﬂer. See EXHAUST SYSTEM in Section 2.

PRODUCTION CHANGE

See Figure 1-17. Beginning with motorcycles built in early January 1996, the outer clutch release ramp has been changed. The clutch adjustment and lever freeplay procedures remain the same. The change was made to prevent an y possible contact between the coupler and the primary cover.

Lubricant level

Figure 1-16. Lubricant Level

5671

New style Old style

Figure 1-17. Ramp Change

1-19

Page 60

ADJUSTMENT

Check clutch adjustment:

●

At the 500 mile (800 km) service interval.

●

At every 5000 mile (8000 km) service interval thereafter.

If clutch slips under load or drags when released, ﬁrst check control cable adjustment. If cable adjustment is within speciﬁcations, adjust clutch mechanism as described below.

When necessary, lubricate cable with LUBIT-8 TUFOIL CHAIN AND CABLE LUBE (Part No. HD-94968-85TV).

1. Raise rear of vehicle off the ﬂoor using REAR WHEEL

SUPPORT STAND (Part No. B-41174).

2. See Figure 1-18. Slide rubber boot (1) upward to expose adjuster mechanism. Loosen jam nut (3) from adjuster (4). Turn adjuster to shorten cable housing until there is a large amount of freeplay at clutch hand lever.

3. See Figure 1-19. Remove TORX screws with w ashers (1) from clutch inspection cover (2). Remove clutch inspection cover from primary cover, but leave Quad ring (3) in place.

NOTE

Quad ring removed from primary cover for illustrative purposes only in Figure 1-19.

5594

1. Rubber boot

2. Cable end Figure 1-18. Clutch Cable Adjuster Mechanism

b0152x6x

3. Jam nut

4. Adjuster

4. Remove spring (4) and adjusting screw lockplate (5). Turn adjusting screw counterclockwise until it lightly bottoms.

5. Turn clutch adjusting screw (6) clockwise 1/4 turn. Install lockplate (5) and spring (4) on adjusting screw ﬂats. If hex on lockplate does not align with recess in outer ramp , rotate adjusting screw clockwise until it aligns.

6. Squeeze clutch lever to maximum limit three times to set ball and ramp mechanism. Pull outer cable conduit and at the same time adjust cable adjuster to provide 1/16-1/8 in. (1.6-3.2 mm) freeplay at hand lever. Adjust as follows.

a. See Figure 1-20. Pull clutch cable ferrule (end of

cable housing) away from clutch hand lever bracket. Gap between ferrule and bracket should be 1/16-1/8 in. (1.6-3.2 mm).

b. See Figure 1-18. Adjust freeplay by turning cable

adjuster (4). c. Tighten jam nut (3) against adjuster (4). d. Slide boot (1) over cable adjuster mechanism.

7. Change or add transmission ﬂuid if necessary.

8. Install clutch inspection cover (2). Tighten TORX screws with washers (1) in a crosswise pattern to 7-9 ft-lbs (912 Nm).

1. Torx screw with washer

2. Clutch inspection cover

3. Quad ring Figure 1-19. Clutch Release Mechanism

5595

Adjust for 1/16-1/8 in. (1.6-3.2 mm) gap between ferrule and bracket

4. Spring

5. Lockplate

6. Adjusting screw

9. Check clutch cable freeplay. See Step 6 above.

1-20

Figure 1-20. Adjusting Clutch Freeplay

Page 61

REAR BELT DEFLECTION

INSPECTION

Check rear belt deﬂection:

● Inspect before every ride.

● Adjust at the 500 mile (800 km) service interval.

● Adjust at every 5000 mile (8000 km) service interval

thereafter.

The secondary drive belt should be checked for unusual wear, cracking or loss of teeth. Check the belt sprocket for unusual wear, broken teeth or damaged ﬂange. When checking deﬂection, have:

● No rider or cargo weight on motorcycle.

● Transmission in neutral.

● Belt and sprockets at room temperature.

● Motorcycle upright (not on side stand).

1. See Figure 1-21. At the lower strand, position “A”, mid- way between transmission sprocket and rear wheel sprocket, apply 10 Ibs (4.5 kg) of upward force on lower span of rear belt using BELT TENSION GAUGE (Part No.

HD-35381).

2. Measure belt deﬂection “B” several times, each time with belt moved (by rotating rear wheel) to a different position on sprockets. With sprockets rotated to tightest belt position, belt deﬂection “B” (measured at position “A”) should be 7/8-1 in. (22.2-25.4 mm).

b0086x6x

Belt deﬂection should be

7/8-1 in. (22.2-25.4 mm)

Figure 1-21. Checking Belt Deﬂection

5574

Apply 10 lbs (4.5 kg)



of upward force

ADJUSTMENT

1. Adjust shock absorber spring preload. See REAR PRE-

LOAD ADJUSTMENT on page 1-23.

2. See Figure 1-22. Loosen rear axle nut (metric), if not already performed.

NOTE After you loosen the axle nut, turn the axle and nut so the rearmost ﬂat on each side is parallel with the ends of the swingarm.

Check to be sure rear wheel axle is parallel with swingarm pivot shaft.

3. See Figure 1-23. Measure each side from the ﬂat to the

end of the swingarm, to be sure rear axle is correctly located.

4. Turn axle adjuster nuts (metric) on each side of swing-

arm to adjust belt deﬂection. a. Turn clockwise to decrease deﬂection (increase ten-

sion).

b. Turn counterclockwise to increase belt deﬂection

(decrease tension).

Turn each adjuster nut exactly the same number of turns to maintain rear wheel alignment

5. Tighten axle nut (metric) to 66-73 ft-lbs (89.5-98.9 Nm).

Axle adjuster nut

Rear axle nut

Figure 1-22. Rear Axle

5585

Measure each side to check wheel alignment

Figure 1-23. Checking Rear Wheel Alignment,

Right Side Shown

CLEANING

Keep dirt, grease, oil, and debris off the belt and sprockets. Clean the belt with a rag which is slightly damp with light cleaning agent.

1-21

Page 62

PRIMARY CHAIN

INSPECTION

Check primary chain:

● At the 500 mile (800 km) service interval.

● At every 5000 mile (8000 km) service interval thereafter.

Check primary chain for correct tension by measuring its vertical freeplay through the primary chain inspection cover opening located near the top of the primary cover.

1. See Figure 1-24. Remove two scre ws from primary chain inspection cover.

2. Remove primary chain inspection cover.

3. See Figure 1-25. Check primary chain tension by mea- suring vertical freeplay (measuring midway between sprockets) several times, each time with primary chain moved (by rotating engine) to a different position on sprockets.

4. Check primary chain tension against Table 1-7. If neces- sary, adjust as described below.

NOTE

●

Measurements are taken with sprockets rotated to tightest chain position.

●

The initial primary chain vertical freeplay speciﬁcation used at the assembly plant is 1/4-1/2 in. (6.3-12.7 mm) with a cold engine. The 1/4 in. (6.3 mm) minimum is only allowed at the absolute tightest point in the drive, as measured with specialized factory equipment. If a chain has less than 1/4 in. vertical freeplay (with a cold engine), adjust freeplay to the “ﬁeld” speciﬁcation of 3/81/2 in. (9.5-12.7 mm).The looser speciﬁcation will avoid overtightening, which might otherwise occur during adjustment using “non-factory” equipment and methods.

Table 1-7. Primary Chain Tension

5583

b0085x6x

Primary chain

inspection cover

Screws

Figure 1-24. Primary Chain Inspection Cover

Front sprocket

Figure 1-25. Measuring Primary Chain Tension

Rear sprocket

ENGINE TEMPERA TURE FREEPLA Y

Cold 3/8-1/2 in.

(9.5-12.7 mm)

Hot (normal running temperature) 1/4-3/8 in.

(6.4-9.5 mm)

5. Install primary chain inspection cover. Tighten screws to 40-60 in-lbs (4.5-6.8 Nm).

ADJUSTMENT

NOTE If vertical freeplay cannot be set within the limits speciﬁed, then primary chain and/or chain adjuster are worn beyond adjustment limits. Replace parts as necessary. See Section 6.

1. See Figure 1-26. Loosen locknut and turn adjusting

screw: a. Turn clockwise (inward) to reduce freeplay. b. Turn counterclockwise (outward) to increase free-

play.

2. Tighten locknut to 20-25 ft-lbs (27.1-33.9 Nm).

1-22

5592

Locknut

Adjusting screw

Figure 1-26. Primary Chain Adjustment

Page 63

REAR PRELOAD ADJUSTMENT

GENERAL

Adjust rear preload:

● When a new rider buys the motorcycle.

● When there is a change in load (luggage, etc.)

● Before changing front fork or rear shock suspension

settings.

Rear suspension spring preload assures that the rear suspension has the proper amount of travel.

ADJUSTMENT

You will need three people to carry out this adjustment.

1. Verify correct front and rear tire pressure. See TIRES

AND WHEELS on page 1-18.

2. Remove all accessories from motorcycle including tank bag and/or saddlebags.

3. Take the motorcycle off the side stand and bounce the rear up and down a few times to be sure the suspension is free and not binding.

4. See Figure 1-27. Measure the distance from the center of the rear axle nut to the rear turn signal mounting bolt without rider/passenger/cargo/accessories on the motorcycle.

5. Install items removed in Step 2. Load all cargo.

6. Bounce a few times on the seat to be sure the suspension is free and not binding.

7. With the help of an assistant, take the same measurement with the vehicle fully loaded (rider/passenger/luggage/cargo). The assistant should help balance the motorcycle so the rider can keep both feet on the footrests.

8. Subtract the second measurement from the ﬁrst. The difference, which is the squat, should be 0.25-0.75 in. (6.4-

19.1 mm). If it is not, you will have to adjust the spring preload.

1CAUTION

● Be sure to apply the same number of turns to each

mechanical preload adjusting nut to ensure that the end plates do not become misaligned. Misaligned end plates will cause the shock absorber spring to bind against the adjustment rods.

● Be sure the plates are parallel within 1/64 in. (0.4 mm).

Misaligned end plates will cause the shock absorber spring to bind against the adjustment rods.

9. See Figure 1-28. Change the spring preload by adjusting the mechanical preload adjusting nuts (metric) on the rods that connect the end plates.

a. Increase the preload by tightening the nuts. b. Decrease the preload by loosening the nuts.

5540

Rear turn signal mounting bolt

Rear axle nut

Figure 1-27. Checking Rear Preload

Preload adjusting nuts (metric)

Figure 1-28. Adjusting Rear Preload

1-23

Page 64

SUSPENSION

ADJUSTMENT

Adjust front forks by ﬁrst turning the slotted dial clockwise with a screwdriver until it stops. Then turn the dial counterclockwise the recommended 12 or 20 positions. A higher number of clicks increases damping.

NOTE

Rear spring preload must be set before adjusting any other suspension settings. See REAR PRELOAD ADJUSTMENT on page 1-23.

Table 1-8. Suspension Settings

ADJUSTMENT

Front fork compression

Front fork rebound

Rear shock rebound

Rear shock compression

RANGE IN

CLICKS

28 20 1-29

28 12 1-29

731-30

11 5 1-31

F ACT OR Y

SETTING

SEE

FIGURE

5542

Front fork rebound damping adjuster

Figure 1-29. Front Fork Adjustments

5572

Figure 1-30. Rear Shock Rebound Adjuster

Front fork compression damping adjuster

Rear shock rebound damping adjuster

REAR SHOCK

Check rear shock:

● At the 500 mile (800 km) service interval.

● At every 5000 mile (8000 km) service interval thereafter.

Inspect the rear shock absorber for loose mounting hardware , leaks or rod-to-spring contact. Tighten the front and rear mounts 40-45 ft-lbs (54.2-61.0 Nm).

5571

Rear shock compression

damping adjuster

Figure 1-31. Rear Shock Compression Adjuster

1-24

Page 65

FRONT FORK

STEERING HEAD BEARINGS

Check steering head bearings:

● At the 500 mile (800 km) service interval.

● At every 5000 mile (8000 km) service interval thereafter.

● Lubricate every 10,000 mile (16,000 km) service interval.

1. See Figure 1-32. Lift motorcycle using FRONT WHEEL

SUPPORT STAND (Part No. B-41395) and S1 LIFT ADAPTER (Part No. B-41686) so front wheel is off the

ground.

2. Turn front wheel to full right lock.

3. Hook a spring scale into the axle hole and pull front wheel to center position.

It should take 3.5-5.5 lbs (1.6-2.5 kg) to pull front wheel to center.

NOTE

Check that clutch and throttle cables do not bind when measuring bearing resistance.

Lubrication

At 10,000 miles (16,000 km) and every 10,000 miles (16,000 km) thereafter, grease the steering head bearings with WHEEL BEARING GREASE (Part No. 99855-89).

See FORK STEM AND BRACKET ASSEMBLY in Section 2 for lubrication procedure.

5591

3.5-5.5 lbs (1.6-2.5 kg)

Figure 1-32. Checking Steering Head Bearings

b0031a2x

ADJUSTMENT

1. Raise front wheel off ﬂoor using FRONT WHEEL SUP-

PORT STAND (Part No. B-41395) and S1 LIFT ADAPTER (Part No. B-41686).

2. Turn front wheel to full right lock.

3. See Figure 1-32. Hook spring scale into front axle hole. Pull front wheel to center position. It should take 3.5-5.5 lbs (1.6-2.5 kg) to pull front wheel to center.

4. Loosen pinch screws (7) on upper and lower triple clamps.

5. See Figure 1-33. Tighten or loosen fork stem bolt (1) to set proper tension.

6. Recheck tension using spring scale. See Step 3.

7. Tighten triple clamp pinch screws (7) to 18-20 ft-lbs (24.4-

27.1 Nm).

1. Fork stem bolt

2. Upper triple clamp

3. Dust shield (2)

4. Roller bearing (2)

5. Bearing cup (2) Figure 1-33. Steering Head Assembly

5 4

6. Lower triple clamp

7. Screw (5)

8. Steering head lock

9. Steering lock key

1-25

Page 66

FORK OIL CHANGE

Replace fork oil:

● At every 10,000 mile (16,000 km) service interval.

● If fork should be submerged in water.

1. Remove and disassemble front forks. See FRONT FORK in Section 2.

NOTE

If fork oil is emulsiﬁed, aerated or light brown in color, then it has been contaminated by water. If this happens, replace the fork oil seals.

2. Drain forks of oil.

5750

Outer tube

9 in. (229 mm)

maximum

3. With fork in fully compressed stage, add WP FORK OIL, 5 WEIGHT to above red retaining cap.

1CAUTION

See Figure 1-34. Raise outer tube no higher than 9 in. (229 mm) or ﬂuid loss will occur.

4. See Figure 1-35. Grasp damper assembly by the adjuster. Pull damper assembly through several full strokes to bleed air from the fork.

5. With front fork fully compressed, clamp vertically in

FRONT FORK HOLDING TOOL (Part No. B-41177).

6. Measure distance from fork oil surface to top of tube using PRO-LEVEL OIL GAUGE (Part No. B-59000A). Add or drain fork oil as needed until distance from top of fork tube to oil surface measures 4.33 in. (110 mm). See

Figure 1-36.

7. Assemble front fork and install. See FRONT FORK in Section 2.

Figure 1-34. Maximum Outer Tube Lift

5758

Damper

assembly

Figure 1-35. Bleeding Fork

b0038bx2x

1-26

1. Outer tube

2. Adjuster Figure 1-36. Correct Fork Oil Level

Correct fork oil level is

4.33 in. (110 mm) below top of fork tube

Use only WP FORK OIL, 5 WEIGHT

3. Damper assembly

4. Fork oil level

Page 67

SPARK PLUGS

INSPECTION

Check spark plugs:

● Inspect at every 5000 mile (8000 km) service interval.

● Replace every 10,000 mile (16,000 km) service interval.

1. Disconnect cables from both spark plugs.

2. Remove spark plugs.

3. See Figure 1-37. Compare your observations of the plug deposits with the descriptions provided below.

a. A wet, black and shiny deposit on plug base, elec-

trodes and ceramic insulator tip indicates an oil fouled plug. The condition may be caused by one or more of the following: worn pistons, worn piston rings, worn valves, worn valve guides, worn valve seals, a weak battery or a faulty ignition system.

b. A dry, ﬂuffy or sooty black deposit indicates a carbu-

retor air-fuel mixture that is too rich, engine idling for excessive periods of time and/or enrichener usage for excessive periods of time.

c. A light brown, glassy deposit indicates an over-

heated plug. This condition may be accompanied by cracks in the insulator or by erosion of the electrodes and is caused by an air-fuel mixture that is too lean, a hot-running engine, valves not seating or improper ignition timing. The glassy deposit on the spark plug is a conductor when hot and may cause high-speed misﬁring. A plug with eroded electrodes, heavy deposits or a cracked insulator must be replaced.

4636

Figure 1-37. Typical Spark Plug Deposits

5581

d. A plug with a white, yellow, tan or rusty brown pow-

dery deposit indicates balanced combustion. Clean off spark plug deposits at regular intervals.

4. If the plugs require cleaning between tune-ups, proceed as follows:

a. Degrease ﬁring end of spar k plug using ELECTRI-

CAL CONTACT CLEANER. Dry plug with compressed air.

b. Use a thin ﬁle to ﬂatten spark plug electrodes. A

spark plug with sharp edges on its electrodes requires 25%-40% less ﬁring voltage than one with rounded edges.

5. If the plugs cannot be cleaned, replace with No. 6R12 spark plugs.

6. Check electrode gap with a wire-type feeler gauge. Gap should be 0.038-0.045 in. (0.96-1.14 mm).

7. See Figure 1-38. Apply LOCTITE ANTI-SEIZE to plugs. Install and tighten spark plugs to 11-18 ft-lbs (15-24 Nm).

8. Connect spark plug cables. Verify that cables are securely connected to coil and spark plugs.

Tighten to 11-18 ft-lbs (15-24 Nm)

Figure 1-38. Spark Plugs

1-27

Page 68

AIR CLEANER FILTER

REMOVAL

Check air cleaner ﬁlter:

● Inspect at the 500 mile (800 km) service interval.

● Replace at every 5000 mile (8000 km) service interval

thereafter.

NOTE

Service air cleaner more often if the motorcycle is run in a dusty environment.

1CAUTION

Do not run engine without ﬁlter element in place. Debris could be drawn into the engine causing damage.

1. See Figure 1-39. Remove screw and nylon washer on top of air cleaner cover.

2. Remove screw, nylon washer and locknut at rear of air cleaner cover. Remove cover.

3. See Figure 1-40. Remove ﬁlter box from snorkel tube.

4. Remove ﬁlter from ﬁlter box.

INSTALLATION

1. Replace ﬁlter element if damaged or if ﬁlter media cannot be adequately cleaned.

5705

1. Screw and nylon washer

2. Screw, nylon washer and locknut Figure 1-39. Air Cleaner Cover

5749

1WARNING

● Low pressure air can blow debris in your face and

eyes. Not wearing eye protection or a face shield when using pressurized air may result in personal injury.

● Do not use gasoline or solvents to clean the ﬁlter ele-

ment. Volatile/ﬂammable cleaning agents may cause an intake system ﬁre which may result in personal injury.

2. Wash element in luke warm water with a mild detergent. Dry the ﬁlter element using low-pressure (32 psi/221 kPa maximum) compressed air. Rotate element while moving air nozzle up and down the element interior. Do not rap the element on a hard surface.

Hold ﬁlter element up to strong light source. The element can be considered sufﬁciently clean if light is uniformly visible through the element.

3. Thoroughly clean backplate, ﬁlter box and inside of cover.

4. See Figure 1-40. Place ﬁlter in ﬁlter box. Attach ﬁlter box to snorkel tube.

5. See Figure 1-39. Place cover over backplate assembly. Install top screw and nylon washer.

6. Install screw, nylon washer and locknut on rear mount. Tighten to 6-8 ft-lbs (8.1-10.8 Nm).

1. Filter element

2. Filter box

3. Snorkel tube Figure 1-40. Snorkel Tube

1-28

Page 69

CARBURETOR

CABLE ADJUSTMENT

1WARNING

Throttle cables must not pull tight when handlebars are turned fully to left or right fork stops. Be sure wires and throttle cables are clear of fork stops at steering head so they will not be pinched when fork is turned against stops. Steering must be smooth and free with no binding or interference. Anything interfering with carburetor operation may cause loss of vehicle control and per sonal injury.

Check throttle cable adjustment:

● Before every ride.

● At every scheduled service interval.

Check throttle cable adjustment with engine running. Turn handlebars through full range of travel. If engine speed changes during this maneuver, adjust throttle cables as follows:

1. Remove air cleaner. See AIR CLEANER, REMOVAL in Section 4.

2. See Figure 1-41. Slide rubber boot (4) off cable adjusters (3).

3. Loosen jam nut on each adjuster.

NOTE

Cable adjusters (3) and jam nuts are metric.

4. Turn adjusters in direction which will shorten cable housings to minimum length.

5. Point front wheel straight ahead. Twist throttle control grip to fully open position; hold in position.

6. Turn adjuster (3) on throttle control cable (1) until throttle cam stop (5) touches carburetor stop plate (6). Tighten jam nut on throttle control cable (1) adjuster (3); release throttle control grip.

7. Turn handlebars fully to right. Turn adjuster (3) on idle control cable (2) until end of cable housing just touches the carburetor cable guide.

8. Twist and release throttle control grip a few times. Carburetor throttle must return to idle position each time throttle grip is released. If this is not the case, turn adjuster (3) on idle control cable (2) (shortening cable housing) until throttle control functions properly.

9. Tighten jam nut on idle control cable (2) adjuster (3). Recheck operation of throttle control (Step 7).

10. Slide rubber boot (4) over each cable adjuster (3). Recheck engine slow idle speed; adjust if required.

11. Install air cleaner. See AIR CLEANER, INSTALLATION in Section 4.

5587

5609

1. Throttle control cable

2. Idle control cable

3. Cable adjuster Figure 1-41. Carburetor

4. Rubber boot

5. Throttle cam stop

6. Carburetor stop plate

IDLE ADJUSTMENT

Check idle adjustment:

● Before every ride.

● At every scheduled service interval.

See IGNITION TIMING on page 1-30.

1-29

Page 70

IGNITION TIMING

INSPECTION

Check ignition timing:

● At every 5000 mile (8000 km) service interval.

Check for proper RPM and ignition timing as follows:

1. See Figure 1-42. Thread TIMING MARK VIEW PLUG

(Part No. HD 96295-65D) into timing inspection hole. Be

sure view plug does not touch ﬂywheel.

2. Connect leads of INDUCTIVE TIMING LIGHT (Part No.

HD-33813) to front spark plug cable, to battery positive

terminal and to ground.

3. Be sure vacuum hose is properly installed at carburetor and at vacuum-operated electric switch (V.O.E.S.).

4. Start engine. Set engine speed by turning idle adjustment screw clockwise to increase speed or counterclockwise to decrease speed. Use CARBURETOR IDLE

ADJUSTMENT TOOL (Part No. HD-33413) and TIP

(SNAP-ON Part No. TMP23A) as shown in Figure 1-43. a. On world models, idle speed is 950-1050 RPM. b. On California models, idle speed is 1150-1250 RPM.

5. Timing light will ﬂash each time ignition spark occurs. Aim timing light into timing inspection hole. Front cylinder advance timing mark should be centered in timing inspection hole. If not, see ADJUSTMENT on page 1-31.

6. Set engine slow idle speed as described in Step 4 with engine running at normal operating temperature and with enrichener control knob pushed in fully.

NOTE

●

Buells have an enrichener circuit that will cause the engine to idle at approximately 2000 RPM with the engine at normal operating temperature and the enrichener knob pulled out fully. The increase in idle speed is intended to alert the rider that the engine is warmed up to normal operating temperature and that the enrichener knob should be pushed in all the way. Continuing to use the enrichener circuit when the engine is at normal operating temperature will cause fouled plugs.

●

Be sure the engine is warmed up to normal operating temperature and the enrichener knob is pushed all the way in bef ore adjusting engine idle speed. Be aware that, because there are variations in individual components, it is possible for a properly warmed-up engine to idle at 2000 RPM with the enrichener knob pulled out partially.

x0001c2x

Inspection hole

Timing mark

Figure 1-42. Timing Inspection Hole

5599

1 2

1. Carburetor idle adjustment tool (Part No. HD-33413)

2. Tip (Snap-On Part No. TMP23A)

Figure 1-43. Adjusting Idle Speed

1-30

Page 71

1. Pop rivet (2)

2. Timer cover

3. Screw (2)

4. Inner cover

5. Ignition gasket

6. Timer plate stud (2)

7. Bolt

8. Sensor assembly

9. Trigger rotor

10. Seal

11. Gearcase cover

12. Spark plug (2)

13. Ignition coil

14. Front spark plug cable

15. Rear spark plug cable

16. V.O.E.S. connector [P7]

17. V.O.E.S.

18. Cable strap

19. Terminal pin

20. Timer connector [P16]

21. Secondary lock

22. Ignition module connector [P10]

23. Ignition module

24. Washer (2)

25. Screw (2)

b0223x7x

Figure 1-44. Ignition System Components

ADJUSTMENT

1. See Figure 1-44. Remove outer cover pop rivets (1), outer timer cover (2), inner cover screws (3), inner cover (4) and gasket (5).

2. Loosen timer plate studs (6) just enough to allow sensor assembly (8) to be rotated using a screwdriver in the plate’s notch.

3. With timing light aimed into inspection hole, rotate sensor assembly (8) until front cylinder advance timing mark is centered in timing inspection hole.

4. Tighten timer plate studs (6).

5. Install gasket (5), inner cover (4), inner cover screws (3), timer cover (2) and new outer cover rivets (1).

6. Remove TIMING MARK VIEW PLUG from timing inspection hole. Install hex socket timing plug.

1-31

Page 72

VACUUM-OPERATED ELECTRIC SWITCH (V.O.E.S)

ADJUSTMENT/TESTING

Timing Mark Method

Verify engine ignition timing. See IGNITION TIMING on

page 1-30. Adjust ignition timing, if necessary, and then per-

form the following V.O.E.S. check:

1. Run engine at regular idle. Disconnect V.O.E.S. vacuum hose from carburetor ﬁtting. See VACUUM-OPERATED

ELECTRIC SWITCH (V.O.E.S) in Section 7.

a. On world models, idle speed is 950-1050 RPM. b. On California models, idle speed is 1150-1250 RPM.

2. Temporarily plug the open carburetor ﬁtting. Ignition timing should retard (front cylinder advance timing mark disappears from view in timing inspection hole) and engine RPM should decrease.

3. Connect V.O.E.S. vacuum hose to carburetor ﬁtting. Timing mark should reappear and engine speed should increase to previous RPM.

If speed does not ﬁrst decrease and then increase as described, check V.O.E.S. wire connection to ignition module.

2855

1. V .O .E.S.

2. V.O.E.S. leads

3. Ohmmeter Figure 1-45. Checking V.O.E.S. Using Ohmmeter

and Vacuum Pump

4. Ohmmeter probes

5. Vacuum pump

Ohmmeter and Vacuum Pump Method

The V.O.E.S. can also be checked using an ohmmeter and a

VACUUM PUMP (Part No. HD-23738).

1. Remove V.O.E.S. from vehicle. See VACUUM-OPER-

ATED ELECTRIC SWITCH (V.O.E.S) in Section 7.

2. See Figure 1-45. Connect two ohmmeter leads to the two V.O.E.S. leads.

3. Connect vacuum pump to V.O.E.S. vacuum ﬁtting.

4. Slowly squeeze vacuum pump handle. Obser ve vacuum gauge and ohmmeter readings. Ohmmeter should indicate switch closed (zero ohms) with an applied vacuum of 5.0-6.0 in. (127.0-152.4 mm) mercury (Hg). If a vacuum reading of more than 6.0 in. (152.4 mm) Hg or less than 5.0 in. (127.0 mm) Hg is required to close the switch, then the switch must be replaced.

5. Install V.O.E.S. See VACUUM-OPERATED ELECTRIC

SWITCH (V.O.E.S) in Section 7.

1-32

Page 73

HANDLEBARS

INSPECTION

Check handlebar adjustment:

● Before every ride.

1. See Figure 1-46. Check steering motion range to both fork stops. Each handlebar should be spaced equally between the windscreen and fuel tank and parts should not make contact.

2. Handlebars should be equally spaced between outside edge of handlebar clamp and inside edge of mirror mounts.

If necessary, adjust handlebars as described below.

ADJUSTMENT

CAUTION

Never adjust handlebars using excessive force or damage to handlebars might result.

NOTE

5589

5590

Windscreen and instrument support must be removed to access front clamp screws.

1. Remove windscreen. See WINDSCREEN in Section 2.

2. Remove instrument support. See SPEEDOMETER AND

TACHOMETER in Section 2.

3. See Figure 1-47. Loosen clamp screws.

4. Move handlebar to desired position.

5. Tighten clamp screws to 10-12 ft-lbs (13.6-16.2 Nm).

NOTE

Tighten front clamp screws ﬁrst.

6. Install instrument support. See SPEEDOMETER AND

TACHOMETER in Section 2.

7. Install windscreen. See WINDSCREEN in Section 2.

8. Check steering motion range to both fork stops. Each handlebar should be spaced equally between windscreen and fuel tank and parts should not make contact.

If handlebar needs further adjustment, repeat ADJUST-

MENT beginning with Step 1.

Figure 1-46. Testing Handlebars

5576

Clamp

Figure 1-47. Adjusting Handlebars

1-33

Page 74

HEADLAMP

INSPECTION

1WARNING

Do not modify ignition wiring to permit motorcycle operation with headlamp off. Operating with headlamp off may reduce your visibility to other motorists and could cause an accident resulting in personal injury.

Check headlamp alignment:

● When a new rider buys the motorcycle.

● When there is a change in load (luggage, etc.)

Check headlamp beam for proper height and lateral alignment as follows:

1. Verify correct front and rear tire inﬂation pressure. See

TIRES AND WHEELS on page 1-18.

2. Place motorcycle on level ﬂoor (or pavement) in an area with minimum light.

3. See Figure 1-48. Point front of motorcycle toward a screen or wall which is 25 ft (7.62 M) away from front tire contact patch on ﬂoor (i.e., directly below front axle).

4. Draw a horizontal line, on screen or wall, which is 35 in. (889 mm) above ﬂoor.

b0008b7x

Figure 1-48. Checking Headlamp Alignment

5601

35 in.

(889 mm)

25 ft

(7.62 M)

5. Have a person whose weight is roughly the same as that of the principal rider sit on motorcycle seat. Weight of rider will compress vehicle suspension slightly.

6. Stand motorcycle upright with both tires resting on ﬂoor and with front wheel held in straight alignment (directly forward).

7. Turn ignition switch to IGN. Set handlebar headlamp switch to HIGH beam position.

8. Check light beam for proper height alignment. Main beam of light (broad, ﬂat pattern of light) should be centered on horizontal line on screen or wall (i.e. equal area of light above and below line).

9. Check light beam for proper lateral alignment. Main beam of light should be directed straight ahead (i.e. equal area of light to right and left of center).

ADJUSTMENT

If headlamp requires adjustment, perform the following:

1. See Figure 1-49. Loosen both adjuster screws (metric).

2. See Figure 1-48. Tilt headlamp up or down to aim it in relation to the horizontal line. At the same time, turn headlamp right or left to direct light beam straight ahead.

Headlamp adjuster

screw (metric)

Figure 1-49. Adjusting Headlamp

3. Tighten both adjuster screws (metric) to 6-8 ft-lbs (8.1-

10.8 Nm).

1-34

Page 75

STORAGE

GENERAL

If the motorcycle will not be operated for sev er al months , such as during the winter season, there are several things which should be done to protect parts against corrosion, to preserve the battery and to prevent the buildup of gum and varnish in the carburetor.

This work should be performed by your local Buell dealer following Service Manual procedures.

1WARNING

Gasoline is ﬂammable. Do not store motorcycle having gasoline in tank within the home or garage where open ﬂames, pilot lights, sparks or electric motors are present. Inadequate safety precautions may cause an accident resulting in personal injury.

1. Fill fuel tank and add a gasoline stabilizer. Use one of the commercially available gasoline stabilizers following the manufacturer’s instructions. Run engine until gasoline has had a chance to reach carburetor ﬂoat bowl. Turn fuel supply valve OFF.

2. Fill the oil tank. Pinch off (or remove and plug) the line leading from the oil tank bottom to the oil pump feed ﬁtting. This prevents oil from seeping past the check ball into the oil pump and ﬁlling the engine ﬂywheel compartment.

3. Remove the spark plugs, inject a few squirts of engine oil into each cylinder and crank the engine 5-6 revolutions. Reinstall spark plugs.

4. Adjust primary chain.

5. Adjust secondary drive belt.

6. Check tire inﬂation. If the motorcycle will be stored for an extended period of time, securely support the motorcycle under the frame so that all weight is off the tires.

1WARNING

Do not apply any oil to brake rotors or brake pads. Oil on brake pads degrades braking efﬁciency and can result in an accident causing personal injury.

7. Wash painted and chrome-plated surfaces. Apply a light ﬁlm of oil to exposed unpainted surfaces.

8. If motorcycle is to be covered, use a material that will breathe, such as light canvas. Plastic materials that do not breathe promote the formation of condensation.

REMOVAL FROM STORAGE

WARNING

After extended periods of storage and prior to starting vehicle, place transmission in gear, disengage clutch and push vehicle back and forth a few times to ensure proper clutch disengagement. Improper clutch disengagement could result in personal injury.

1. Remove and inspect spark plugs. Replace if necessary.

2. Clean air ﬁlter element and lubricate if necessary.

3. If fuel tank was drained, ﬁll fuel tank with fresh gasoline.

4. If oil feed line was pinched off or plugged, unplug it and reconnect.

5. Start the engine and run until it reaches normal operating temperature. Check ﬂuids and reﬁll to proper levels if required.

a. Check engine oil level. b. Check the transmission lubricant level.

6. Perform all of the checks in the PRE-RIDING CHECK LIST in the Owner’s Manual.

1-35

Page 76

TROUBLESHOOTING

GENERAL

The following check list can be helpful in locating most operating troubles. Refer to the appropriate sections in this Service Manual for detailed procedures.

ENGINE

Starter Motor Does Not Operate or Does Not Turn Engine Over

1. Engine stop switch in OFF position.

2. Ignition key switch not ON.

3. Discharged battery or loose or corroded connections. (Solenoid chatters.)

4. Starter control relay or solenoid not functioning.

5. Electric starter shaft pinion gear not engaging or overrunning clutch slipping.

Engine Turns Over But Does Not Start

1. Fuel tank empty.

2. Fuel supply valve turned OFF.

3. Fuel supply valve or ﬁlter clogged.

4. Discharged battery, loose or broken battery terminal connections.

5. Fouled spark plugs.

6. Loose or shorting spark plug cables or connections.

7. Ignition timing badly out of adjustment.

8. Loose wire connection at coil or battery connection or plug between ignition sensor and module.

9. Ignition coil not functioning.

10. Ignition module not functioning.

11. Ignition sensor not functioning.

12. Sticking or damaged valve or valves.

13. Engine ﬂooded with gasoline as a result of overchoking.

14. Engine oil too heavy (winter operation).

Starts Hard

1. Spark plugs in bad condition, have improper gap or are partially fouled.

2. Spark plug cables in bad condition and shorting.

3. Battery nearly discharged.

4. Loose wire connection at one of the battery terminals, at coil or at plug between ignition sensor and module.

5. Carburetor controls not adjusted correctly.

6. Ignition coil not functioning.

7. Engine oil too heavy (winter operation).

8. Ignition not timed properly. See dealer.

9. Vapor vent valve plugged or carburetor fuel line closed off restricting fuel ﬂow.

10. Water or dirt in fuel system and carburetor.

11. Enrichener valve inoperative.

12. Air leak at intake manifold.

13. Valves sticking.

Starts But Runs Irregularly or Misses

1. Spark plugs in bad condition or partially fouled.

2. Spark plug cables in bad condition and shorting.

3. Spark plug gap too close or too wide.

4. Ignition coil not functioning.

5. Ignition module not functioning.

6. Ignition sensor not functioning.

7. Battery nearly discharged.

8. Damaged wire or loose connection at battery terminals or coil.

9. Intermittent short circuit due to damaged wire insulation.

10. Water or dirt in fuel system and carburetor or ﬁlter.

11. Fuel tank ﬁller cap vent plugged or carburetor ﬂoat bowl vent closed off.

12. Carburetor controls improperly adjusted.

13. Air leak at intake manifold or air ﬁlter.

14. Damaged intake or exhaust valve.

15. Weak or broken valve springs.

16. Incorrect valve timing.

Spark Plug Fouls Repeatedly

1. Incorrect spark plug.

2. Piston rings badly worn or broken.

3. Fuel mixture too rich for conditions (see CARBURETOR TROUBLESHOOTING).

4. Valve stem seals worn or damaged.

5. Valve guides badly worn.

Pre-Ignition or Detonation (Knocks or Pings)

1. Excessive carbon deposit on piston head or combustion chamber.

2. Incorrect heat range spark plug.

3. Spark plugs not ﬁring.

4. Ignition timing advanced.

5. Fuel octane rating too low.

6. Intake manifold vacuum leak.

Overheating

1. Insufﬁcient oil supply or oil not circulating.

2. Leaking valves.

3. Heavy carbon deposit.

4. Ignition timing retarded.

Valve T rain Noise

1. Hydraulic lifter not functioning properly.

2. Bent push rod.

3. Cam, cam gears or cam bushings worn.

4. Rocker arm binding on shaft.

5. Valve sticking in guide.

1-36

Page 77

Excessive Vibration

FUEL

1. Engine tie-bars loose, broken or improperly spaced.

2. Lower mounting bolts loose.

3. Broken frame.

4. Primary chain badly worn or links tight as a result of insufﬁcient lubrication.

5. Wheels not aligned and/or tires worn.

6. Internal engine problem.

ENGINE LUBRICATION SYSTEM

Oil Does Not Return To Oil Tank

1. Oil tank empty.

2. Return pump gears damaged.

3. Oil feed pump not functioning.

4. Restricted oil lines or ﬁttings.

Engine Uses Too Much Oil or Smokes Excessively

1. Piston rings badly worn or broken.

2. Valve stem seals worn or damaged.

3. Valve guides worn.

Carburetor Floods

1. Excessive “pumping” of throttle control grip.

2. Inlet valve sticking.

3. Inlet valve and/or valve seat worn or damaged.

4. Dirt or other foreign matter between valve and its seat.

5. Float misadjusted or ﬁlled with fuel.

TRANSMISSION

Shifts Hard

1. Clutch dragging slightly.

2. Shifter forks (inside transmission) damaged.

3. Corners worn off shifter clutch dogs (inside transmission).

Jumps Out of Gear

1. Shifter pawl improperly adjusted.

2. Shifter engaging parts (inside transmission) badly worn and rounded.

3. Shifter forks bent.

4. Damaged gears.

Engine Leaks Oil From Cases, Push Rods, Hoses, Etc.

1. Loose parts.

2. Imperfect seal at gaskets, push rod cover, washers, etc. To aid locating leaks, use BLACK LIGHT LEAK

DETECTOR (Part No. HD-35457).

3. Restricted oil return line to tank.

4. Restricted breather passage(s) to air cleaner.

ELECTRICAL SYSTEM

Alternator Does Not Charge

1. Regulator-rectiﬁer module not functioning.

2. Rectiﬁer not grounded.

3. Engine ground wire loose or broken.

4. Loose or broken wires in charging circuit.

5. Stator not functioning.

6. Rotor not functioning.

Alternator Charge Rate Is Below Normal

1. Regulator-rectiﬁer module not functioning.

2. Stator not functioning.

3. Rotor not functioning.

4. Weak battery.

5. Loose connections.

CLUTCH

Slips

1. Clutch controls improperly adjusted.

2. Worn friction plates.

Drags or Does Not Release

1. Clutch controls improperly adjusted.

2. Clutch plates excessively warped.

Chatters

1. Friction or steel plates worn, warped or dragging.

CHASSIS

Irregular/Inadequate Brake Action

1. Master cylinder low on ﬂuid.

2. Brake line contains air bubbles.

3. Master or wheel cylinder piston worn.

4. Brake pads covered with grease or oil.

5. Brake pads badly worn (1/16 in. (1.6 mm) minim um lining thickness).

6. Brake rotor badly worn or warped.

7. Brake pads dragging or excessive braking (brake fades due to heat buildup).

8. Insufﬁcient brake pedal or hand lever freeplay (brake drags).

1-37

Page 78

Handling Irregularities

1. Tires improperly inﬂated. Check TIRES AND WHEELS on page 1-18. Do not overinﬂate.

2. Loose wheel axle nuts. Tighten front nut to 48-53 ft-lbs (65.1-71.9 Nm). Tighten rear nut to 66-73 ft-lbs (90-99 Nm).

3. Excessive wheel hub bearing play.

4. Rear wheel out of alignment with frame and front wheel.

5. Rims and tires out-of-true sideways (tire runout should not be more than 0.080 in. (2.03 mm)).

6. Rims and tires out-of-round or eccentric with hub (tire runout should not be more than 0.090 in. (2.29 mm)).

7. Irregular or peaked front tire tread wear.

8. Tire and wheel unbalanced.

9. Steering head bearings improperly adjusted. Correct adjustment and replace pitted or worn bearings and races. See FORK STEM AND BRACKET ASSEMBLY in Section 2.

10. Shock absorber not functioning normally.

11. Heavy front end loading. Non-standard equipment on the front end (such as heavy radio receivers, extra lighting equipment or luggage) tends to cause unstable handling.

1-38

Page 79

SPECIFICATIONS

DIMENSIONS IN. MM

Wheel Base 55 1397 Overall Length 79.5 2019 Overall Width 30 762 Seat Height 29.5 749

CHASSIS IN. MM

Road Clearance 5.2 132 Front Wheel Travel 4.7 119.4 Rear Wheel Travel 4.9 124.5 Trail 3.9 99 Rake 25 degrees

WEIGHT LBS. KG

S1 Shipping weight 446 202 GVWR 820 372 GAWR - Front 340 154 GAWR - Rear 480 218

NOTE Gross Vehicle Weight Rating (GVWR) (maximum allowable loaded vehicle weight) and corresponding Gross Axle Weight Ratings (GAWR) are giv en on an inf ormation decal located on the front frame steering head.

CAPACITIES U.S. LITERS

Fuel Tank (including reserve) 4.0 gallons 15.14 Reserve 0.6 gallons 2.27 Oil T ank 2.0 quarts 1.89 Transmission 1.0 quart 0.95

PRESSURE

TIRE AND POSITION

Front-Dunlop Sportmax Radial II 120/70 ZR 17

Rear-Dunlop Sportmax Radial II 170/60 ZR 17

Do not inﬂate any tire beyond its maxim um inﬂation pressure as speciﬁed on tire sidewall. Overinﬂation may cause tire to suddenly deﬂate leading to personal injury.

BRAKE ROTORS IN. MM

Front rotor minimum thickness 0.17 4.3 Rear rotor minimum thickness 0.19 4.8

FOR SOLO

RIDING

32 PSI

(2.2 bar)

36 PSI

(2.5 bar)

WARNING

PRESSURE

AT GVWR

36 PSI

(2.5 bar)

38 PSI

(2.8 bar)

2-1

Page 80

ITEM TORQUE NOTES

Clutch cable, primary cover ﬁtting

Clutch clamp screw 30-33 Drive support fastener 30-35 ft-lbs 40.7-47.4 Nm page 2-53 Exhaust manifold nuts 6-8 ft-lbs 8.1-10.8 Nm page 2-50 Fender mounting screw, lower 10-15 Fender mounting screw, upper 20-25

Front axle nut 48-53 ft-lbs 65.1-71.9 Nm

Front axle pinch screw 13-15 ft-lbs 17.6-20.3 Nm metric, page 2-10 Front brake caliper screw 26-28 ft-lbs 35.2-38.0 Nm 2 sizes, page 2-21 Front brake carrier screw 7.5-8.5 ft-lbs 10.2-11.5 Nm LOCTITE THREADLOCKER 242 (blue), page 2-9 Front brake line clamp screw 30-35 Front brake master cylinder

clamp screw Front brake rotor carrier screw 20-22 ft-lbs 27.1-29.8 Nm LOCTITE THREADLOCKER 242 (blue), page 2-9 Front caliper banjo bolt 16-20 ft-lbs 21.7-27.1 Nm page 2-21, page 2-22 Front caliper bleeder valve 4-6 ft-lbs 5.4-8.1 Nm page 2-22

3-5 ft-lbs 4-6.87 Nm turn clockwise to install, page 2-45

80-90

in-lbs

in-lbs in-lbs

in-lbs

3.4-4.0 Nm metric, page 2-45

1.1-1.7 Nm page 2-54

2.3-2.8 Nm metric, page 2-54 LOCTITE THREADLOCKER 242 (blue), metric,

page 2-6, page 2-10

3.4-4.0 Nm page 2-22

9.0-10.2 Nm metric, page 2-19

Front caliper center bolt 11-13 ft-lbs 14.9-17.6 Nm page 2-21 Front caliper mounting bolt 30-33 ft-lbs 40.7-44.7 Nm page 2-21 Front fork triple clamp screw 18-20 ft-lbs 24.4-27.1 Nm LOCTITE ANTI-SEIZE, page 2-31 Front master cylinder

banjo bolt Front master cylinder

cover screw Fuel tank screw 9-11 ft-lbs 12.2-14.9 Nm page 2-55 Handlebar bolt, lower clamp 30-33 ft-lbs 40.7-44.7 Nm page 2-49 Handlebar screw, upper clamp 10-12 ft-lbs 13.6-16.2 Nm page 2-49 Header tiebar screw 5-7 ft-lbs 6.8-9.5 Nm page 2-50 Headlamp adjusting screw 6-8 ft-lbs 8.1-10.8 Nm metric, page 2-56 Instrument support screw 7-9 ft-lbs 9.5-12.2 Nm page 2-46 Mufﬂer clamp 50-55 ft-lbs 67.8-74.6 Nm discard after use, page 2-50 Mufﬂer mounting bolt, front 22-25 ft-lbs 29.8-33.9 Nm page 2-50 Mufﬂer mounting bolt, rear 22-25 ft-lbs 29.8-33.9 Nm page 2-50 Mufﬂer support mounting

bolt, front

17-20 ft-lbs 23.0-27.1 Nm metric, page 2-19, page 2-22

9-13

in-lbs

30-33 ft-lbs 40.7-44.7 Nm page 2-50

1.0-1.5 Nm page 2-19, page 2-21

Mufﬂer support mounting bolt, rear

2-2

12-15 ft-lbs 16.3-20.3 Nm page 2-50

Page 81

ITEM TORQUE NOTES

Rear axle nut 66-73 ft-lbs 89.5-98.9 Nm metric, page 2-6, page 2-13 Rear brake caliper banjo bolt 9.5-12.5 ft-lbs 12.9-17.0 Nm metric, page 2-26, page 2-27 Rear brake caliper

bleeder valve Rear brake caliper

mounting screw Rear brake lamp switch 7-8 ft-lbs 9.5-10.8 Nm LOCTITE SEALANT WITH TEFLON, page 2-27 Rear brake line clamp screw 10-12 ft-lbs 13.6-16.2 Nm page 2-27 Rear brake reservoir

mounting screw

Rear brake rotor screw 35-40 ft-lbs 47.5-54.2 Nm

Rear master cylinder banjo bolt 10-12 ft-lbs 13.6-16.2 Nm metric, page 2-24, page 2-27 Rear master cylinder

mounting screw Rear master cylinder rod to

brake pedal screw Rear shock mounting screw 40-45 ft-lbs 54.2-61.0 Nm metric, page 2-37 Sprocket bolt 55-65 ft-lbs 74.6-88.1 Nm LOCTITE THREADLOCKER 272 (red), page 2-12 Sprocket cover mounting screw 12-17 Sprocket cover screw 4-6 ft-lbs 5.4-8.6 Nm page 2-53

6-9 ft-lbs 8.1-12.2 Nm metric, page 2-26, page 2-27

18-22 ft-lbs 24.4-29.8 Nm metric, page 2-26

12-15

in-lbs

8-10 ft-lbs 10.8-13.6 Nm page 2-24

10-12 ft-lbs 13.6-16.2 Nm page 2-24

in-lbs

1.4-1.7 Nm page 2-24

LOCTITE THREADLOCKER 242 (blue), metric,

page 2-12

1.4-1.9 Nm page 2-53

Swingarm pinch screw 27-30 ft-lbs 36.6-40.7 Nm LOCTITE THREADLOCKER 242 (blue), page 2-34 Swingarm/drive support screw 20-25 ft-lbs 27.1-33.9 Nm page 2-53 Switchgear housing screws,

left side Switchgear housing screws,

right side Tie bar bolt 30-33 ft-lbs 40.7-44.7 Nm page 2-34 Valve stem nut 42-44

25-33

12-17

in-lbs

2.8-3.7 Nm metric, page 2-45

1.4-1.9 Nm metric, page 2-43

4.7-5.0 Nm page 2-16

2-3

Page 82

TIRE SPECIFICATIONS

GENERAL

WARNING Tires must be correctly matched to wheel rims. Only the tires listed in the ﬁtment tables below can be used for replacement. Mismatching tires and rims can cause damage to the tire bead during mounting. Using tires other than those speciﬁed can adversely affect motorcycle handling and may result in personal injury.

Tire sizes are molded on the sidewall. Rim size and contour are marked on the rim’s exterior surface.

Example:

bead seat measured in inches. The ter of the rim in inches, measured at the bead seat diameter.

DOT

Federal Motor Vehicle Safety Standards. See the tables below.

MT 3.5 x 17.0 DOT

designates the rim contour. The

means that the rim meets Department of Transportation

Table 2-1. Tire Fitment – Tubeless Cast Marchesini Wheels

WHEEL SIZE

& POSITION

17 in. – Front MT 3.5 x 17.0 DOT 0.33 in. 120/70 ZR17

17 in. – Rear MT 5.0 x 17.0 DOT 0.33 in. 170/60 ZR17

CONTOUR &

RIM SIZE

RIM V AL VE

HOLE DIAMETER

DUNLOP SPORTMAX RADIAL II

Table 2-2. Tire Fitment – Tubeless Aluminum P/M Wheels

3.5

is the width of the

17.0

is the normal diame-

TIRE SIZE

WHEEL SIZE

& POSITION

17 in. – Front MT 3.5 x 17.0 DOT 0.33 in. 120/70 ZR17

17 in. – Rear MT 5.5 x 17.0 DOT 0.33 in. 170/60 ZR17

CONTOUR &

RIM SIZE

RIM V AL VE

HOLE DIAMETER

DUNLOP SPORTMAX RADIAL II

TIRE SIZE

2-4

Page 83

VEHICLE IDENTIFICATION NUMBER

GENERAL

A 17-digit serial number, or Vehicle Identiﬁcation Number (V.I.N.), is stamped on the right side of the steering head (ex., 4MZSS11J1T3200001). Also afﬁxed to the steering head at this location is an information plate bearing the V.I.N. code.

See Figure 2-1. An abbreviated V.I.N. is stamped on the front left side of the crankcase.

NOTE Always give the V.I.N. or abbreviated V.I.N. when ordering parts or making inquiries about your Buell motorcycle.

Motorcycle Made in U.S.A.

Manufacturer and Make: Buell Motorcycle Company

Model Designation: SS = S1 Lightning

5711

Figure 2-1. Abbreviated V.I.N. Location

Engine

4MZSS 11 J*T320 0001 *Varies - can be 0 through 9 or X

Sample V.I.N. as it appears on the steering head - 4MZSS11J1T3200001 Sample abbreviated V.I.N. as it appears on the left side crankcase- SS11T200001

Two market destination characters have been used beginning with sequential number 38.

Figure 2-2. Vehicle Identiﬁcation Number (V.I.N.)

11 = 49 state 56 = California

Horsepower Code

Factory Check Digit: Can be 0-9 or x

Year of Manufacture: T = 1996

Market Designation

NOTE

See Note

Sequential Number

20 = World 22 = California

2-5

Page 84

WHEELS

GENERAL

Good handling and maximum tire mileage are directly related to the care of wheels and tires. Regularly inspect wheels and tires for damage and wear. If handling problems occur, check the TROUBLESHOOTING guide in Section 1 or see the table below for a list of probable causes.

See TIRES AND WHEELS in Section 1. Keep tires inﬂated to the recommended air pressure. Always balance the wheel after replacing a tire.

WARNING

Do not inﬂate any tire beyond its maxim um inﬂation pressure as speciﬁed on tire sidewall. Overinﬂation may cause tire to suddenly deﬂate leading to personal injury.

TROUBLESHOOTING

See Figure 2-3. Check tire inﬂation pressure at least once each week. At the same time, inspect tire tread for punctures, cuts, breaks and other damage. Repeat the inspection before long trips.

Table 2-3. Wheel Service

b0195x2x

Figure 2-3. Checking Tire Inﬂation Pressure

CHECK FOR REMEDY

1. Loose axle nuts. Tighten front axle nut (metric) to 48-53 ft-lbs (65.1-71.9 Nm). Tighten rear axle nut (metric) to 66-73 ft-lbs (89.5-98.9 Nm).

2. Excessive side-play or radial (up-and-

down) play in wheel hubs.

3. Alignment of rear wheel in frame or

with front wheel.

4. Rims and tires out-of-true sideways;

should not be more than 0.080 in. (2.03 mm).

5. Rims and tires out-of-round or eccen-

tric with hub; should not be more than

0.090 in. (2.29 mm).

6. Irregular or peaked front tire wear. Replace as described under FRONT WHEEL (page 2-8), REAR WHEEL

7. Correct tire inﬂation. Inﬂate tires to correct pressure. See SPECIFICATIONS on page 2-1.

8. Correct tire and wheel balance. Static balance may be satisfactory if dynamic balancing facilities are not

9. Steering head bearings. Correct adjustment and replace pitted or worn bearings. See FORK STEM

Replace wheel hub bearings.

Check WHEEL BALANCING on page 2-17 or repair swingarm as described under SWINGARM on page 2-33.

Replace rims. See TIRES, INSTALLATION on page 2-16.

See Item 4 above.

(page 2-11) and TIRES (page 2-15).

available. However, dynamic balancing is strongly recommended.

AND BRACKET ASSEMBLY on page 2-32.

10. Damper tubes. Check for leaks. See FRONT FORK on page 2-28.

11. Shock absorbers. Check damping action and mounts. See SWINGARM on page 2-33.

12. Swingarm bearings. Check for looseness. See SWINGARM on page 2-33.

2-6

Page 85

WARNING To prevent personal injury, use the following guidelines when installing a new tire or repairing a ﬂat:

1. Always locate and eliminate the cause of the original

tire failure.

2. Do not patch or vulcanize a tire casing. These proce-

dures weaken the casing and increase the risk of a blowout.

3. The use of tires other than those speciﬁed can

adversely affect handling resulting in personal injury.

4. Tires and wheels are critical safety items. Since the

servicing of these components requires special tools and skills, Buell recommends that you see your dealer for these services.

WARNING

Excessively worn tires adversely affect motorcycle traction, steering and handling and could result in personal injury.

At regular intervals of 5000 miles (8000 km) or whenever handling irregularities are noted, perform the recommended service checks. See Table 2-3.

If tires must be replaced, same as original equipment tires must be used. Other tires may not ﬁt correctly and may be hazardous to use.

2-7

Page 86

FRONT WHEEL

REMO V AL

1. See Figure 2-4. Raise front wheel off ﬂoor using FRONT

WHEEL SUPPORT STAND (Part No. B-41395) and S1 LIFT ADAPTER (Part No. B-41686).

2. Remove front brake caliper. See FRONT BRAKE CALI-

PER, REMOVAL/DISASSEMBLY on page 2-20.

NOTE Do not operate front brake lever with front wheel removed or caliper pistons may be forced out. Reseating pistons requires caliper disassembly.

3. See Figure 2-5. Insert screwdriver/rod through hole in

axle (1) and loosen front axle nut (4) (metric).

4. Loosen pinch screws (2) (metric).

5. Remove front axle nut (4) and washer (3). Pull front axle

out of hub while supporting front wheel.

6. See Figure 2-6. Detach speedometer drive spacer (3)

and speedometer drive (4) from left side of wheel. Remove front wheel.

DISASSEMBLY

1. See Figure 2-6. Move wheel to bench area. On the side

of the wheel opposite the brake rotor, remove left axle spacer (5).

2. On brake rotor side of wheel, remove right axle

spacer (12).

3. Remove wheel bearings (6, 11) using BUSHING AND

BEARING PULLER (Part No. HD-95760-69A) and 3/4 in. COLLET (Part No. HD-95767-69A).

4. Remove six locknuts (14), washers (21), spring washers

(20), screws (19) and brake drive pins (18). Remove brake rotor (17).

5. Remove ﬁve screws (16) and front brake carrier (15).

6. Remove tire. See TIRES, REMOVAL on page 2-15.

5680

Figure 2-4. Front Wheel Support Stand (Part No. B-41395)

with S1 Lift Adapter (Part No. B-41686)

5710

CLEANING, INSPECTION AND REPAIR

1. Thoroughly clean all parts in solvent.

WARNING Never use compressed air to “spin-dry” bearings. Very high bearing speeds can damage unlubricated bearings. Spinning bearings with compressed air can also cause a bearing to ﬂy apart, which may result in personal injury.

2. Inspect all parts for damage or excessive wear.

3. Inspect brake rotor. Replace rotor if warped or badly

scored. Measure rotor thickness for excessive wear. Minimum rotor thickness is 0.17 in. (4.4 mm).

2-8

1. Hole in front axle

2. Pinch screws (4) (metric)

Figure 2-5. Front Wheel Mounting

3. Washer

4. Front axle nut (metric)

Page 87

b0196x2x

1. Nut (metric)

2. Washer

3. Speedometer drive spacer

4. Speedometer drive

5. Left axle spacer

6. Wheel bearing

7. Wheel

8. Valve stem

9. Wheel weight

10. Spacer

11. Wheel bearing

12. Right axle spacer

13. Front axle

14. Locknut (6)

15. Front brake carrier

16. Screw (5)

17. Front brake rotor

18. Brake drive pin (6)

19. Screw (6)

20. Spring washer (6)

21. Washer (6)

Figure 2-6. Front Wheel

ASSEMBLY

WARNING Do not allow brake ﬂuid, bearing grease, lubricants, etc. to contact brake rotor or reduced braking ability will occur, possibly resulting in personal injury.

1. See Figure 2-6. Verify that the front brake carrier is thor-

oughly clean. Apply LOCTITE THREADLOCKER 242 (blue) to each screw (16). Install carrier (15) on hub with ﬁve screws. Tighten to 20-22 ft-lbs (27.1-29.8 Nm).

2. Verify that the brake rotor is thoroughly clean. Apply LOC-

TITE THREADLOCKER 242 (blue) to each screw (19). Install rotor on front brake carrier with six screws, brake drive pins (18), spring washers (20), washers (21) and locknuts (14). Tighten to 7.5-8.5 ft-lbs (10.2-11.5 Nm).

3. Install spacer (10).

4. Install

5. On the side of the wheel opposite the brake rotor insert

6. On the right side of the wheel insert right axle spacer

7. Install tire, if removed. See TIRES, INSTALLATION on

8. Verify that wheel and tire are true. See CHECKING

new

wheel bearings (6, 10) into hub using suitable

driver. Press on outer race only.

left axle spacer (5) into hub until it seats in bore. Spacer sleeve must not be cocked or tilted in bore.

(12) into hub until it seats in bore. Spacer sleeve must not be cocked or tilted in bore.

page 2-16.

CAST RIM RUNOUT on page 2-14.

2-9

Page 88

INSTALLATION

1. Apply LOCTITE ANTI-SEIZE LUBRICANT to axle.

2. Position wheel between forks with brake rotor on right side of vehicle. With pinch screws (metric) loose, insert threaded end of axle through right side fork. Push axle through fork and wheel hub until axle begins to emerge from left side of hub.

CAUTION

Speedometer drive tab must be properly inserted or damage to the unit will occur. If drive tab is damaged, it must be replaced.

3. See Figure 2-7. Align speedometer drive tab and wheel hub. Push axle through speedometer drive, speedometer drive spacer and left fork leg.

b0197x2x

Speedometer drive tab

Speedometer drive

4. Compress the front suspension to make sure it is free and not binding.

5. See Figure 2-6. Apply LOCTITE THREADLOCKER 242 (blue) to axle nut. Install w asher (2) and axle nut (1) (metric) over threaded end of axle. Insert screwdriver or steel rod through hole in axle on right side of vehicle. While holding axle stationary, tighten axle nut to 48-63 ft-lbs (65.1-71.9 Nm).

6. See Figure 2-5. Tighten the four front axle pinch screws (2) (metric) to 13-15 ft-lbs (17.6-20.3 Nm).

7. Install front brake caliper. See FRONT BRAKE CALI-

PER, INSTALLATION on page 2-21.

Figure 2-7. Speedometer Drive

2-10

Page 89

REAR WHEEL

REMO V AL

1. Raise rear wheel off ﬂoor using REAR WHEEL SUP-

PORT STAND (Part No. B-41174).

2. Remove rear fender. See FENDERS, REMOVAL/

INSTALLATION on page 2-54.

3. Remove rear brake caliper. See REAR BRAKE CALI-

PER, REMOVAL/DISASSEMBLY on page 2-25.

NOTE Do not operate rear brake pedal with rear wheel removed or caliper piston may be forced out. Reseating piston requires caliper disassembly.

4. See Figure 2-8. Loosen rear axle nut (metric).

5. Loosen rear axle adjuster nuts. Push wheel as far for-

ward as possible.

6. Slip secondary drive belt from bottom of rear wheel

sprocket and remove.

7. See Figure 2-9. Remove rear axle nut (14) (metric), lock-

washer (13), and washer (12). Pull axle (3) and washer (4) out from left side and remove wheel.

b0013a2x

5574

Rear axle

nut (metric)

Axle adjuster nut

Figure 2-8. Rear Wheel Mounting

1. Screw (4) (metric)

2. Rear brake rotor

3. Rear axle

4. Washer

5. Wheel bearing

6. Spacer sleeve

7. Wheel

8. Valve stem

9. Wheel weight

10. Bearings (2)

11. Right axle spacer

12. Washer

13. Lockwasher

14. Axle nut (metric)

15. Belt sprocket

16. Washer (5)

17. Bolt (5)

Figure 2-9. Rear Wheel

2-11

Page 90

DISASSEMBLY

1. See Figure 2-10. Move wheel to bench area. On the brake rotor side of the wheel, remove bearing using

BUSHING AND BEARING PULLER (Part No. HD95760-69A) and 1 1/8 in. COLLET (Part No. HD-95769-

69).

2. Remove two bearings from sprocket side of wheel.

3. See Figure 2-9. Remove four screws (1) (metric) to remove rear brake rotor (2) from hub.

4. Remove ﬁve bolts (17) and w ashers (16) on belt sproc ket (15). Remove belt sprocket from wheel.

CLEANING, INSPECTION AND REPAIR

1. Thoroughly clean all parts in solvent.

2. Inspect all parts for damage or excessive wear.

3. Inspect brake rotor. Replace rotor if warped or badly

scored. Measure rotor thickness for excessive wear. Minimum acceptable thickness (0.19 in. (4.8 mm)) is stamped on side of rotor.

4878

ASSEMBLY

WARNING

Do not allow brake ﬂuid, bearing grease, lubricants, etc. to contact brake rotor or reduced braking ability will occur, possibly resulting in personal injury.

1. See Figure 2-9. Verify that brake rotor (2) is thoroughly

clean. Apply LOCTITE THREADLOCKER 242 (blue) to each screw (1) (metric). Fasten rotor to hub with four screws. Tighten to 35-40 ft-lbs (47.5-54.2 Nm).

NOTE

P/M wheels use a nut (not shown) with each screw (1).

2. Apply two drops of LOCTITE THREADLOCKER 272

(red) to threads of each sprocket bolt (17). Install belt sprocket (15) using ﬁve bolts (17) and washers (16). Tighten bolts to 55-65 ft-lbs (74.6-88.1 Nm).

Figure 2-10. Removing Wheel Bearing Using Bushing/

Bearing Puller (Part No. HD-95760-69A) and

1 1/8 in. Collet (Part No. HD-95769-69)

3. On the sprocket side of the wheel, insert two bearings (10) into hub until they contact shoulder for spacer sleeve. Press bear ings in separately, pressing on outer race only.

4. Insert spacer sleeve (6) into hub.

5. On the brake rotor side of the wheel, insert bearing (5) into hub until it contacts end of spacer sleeve. Press on outer race only.

6. Install tire, if removed. See TIRES, INSTALLATION on

page 2-16.

7. Verify that wheel and tire are true. See CHECKING

CAST RIM RUNOUT on page 2-14.

2-12

Page 91

INSTALLATION

1. Place wheel centrally in the swingarm with the brake rotor in the caliper. Slide wheel far enough forward to slip belt over sprocket and then slide wheel back.

2. See Figure 2-9. Apply LOCTITE ANTI-SEIZE LUBRI- CANT to axle (3).

3. Insert axle (3) through washer (4), left side of swingarm, rear brake caliper mount, wheel assembly, spacer (11) and right side of swingarm.

4. Install washer (12), lockwasher (13), and axle nut (14) (metric) on right side of axle. Do not fully tighten rear axle nut at this time.

5. Install rear brake caliper. See REAR BRAKE CALIPER,

INSTALLATION on page 2-26.

6. Check for proper belt tension and wheel alignment. See

REAR BELT DEFLECTION in Section 1.

7. Tighten rear axle nut (14) (metric) to 66-73 ft-lbs (89.5-

98.9 Nm).

8. Install rear fender. See FENDERS, REMOVAL/INSTAL-

LATION on page 2-54.

2-13

Page 92

CHECKING CAST RIM RUNOUT

GENERAL

Check wheels for lateral and radial runout before installing a

new

tire.

Rim Lateral Runout

1. See Figure 2-11. Install truing arbor in wheel hub and place wheel in WHEEL TRUING AND BALANCING

STAND (Part No. HD-99500-80).

2. Tighten arbor nuts so hub will turn on its bearings.

3. Check rim lateral runout by placing a gauge rod or dial indicator near the rim bead. Replace wheel if lateral runout exceeds speciﬁcation shown in Table 2-4.

Rim Radial Runout

1. See Figure 2-12. Install truing arbor in wheel hub and place wheel in WHEEL TRUING AND BALANCING

STAND (Part No. HD-99500-80).

f1378x2x

Wheel Truing and Balancing Stand (Part No. HD-99500-80)

Gauge rod

Figure 2-11. Checking Cast Rim Lateral Runout

f1379x2x

2. Tighten arbor nuts so hub will turn on its bearings.

3. Check radial runout as shown. Replace wheel if runout exceeds speciﬁcation shown in Table 2-4.

Table 2-4. Wheel Runout

MAXIMUM

WHEEL TYPE

Cast Marchesini 0.040 in.

Aluminum P/M 0.020 in.

LA TERAL

RUNOUT

(1.02 mm)

(0.51 mm)

MAXIMUM

RADIAL

RUNOUT

0.030 in.

(0.76 mm)

0.020 in.

(0.51 mm)

Wheel Truing and Balancing Stand (Part No. HD-99500-80)

Gauge rod

Figure 2-12. Checking Cast Rim Radial Runout

2-14

Page 93

TIRES

GENERAL

Tires should be inspected for punctures, cuts, breaks and wear at least weekly.

WARNING

Always check both tire sidewalls for arrows indicating forward rotation. Some tires require different tire rotation depending on whether tire is used on front or rear wheel. Installing a tire with the wrong rotation could result in personal injury.

Some tires have arrows molded into the tire sidewall. These tires should be mounted on the rim with the arrow pointing in the direction of forward rotation. The red circle on the sidewall is a balance mark and should be located next to the valve stem hole.

REMOVAL

1. Remove wheel from motorcycle. See FRONT WHEEL,

REMOVAL on page 2-8 or REAR WHEEL, REMOVAL

on page 2-11.

2. Deﬂate tire.

3. See Figure 2-13. Loosen both tire beads from rim ﬂange.

b0198x2x

A bead breaker machine simplifies tire removal

Figure 2-13. Loosening Beads from Rim Flange

b0199x2x

Pry bead over rim edge and

remove tire from rim

WARNING

Do not use excessive force when starting bead over rim. Excessive force may damage tire or rim and adversely affect handling resulting in personal injury.

4. If a bead breaker machine is not available, attach RIM

PROTECTORS (Part No. HD-01289) to the rim. Using

tire tools (not sharp instruments), star t upper bead over edge of rim at valve. Repeat all around rim until ﬁrst bead is over rim.

5. See Figure 2-14. Push lower bead into rim well on one side and insert tire tool underneath bead from opposite side. Pry bead over rim edge. Remove tire from rim.

6. Remove valve stem if it is damaged or leaks.

7. Mount tire on TIRE SPREADER (Part No. HD-21000) for inspection and repair procedures.

CLEANING, INSPECTION AND REPAIR

1. Clean inside of tire.

2. If rim is dirty or corroded, clean with a stiff wire brush.

Figure 2-14. Starting Tire Off RIm

b0200x2x

Lubricate rim flange and both

beads before installation

3. Inspect tire for wear and damage. Replace worn tires. Use TIRE REPAIR KIT (Part No. HD-20000) for tire repair. Follow the kit manufacturer’s instructions.

Figure 2-15. Starting Bead on Rim

2-15

Page 94

INSTALLATION

WARNING

● Only install original equipment (stock) tire valves

and valve caps. A valve or valve and cap combination that is too long may interfere with (strike) adjacent components, damage the valve and cause rapid tire deﬂation. Rapid tire deﬂation could cause loss of control and personal injury.

● Also, aftermarket valve caps that are heavier than the

stock cap may have c learance at slow speeds; but, at high speed the valve/cap will be moved outward by centrifugal force. This outward movement could cause the valve/cap to strike the adjacent components, damage the valve and cause rapid tire deﬂation. Rapid tire deﬂation could cause loss of control and personal injury.

1. Damaged or leaking valve stems must be replaced. Place rubber grommet on valve stem with shoulder in recess of the valve stem head.

2. Install and tighten nut to 42-44 in-lbs (4.7-5.0 Nm).

3. Thoroughly lubricate rim ﬂanges and both beads of tire with tire lubricant.

4. See Figure 2-15. Starting at the valve stem, start ﬁrst bead into the rim well using a bead breaker machine. If no machine is available, work bead on as far as possible by hand. Use a tire tool to pry the remaining bead over rim ﬂange.

5. Start 180° from valve stem hole and place second bead on rim. Work bead onto rim with tire tools, working toward valve in both directions.

1WARNING

Do not inﬂate over 40 psi (2.8 bars) to seat the beads. Inﬂating the tire beyond 40 psi (2.8 bars) to seat the beads can cause the tire rim assembly to burst with f orce sufﬁcient to cause personal injury. If the beads fail to seat to 40 psi (2.8 bars), deﬂate and relubricate the bead and rim and reinﬂate to seat the beads, but do not e xceed 40 psi (2.8 bars).

b0087x2x

Tire lateral runout 0.080 in. (2.03 mm) maximum

Gauge

Figure 2-16. Checking Tire Lateral Runout

b0088x2x

Tire radial runout 0.060 (1.52 mm) maximum

Gauge

6. Apply air to stem to seat beads on rim. It may be necessary to use a TIRE BEAD EXPANDER (Part No. HD-

28700) on the tire until beads seal on rim.

Checking Tire Lateral Runout

1. See Figure 2-16. Turn wheel on axle and measure amount of displacement from a ﬁxed point to tire sidewall.

2. Tire tread lateral runout should be no more than 0.080 in. (2.03 mm). If runout is more than 0.080 in. (2.03 mm), remove tire from rim.

3. Check rim bead side runout. See CHECKING CAST RIM

RUNOUT on page 2-14. Replace rims not meeting spec-

iﬁcations.

4. Install tire and check again for tire tread lateral runout.

2-16

Figure 2-17. Checking Tire Radial Runout

Checking Tire Radial Runout

1. See Figure 2-17. Tur n wheel on axle and measure tread radial runout.

2. Tire tread radial runout should not be greater than 0.060 in. (1.52 mm). If runout exceeds speciﬁcation, remove tire from rim.

3. Check rim bead runout. See CHECKING CAST RIM

RUNOUT on page 2-14. Replace rims not meeting spec-

iﬁcations.

4. Install tire and check tire tread radial runout again.

Page 95

ADJUSTMENT

Wheel Balancing

Wheel balancing is recommended to improve handling and reduce vibration, especially at high road speeds.

In most cases, static balancing using WHEEL TRUING AND

BALANCING STAND (Part No. HD-99500-80) will produce

satisfactory results. However, dynamic balancing, utilizing a wheel spinner, can be used to produce ﬁner tolerances for best high-speed handling characteristics. Follow the instructions supplied with the balance machine you are using.

WEIGHTS FOR CAST WHEELS

The maximum weight permissible to accomplish balance is 1 oz. (28 g) (total weight applied to the rim). Wheels should be balanced to within 1/4 oz. (7 g) at 60 MPH (97 KM/H).

These weights are applied to the ﬂat surface of the wheel rim according to the following procedures.

1. Make sure that area of application is completely clean, dry, and free of oil and grease.

2. Remove paper backing from weight. For additional adhesive strength, apply three drops of LOCTITE SUPERBONDER 420 to adhesive side of weight. Place weight on ﬂat surface of wheel rim. Press weight ﬁrmly in place and hold for ten seconds.

Buell speciﬁes WHEEL WEIGHTS (Part No. 43692-94Y) which have special self-adhesive backings.

3. Allow eight hours for adhesive to cure completely before using wheel.

2-17

Page 96

BRAKES

GENERAL

The front and rear brakes are fully hydraulic disc brake systems that require little maintenance. The front brake master cylinder is an integral part of the brake hand lever assembly. The rear brake master cylinder is located on the right side of the motorcycle near the brake pedal.

Check the master cylinder reservoirs for proper ﬂuid levels every 5000 miles (8000 km). See BRAKES in Section 1.

Check brake pads and rotors f or wear every 2500 miles (4000 km). Replace brake pads if friction material is worn to 1/16 in. (1.6 mm) or less. Replace brake rotors not meeting minimum rotor thickness. See BRAKES in Section 1.

If determining probable causes of poor brake operation, see

Table 2-5.

Table 2-5. Brake Troubleshooting

CONDITION CHECK FOR REMEDY

1WARNING

● Clean brake system components using denatured

alcohol. Do not use mineral-base cleaning solvents, such as gasoline or paint thinner. Use of mineralbase solvents causes deterioration of rubber parts that continues after assembly. This could result in improper and unsafe brake operation which may cause personal injury.

● Always test motorcycle brakes at low speed after

servicing or bleeding system. To prevent personal injury, Buell recommends that all brake repairs be performed by a Buell dealer or other qualiﬁed mechanic.

● Exercise caution when handling brake ﬂuid. Brake

ﬂuid can cause irritation of eyes and skin and may be harmful or fatal if swallowed. If swallowed, administer two tablespoons of salt in a glass of warm water to induce vomiting. Call a doctor immediately. In case of contact with skin or eyes, ﬂush with plenty of water. Get medical attention for eyes. KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN.

Excessive lever/pedal travel or

spongy feel.

Chattering sound when brake is

applied.

Ineffective brake –

lever/pedal travels to limit.

Ineffective brake –

lever/pedal travel normal.

Brake pads drag on rotor –

will not retract.

Air in system. Master cylinder low on ﬂuid.

Worn pads. Loose mounting bolts. Warped rotor.

Low ﬂuid level. Piston cup not functioning.

Distorted or glazed rotor. Distorted, glazed or contaminated

brake pads.

Cup in master cylinder not uncovering

relief port.

Rear brake pedal linkage out of

adjustment.

Bleed brake(s). Fill master cylinder with approved

brake ﬂuid.

Replace brake pads. Tighten bolts. Replace rotor.

Fill master cylinder with approved

brake ﬂuid, and bleed system.

Rebuild cylinder. Replace rotor.

Replace pads. Inspect master cylinder.

Adjust linkage.

2-18

Page 97

FRONT BRAKE MASTER CYLINDER

REMOVAL

NOTE

The front master cylinder contains no user serviceable parts. Do not remove the master cylinder unless problems are being experienced. Replace the entire assembly when necessary.

1. Remove mirror mounting hardware (metric, left hand threads).

2. Open bleeder nipple cap on front caliper. Install end of a length of plastic tubing over caliper bleeder valve, while placing free end in a suitable container. Open bleeder valve about 1/2-turn. Pump brake hand lever to drain brake ﬂuid.

3. See Figure 2-18. Remove banjo bolt (6) (metric) and two gaskets (4) to disconnect brake line from master cylinder. Discard gaskets.

4. Remove screw (10), lockwasher (9) and washer (8) to detach brake lamp switch (7).

NOTE

The individual parts of the brake lamp switch are not serviceable. Replace switch upon failure.

5. Remove two screws (1) (metric) and clamp to free master cylinder assembly from handlebar.

INSTALLATION

1. See Figure 2-18. Fasten master cylinder to handlebar by installing clamp (2) and screws (1) (metric). Tighten screws to 80-90 in-lbs (9.0-10.2 Nm).

1CAUTION

To avoid leakage, verify that gaskets, banjo bolt, hydraulic brake line and master cylinder bore are completely clean.

2. Place new gaskets on each side of the hydraulic brake line. Install banjo bolt through gaskets and brake line ﬁtting into master cylinder. Tighten banjo bolt (6) (metric) to 17-20 ft-lbs (23.0-27.1 Nm).

3. Attach brake lamp switch (7) with screw (10), lockwasher (9) and washer (8).

4. Remove both master cylinder cover screws (3) and cover.

5. With the master cylinder in a level position, add D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID. Bring ﬂuid level to within 1/8 in. (3.2 mm) of molded boss inside front master cylinder reservoir.

b0203a2x

1. Clamp screws (2) (metric)

2. Clamp

3. Master cylinder cover screws (2)

4. Gaskets (2)

5. Brake line

Figure 2-18. Front Master Cylinder Banjo Bolt

6. Banjo bolt (metric)

7. Front brake lamp switch

8. Washer

9. Lockwasher

10. Screw

1WARNING

A plugged or covered relief port can cause brake drag or lockup, which may result in loss of vehicle control and possible personal injury.

6. Verify proper operation of the master cylinder relief por t. Actuate the brake lever with the reservoir cover removed. A slight spurt of ﬂuid will break the surface if all internal components are working properly.

7. Install master cylinder cover screws (3) and cover. Tighten cover screws to 9-13 in-lbs (1.0-1.5 Nm).

8. Bleed brake system. See BRAKES in Section 1.

9. Install mirror parallel to handlebars. Mirror mount has metric, left hand threads.

10. Test brake lamp operation with the brake hand lever applied and the ignition/headlamp switch turned to IGN.

2-19

Page 98

FRONT BRAKE CALIPER

REMOVAL/DISASSEMBLY

NOTE

Step 1 (draining ﬂuid) is not required for caliper removal. Drain brake ﬂuid only when disassembling caliper.

1. See Figure 2-19. Remove banjo bolt (4) and gaskets to disconnect brake line from caliper . Drain brake ﬂuid into a clean, suitable container. Discard gaskets.

2. Remove cotter and support pins (1).

3. Remove center caliper bolt (2) and spacer.

4. Remove brake pads from front brake caliper. Pads must be removed in order to remove caliper from rotor.

5. Remove both caliper mounting bolts (3).

6. Free caliper from front brake rotor.

7. Move caliper assembly to bench area.

8. See Figure 2-20. Remove screws (13, 14) to separate caliper halves (7, 12). Remove O-rings (11) and discard.

b0016a2x

5712

1. Cotter and support pins

2. Center caliper bolt

Figure 2-19. Front Brake Caliper Mounts

3. Caliper mounting bolts

4. Banjo bolt

5. Wire guide

Front caliper rebuild kit, Part No. 44148-94Y

1. Support pins (2)

2. Cotter pins (2)

3. Center caliper bolt

4. Caliper mounting bolts (2)

5. Banjo bolt

6. Gaskets (2)

7. Right caliper half

8. Bleeder valve

9. O-ring (3 sizes, 2 each)

10. Pistons (3 sizes, 2 each)

11. O-ring (2)

12. Left caliper half

13. Screw

14. Screw (3)

15. Brake pads (2)

16. Spacer

2-20

Figure 2-20. Front Brake Caliper

Page 99

1WARNING

When using air pressure to remove pistons from caliper, pistons may be ejected with considerable force. Wear safety glasses, heavy gloves and hold caliper with heavy towel to prevent personal injury.

1CAUTION

Exercise care to avoid dropping piston on hard surface. Any damage requires piston replacement.

9. See Figure 2-21. Use BRAKE CALIPER PISTON

REMOVER (Part No. B-42079) to remov e caliper pistons .

10. See Figure 2-20. Pry O-rings (9) out of their respective grooves on each side of caliper. Discard O-rings.

CLEANING, INSPECTION AND REPAIR

5737

1WARNING

Clean brake system components using denatured alcohol. Do not use mineral-base cleaning solvents, such as gasoline or paint thinner. Use of mineral-base solvents causes deterioration of rubber parts that continues after assembly. This could result in improper and unsafe brake operation which may cause personal injury.

1. Thoroughly clean brake system components using denatured alcohol. Blow dry using compressed air. Carefully inspect all components. Replace any parts that appear damaged or worn. Do not hone caliper piston bore.

2. Inspect brake rotor. Replace if warped or badly scored. Measure rotor thickness for excessive wear. Replace rotors less than 0.17 in. (4.3 mm) thick.

1WARNING

Always replace brake pads in complete sets for correct and safe brake operation. Never replace just one brake pad. Failure to install brake pads as a set may cause personal injury.

3. Inspect brake pads for damage or wear. Replace both pads as a set if the friction material of either pad is worn to 1/16 in. (1.6 mm) or less.

ASSEMBLY

1. See Figure 2-20. Install new O-rings (11) in groove of each caliper half (7, 12). Install new O-rings (9) in groove of piston bores.

2. Install pistons (10) in each caliper piston bore.

3. Tighten caliper halves together with four screws (13, 14). Smallest screw (13) is placed on top next to bleeder valve (8). Tighten screws to 26-28 ft-lbs (35.2-38.0 Nm).

INSTALLATION

1. Fit caliper on front brake rotor without brake pads.

2. See Figure 2-20. Tighten both caliper mounting bolts (4) to 30-33 ft-lbs (40.7-44.7 Nm).

3. Insert brake pads (15) from top.

Figure 2-21. Removing Brake Caliper Pistons Using

Brake Caliper Piston Remover (Part No. B-42079)

4. Install center caliper bolt (3) and spacer (16). Tighten center caliper bolt to 11-13 ft-lbs (14.9-17.6 Nm).

5. Install two support pins (1) and new cotter pins (2).

6. Connect brake line to caliper using new gaskets. Tighten banjo bolt (5) to 16-20 ft-lbs (21.7-27.1 Nm).

7. With the master cylinder in a level position, v erify that the brake ﬂuid level is 1/8 in. (3.2 mm) from molded boss inside reservoir. Add D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID if necessary.

1WARNING

A plugged or covered relief port can cause brake drag or lockup, which may result in loss of vehicle control and possible personal injury.

8. Verify proper operation of the master cylinder relief por t. Actuate the brake lever with the reservoir cover removed. A slight spurt of ﬂuid will break the surface if all internal components are working properly.

9. Install cover gasket, cover and screws. Tighten screws to 9-13 in-lbs (1.0-1.5 Nm).

10. Depress front brake le ver several times to set brak e pads to proper operating position within caliper. Bleed brake system. See BRAKES in Section 1.

11. Test brake lamp operation with the brake hand lever applied and the ignition/headlamp switch turned to IGN.

NOTE

To allow new brake pads to “wear in” properly with the brake rotor, av oid making hard stops f or the ﬁrst 100 miles (160 km).

2-21

Page 100

FRONT BRAKE LINE

REMOVAL

1. Open bleeder nipple cap on front brake caliper. Install end of a length of plastic tubing over caliper bleeder valve, while placing free end in a suitable container. Open bleeder valve about 1/2-turn. Pump brake hand lever to drain brake ﬂuid.

2. See Figure 2-22. Remove screw (4) to detach brake line clamp (5) from lower triple clamp (right side).

3. Slide brake line out of wire guide (6) on front fender.

4. Remove master cylinder banjo bolt (1) (metric) and two gaskets (2) to detach brake line from master cylinder body. Discard gaskets.

5. Remove caliper banjo bolt (7) and two gaskets (8) to detach brake line from front brake caliper. Discard gaskets.

6. Carefully inspect the brake line for dents, cuts or other defects. Replace the brake line if any damage is noted.

INSTALLATION

1. See Figure 2-22. Position new master cylinder gaskets (2) on each side of the banjo ﬁtting. Insert banjo bolt (1) (metric) through gaskets and banjo ﬁtting. Loosely install bolt into master cylinder.

2. From the master cylinder, the brake line runs downward in front of the right handlebar, where it turns inboard at the upper triple clamp. Loosely install clamp (5), and screw (4) to attach front brake line to right side of lower triple clamp.

3. Place brake line inside wire guide (6) on front fender.

4. Position new gaskets (8) on each side of banjo ﬁtting at free end of brake line. Insert caliper banjo bolt (7) through gaskets. Loosely install bolt into caliper.

5. Tighten clamp screw (4) on lower triple clamp to 30-35 in-lbs (3.4-4.0 Nm).

6. Tighten master cylinder banjo bolt (1) (metric) to 17-20 ftlbs (23.0-27.1 Nm).

7. Tighten brake caliper banjo bolt (7) to 16-20 ft-lbs (21.7-

27.1 Nm).

8. Install bleeder valve if removed. Reﬁll master cylinder and bleed brakes. See BRAKES in Section 1.

9. Test operation of brake lever.

10. Tighten front bleeder valve to 4-6 ft-lbs (5.4-8.1 Nm). Install bleeder cap.

11. Test brake lamp operation with the brake hand lever applied and ignition/headlamp switch turned to IGN.

b0203x2x

Lower right side-

brake caliper

1. Master cylinder banjo bolt (metric)

2. Master cylinder gasket (2)

3. Brake line

Figure 2-22. Front Brake Line

Top right side-

master cylinder

4. Screw

5. Clamp

6. Wire guide

7. Caliper banjo bolt

8. Caliper gasket (2)

2-22