BUELL XB12 User Manual

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Page 1

2004 BUELL LIGHTNING

SERVICE MANUAL

Part Number 99490-04Y

Section 1: Maintenance

Section 2: Chassis

Section 3: Engine

Section 4: Fuel System

Section 5: Starter

Section 6: Drive/Transmission

Section 7: Electrical

Appendices

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APPENDIX A–TOOLS

Part No. B-41174 Rear Wheel Support Stand and

Part No. B-41174-2 Replacement Pad

Part No. B-42887 Brake Caliper Piston Remover

Part No. B-43993-7/-8 Wheel Bearing Collets

Part No. B-45521 Steering Head Bearing Remover/

Installer

Part No. B-43721 Front Fork Seal Driver

Part No. B-46279 7/8" Axle Wrench (Hex)

Part No. HD-39302 Steering Head Bearing Race Installer

(Used with B-45521)

Part No. B-59000B Pro Level Oil Gauge

Appendix A A-1

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Part No. HD-01289 Rim Protectors

Part No. HD-45966 Fork Spring Compressing Tool

Part No. HD-33418 Universal Puller Forcing Screw

Part No. HD-94700-52C Shock Spanner Preload

Adjustment Tool

Part No. HD-28700 Tire Bead Expander

Part No. HD-33416 Universal Driver Handle

A-2 Appendix A

Part No. HD-44060 Wheel Bearing Remover/Installer

Part No. HD-99500-80 Wheel Truing

and Balancing Stand

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CYLINDER LEAKDOWN TESTER

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CYLINDER LEAKDOWN TESTER

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Bdhgkjsbkdv Majjlkn Nolk

knsdl hlno hslnsln ndpob npond Bdhgkjsbkdv hlno hslnslp knsdl hlno hslnsln ndpob npond

Part No. HD-95637-46A Wedge Attachment for

Claw Puller. Use with HD-95635-46.

Part No. HD-96921-52A Oil Pressure Gauge

Part No. HD-35667A Cylinder Leakdown Tester

Part No. HD-34902-B Bearing Race Remover/Installer

Part No. HD-35457 Black Light Leak Detector

Part No. HD-33223-1 Cylinder Compression Gauge

Part No. HD-43984 Crankshaft Locking Tool

Part No. HD-38362 Sprocket Locking Link (XB9S)

Part No. HD-46283 Sprocket Locking Link (XB12S)

Appendix A A-3

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Part No. HD-39964 Reamer Lubricant (Cool Tool)

Part No. HD-39782 Cylinder Head Support

Part No. B-45524 Valve Guide Installer

Part No. B-45523 Valve Guide Reamer (7mm)

Part No. HD-39786 Cylinder Head Holding Fixture

Part No. HD-34736B Valve Spring Compressor

A-4 Appendix A

Part No. B-45525 Valve Guide Hone

Part No. HD-34751 Nylon Valve Guide Brush

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Part No. HD-94804-57 Rocker Arm Bushing Reamer

Part No. HD-33446A Cylinder Torque Plates

and Torque Plate Bolts Part No. HD-33446-86

Part No. HD-96333-51C Piston Ring Compressor

Part No. HD-95952-33B Connecting Rod

Clamping Tool

Part No. HD-34623C Piston Pin

Retaining Ring Installer/Remover

Part No. HD-42322 Piston Support Plate

Part No. HD-95970-32D Piston Pin Bushing Tool

Part No. HD-94800-26A Connecting Rod Bushing

Reamers and Pilots

Appendix A A-5

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Part No. HD-35102 Wrist Pin Bushing Hone (20 mm)

Part No. HD-38515-A Clutch Spring Compressing Tool

and Part No. HD-38515-91 Forcing Screw

Part No. HD-95760-69A Bushing/Bearing Puller Tool Set.

Set includes items 1-7. Items 8 (HD-95769-69), 9 (HD-

95770-69) and 10 (HD-95771-69) are optional.

Part No. HD-39965 Deutsch Terminal Crimp Tool

Part No. J-5586 Transmission Shaft

Part No. HD-97292-61 Two Claw Puller

A-6 Appendix A

Part No. HD-41354 Speedometer Tester

Retaining Ring Pliers

Part No. HD-41609 Amp Terminal Crimp Tool

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AMP MULTILOCK ELECTRICAL CONNECTORS B.1

REMOVING SOCKET/PIN TERMINALS

1. Remove connector from the retaining de vice, either attachment or rosebud clip.

2. Depress the b utton on the soc ket terminal side of the connector (plug) and pull apar t the pin and soc ket halves.

3. Bend back the latch slightly and free one side of secondary lock, then repeat the step to release the other side . Rotate the secondar y lock outward on hinge to access terminals in chambers of connector housing.

4. Looking in the ter minal side of the connector (opposite the secondary lock), take note of the ca vity next to each terminal.

5. See Figure B-1. With the flat edge against the te minal, insert the pic k tool (Snap-On TT600-3) into the ca vity until it stops. Pivot the end of the pick away from the terminal (locktab is inside housing) and gently tug on wire to pull terminal from chamber. Do not tug on the wire until the tang is released or the ter minal will be difficult t remove. A “click” is heard if the tang is engaged but then

inadvertently released. Repeat the step without releasing the tang.

NOTE

●

If pick tool is not available, a push pin/safety pin may be used instead.

●

An ELECTRICAL TERMINAL CRIMP TOOL (Part No. HD-41609) is used to install Amp Multi lock pin and socket terminals on wires. If new terminals must be installed, see Crimping Instructions on the next page.

INSTALLING SOCKET/PIN TERMINALS

NOTE For wire location purposes, numbers are stamped into the secondary locks of both the socket and pin housings. See

Figure B-2.

1. From the secondary lock side of the connector, insert the

terminal into its respectiv e numbered chamber until it snaps in place . For proper fit, the slot in the te minal must face the tang in the chamber.

d0242x3x

Latch

Pin terminal

Secondary lock open

Pin housing

Socket housing

Secondary lock open

Button

Latch

Secondary lock open

Figure B-1. 10-Place Amp Multilock Connector

2004 Buell Lightning: Appendix B B-1

Socket terminal

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d0243x8x

Pin terminal

Socket terminal

Secondary lock open

Pin housing

Secondary lock open

Socket housing

Pick tool

1. Open secondary lock.

2. Insert pick into cavity on inboard side of connector.

3. Pivot end of pick to release tang.

4. Gently tug on wire to remove terminal from housing.

Figure B-2. Release Tang and Back Out Terminals

NOTES

●

See Figure B-3. The tang in the chamber engages the slot to lock the terminal in position.

●

On the pin side of the connector, tangs are positioned at the bottom of each chamber, so the slot in the pin terminal (on the side opposite the crimp tails) must face downward.

●

On the socket side, tangs are at the top of each chamber , so the socket terminal slot (on the same side as the crimp tails) must face upward.

Up and down can be determined by the position of the

●

release button (used to separate the pin and socket halves). Consider the button to always be on top of the connector.

2. Gently tug on wire end to v erify that the ter minal is locked in place and will not back out of chamber.

3. Rotate the hinged secondar y lock inward until tabs fully engage latches on both sides of connector.

4. Insert the soc ket housing (plug) into the pin housing (receptacle) until it snaps in place.

5. Install connector on retaining de vice, either attachment or rosebud clip.

Pin housing

Tang

d0244x8x

Figure B-3. Multilock Connector Cutaway View

Socket housing

Button

Tang

B-2 2004 Buell Lightning: Appendix B

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Secondary locks open (socket housings shown)

43 2 1

Stamped numbers on secondary locks indicate wire color locations

– AMP

123

– AMP

123456

3-place 6-place 12-place

Secondary lock

Pin terminal

Socket housing

Button

Pin housing

Secondary lock

Pin terminal

56 78 910

d0245x2x

Latch

Pin housing

Figure B-4. 3-Place and 6-Place Amp Multilock Connectors

Secondary lock

Socket terminal

Button

Latch

Socket housing

Secondary lock

Socket terminal

2004 Buell Lightning: Appendix B B-3

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CRIMPING INSTRUCTIONS

1. Squeeze the handles to cycle the cr imp tool (Part No. HD-41609) to the fully open position.

2. Raise locking bar by pushing up on bottom flang . With the crimp tails facing upward, insert contact (socket/pin) through locking bar, so that the closed side of the contact rests on the front nest (conca ve split le vel area of the crimp tool). See Figure B-3.

3. Release locking bar to loc k position of contact. When correctly positioned, the loc king bar fits s ugly in the space at the front of the core crimp tails.

1. Insulating crimp tail

2. Core crimp tail

3. Locking bar groove

4. Tang slot

4. Strip lead remo ving 5/32 in. (4 mm) of insulation. Insert wires between crimp tails until ends mak e contact with locking bar. Verify that wire is positioned so that shor t pair of crimp tails squeeze bare wire str ands, while long pair folds over insulation material.

5. Squeeze handle of cr imp tool until tightly closed. Tool automatically opens when the cr imping sequence is complete. Raise up locking bar and remove contact.

6. Inspect the quality of the core and insulation crimps. Distortion should be minimal.

1. Raise locking bar and seat contact on front nest of crimp tool. Release locking bar

d0246x8x

B-4 2004 Buell Lightning: Appendix B

3. Close and squeeze crimp tool. 4. Raise locking bar and remove contact.

Figure B-5. Amp Multilock Crimping Procedure

2. Insert stripped lead until it contacts locking bar.

GAUGE

WIRE

CRIMP TOOL

NEST

20 Front

16 Middle

18 Rear

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4566

s0545x8x

DEUTSCH ELECTRICAL CONNECTORS B.2

GENERAL

Deutsch Connectors feature a superior seal to protect electrical contacts from dir t and moisture in harsh en vironments. The connector also pro vides superior pin retention.

See Figure B-8. This 12-pin connector illustr ates the various parts of the Deutsch connector . The following instructions may be followed for all 2-pin through 12-pin Deutsch connectors.

Socket housing:

ondary locking wedge, internal seal, wire seal, seal pin.

Seal pins or plugs are installed in the wire seals of unused pin and socket locations. If removed, seal pins must be replaced to maintain the integrity of the environmental seal.

Pin housing:

attachment clip, secondary locking wedge, wire seal, seal pin.

alignment tabs and/or e xternal latch, sec-

NOTE

alignment grooves and/or external latch cover,

REMOVING/DISASSEMBLING

Attachment clips are attached to the pin housings of most connectors. The clips are then attached to T-studs on the motorcycle frame. T-studs give positive location to electr ical connectors and wire har ness. Consistent location reduces electrical problems and improves serviceability.

1. Push the connector to disengage small end of slot on attachment clip from T-stud. Lift connector off T-stud.

2. Depress the e xternal latch(es) on the soc ket housing side and use a roc king motion to separ ate the pin and socket halves. Two-, three-, f our- and six-pin Deutsch connectors have one e xternal latch, while eight- and twelve-pin connectors have two, both of which m ust be pressed simultaneously to separ ate the connector halves.

Figure B-6. Remove Secondary Locking Wedge

NOTE

With few exceptions, the socket housing can always be found on the accessory side, while the pin side of the connector is connected to the wiring harness.

REMOVING/INSTALLING SOCKETS

1. See Figure B-7. Remove the secondar y locking wedge. Insert the b lade of a small scre wdriver between the socket housing and locking wedge inline with the g roove (inline with the pin holes if the groove is absent). Turn the screwdriver 90 degrees to pop the wedge up.

2. See Figure B-8. Gently depress terminal latches inside socket housing and bac k out soc kets through holes in rear wire seal.

Figure B-7. Depress Terminal Latches/Back Out Pins

NOTE

An ELECTRICAL TERMINAL CRIMP TOOL (Part No. HD-

39965) is used to install Deutsch pin and socket terminals on wires. If tions included with the crimping tool or see Crimping Instructions in this section.

Fit rear wire seal into bac k of soc ket housing, if remo ved. Grasp socket approximately 1.0 in. (25.4 mm) behind the contact barrel. Gently push sockets through holes in wire seal into their respectiv e chambers. Feed socket into chamber until it “clicks” in place. Verify that socket will not bac k out of chamber; a slight tug on the wire will confi m that it is properly locked in place.

new

terminals must be installed, follow the instruc-

2004 Buell Lightning: Appendix B B-5

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d0248x8x

terminal

Wire seal

Pin housing

Locking wedge

Latch cover

Alignment grooves

Alignment tabs

Figure B-8. 12-pin Deutsch Connector (Exploded View)

3. Install internal seal on lip of soc ket housing, if removed. Insert tapered end of secondar y locking wedge into socket housing and press do wn until it snaps in place . The wedge fits into the center roove within the soc ket housing and holds the terminal latches tightly closed.

NOTES

●

While rectangular wedges do not require a special orientation, the conical secondary locking wedge of the 3-pin connector must be installed with the arrow pointing toward the external latch. See Figure B-9.

●

If the secondary locking wedge does not slide into the installed position easily, verify that all terminals are fully installed in the socket housing. The lock indicates when terminals are not properly installed by not entering its fully installed position.

Internal seal

Socket housing

Wire seal

Seal pin

External latch

Socket terminal

d0249x3x

housing

Arrow points to

external latch

REMOVING/INSTALLING PINS

1. Remove the secondar y locking wedge. Use the hook ed end of a stiff piece of mechanics wire a needle nose pliers, or a suitable pick tool (Part No. HD-41475-100). See

Figure B-10.

2. Gently depress ter minal latches inside pin housing and back out pins through holes in wire seal.

B-6 2004 Buell Lightning: Appendix B

Socket

housing

Figure B-9. Depress Terminal Latches/Back Out Pins

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5893

5892

5891

Lock tab

Lock bar

Pin housing

Attachment clip

Attachment clip installed

NOTE

An ELECTRICAL TERMINAL CRIMP TOOL (Part No. HD-

39965) is used to install Deutsch pin and socket terminals on wires. If

new

terminals must be installed, see Crimping

Instructions in this section.

3. Fit wire seal into bac k of pin housing. Grasp crimped pin approximately 1.0 in. (25.4 mm) behind the contact barrel. Gently push pins through holes in wire seal into their respective numbered locations. Feed pin into chamber until it “clicks” in place. Verify that pin will not bac k out of chamber; a slight tug on the wire will confi m that it is properly locked in place.

4. Insert tapered end of secondar y locking wedge into pin housing and press do wn until it snaps in place . The wedge fits in the center roove within the pin housing and holds the terminal latches tightly closed.

NOTES

●

If the secondary locking wedge does not slide into the installed position easily, verify that all terminals are fully installed in the pin housing. The lock indicates when terminals are not properly installed by not entering its fully installed position.

Figure B-10. Deutsch Connector Pick Tool

(Part No. HD-41475-100)

ASSEMBLING/INSTALLING

1. Insert socket housing into pin housing until it snaps in place. Two-, three-, four- and six-pin Deutsch connectors have one external latch on the socket half of the connector. To fit the hal es of the connector together , the latch on the soc ket side must be aligned with the latch co ver on the pin side.

For those connectors with tw o external latches (8-pin and 12-pin), a diff erent system is used to pre vent improper assembly. Align the tabs on the socket housing with the grooves on the pin housing. Push the connector halves together until the latches “click.” If latches do not click (latch), press on one side of the connector until that latch engages, then press on the opposite side to engage the other latch.

Deutsch connectors are color coded for location purposes. Those connectors associated with as the front and rear nectors, including those associated with right side accessories, are black.

If it should become necessary to replace a plug or receptacle, please note that the 8-pin and 12-pin gray and black connectors are not interchangeable. Since location of the alignment tabs differ between the black and gray connectors, plugs or receptacles must be replaced by those of the same color. If replacing both the socket and pin halves, then the black may be substituted for the gra y, and vice versa. The socket and pin halves of all other connectors are interchangeable, that is, the black may be mated with the gray, since the alignment tabs are absent and the orientation of the external latch is the same.

NOTE

left

turn signals, are

left

side accessories, such

gray

. All other con-

Figure B-11. Attachment Clip Installation

2. See Figure B-11. Fit the attachment clip to the pin housing, if remo ved. Place large end of slot on attachment clip over T-stud on fr ame. Push assemb ly forward to engage small end of slot.

2004 Buell Lightning: Appendix B B-7

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d0250x8x

Locking bar

1. Insert contact through middle hole in locking bar.

3. Close and squeeze crimp tool 4. Raise locking bar and remove

Insulation crimp Core crimp

Figure B-12. Deutsch Crimping Procedure

2. Insert stripped lead until it contacts locking bar.

contact.

CRIMPING INSTRUCTIONS

1. See Figure B-12. Squeeze the handles to cycle the crimp tool to the fully open position.

2. Raise locking bar by pushing up on bottom flang . With the crimp tails facing upward and the rounded side of the contact barrel resting on the conca ve split level area of the crimp tool, insert contact (socket/pin) through middle hole of locking bar.

3. Release locking bar to loc k position of contact. If the crimp tails are slightly out of vertical alignment, the crimp tool automatically rotates the contact so that the tails face straight upward. When correctly positioned, the locking bar fits s ugly in the space betw een the contact band and the core crimp tails.

B-8 2004 Buell Lightning: Appendix B

5. Squeeze handle of cr imp tool until tightly closed. Tool automatically opens when the cr imping sequence is complete. Raise up locking bar and remove contact.

6. Inspect the quality of the core and insulation crimps. Distortion should be minimal.

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d0251x3x

2-pin connector

SOCKET SIDE PIN SIDE

1. Socket terminal

2. Wire seal

3. Socket housing

4. External latch

5. Internal seal

6. Locking wedge

7. Locking wedge

8. Latch cover

9. Pin housing

10. Wire seal

11. Pin terminal

3-pin connector

4-pin connector

Figure B-13. 2-Pin, 3-pin and 4-pin Deutsch Connectors

2004 Buell Lightning: Appendix B B-9

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PACKARD ELECTRICAL CONNECTORS B.3

GENERAL

From a ser vicing standpoint, there are tw o basic types of Packard electrical connectors, those with pull-to-seat ter minals and those with push-to-seat terminals.

Look into the mating end of the connector . If it appears that the terminal can be extracted from this side , then it is probably the pull-to-seat type.

At least one Packard pull-to-seat terminal can be easily recognized by the presence of a locking ear. The ear engages a slot in the connector housing and pre vents the terminal from being removed from the wire end side of the connector . The ear also acts as a str ain relief in the e vent that the wires are pulled and fur ther inhibits mo vement of the ter minal inside the chamber. For an example of this type of connector , note the MAP sensor connector [80].

d0258x8x

Unlike most connectors , where the ter minals are pulled out the wire end of the connector , to remove the terminals from the pull-to-seat connectors , the ter minal is pushed out the mating end of the connector. Once a onto the end of the wire , the wire is pulled to dr aw the terminal back inside the chamber of the connector housing.

Tw o types of P ackard pull-to-seat electr ical connectors are used. One type has an e xternal latch to loc k the pin and socket halves together, while the other mak es use of a wireform. See Figure B-14. The manner in which the ter minals are picked differs between these two types of connectors, as further described below.

new

terminal is crimped

Locate tang on latch side of chamber.

Pivot end of pin to depress tang.

Push on wire end of lead to remove terminal.

Raise tang and re-install terminal.

Figure B-14. Packard Connectors

B-10 2004 Buell Lightning: Appendix B

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PULL-TO-SEAT TERMINALS

Removing External Latch Type

To remove a pull-to-seat terminal from connectors with external latches, proceed as follows:

1. Remove the connector from the retaining de vice, if present.

2. Bend back the e xternal latch(es) slightly and separ ate the pin and socket halves of the connector.

3. To free a pull-to-seat ter minal from the connector housing, first look into the mating end of the connector to fi the locking tang. See A in Figure B-14. The tangs are always positioned in the middle of the chamber and are on the same side as the external latch. On those connectors with loc king ears, the tang is on the side opposite the ear.

4. At a slight angle , gently inser t the point of a one inch safety pin do wn the middle of the chamber (about 1/8 inch) and piv ot the end of the pin to ward the ter minal body. When a click is heard, remo ve the pin and repeat the procedure. See B in Figure B-14. The click is the sound of the tang retur ning to the loc ked position as it slips from the point of the pin. Pick at the tang in this manner until the clicking stops and the pin seems to slide in at a slightly greater depth than it had previously. This is an indication that the tang has been depressed.

NOTES

●

On those terminals that have been extracted on a previous occasion, no clicking sound may be heard when the pin is pivoted to depress the tang, but proceed as if the clicking is audible and then push on the wire end of the lead to check if the terminal is free.

When picking multiple terminals, the end of the pin may

●

become malleable. For best results, continue the procedure with a new safety pin.

5. Remove the pin and push on the wire end of the lead to extract the ter minal from the mating end of the connector. See C in Figure B-14. If necessary, pull back the conduit and remo ve the wire seal at the bac k of the connector to introduce some slack in the wires.

NOTE A series of Packard Electrical Terminal Crimp Tools are available to install Packard pin and socket terminals on wires. If

new

terminals must be installed, see Crimping Instructions.

Installing External Latch Type

NOTE For wire location purposes, alpha characters are stamped into the socket housings.

1. To install a terminal back into the chamber of the connec-

tor housing, use a thin flat lade, like that on an X-Acto knife, and carefully bend the tang outward away from the terminal body. See D in Figure B-14.

2. Gently pull on the lead at the wire end of the connector to

draw the terminal back into the chamber. A click is heard when the terminal is properly seated.

3. Push on the lead to v erify that the ter minal is locked in

place.

4. Push the pin and socket halves of the connector together

until the latches “click.”

2004 Buell Lightning: Appendix B B-11

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PUSH-TO-SEAT TERMINALS

The Packard push-to-seat terminal connectors found on Softail model vehicles are listed below.

●

Ignition Switch [33]

●

Fuse Terminals

MAP Sensor [80]

●

Removing Push-to-Seat Terminals

Like most connectors , Packard push-to-seat ter minals are pulled out the wire end of the connector . To remove a pushto-seat terminal, proceed as follows:

1. Remove the connector from the retaining de vice, if present.

2. Bend back the e xternal latch(es) slightly and separ ate the pin and socket halves of the connector.

NOTE Both the Ignition Light/Key Switch and the Main Power connectors are provided with secondary locks. The secondary lock, which may be molded onto the connector or exist as a separate piece, aids in terminal retention. Secondary locks must be opened (or removed) before the ter minals can be extracted from the connector housing.

3. Open or remove the secondary lock. Bend back the latch

slightly and free one side of the secondar y lock, then repeat the step to release the other side. Rotate the secondary lock outward on hinge to access the ter minals in the chambers of the connector housing.

4. Looking in the mating end or terminal side of the connec-

tor (opposite the secondary lock), take note of the larger cavity next to each terminal.

5. Insert the pick (Snap-On TT600-3) into the cavity until it

stops. Pivot the end of the pic k toward the ter minal to depress the loc king tang. Remove the pic k and gently tug on the wire to pull the ter minal from the wire end of the connector. Repeat the step if the ter minal is still locked in place.

NOTE A series of Packard Electrical Terminal Crimp Tools are available to install Packard pin and socket terminals on wires. If new terminals must be installed, see Crimping Instructions.

Installing Push-to-Seat Terminals

NOTE For wire location purposes, alpha characters are stamped onto the secondary locks or onto the wire end of the connector housing.

1. To install a terminal back into the chamber of the connec-

tor housing, use a thin flat lade, like that on an X-Acto knife, and carefully bend the tang outward away from the terminal body.

2. Push the lead into the chamber at the wire end of the

connector. A click is heard when the ter minal is properly seated.

3. Gently tug on the wire end to v erify that the ter minal is

locked in place and will not back out of the chamber.

4. Close or install the secondar y lock. Rotate the hinged

secondary lock inward until tabs fully engage latches on both sides of connector.

5. Push the pin and socket halves of the connector together

until the latches “click.”

6. Install connector on retaining device, if present.

B-12 2004 Buell Lightning: Appendix B

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Tool tip

Packard 115 Packard 271

d0259x8x

d0260x8x

1. Insulation

2. Insulation crimp

3. Core crimp

1 2

CRIMPING INSTRUCTIONS

1. Strip wire lead removing 5/32 in. (4 mm) of insulation.

2. Compress handles until ratchet automatically opens.

NOTE

Always perform core crimp before insulation/seal crimp.

3. See Ta b le B-1. Determine the correct dye or nest for the core crimp.

NOTE

When the word “TIP” appears in the Cr imp Table, use the tip of the tool speciﬁed to perform the core crimp procedure. See

Figure B-15.

4. Lay the back of the core cr imp tails on the appropr iate nest. Be sure the core cr imp tails are pointing to wards the forming jaws.

5. Gently apply pressure to handles of tool until cr impers slightly secure the core crimp tails.

6. Insert stripped wire between crimp tails. Verify that wire is positioned so that shor t pair of cr imp tails squeez e bare wire strands, while long pair folds over insulation or seal material.

7. Squeeze handle of cr imp tool until tightly closed. Tool automatically opens when the cr imping sequence is complete.

8. Ta ble B-1. Determine the correct dye or nest for the insulation/seal crimp.

Figure B-15. Packard Terminal Crimp Tools

Table B-1. Packard Terminal Crimp Tools

SPECIFICATION PACKARD 115 PACKARD 271

Part No. HD-38125-8 HD-38125-7

Non-sealed

Ty p e of Crimp

Dye/nests F-G A-E

terminals,

butt splices

Non-sealed

terminals

9. Lay the bac k of the insulation/seal cr imp tails on the appropriate nest. Be sure the insulation/seal cr imp tails are pointing towards the forming jaws.

10. Squeeze handle of cr imp tool until tightly closed. Tool automatically opens when the cr imping sequence is complete.

11. See Figure B-16. Inspect the quality of the core (3) and insulation/seal (2) crimps. Distortion should be minimal.

Figure B-16. Inspect Core and Insulation/Seal Crimps

2004 Buell Lightning: Appendix B B-13

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ELECTRICAL CONNECTORS B.4

GENERAL

The following table provides a brief description of the connectors found on the Buell Lightning.

Connector numbers are listed in [brackets] in this manual.

Table B-2. Electrical Connector and Location Table

CONNECTOR COMPONENT(S) DESCRIPTION LOCATION

[10] ECM (black) 12-place Deutsch under seat

[11] ECM (gray) 12-place Deutsch under seat

[14] cam position sensor 3-place Deutsch under sprocket cover

[18] right rear turn signal 2 1-place bullet under seat

[19] left rear turn signal 2 1-place bullet under seat

[22] right hand controls 4-place Multilock behind windscreen

[24] left hand controls 4-place Multilock behind windscreen

[30] flashe 5-place Amp behind windscreen

[31] right front turn signal 2 1-place bullet behind windscreen

[31] left front turn signal 2 1-place bullet behind windscreen

[33] ignition switch 4-place Augat behind windscreen

[38] headlamp connector 4-place Amp behind windscreen

[39] instrument module 20-place Multilock in front modules behind windscreen

[45] license plate lamp 2 1-place bullet under seat

[46] stator 4-place Deutsch under sprocket cover

[65] vehicle speed sensor 3-place Deutsch under sprocket cover

[77] voltage regulator 2-place Packard under sprocket cover

[83] ignition coil 3-place Packard beneath airbox base

[84] front fuel injector 2-place Packard beneath airbox base

[85] rear fuel injector 2-place Packard beneath airbox base

[86] fuel pump 4-place Multilock left side of rear shock absorber

[88] throttle position sensor 3-place Packard right side of engine between cylinders

[89] intake air temperature sensor 2-place Amp in airbox base

[90] engine temperature sensor 1-place bullet beneath airbox base

[91A] data link 4-place Deutsch under seat, right side of vehicle

2-place spade

[93] tail light

1-place spade (ground)

back of tail light, under seat

[95] clutch switch 2-place Multilock underside of clutch lever assembly

[97] cooling fan 2-place Multilock behind rear cylinder, under seat

[120] oil pressure switch post terminal crankcase above oil filte

B-14 2004 Buell Lightning: Appendix B

Page 22

HOME

Table B-2. Electrical Connector and Location Table

CONNECTOR COMPONENT(S) DESCRIPTION LOCATION

[121] front brake switch 2-place Multilock

[121] rear brake switch 2-place Multilock under seat

[122] horn spade terminals behind windscreen

[128] starter solenoid spade terminals top of starter

[131] neutral switch 1-place bullet under sprocket cover

[134] bank angle sensor 6-place Sumitomo under seat

[137] oxygen sensor 1-place Packard behind rear cylinder head

underside of front master cylinder assembly

2004 Buell Lightning: Appendix B B-15

Page 23

HOME

INDEX TO WIRING DIAGRAMS B.5

Table B-3. Wiring Diagrams

DIAGRAM PAGE

Main harness B-17

Engine management circuit B-18

Lighting circuit B-19

Horn and instruments circuit B-20

Starting circuit B-21

Charging circuits B-22

Component Circuits B-23

B-16 2004 Buell Lightning: Appendix B

Page 24

HOME

bs0016xx

GN/GY

Y/BK

WYBE

LT.GN/Y

R/Y TN/Y TN/Y

GY/O

R/GY

R/BK

V/BN

LT.GN/R

[88B] [88A]

BK/W

O O R

R R

BK/W

11 2

V/Y

R/W

IAT

1 2

[89B]

[91A]

25 BK

[61B]

TN/LT.GN

R/BK

Y/BN

R/BK

O/W

BATTERY

DIODE

BRAKE/HORN/MUFFLER

COOLING FAN

IGNITION

ACCESSORY

SPARE

ECM

LIGHTS

KEY SWITCH

OBNV

[24A]

DATA LINK

1 2

V/R

IGNITION SWITCH WIRING DIAGRAM

KEY POSITION

PARK

LOCK

OFF

WIRE COLOR

WIRE SECT mm

CONNECTING

ECM

5V SENSOR POWER

THROTTLE POS SENSOR

(GY)

CAMSHAFT POS SENSOR

[11B]

VEHICLE SPEED SENSOR

ENGINE TEMP INPUT

SERIAL DATA RECEIVE

SERIAL DATA TRANSMIT

ACTIVE MUFFLER CONTROL

[164B]

(BK)

[10B]

SWITCHED IGNITION

SYSTEM GROUND A

FUEL PUMP OUTPUT

CHECK ENGINE LAMP

INJECTOR FRONT OUTPUT

FRONT COIL PRIMARY

REAR COIL PRIMARY

INJECTOR REAR OUTPUT

ACTIVE MUFFLER FEEDBACK

BANK ANGLE SENSOR

SYSTEM GROUND B

TACHOMETER OUTPUT

HORN

23456789

BATTERY

TN/Y

NEUTRAL

LEFT TURN

RIGHT TURN

GN/Y

BK/Y

WBNV

HIGH BEAM

OIL PRESSURE

CHECK ENGINE

R/BK

BATTERY

USER + USER +

BATTERY

[30B]

KEEP ALIVE

11 22

12 2019181716151413

GROUND

IGNITION

12345

V/BN

BK Y/BK

[122B]

Y/R

PKBKO/W

LFW

TACH IN

FLASHER

OXYGEN SENSOR

FAN CONTROL

SENSOR GROUND

AIR TEMP INPUT

[122A]

10 12 201918171615141311

O/W

1 2 3 4 5 6 7 8

9 10 11 12

VSS IN

R/GY

R/W V/Y GN/W V/GY Y BK/O BK/W W PK/Y LT.GN/Y LT.GN/R V/R

GY BK BN/Y BK/Y W/Y Y/BE BE/O GN/GY TN/V LT.GN/GY BK PK

[39B]

DYNO LOOP

FUSE/RELAY

ASSEMBLY

IGNITION

SPEEDOMETER

[39A]

START

KEY SW

BRAKE SW

1 1

R/Y

[121B]

IGN

RH CONTROLS

[22A]

Y/BE

[62B]

BK/R

W/BK

W/BK W/BK BK GY/O GY/O GY

BK/R TN/LT.GN R/BK R/BK GN R/BK R/BK BK

R/BK

W/BK

GY/O

IGN

LOCK

R/GY

RH TURN SIGNAL

[31B]

[33A]

[33B]

R/BK

[GRD1]

LT.GN/GY

BANK ANGLE SENSOR

LH TURN SIGNAL

[31B]

FRONT INJECTOR

[84B]

[GRD3]

1 2 3 4

R/W

5 6

BK/W

[134B]

W/Y

TN/LT.GN

CLUTCH SW

[95B]

THROTTLE POSITION SENSOR

REAR INJECTOR

[85B]

112131415162728

LH CONTROLS

FUSE/RELAY ASSEMBLY

[83B] [83A]

HEADLAMP

O/W

[38B]

GN/Y

Y/BE

BE/O

GN/Y

OIL PRESSURE SW

[120B]

[120A]

IGN. COIL

ENGINE TEMP SENSOR

PK/Y

[90B] [90A]

[137B] [137A]

[97B]

OXYGEN SENSOR

V/GY

Y/BN BK/O

COOLING FAN

[GRD2]

FUEL PUMP

Y/R Y/R

BN/Y BN/Y

[14B] [14A]

[97A]

R/Y

O/W

FOOT BRAKE SW

R/Y

[121A] [121B]

O/W

R/Y

LH TURN SIGNAL

AA BB

BK BK

CC DD

GY GY

[86B][86A]

NEUTRAL SW

TN/Y

[131B]

R/W

BK/W

[65B]

CMP

R/W R/W

GN/W GN/W

BK/W BK/W

VOLTAGE REGULATOR

[77B]

MALE

FEMALE

O W

TN/V

111 212

TAIL LIGHT

[93B]

[19B]

VSS

AA BB CC

GROUND

ACTIVE MUFFLER

CONTROL SUB-

HARNESS

[165A]

LIC. PLATE LAMP

[45B]

R/Y

RH TURN SIGNAL

[18B]

[131A]

[65A]

STARTER SOLENOID

[128A]

[128B]

MTR

LOW FUEL SENSOR

2004 Lightning Models Main Harness

2004 Buell Lightning: Electrical B-17

Page 25

HOME

bs0017xx

IGNITION SWITCH WIRING DIAGRAM

KEY POSITION

PARK

LOCK

OFF

WIRE COLOR

WIRE SECT mm

CONNECTING

BATTERY

ECM

5V SENSOR POWER

(GY)

(BK)

THROTTLE POS SENSOR

CAMSHAFT POS SENSOR

[11B]

ACTIVE MUFFLER CONTROL

[164B]

[10B]

ACTIVE MUFFLER FEEDBACK

OXYGEN SENSOR

SENSOR GROUND

VEHICLE SPEED SENSOR

ENGINE TEMP INPUT

AIR TEMP INPUT

SERIAL DATA RECEIVE

SERIAL DATA TRANSMIT

SWITCHED IGNITION

SYSTEM GROUND A

FUEL PUMP OUTPUT

CHECK ENGINE LAMP

INJECTOR FRONT OUTPUT

FRONT COIL PRIMARY

REAR COIL PRIMARY

INJECTOR REAR OUTPUT

BANK ANGLE SENSOR

SYSTEM GROUND B

TACHOMETER OUTPUT

KEEP ALIVE

FAN CONTROL

1 2 3 4 5 6 7 8

9 10 11 12

R/GY

R/W V/Y GN/W V/GY Y BK/O BK/W W PK/Y LT.GN/Y LT.GN/R V/R

GY BK BN/Y BK/Y W/Y Y/BE BE/O GN/GY TN/V LT.GN/GY BK

R/BK

BATTERY

USER + USER +

DYNO LOOP

Y/BE

RH CONTROLS

[22A]

W/BK

GY/O

IGN SW

IGN

LOCK

1 1

1 2 3

GN/GY

[88A]

BK/W V/Y R/W

LT.GN/Y

BK/W

IAT

[83B] [83A]

Y/BE

BE/O

[89B]

IGN.

COIL

COOLING FAN

[97B] [97A]

[GRD2]

ENGINE TEMP SENSOR

[90B]

PK/Y

[137B] [137A]

V/GY

Y/BN

BK/O

[90A]

OXYGEN SENSOR

Y BK

THROTTLE POSITION SENSOR

[33A]

[33B]

R/BK

FRONT INJECTOR

W/Y

[84B]

[88B]

REAR INJECTOR

[85B]

R/Y

ACTIVE MUFFLER SUB HARNESS

[GRD1]

[GRD3]

FUSE/RELAY ASSEMBLY

TN/Y TN/Y

GY/O

BATTERY

R/Y

DIODE

BRAKE/HORN/MUFFLER

29 23

COOLING FAN

IGNITION

[61B]

TN/LT.GN

R/BK

Y/BN

R/BK

O W

TN/V

[165A]

MUFFLER VALVE

ACTUATOR

MOTOR

POSITION

SENSOR

TN/V

[165B]

bat

TN/V

[161A]

CONTROL ELECTRONICS

Some 2004 XB9S models may not have the circuitry for the active muffler.

HALL SENSOR

GROUND

[161B]

CONTROL SIGNAL

BK/Y

TN/Y

23456789

NEUTRAL

BATTERY

HIGH BEAM

LEFT TURN

RIGHT TURN

OIL PRESSURE

CHECK ENGINE

SPEEDOMETER

10 12 201918171615141311

TACH IN

GROUND

IGNITION

LFW

VSS IN

[39B]

[39A]

FUSE/RELAY

ASSEMBLY

IGNITION

KEY SW

ECM

KEY SWITCH

[62B]

W/BK

GY/O

R/BK

LT.GN/GY

BANK ANGLE SENSOR

R/W

BK/W

2 3

[134B]

4 5 6

CLUTCH SW

[95B]

TN/LT.GN

DATA LINK

LT.GN/R

V/R

1 2

3 4

[91A]

HEADLAMP

1 2 3 4

[38B]

FUEL PUMP

AA BB

BK BK

BN/Y BN/Y

[86A]

CC DD

GY GY

[131B]

R/W

BK/W

[65B]

CMP

R/W R/W GN/W GN/W BK/W BK/W

[14B]

[86B]

NEUTRAL SW

TN/Y

VSS

AA BB CC

[14A]

[65A]

[131A]

MTR

LOW FUEL

SENSOR

2004 Lightning Models Engine Management Circuit

2004 Buell Lightning: Electrical B-18

Page 26

HOME

bs0018x

IGNITION SWITCH WIRING DIAGRAM

KEY POSITION

PARK

LOCK

OFF

WIRE COLOR

WIRE SECT mm

CONNECTING

BATTERY

FLASHER

R/BK

USER + USER +

BATTERY

12345

[30B]

V/BN

O/W

O R/Y

[121B]

IGN SW

LOCK

IGN

2 2

R/GY

RH TURN SIGNAL

[31B]

[33A]

[33B]

[GRD1]

[GRD2]

R/Y

LIC. PLATE LAMP

O/W

[45B]

FUSE/RELAY ASSEMBLY

BATTERY

R/Y

BRAKE/HORN/MUFFLER

ACCESSORY

R/GY

R/BK

O/W

[61B]

FOOT BRAKE SW

111

R/Y

[121A] [121B]

O/W

R/Y

212

TAIL LIGHT

[93B]

R/Y

LH TURN SIGNAL

[19B]

RH TURN SIGNAL

[18B]

BRAKE SW

R/GY

1 1 2

WBNV

23456789

NEUTRAL

BATTERY

LEFT TURN

10 12 201918171615141311

HIGH BEAM

RIGHT TURN

OIL PRESSURE

CHECK ENGINE

SPEEDOMETER

BKRO/W

TACH IN

GROUND

IGNITION

LFW

VSS IN

[39B]

[39A]

FUSE/RELAY

ASSEMBLY

START

KEY SW

LIGHTS

KEY SWITCH

[24A]

OBNV

HEADLAMP

O/W

[38B]

3 4

R/BK

R R

WBEY

V/BN

[62B]

R/BK

LH TURN SIGNAL

[31B]

112131415162728

LH CONTROLS

2004 Lightning Lighting Circuit

2004 Buell Lightning: Electrical B-19

Page 27

HOME

bs0019xx

ECM

5V SENSOR POWER

(GY)

[11B]

(BK)

[10B]

23456789

BATTERY

THROTTLE POS SENSOR CAMSHAFT POS SENSOR

OXYGEN SENSOR

FAN CONTROL

SENSOR GROUND

VEHICLE SPEED SENSOR

ENGINE TEMP INPUT

AIR TEMP INPUT

SERIAL DATA RECEIVE

SERIAL DATA TRANSMIT

SWITCHED IGNITION

SYSTEM GROUND A

FUEL PUMP OUTPUT

CHECK ENGINE LAMP

INJECTOR FRONT OUTPUT

FRONT COIL PRIMARY

REAR COIL PRIMARY

INJECTOR REAR OUTPUT

ACTIVE MUFFLER FEEDBACK

BANK ANGLE SENSOR

SYSTEM GROUND B

TACHOMETER OUTPUT

[122A]

HIGH BEAM

LEFT TURN

RIGHT TURN

CHECK ENGINE

GN/Y

10 12 201918171615141311

OIL PRESSURE

TN/Y

NEUTRAL

KEEP ALIVE

HORN

Y/BK

[122B]

Y/R

O/W

LFW

TACH IN

GROUND

IGNITION

1 2 3 4 5 6 7 8

9 10 11 12

VSS IN

R/W

BK/W W

GY BK

BK PK

[39B]

FUSE/RELAY

ASSEMBLY

[62B]

IGN SW

LOCK

1 1

IGN

2 2

3 3

R/GY

IGNITION SWITCH WIRING DIAGRAM

KEY POSITION

PARK

[GRD1]

LOCK

OFF

WIRE COLOR

WIRE SECT mm

CONNECTING

[GRD3]

BATTERY

[33A]

4 4

[33B]

R/BK

USER + USER +

BATTERY

R/GY

FUSE/RELAY ASSEMBLY

BATTERY

R/Y TN/Y TN/Y

R/GY

Y/BK

12345678

DIODE

BRAKE/HORN/MUFFLER

ACCESSORY

KEY SWITCH

[24A]

[61B]

TN/LT.GN

R/BK

O/W

[GRD2]

R/Y

FUEL PUMP

Y/R Y/R

BK BK

GY GY

[86A]

AA BB CC DD

[86B]

NEUTRAL SW

TN/Y

[131B]

VSS

R/W

BK/W

[65B]

[131A]

R BB CC

[65A]

MTR

LOW FUEL

SENSOR

LH CONTROLS

SPEEDOMETER

[39A]

START

KEY SW

TN/LT.GN

R/BK

GN/Y

[120B]

OIL PRESSURE SW

[120A]

2004 Lightning Models Horn & Instruments Circuit

2004 Buell Lightning: Electrical B-20

Page 28

HOME

bs0018xx

IGNITION SWITCH WIRING DIAGRAM

KEY POSITION

PARK

LOCK

OFF

WIRE COLOR

WIRE SECT mm

CONNECTING

BATTERY

FLASHER

R/BK

USER + USER +

BATTERY

12345

[30B]

V/BN

O/W

O R/Y

[121B]

IGN SW

LOCK

1 1

IGN

2 2

R/GY

RH TURN SIGNAL

[31B]

[33A]

[33B]

[GRD1]

[GRD2]

R/Y

LIC. PLATE LAMP

O/W

[45B]

FUSE/RELAY ASSEMBLY

BATTERY

R/Y

BRAKE/HORN/MUFFLER

R/GY

ACCESSORY

R/BK

O/W

[61B]

FOOT BRAKE SW

111

R/Y

[121A] [121B]

O/W

R/Y

212

TAIL LIGHT

[93B]

R/Y

LH TURN SIGNAL

[19B]

RH TURN SIGNAL

[18B]

BRAKE SW

R/GY

1 1 2

WBNV

23456789

NEUTRAL

BATTERY

LEFT TURN

10 12 201918171615141311

HIGH BEAM

RIGHT TURN

OIL PRESSURE

CHECK ENGINE

SPEEDOMETER

BKRO/W

TACH IN

GROUND

IGNITION

LFW

VSS IN

[39B]

[39A]

FUSE/RELAY

ASSEMBLY

START

KEY SW

LIGHTS

R/BK

V/BN

OBNV

WBEY

[62B]

R/BK

LH TURN SIGNAL

[31B]

112131415162728

LH CONTROLS

KEY SWITCH

[24A]

HEADLAMP

O/W

[38B]

3 4

2004 Lightning Models Starting Circuit

2004 Buell Lightning: Electrical B-21

Page 29

HOME

bs0021xx

BATTERY

[GRD2]

BATTERY CABLE

[128A]

STARTER

MOTOR

STARTER

SOLENOID

VOLTAGE

REGULATOR

STATOR

(HD 3-PHASE)

FUSE/RELAY ASSEMBLY

BATTERY, 30A

R/Y

[61B]

TO VOLTAGE REGULATOR

[77B]

[77A]

[46A]

[46B]

2004 Lightning Models Charging Circuit

2004 Buell Lightning: Electrical B-22

Page 30

HOME

bs0020xx

TO MAIN HARNESS

O/W

W Y

HEADLIGHT

SUB-HARNESS(ES)

[38LA]

H7-55W HI AND LO BEAMS

[38HA]

[29A]

POSITION LAMPS

(HDI ONLY)

MAIN HARNESS

FRONT TURN SIGNALS

LH TURN SIGNALS

[31A]

RH TURN SIGNALS

[31A]

[29B]

O/W

1 2

[31B]

111

222

[31B]

FLASHER

[30A]

[30B]

O/W

V/BN

MAIN HARNESS

CLUTCH SW.

FRONT INJECTOR

54321

[95A]

BRAKE SW.

[121A]

RH CONTROLS

BK/R

W/BK

[22B]

W/BK

LH CONTROLS

111

222

Y/BK

BE/W

[24B]

[24A]

REAR INJECTOR

[84A]

W/Y

[84B]

[85A]

[85B]

GN/GY

HORN

[122A]

Y/BK

[122B]

OIL PRESSURE SWITCH

GN/Y

[120B]

GN/Y

[120A]

ENGINE TEMP SENSOR

PK/Y

[90B]

[90A]

BATTERY

FUSE/RELAY ASSEMBLY

VOLTAGE

REGULATOR

STATOR

(HD 3-PHASE)

TAIL LAMP/REAR TURNING LIGHTS

BATTERY CABLE

[GRD2]

BATTERY, 30A

R/Y

[61B]

TO VOLTAGE REGULATOR

[46A]

[77A]

[46B]

TO MAIN HARNESS

[77B]

TAIL LIGHT

[93A]

[128A]

STARTER

MOTOR

MUFFLER ACTUATOR

SUB-HARNESS

121

FUEL PUMP

STARTER

SOLENOID

Y0206.1AA

TO MAIN HARNESS

VEHICLE SPEED SENSOR

[65A]

MUFFLER VALVE ACTUATOR

POSITION SENSOR

CONTROL ELECTRONICS

1432

[165B]

TN/V

LH TURN SIGNAL

LIC PLATE LAMP

RH TURN SIGNAL

[19A]

[45A]

[18A]

O/W

WRB

MTR

[161A]

TN/V

[161B]

TO MAIN HARNESS

BANK ANGLE SENSOR

11 22 33

R/W

BK/W

44 55 66

[134A]

LT.GN/GY

[134B]

Y/R

[89A]

INTAKE AIR TEMP

[89B]

BK/W

LT.GN/Y

BN/Y

[86B]

LOW FUEL

SENSOR

2004 Lightning Models Component Circuits

2004 Buell Lightning: Electrical B-23

MTR

Page 31

HOME

APPENDIX C–METRIC CONVERSIONS

Table C-1. Metric Conversions

MILLIMETERS TO INCHES

(MM X 0.03937 = INCHES)

INCHES TO MILLIMETERS

(INCHES X 25.40 = MM)

mm in. mm in. mm in. mm in. in. mm in. mm in. mm in. mm

.0039

.0078

.0118

.0157

.0197

.0236

.0275

.0315

.0354

.0394

.0787

.1181

.1575

.1968

.2362

.2756

.9842

1.024

1.063

1.102

1.142

1.181

1.220

1.260

1.299

1.338

1.378

1.417

1.456

1.496

1.535

1.575

2.283

2.323

2.362

2.401

2.441

2.480

2.519

2.559

2.598

2.638

2.677

2.716

2.756

2.795

2.834

2.874

100

101

102

103

104

105

106

3.582

3.622

3.661

3.701

3.740

3.779

3.819

3.858

3.897

3.937

3.976

4.016

4.055

4.094

4.134

4.173

.001

.002

.003

.004

.005

.006

.007

.008

.009

.010

.020

.030

.040

.050

.025

.051

.076

.102

.127

.152

.178

.203

.229

.254

.397

.508

.762

.794

1.016

1.270

1 1/

1.1

1 1/

1 3/

1.2

15.240

15.875

17.462

17.780

19.050

20.320

20.638

22.225

22.860

23.812

25.40

26.99

27.94

28.57

30.16

30.48

2 1/

2.1

2 1/

2 3/

2.2

2 1/

2.3

2 5/

2 3/

2.4

2 7/

2 1/

2 9/

2.6

49.21

3 5/

84.14

50.80

3 3/

85.72

52.39

3.4

53.34

3 7/

53.97

3 1/

55.56

3 9/

55.88

3.6

57.15

3 5/

58.42

58.74

3.7

60.32

3 3/

60.96

3.8

61.91

63.50

3 7/

65.09

3.9

66.04

86.36

87.31

88.90

90.49

91.44

92.07

93.66

93.98

95.25

96.52

96.84

98.42

99.06

100.01

.3149

.3543

.3937

.4331

.4724

.5118

.5512

.5905

.6299

.6693

.7086

.7480

.7874

.8268

.8661

.9055

.9449

1.614

1.653

1.693

1.732

1.772

1.811

1.850

1.890

1.929

1.968

2.008

2.047

2.086

2.126

2.165

2.205

2.244

2.913

2.953

2.992

3.031

3.071

3.110

3.149

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.464

3.504

3.543

107

108

109

110

111

112

113

114

115

116

117

118

119

120

121

122

123

4.212

4.252

4.291

4.331

4.370

4.409

4.449

4.488

4.527

4.567

4.606

4.645

4.685

4.724

4.764

4.803

4.842

.060

.070

.080

.090

1.524

1.588

1.778

2.032

2.286

2.540

3.175

4.762

5.080

6.350

7.620

7.938

9.525

10.160

11.112

12.700

14.288

1 1/

1.3

1 5/

1 3/

1.4

1 7/

1 1/

1 9/

1.6

1 5/

1.7

1 3/

1.8

1 7/

1.9

31.75

33.02

33.34

34.92

35.56

36.51

38.10

39.69

40.64

41.27

42.86

43.18

44.45

45.72

46.04

47.62

48.26

2 5/

2.7

2 3/

2.8

2 7/

2.9

3 1/

3.1

3 1/

3 3/

3.2

3 1/

3.3

66.67

101.6

68.26

4 1/

102.19

68.58

4.1

104.14

69.85

4 1/

104.77

71.12

4 3/

106.36

71.44

4.2

106.68

73.02

4 1/

107.95

73.66

4.3

109.22

74.61

4 5/

109.54

76.20

4 3/

111.12

77.79

4.4

111.76

78.74

4 7/

112.71

79.37

4 1/

114.30

80.96

4 9/

115.89

81.28

4.6

116.84

82.55

4 5/

117.47

83.82

119.06

2004 Buell Lightning: Appendix C C-1

Page 32

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UNITED STATES SYSTEM

Unless otherwise specified,

in this Ser vice Manual are e xpressed in United States (U.S.) units-of-measure.

●

1 pint (U.S.) = 16 fluid ounces ( .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 olume measurements

See below:

METRIC SYSTEM

Fluid volume measurements in this Ser vice 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 metr ic units-of-measure (or vice v ersa), refer to the following:

●

fluid ounces ( .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 ( .S.)

●

liters x 2.113 = pints (U.S.) liters x 1.057 = quarts (U.S.)

●

liters x 0.264 = gallons (U.S.)

●

BRITISH IMPERIAL SYSTEM

Fluid volume measurements in this Ser vice Manual do not include the British Imperial (Imp.) system equivalents. The following conversions exist in the British Imperial system:

●

1 pint (Imp.) = 20 fluid ounces (Im .) 1 quart (Imp.) = 2 pints (Imp.)

●

1 gallon (Imp.) = 4 quarts (Imp.)

●

Although the same unit-of-measure ter minology as the U .S. system is used in the Br itish Imperial (Imp.) system, the actual volume of each British Imperial unit-of-measure differs from its U.S. counterpart. The U.S. fluid ounce is larger tha the British Imperial fluid ounc . However, the U.S. pint, quart, and gallon are smaller than the Br itish Imperial pint, quar t, and gallon, respectiv ely. Should y ou need to con vert from U.S. units to British Imperial units (or vice v ersa), refer to the following:

●

fluid ounces ( .S.) x 1.042 = fluid ounces (Im .)

●

pints (U.S.) x 0.833 = pints (Imp.)

●

quarts (U.S.) x 0.833 = quarts (Imp.) gallons (U.S.) x 0.833 = gallons (Imp.)

●

fluid ounces (Im .) x 0.960 = fluid ounces ( .S.)

●

pints (Imp.) x 1.201 = pints (U.S.)

●

quarts (Imp.) x 1.201 = quarts (U.S.) gallons (Imp.) x 1.201 = gallons (U.S.)

●

C-2 2004 Buell Lightning: Appendix C

Page 33

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HOSE AND WIRE ROUTING

2004 Buell Lightning: Appendix D D-1

b1114xasx

Front and Rear Brake Systems, Right Side View

Page 34

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D-2 2004 Buell Lightning: Appendix D

b1115xbsx

Rear Brake Systems, Top View

Page 35

2004 Buell Lightning: Appendix D D-3

HOME

b1116xcsx

Rear Brake Systems, Left Side View

Page 36

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D-4 2004 Buell Lightning: Appendix D

b1117xasx

Carbon canister

Evaporative Emissions Control, California Models, Top View

Page 37

2004 Buell Lightning: Appendix D D-5

HOME

b1118xbsx

1. To induction module

2. From induction module (California)

3. From fuel tank (California)

4. From fuel tank to atmosphere (49 state)

Evaporative Emissions Control, California and 49 State Models, Left Side View

Page 38

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D-6 2004 Buell Lightning: Appendix D

b1119xasx

1. Intake air temperature sensor (IAT) 2. Fuel pump

Wiring Harness, Left Side View

Page 39

2004 Buell Lightning: Appendix D D-7

HOME

b1120xbsx

1. Fuel injector (2)

2. Throttle position sensor (TPS)

3. Intake air temperature (IAT) sensor

4. Oxygen (O2) sensor

Wiring Harness, Top View

Page 40

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D-8 2004 Buell Lightning: Appendix D

b1121xcsx

1. Speedometer sensor

2. Cable, starter to battery positive

3. Solenoid

4. Transmission vent line

5. Voltage regulator

6. Switch, oil pressure

7. Cam position sensor

Wiring Harness, Right Side View

Page 41

2004 Buell Lightning: Appendix D D-9

HOME

b1122xasx

1. Vent line

2. Feed oil line

3. Return oil line

4. Feed oil line from the oil pump to the oil cooler

5. Return oil line from the oil cooler to the oil filter housin

Oil Lines, Right Side View

Page 42

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D-10 2004 Buell Lightning: Appendix D

b1123xbsx

1. Vent line 2. Feed oil line 3. Return oil line

Oil Lines, Bottom View

Page 43

2004 Buell Lightning: Appendix D D-11

HOME

b1124xasx

Clutch Cable, Right Side View

Page 44

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D-12 2004 Buell Lightning: Appendix D

b1125xbsx

Cable, seat lock

Clutch, Throttle and Seat Release Cables, Left Side View

Page 45

2004 Buell Lightning: Appendix D D-13

HOME

b1126xcsx

TPS adjuster

Cable, seat lock

Clutch, Throttle and Seat Release Cables, Top View

Page 46

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NOTES

D-14 2004 Buell Lightning: Appendix D

Page 47

MAINTENANCE 1

able Of Contents

SUBJECT PAGE NO.

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Fuel and Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.3 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

1.4 Care of Molded-in-Color Body Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.5 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

1.6 Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

1.7 Brake System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

1.8 Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

1.9 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

1.10 Drive Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

1.11 Primary Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

1.12 Suspension Damping Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31

1.13 Steering Head Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35

1.14 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

1.15 Air Cleaner Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

1.16 Throttle Cable and Idle Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40

1.17 Interactive Exhaust Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41

1.18 Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43

1.19 Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45

1.20 Throttle Position Sensor (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-47

1.21 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48

1.22 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49

Page 48

Page 49

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1WARNING1WARNING

GENERAL 1.1

SERVICING A NEW MOTORCYCLE

1WARNING1WARNING

Always follow the listed service and maintenance recommendations, because the y affect the saf e operation of the motorcycle and the personal welfare of the rider. Failure to f ollow recommendations could result in death or serious injury.

Service operations to be performed before customer delivery are specified in the applica le model y ear 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. See 1.3 MAINTENANCE SCHEDULE for details.

SAFE OPERATING MAINTENANCE

CAUTION

●

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

SHOP PRACTICES

Repair Notes

NOTE

General maintenance practices are given in this section.

●

Repair = Disassembly/Assembly.

●

Replace = Removal/Installation.

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

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

Safety

Safety is always the most impor tant consideration when performing any job. Be sure you have a complete understanding of the task to be perf ormed. Use common sense . Use the proper tools. Protect y ourself 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 remo ve some parts. The lengths of chains or cables from the hoist to the part should be equal and par allel and should be positioned directly o ver the center of the par t. Be sure that no obstructions will interf ere with the lifting oper ation. Never leave a part suspended in mid-air.

●

During the initial break-in period, use onl y HarleyDavidson 20W50 engine oil. Failure to use the recommended oil will result in impr oper break-in of the engine cylinders and piston rings.

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

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 l vel and condition. Hydraulic lines and fit tings for leaks. Also, check brake pads and rotors f or wear.

5. Cables for fraying, crimping and free operation.

6. Engine oil and transmission fluid l vels.

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

Always check the capacity rating and condition of hoists, slings, chains or cables before use. Failure to do so can lead to an accident which could result in death or serious injury.

Always use blocking or proper stands to support the part that has been hoisted. If a par t cannot be removed, verify that all bolts and attaching hardw are have been remo ved. 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.

Cleaning

If you intend to reuse par ts, follow good shop pr actice and thoroughly clean the par ts before assembly. Keep all dirt out of parts; the unit will perform better and last longer. Seals, fil ters and covers are used in this v ehicle to keep out environmental dirt and dust. These items m ust be k ept in good condition to ensure satisfactory operation.

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

Always clean around lines or covers before they are removed. Plug, tape or cap holes and openings to k eep out dir t, dust and debris.

2004 Buell Lightning: Maintenance 1-1

Page 50

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Disassembly and Assembly

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

Operate the v ehicle to perf orm any final che k or adjustments. If all is correct, the v ehicle is ready to go bac k to the customer.

REPAIR AND REPLACEMENT PROCEDURES

Hardware and Threaded Parts

Install helical thread inser ts when inside threads in castings are stripped, damaged or not capab le of withstanding specified torqu .

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 thread chaser.

Replace all damaged or missing lubrication fitting .

Use Teflon pipe sealant on pipe fitting threa .

Wiring, Hoses and Lines

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

Bushings

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

When pressing or driving bushings, be sure to apply pressure in line with the b ushing bore. Use a bear ing/bushing driver or a bar with a smooth, flat end Never use a hammer to dr ive bushings.

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

Gaskets

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

new

gas-

Lip Type Seals

Lip seals are used to seal oil or g rease and are usually installed with the sealing lip f acing the contained lubr icant. Seal orientation, however, may vary under diff erent applications.

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

Leaking oil or g rease 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.

Instruments and Gauges

Replace broken or def ective instruments and gauges . Replace dials and glass that are so scr atched or discolored that reading is difficult

Bearings

Anti-friction bearings must be handled in a special w ay. To keep out dir t and abr asives, cover the bearings as soon as they are removed from the package.

Wash bearings in a non-flamma le cleaning solution. Knock out packed lubricant inside by tapping the bear ing 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 chamf ered side of the bear ing always faces the shoulder (when bear ings installed against shoulders). Lubricate bearings and all metal contact surf aces before pressing into place . Only apply pressure on the par t of the bearing that makes direct contact with the mating par t. Install bearings with numbered side facing out.

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

Bearings do not usually need to be remo ved. Only remo ve bearings if necessary.

O-Rings (Preformed Packings)

Always discard O-r ings after remo val. Replace with rings. To prevent leaks, lubricate the O-r ings before installation. Apply the same type of lubr icant as that being sealed. Be sure that all gask et, O-ring and seal mating surf aces 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 n uts, bolts or retaining r ings have been removed. Check to see if other parts are in the way before using force.

Shafts fitted to tapered splines should be ery tight. If shafts are not tight, disassemb le and inspect tapered splines . Discard parts that are w orn. 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.

Part Replacement

Always replace worn or damaged parts with

new

parts.

1-2 2004 Buell Lightning: Maintenance

Page 51

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CLEANING

Part Protection

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

Cleaning Process

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

Rust or Corrosion Removal

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

TOOL SAFETY

Air Tools

●

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

On all po wer tools, use only recommended accessor ies

●

with proper capacity ratings.

Do not exceed air pressure ratings of any power tools.

●

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

Disconnect the air supply line to an air hammer bef ore

●

attaching a bit.

Never point an air tool at yourself or another person.

●

Protect bystanders with approved eye protection.

Hammers

Never strike one hammer against a hardened object,

●

such as another hammer.

●

Always grasp a hammer handle fi mly, 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.

●

Punches/chisels

●

Never use a punch or chisel with a chipped or m ushroomed end; dress m ushroomed chisels and punches with a fil .

Hold a chisel or a punch with a tool holder if possible.

●

When using a chisel on a small piece , clamp the piece fi mly 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 scre wdriver 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.

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 f or 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.

●

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

●

Don’t use a scre wdriver with rounded edges because it will slip – redress with a fil .

Ratchets and Handles

●

Periodically clean and lubricate ratchet mechanisms with a light grade oil. Do not replace par ts individually; ratchets should be reb uilt with the entire contents of ser vice kit.

●

Never hammer or put a pipe e xtension on a r atchet or handle for added leverage.

●

Always support the r atchet head when using soc ket extensions, but do not put your hand on the head or y ou 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 r atchet’s gear wheel is engaged with the pawl.

2004 Buell Lightning: Maintenance 1-3

Page 52

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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 soc kets for use with air or electr ic impact wrenches.

●

Replace sockets showing cracks or wear.

Keep sockets clean.

●

Always use approved eye protection when using po wer or impact sockets.

Storage Units

●

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

●

Close lids and loc k drawers and doors bef ore moving storage units.

●

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

Set the br akes on the loc king casters after the cabinet

●

has been rolled to your work.

1-4 2004 Buell Lightning: Maintenance

Page 53

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FUEL AND OIL 1.2

FUEL

1WARNING1WARNING

Remove filler cap sl wly and fill fuel tank sl wly to prevent spillage; do not overfill or fill ab ve the bottom of the fille neck insert. In ad dition, leave air space to allo w for fuel expansion. Expansion can cause an o verfilled tank to overfl w gasoline through the filler cap onto sur ounding areas. After refueling, be sure filler cap is secure y tightened. Failure to compl y may cause an e xplosion or fir which could result in death or serious injury.

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

GASOLINE BLENDS

CAUTION

Using gasoline that has an alcohol ad ditive, such as methanol, may cause fuel system rubber components’ failure and/or engine damage.

Buell motorcycles w ere designed to giv e the best perf ormance using unleaded gasoline . Some fuel suppliers sell gasoline/alcohol blends as a fuel. The type and amount of alcohol added to the fuel is important.

ENGINE OIL

Use the proper g rade of oil f or the lo west temperature expected before the next oil change.

If it is necessar y to add oil and Har ley-Davidson oil is not available, use an oil cer tified for diesel engines . Acceptable diesel engine oil designations include CF-4, CG-4, CH-4 and CI4. The preferred viscosities f or the diesel engine oils , in descending order, are 20W-50, 15W-40 and 10W -40. At the first opportunity, see a Har ley-Davidson dealer to change back to 100 percent Harley-Davidson oil.

See 1.6 ENGINE LUBRICA TION SYSTEM for all ser vice information.

WINTER LUBRICATION

Combustion in an engine produces w ater vapor. During starting and warm-up in cold w eather, especially in freezing temperatures, the v apor condenses to w ater before the crankcase is hot enough to e xhaust it through the breather system. If the engine is run long enough for the crankcase to become thoroughly heated, the w ater returns to vapor and is then exhausted.

An engine used f or only shor t trips, and seldom allo wed to thoroughly warm up, accumulates increasing amounts of water in the oil pan. Water mixed with oil forms a sludge that causes accelerated engine w ear. In freezing temper atures, the water becomes slush or ice , which may clog oil lines and result in engine failure.

Always change the engine oil more often in winter . If the engine is used f or short runs, change the oil e ven more frequently. The farther below freezing the temperature drops the more often the oil should be changed.

●

DO NOT USE GASOLINES CONTAINING METHANOL. Using gasoline/methanol blends will result in starting and driveability deterioration and damage to cr itical fuel system components.

ETHANOL is a mixture of 10% ethanol (Gr ain alcohol)

●

and 90% unleaded gasoline . Gasoline/ethanol b lends can be used in y our motorcycle if the ethanol content does not exceed 10%.

●

REFORMULATED OR O XYGENATED GASOLINES (RFG): “Reformulated gasoline” is a ter m used to describe gasoline blends that are specifically designed t burn cleaner than other types of gasoline . Your motorcycle will run normally using this type of gas.

Yo u may find that some gasoline lends adversely affect the starting, driveability or fuel efficiency of our bike. If you experience one or more of these problems, we recommend you try a different brand of gasoline or gasoline with a higher octane rating.

2004 Buell Lightning: Maintenance 1-5

Page 54

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MAINTENANCE SCHEDULE 1.3

Table 1-1. Regular Service Intervals

ODOMETER READING SERVICE OPERATIONS (See Chart Code Below)

1 6 0 0

Change engine oil and filter. R RRRRRRRRRR

Inspect air cleaner, service as required. IIIIRIIIRII

Inspect brake pads and rotors for wear. IIIIIIIIIII

Adjust primary chain. AAAAAAAAAAA

Change transmission/primary chaincase lube and clean drain plug. RI RI RI RI RI RI RI RI RI RI RI

Check ignition timing. IIIII

Replace spark plugs. RRRRR

Zero throttle position sensor (TPS). AAAAAA

Check engine idle speed. IIIIIIIIIII

Steering head bearing resistance test. XXXXXXXXXX

Adjust throttle cables. AAAAAAAAAAA

Adjust clutch and clutch cable. AAAAAAAAAAA

Check rear belt and idler pulley.

Replace belt and idler pulley every 25,000 mi. (40,000 km).

IIIIIRIIIIR

Check front and rear tire pressure and inspect tread. IIIIIIIIIII

Clean oil cooler fins. XXXXXXXXXXX

Change front fork oil. XXXXX

Check brake fluid reservoir levels and condition. IIIIIIIIIII

Inspect front and rear brake caliper and master cylinder for leaks every 5000 miles (8000 km) or two years.

IIIIIIIIII

Check operation of all electrical equipment & switches. IIIIIIIIIII

Inspect oil lines and brake system for leaks. IIIIIIIIIII

Lubricate front brake hand lever, throttle control cables, clutch control cables (and hand lever), sidestand pivot, and rear brake pedal bushing (if applicable).

IL IL IL IL IL IL IL IL IL IL IL

Check tightness of all critical fasteners: hand controls, brake system, front and rear axles, upper and lower triple clamps, front fork components, engine mounts, stabilizers, rear

TTTTT

shock.

Inspect motorcycle: Check front and rear brake lines, oil lines, front forks, rear shock, exhaust system, exhaust system mounting.

XXXXXXXXXXX

Road test. XXXXXXXXXXX

Chart Codes:

- Inspect, & if necessary correct, clean or replace.

- Lubricate with specified lubricant.

- Replace or change.

- Tighten to proper

- Adjust.

- Perform.

torque.

1-6 2004 Buell Lightning: Maintenance

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CARE OF MOLDED-IN-COLOR BODY PANELS 1.4

GENERAL

Special care and maintenance are required for the molded-incolor body panels that are standard on your Buell motorcycle.

Molded-in-color surfaces look lik e painted surf aces, but are not. The color pigment is mixed in with the material when the part is made , not applied o ver the surf ace. Molded-in-color panels require different maintenance than painted surfaces to maintain their or iginal shine. Using methods that w ork on painted surfaces may ruin the finish of molded-in-color pa ts.

CAUTION

Use of abrasive pr oducts or powered buffing equipment will cause permanent cosmetic dama ge to molded-incolor body panels. Use only the recommended pr oducts and techniques outlined in this section to a void damaging molded-in-color body panels.

CAUTION

Do not use touch-up paint on molded-in-color panels.

Cleaning Between Washings

Untreated molded-in-color body panels sometimes ha ve a static charge that attracts dust. Applying Harley Gloss or Harley Glaze Polish and Sealant to molded-in-color surf aces will eliminate this condition.

To k eep a high gloss finish on molded-in-color panel between washings:

1. Spray Harley Gloss onto surf ace and wipe with a clean soft natural fiber cloth or Ha ley Softcloth.

NOTE

Rain or water will remove Harley Gloss from body panels.

2. Reapply Harley Gloss as descr ibed above to keep surfaces looking their best.

Polishing

Polishing molded-in-color body panels results in g reater surface gloss and a protective coating.

RECOMMENDED PRODUCTS

Products recommended for the proper care and maintenance of molded-in-color body panels are a vailable at y our Buell dealer and are listed below:

Harley Wash (Part No. 99715-90) or Har ley Sun Wash

●

(Part No. 94659-98)

●

Harley Gloss (Part No. 94627-98)

Harley Glaze Polish and Sealant (Part No. 99704-84)

●

Harley Swirl and Scratch Treatment (Part No. 94655-98)

Harley Softcloth (Part No. 94656-98)

●

CARE AND MAINTENANCE

Washing

To wash molded-in-color panels:

1. Rinse surface with water.

1. Apply Harley Glaze Polish and Sealant every six months or as required to k eep molded-in-color panels protected and looking their best.

2. Clean and dry surfaces to be polished (see

3. Apply Harley Glaze Polish and Sealant to clean, slightly dampened cloth or sponge and apply to surf ace with a light overlapping motion. Make sure to cover all areas.

4. Let Harley Glaze Polish and Sealant dr y to a haz e and buff off residue with a clean soft cloth or Harley Softcloth.

Washing

Minor Scratch Removal

To remove minor scratches from body panels:

1. To remove light surf ace scratches and rubs, use Harley Swirl and Scratch Treatment as recommended.

2. Make sure Swirl and Scratch Treatment is applied with a moist cloth and by hand (not by machine).

3. After scratch or r ub has been repaired, polish surf ace lightly with Harley Glaze.

2. Wash with Harley Wash or Harley Sun Wash.

3. Rinse surface thoroughly with water.

4. Dry with a clean chamois or soft dry natural fiber cloth

Major Scratches

There is no repair procedure f or severely scratched surfaces. Severely scratched body panels must be replaced.

2004 Buell Lightning: Maintenance 1-7

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BATTERY MAINTENANCE 1.5

GENERAL

Buell motorcycle batter ies are per manently sealed, maintenance-free, valve-regulated, lead/calcium and sulfur ic acid batteries. The batteries are shipped pre-charged and ready to be put into service. Do not attempt to open these batteries for any reason.

Inspect the batter y for damage or leaks and f or clean, noncorroded connections:

●

At the 1000 mile (1600 km) service interval.

At every scheduled service interval thereafter.

●

1WARNING1WARNING

All batteries contain electr olyte. Electrolyte is a sulfuric acid solution that is highl y corrosive and can cause severe chemical burns. Avoid contact with skin, eyes, and clothing. Avoid spillage. Always wear protective face shield, rubberized gloves and pr otective clothing when working with batteries.

BATTERY TESTING

Voltmeter Test

See Ta bl e 1-3. The voltmeter test provides a general indicator of battery condition. Check the voltage of the battery to verify that it is in a 100% fully charged condition. If the open circuit (disconnected) voltage reading is belo w 12.6V, charge the battery and then recheck the voltage after the battery has set for one to two hours. If the voltage reading is 12.8V or above, perform the load test described under 7.11 BATTERY.

b1142x7x

1WARNING1WARNING

A warning label is attac hed to the top of the batter y. See

Figure 1-1. Never remove warning label from battery. Fail-

ure to read and under stand all precautions contained in warning label before performing any service on batteries could result in death or serious injury.

1WARNING1WARNING

Battery posts, terminals and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and bir th defects or other reproductive harm. Wash hands after handling.

Table 1-2. Battery Electrolyte Antidotes

CONTACT SOLUTION

External Flush with water.

Drink large quantities of milk or water,

Internal

followed by milk of magnesia, vegetable oil or beaten eggs . Call doctor immediately.

Figure 1-1. Battery Warning Label

Table 1-3. Voltmeter Test

BATTERY CHARGE CONDITIONS

12.8 100%

12.6 75%

12.3 50%

12.0 25%

11.8 0%

Eyes

Flush with water, get immediate medical attention.

1-8 2004 Buell Lightning: Maintenance

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1WARNING1WARNING

CAUTION

f1732x8x

BATTERY DISCONNECTION AND REMOVAL

1. Remove seat. See 2.41 SEAT.

1WARNING1WARNING

Always disconnect the negative batter y cable fi st. If the positive cable should contact gr ound with the negative cable installed, the resulting sparks may cause a batter y explosion which could result in death or serious injury.

2. Unthread fastener and remo ve battery negative cable (black) from battery negative (-) terminal.

3. Pull back terminal cover boot.

4. Unthread fastener and remo ve battery positive cable (red) from battery positive (+) terminal.

5. Unhook strap and remove battery.

CLEANING AND INSPECTION

1. Battery top must be clean and dry. Dirt and electrolyte on top of the batter y can cause batter y to self-discharge . Clean battery top with a solution of baking soda (sodium bicarbonate) and w ater (5 teaspoons baking soda per quart or liter of water). When the solution stops bubbling, rinse off the battery with clean water.

2. Clean cable connectors and batter y terminals using a wire brush or sandpaper. Remove any oxidation.

3. Inspect the battery screws, clamps and cables for breakage, loose connections and corrosion. Clean clamps.

4. Check the batter y posts for melting or damage caused by overtightening.

5. Inspect the batter y for discoloration, raised top or a warped or distor ted case, which might indicate that the battery has been frozen, overheated or overcharged.

6. Inspect the battery case for cracks or leaks.]

STORAGE

Always store batteries where they cannot be reac hed by children. Contact with the batter y’s sulfuric acid could result in death or serious injury.

The electrolyte in a disc harged battery will freez e if exposed to freezing temperatures. Freezing ma y crack the battery case and buckle battery plates.

If the motorcycle will not be oper ated for several months, such as dur ing the winter season, remo ve the batter y from the motorcycle and fully charge. See 7.11 BATTERY.

See Figure 1-2. Self-discharge is a normal condition and occurs continuously at a rate that depends on the ambient temper ature and the battery’s state of charge . Batteries discharge at a faster rate at higher ambient temper atures. To reduce the self-discharge rate, store battery in a cool (not freezing), dry place.

Charge the batter y every month if stored at temper atures below 60° F. (16° C). Charge the batter y more frequently if stored in a warm area above 60° F. (16° C).

NOTE The H-D Battery Tender Automatic Battery Charger (Part No. 99863-93TA) may be used to maintain battery charge for extended periods of time without risk of overcharging or boiling.

When returning a battery to service after storage, fully charge the battery. See 7.11 BATTERY.

Effect of Temperature on

Battery Self-Discharge Rate

100%

C A

75%

50%

P A C

I T Y

at 105°F

MONTHS OF STAND

3691215

at 77

Figure 1-2. Battery Self-Discharge Rate

2004 Buell Lightning: Maintenance 1-9

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BATTERY INSTALLATION AND CONNECTION

1. Place the fully charged batter y in the mounting position, terminal side to the rear of motorcycle.

2. Hook rubber strap around body of battery.

CAUTION

Connect the cab les to the correct batter y terminals or damage to the motorcycle electrical system will occur.

1WARNING1WARNING

Always connect the positive battery cable fi st. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion which could result in death or serious injury.

CAUTION

Overtightening fasteners can damage battery terminals.

3. Insert fastener through batter y positive cable (red) into threaded hole of battery positive (+) terminal and tighten fastener to 72-96

4. Install terminal cover boot.

5. Insert fastener through battery negative cable (black) into threaded hole of battery negative (-) terminal and tighten fastener to 72-96

6. Apply a light coat of petroleum jelly or corrosion retardant material to both battery terminals.

in-lbs

(8-11 Nm).

1WARNING1WARNING

After installing seat, pull upwar d on front of seat to be sure it is locked in position. If seat is loose, it could shift during vehicle operation and star tle the rider , causing loss of contr ol which could result in death or serious injury.

7. Install seat. See 2.41 SEAT.

1-10 2004 Buell Lightning: Maintenance

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8374

Operating Range

8352

ENGINE LUBRICATION SYSTEM 1.6

GENERAL

Check engine oil level (hot check) at every refueling stop.

Inspect oil lines and filter or leaks:

At 1000 mi (1600 km) initial ser vice and every 5000 mi

●

(8000 km) service interval.

Change engine oil and filter under in warm or moderate temperatures:

●

At 1000 mi (1600 km) initial ser vice and every 2500 mi (4000 km) interval thereafter.

●

When storing or removing the motorcycle for the season.

Change engine oil and filter under in warm or moder ate temperatures (severe dust, temper atures above 80oF/27oC, extensive idling or speeds in e xcess of 65 mph/105 km/h):

●

At 1000 mi (1600 km) initial ser vice and every 5000 mi (8000 km) service interval thereafter.

●

When storing or removing the motorcycle for the season.

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.

NOTE

normal service

severe service

conditions

CAUTION

Do not switch oil brands indiscriminately because some oils interact c hemically when mixed. Use of inf erior oils or non-detergent oils can damage the engine.

Ride motorcycle f or approximately 10 min utes to ensure the oil is hot and the engine is at normal operating temperature.

1. The motorcycle m ust be on le vel ground, on the sidestand, with the engine off.

CHECKING ENGINE OIL LEVEL

An accurate engine oil le vel reading can only be obtained with the engine at nor mal operating temperature (hot check). The engine will require a longer w arm up per iod in colder temperatures.

For pre-ride inspection, simply v erify that there are no oil leaks from the oil filter and oil lines p ior to oper ating the motorcycle.

● Perform a hot chec k of the engine oil le vel at each fuel

stop.

Do not allow hot oil level to fall below lower mark on dipstick. To do so ma y result in equipment dama ge and/or malfunction.

Do not o verfill oil tank. Overfilling oil tank m y result in oil carryover to the air cleaner, equipment damage and/or equipment malfunction.

CAUTION

Figure 1-3. Dipstick Location/Engine Oil Level

2. See Figure 1-3. Unscrew and remo ve dipstick from oil tank/swingarm filler hol . Wipe dipstick clean.

3. Insert dipstick into oil tank filler hol , screwing dipstick in completely. DO NOT OVER TIGHTEN.

NOTE

The area between the upper and lower registration marks is the operating range.

4. See Figure 1-5. Unscrew and remo ve dipstick and note oil level.

a. Oil level should be within the oper ating range

(between upper and lo wer registration marks) on dipstick.

b. If oil level is below lower registration mark, add only

enough oil to bring oil level between lower and upper registration marks.

2004 Buell Lightning: Maintenance 1-11

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CHANGING ENGINE OIL AND FILTER

Ride motorcycle f or approximately 10 min utes to ensure the oil is hot and the engine is at nor mal operating temperature. Tu rn engine off.

NOTE

Secure rear wheel on lift or place scissor jack under jacking point.

Draining Oil

1. See Figure 1-4. Place a suitab le container under the drain plug.

8375

Changing Filter

1. Remove chin fairing See 2.34 CHIN FAIRING.

8418

Figure 1-6. Oil Filter

2. See Figure 1-6. Remove oil filter using pliers or belt typ OIL FILTER WRENCH.

3. Clean filter gas et contact surface on crankcase. Surface should be smooth and free of an y debris or old gask et material.

4. Apply a thin film of clean engine oil to filter ga et.

5. Pour 4.0 ounces (0.12 liter) of clean engine oil into new fil ter when changing oil (until filter is appr ximately 1/2 full).

6. Screw filter onto adapter until filter ga et touches crankcase surface. Rotate filter another 1/2-3/4 tu n by hand.

Figure 1-4. Oil Tank Drain Plug

2. Using a 5/8 in. wrench, remove drain plug from under oil tank/swingarm. Wipe any accumulated debris from magnetic tip on drain plug.

8352

1WARNING1WARNING

Be sure no oil g ets on tires when changing oil and filte . Traction will be adversely affected which may lead to loss of control which could result in death or serious injury.

Figure 1-5. Dipstick Location

3. See Figure 1-5. Unscrew and remove dipstick from oil fil hole on top of oil tank/swingarm.

1-12 2004 Buell Lightning: Maintenance

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Replacing Oil

1. Inspect drain plug o-ring for tears or damage. Replace if required. Wipe any foreign material from drain plug.

2. Install drain plug and tighten to 29-31 ft-lbs (40-42 Nm).

3. Fill oil tank through filler (dipsti k) hole with recommended oil from Ta ble 1-4. Oil tank capacity with filte change is appro ximately 2.5 quar ts (2.4 liters) and includes the 4.0 ounces (0.12 liter) poured into the filte . Always verify proper hot oil level on dipstick. Do not overfill

4. Inspect o-ring on dipstic k for rips or tears . Replace as required.

NOTE For ease of installation, apply a light ﬁlm of clean engine oil to the dipstick o-ring.

5. Install dipstick into oil tank/swingarm fill hol . Make sure

dipstick is installed completely . DO NO T OVER TIGHTEN.

Table 1-4. Recommended Oil Grades

6. Remove left side oil cooler scoop . See 2.36 AIR

SCOOPS.

7. Inspect oil cooler fins or debris or damage. Blow out any debris from fins with compressed air from the inside o the cooler outward.

8. Wipe up any spilled oil on muffle .

9. Start engine. Verify that oil pressure signal light on instrument support turns off after a few seconds when engine speed is 1000 RPM or above.

10. Check for oil leaks at oil filte , drain plug, hoses and oil cooler.

11. Install chin spoiler. See 2.34 CHIN FAIRING.

12. Install air scoop 2.36 AIR SCOOPS.

13. Check (hot) oil le vel. See CHECKING ENGINE OIL

LEVEL.

HARLEY-DAVIDSON TYPE VISCOSITY

HARLEY-DAVIDSON

RATING

LOWEST AMBIENT TEMP

°F

COLD WEATHER

STARTS BELOW

50° F

H.D. Multi-Grade SAE 10W40 HD 360 Below 40° (4°C) Excellent

H.D. Multi-Grade SAE 20W50 HD 360 Above 40

H.D. Regular Heavy SAE 50 HD 360 Above 60

H.D. Extra Heavy SAE 60 HD 360 Above 80

(4°C) Good

(16°C) Poor

(27°C) Poor

2004 Buell Lightning: Maintenance 1-13

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BRAKE SYSTEM MAINTENANCE 1.7

GENERAL

Check brake fluid l vel and condition:

● When storing or removing the motorcycle for the season:

Replace D.O.T. 4 BRAKE FLUID.

● Every 2 years:

Front brake hand lever and rear brake foot pedal must have a fi m feel when br akes are applied. If not, b leed system as described.

Inspect front and rear brake lines and replace as required.

● Every 4 years:

Inspect caliper and master cylinder seals and replace as required.

● Every 2 years:

If determining probable causes of poor brake operation, refer to Ta bl e 1-5.

BLEEDING BRAKES

1WARNING1WARNING

D.O.T. 4 brake fluid can cause irritation of yes and skin, and may be harmful if s wallowed. If a lar ge amount of 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 plent of water. Get medical attention f or eyes. KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN. Failure to comply could result in death or serious injury.

1WARNING1WARNING

Never mix D.O.T. 4 with other brake fluids (su h as D.O.T.

5). Use only D.O.T. 4 brake fluid in moto cycles that specify D.O.T. 4 fluid on the rese voir cap. Mixing diff erent types of fluid m y adversely affect braking ability and lead to brake failure whic h could result in death or serious injury.

1WARNING1WARNING

Use only fresh, uncontaminated D .O.T. 4 fluid Cans of fluid that ha ve been opened ma y have been contaminated by moisture in the air or dir t. Use of contaminated brake fluid m y adversely affect braking ability and lead to brake failure whic h could result in death or serious injury

1WARNING1WARNING

Use only copper crush banjo washers (See Parts Catalog for Part No.) with D.O.T. 4 brake fluid Earlier silver banjo washers are not compatib le with D .O.T. 4 fluid and wil not seal pr operly over time. Failure to compl y may adversely affect braking ability and lead to brake failure which could result in death or serious injury.

1WARNING1WARNING

Clean brake system components using denatured alcohol. Do not use mineral-base c leaning solvents, such as gasoline or paint thinner . Use of mineral-base solvents causes deterioration of rubber par ts that continues after assembly. This may result in impr oper brake operation which could result in death or serious injury.

1WARNING1WARNING

Always test motorcycle brakes at low speed after servicing or b leeding system. To prevent death or serious injury, Buell recommends that all brake repair s be per formed by a Buell dealer or other qualified te hnician.

CAUTION

Cover molded-in-color surfaces and right handlebar switches and use care when remo ving brake reser voir cover and ad ding D.O.T. 4 brake fluid Spilling D .O.T. 4 brake fluid on molded-in-color surfaces will result in cos metic damage. Spilling brake fluid on witches may render them inoperative.

1-14 2004 Buell Lightning: Maintenance

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Table 1-5. Brake Troubleshooting

CONDITION CHECK FOR REMEDY

Excessive lever/pedal travel or spongy feel.

Brake fade Moisture in system. Bleed brake(s).

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.

Worn D shape bushings

Loose mounting bolts.

Warped rotor.

Low fluid l vel.

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 fluid in master cylinder with approved brake fluid

Replace brake pads.

Replace rotor and bushings as set.

Tighten bolts.

Replace rotor and bushings as set.

Fill master cylinder with approved brake fluid, and leed system.

Rebuild cylinder.

Replace rotor and bushings as set.

Replace pads.

Inspect master cylinder.

Adjust linkage.

2004 Buell Lightning: Maintenance 1-15

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Bleeding Front Brake

NOTE

Hydraulic brake ﬂuid bladder-type pressure equipment can be used to ﬁll the brake master cylinder through the bleeder valve if master cylinder reservoir cover is removed to prevent pressurization.

1. See Figure 1-7. With motorcycle in upr ight position, install end of plastic tubing o ver front caliper b leeder valve; place other end in a clean container.

CAUTION

2. Cover body surf aces, right handlebar s witches and instrument panel to protect from spillage.

8346

Figure 1-7. Front Caliper Bleeder Valve

8359

3. See Figure 1-8. Remove two fasteners from front master cylinder cover.

4. Add D.O.T. 4 BRAKE FLUID to master cylinder reser- voir. Bring fluid l vel to within 1/8 in. (3.2 mm) of molded boss inside front master cylinder.

NOTE

Do not reuse brake ﬂuid.

5. Slowly depress and release hand le ver several times to build up hydraulic pressure, then hold brake hand lever in the depressed position.

6. While holding br ake hand le ver in the depressed position, open bleeder valve about 1/2-turn counterclockwise. Brake fluid will f w from bleeder valve and through tubing into clean container. When brake lever has moved 1/2 to 3/4 of its full range of travel, close bleeder valve (clockwise). Allow brake lever to retur n slowly to its released position.

7. Repeat steps 5-6 until all air bubbles are purged.

8. Tighten front caliper b leeder valve (metric) to 36-60 in-

lbs (4-7 Nm).

Figure 1-8. Front Master Cylinder Reservoir

9. Verify master cylinder fluid l vel as described in step 4.

10. Attach cover to front master cylinder reser voir and tighten fastener to 9-13 in-lbs (1.0-1.5 Nm).

11. Remove cover from molded-in-color surfaces, right handlebar switches and instrument panel.

1-16 2004 Buell Lightning: Maintenance

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9956

Bleeding Rear Brake

NOTE Hydraulic brake ﬂuid bladder-type pressure equipment can be used to ﬁll the brake master cylinder through the bleeder valve if master cylinder reservoir cover is removed to prevent pressurization.

8348

Figure 1-10. Rear Master Cylinder Reservoir

2. See Figure 1-10. Remove cap and gasket from rear master cylinder reservoir.

3. Add D.O.T. 4 BRAKE FLUID to master cylinder reservoir with motorcycle upr ight (not on sidestand). Bring flui level between upper and lower marks on reservoir.

Figure 1-9. Rear Caliper Bleeder Valve

1. See Figure 1-9. With motorcycle in upr ight position, install end of plastic tubing o ver rear caliper b leeder valve; place other end in a clean container.

CAUTION

Cover molded-in-color surfaces and use care when removing brake reser voir cover and ad ding D.O.T. 4 brake fluid Spilling D .O.T. 4 brake fluid on molded-in color surfaces will result in cosmetic damage.

NOTE

Do not reuse brake ﬂuid.

4. Slowly depress and release brake pedal several times to build up hydraulic pressure, then hold brake pedal in the depressed position.

5. While holding br ake pedal in the depressed position, open bleeder valve about 1/2-tur n counterclockwise. Brake fluid will f w from bleeder valve and through tubing into clean container. When brake pedal has moved 1/2 to 3/4 of its full r ange of tr avel, close b leeder valve (clockwise). Allow brake pedal to retur n slowly to its released position.

6. Repeat steps 5-6 until all air bubbles are purged.

7. Tighten rear caliper b leeder valves (metric) to 36-60 in- lbs (4-7 Nm).

8. Verify master cylinder fluid l vel as described in step 3.

9. Install cover on master cylinder reservoir and tighten cap securely.

2004 Buell Lightning: Maintenance 1-17

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BRAKE PEDAL ADJUSTMENT

1WARNING1WARNING

After completing repair s or bleeding the system, always test motorcycle brakes at lo w speed. If brakes are not operating properly or braking efficien y is poor , testing at high speeds could result in death or serious injur y. (289)

Before every ride, check rear brake pedal operation.

NOTES

● See Figure 1-11. On the very end of the threaded brake

rod, are two ﬂat sides (2). To ensure proper thread engagement with the clevis (3), the ﬂat sides must extend below the extruded nut (1) in the clevis by at least one full thread. This is the minimum rod engagement.

● Also, there should be a minimum of 0.030 in. (0.8 mm)

between brake rod end and brake pedal.

1WARNING1WARNING

Threaded rod should not be adjusted to the point of contacting brake pedal. Improper adjustment could result in death or serious injury.

b0615x1x

Minimum

Engagement

1. See Figure 1-12. Inspect for minimum and maxim um brake rod engagement in br ake clevis (4). Adjust as required.

2. Adjust brake pedal.

a. See Figure 1-12. Loosen locknut (3) while holding

rod adjuster (2). Move locknut away from top surface of clevis (4).

b. Tu rn rod adjuster to set pedal height.

c. Return locknut (3) to fit flush against top su ace of

clevis and tighten to 130-173.5 in-lbs (14.7-19.6 Nm).

NOTE

Brake pedal has no free play adjustment.

1. Extruded nut

2. Flat sides (on the end of the threaded brake rod)

3. Clevis

Figure 1-11. Critical Measurements with Typical

Brake Pedal

8349

1-18 2004 Buell Lightning: Maintenance

1. Bottom of master cylinder

2. Rod adjuster

3. Locknut

4. Clevis

5. Clevis pin

Figure 1-12. Rear Brake Pedal Pushrod Adjustment

Page 67

HOME

7082

1. Friction material

2. Wear groove

3. Backing material

8347

BRAKE PAD THICKNESS

1WARNING1WARNING

Always replace brake pads in complete sets f or correct brake operation. Never replace just one brake pad. Failure to install brake pads as a set could result in death or serious injury. (111)

See Figure 1-13. Inspect brake pads for damage or excessive wear. Replace both pads as a set if fr iction material of either pad is w orn to 0.040 in. (1.0 mm) or less . If this amount of wear occurs, wear grooves will disappear from fr iction material surface.

BRAKE ROTOR THICKNESS

1WARNING1WARNING

Do not allow brake fluid bearing grease, lubricants, etc. to contact brake r otor when ser vicing motorcycle or reduced braking ability will occur , which could result in death or serious injury.

See Figure 1-14. Check brake rotors for minimum thickness:

● At the 1000 mile (1600 km) service interval.

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

● At every scheduled service interval:

1. Measure rotor thickness. Replace rotor if minimum thickness is less than 0.18 in. (4.5 mm). Replace drive bushings, fasteners, washers and spr ings whenever rotor is replaced.

2. Check rotor surface. Replace if warped or badly scored. See 2.5 FRONT WHEEL or 2.6 REAR WHEEL for proce- dure.

Figure 1-13. Brake Pad Thickness

Figure 1-14. Front Brake Rotor

2004 Buell Lightning: Maintenance 1-19

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BRAKE PAD REPLACEMENT

Front Pad Removal

1. See Figure 1-15. Loosen pin hanger (2) b ut do not remove.

2. Rotate wheels so that caliper is centered betw een rotor mounting fasteners (1).

3. Remove lower caliper mounting fastener (4) that secures caliper to fork lower.

4. Loosen but do not remo ve upper caliper mounting f astener (3) that secures caliper to fork lower.

5. Remove pin hanger (2).

6. Rotate caliper counterclockwise to allow access to outer pad.

7. Remove outer pad from right side.

8. Remove inner pad from left side b y pulling rearw ard, rotating pad 90 degrees and pulling through wheel opening.

Front Pad Installation

1. Push pistons in with suitab le tool such as a clean paint scraper until fully seated in bores. Be careful not to damage rotor.

2. Install new inner pad from left side of motorcycle.

3. Install new outer pad from right side of motorcycle.

4. See Figure 1-15. Install pin (2) making sure it engages hole on both pads and spring clip.

5. Rotate caliper clockwise to align mounting fastener hole.

6. See Figure 1-15. Install lower caliper mounting fastener (4).

7. Tighten both caliper mounting fasteners (3, 4) to 35-37 ftlbs (48-50 Nm).

8. Tighten pin (2) to 11-14 ft-lbs (15-19 Nm).

NOTE Avoid making hard stops for the ﬁrst 100 miles (160 km) to allow new brake pads to “wear in” properly with the rotor.

8346

1. Rotor mounting fastener (6)

2. Front caliper pin hanger

3. Upper caliper mounting fastener

4. Lower caliper mounting fastener

Figure 1-15. Front Brake Caliper

1-20 2004 Buell Lightning: Maintenance

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8348

1. Rear caliper mounting fasteners

2. Retainer,

3. Rear caliper pin plug

4. Rear caliper hanger pin

b1143x1x

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Rear Pad Removal

1. See Figure 1-16. Remove rear caliper pin plug (3) and loosen pin (4).

2. Remove fastener securing p-clamp, wire form and brake line assembly to swingarm.

3. Remove two mounting fasteners (1) securing brake caliper and carrier assembly to swingarm.

4. Lift caliper and carrier assembly up and off of rotor.

5. Remove hanger pin (4).

6. Remove inner and outer pads , being careful not to dislodge pad spring.

Rear Pad Installation

1. See Figure 1-16. Check that retainer (2) is present.

2. See Figure 1-17. Check that pad spr ing is present. Should pad spring become dislodged, install with widest area of spring towards piston side of caliper.

3. Push piston in with suitab le tool such as a clean paint scraper until fully seated in bore.

4. Install new inner and outer brake pads

5. See Figure 1-16. Install hanger pin (4) making sure pin engages hole on both pads.

6. Install brake caliper and carrier assembly over rotor.

7. Install two mounting fasteners (1) through swingarm into carrier and tighten to 35-37 ft-lbs (48-50 Nm).

8. Apply LOCKTITE 272 and tighten hanger pin to 11-14 ftlbs (14.9-18.9 Nm).

9. Install pin plug (3). Tighten plug to 18-25 in-lbs (2- 3 Nm).

10. Install fastener securing p-clamp, wire f orm and br ake line assembly to s wingarm and tighten to 36-60 in-lbs (4.1-6.8 Nm).

Avoid making hard stops for the ﬁrst 100 miles (160 km) to allow new brake pads to “wear in” properly with the rotor.

NOTE

Figure 1-16. Rear Brake Caliper

Figure 1-17. Rear Brake Pad Spring

2004 Buell Lightning: Maintenance 1-21

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TIRES AND WHEELS 1.8

TIRE INFLATION

1WARNING1WARNING

Do not inflate a y tire beyond its maximum inflation pres sure as specified on tire sid wall. Overinflation m y cause tire to suddenly deflate whi h could result in death or serious injury.

Check tire pressure and tread:

● Before every ride.

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

Table 1-6. Tire Pressures

TIRE

Front 36 PSI 248 kPa

Rear 38 PSI 262 kPa

PRESSURE FOR

SOLO RIDING

PRESSURE AT

GVWR

Same as solo riding

o0248xox

Wear indicator bar

o0247xox

Wear indicator sidewall arrow

Figure 1-18. Tire Wear Indicator

TIRE REPLACEMENT

See Figure 1-18. Treadwear indicator bars will appear on tire tread surfaces when 1/32 in. (0.8 mm) or less of tire tread remains. Arrows on tire side walls pinpoint location of w ear bar indicators. Always remove tires from ser vice before they reach the treadw ear indicator bars (1/32 in. [0.8 mm] tread pattern depth remaining).

New tires are needed if any of the following conditions exist.

1. Tire wear indicator bars become visible on the tread surfaces.

2. Tire cords or fabric become visible through cracked sidewalls, snags or deep cuts.

3. A bump, bulge or split in the tire.

4. Puncture, cut or other damage to the tire that cannot be repaired.

WHEEL BEARINGS

1WARNING1WARNING

Never use compressed air to “spin-dry” bearings. Very high bearing speeds can dama ge unlubricated bearings. Spinning bearings with compressed air can also cause a bearing to fly apa t, which could result in death or serious injury.

Check front and rear wheel bearings for wear:

● Every time a wheel is removed.

● When storing or removing the motorcycle for the season.

Check wheel bearings for wear and corrosion. Excessive play or roughness indicates w orn bearings. Replace bear ings in sets only.

1-22 2004 Buell Lightning: Maintenance

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8376

b1144x1x

1. Clutch diaphragm spring

2. Clutch adjusting screw

3. Primary cover

4. Correct chaincase lubricant level

CLUTCH 1.9

TRANSMISSION FLUID

Tr ansmission fluid capacity is appr ximately 1.0 quart (0.95 liter). For best results, drain fluid while hot

1. On level surface, stand v ehicle upright (not leaning on sidestand) to pre vent chaincase lubr icant from dr aining out of clutch cover opening when refilled

2. See Figure 1-20. Position a suitab le container under drain plug. Remove plug and drain fluid

3. Wipe any foreign material from the magnetic dr ain plug and apply Loctite 592 Thread Sealant. Reinstall plug and tighten to 11-15 ft-lbs (14.9-20.3 Nm).

4. Remove three fasteners and washers from clutch inspection cover. Remove clutch inspection co ver with gask et from primary cover.

CAUTION

Do not o verfill the transmission with fluid Overfillin may cause rough clutch engagement and incomplete disengagement, clutch drag and/or difficulty finding neutr at engine idle.

Figure 1-19. Clutch Inspection Cover

5. See Figure 1-21. Add SPORT-TRANS FLUID (Part No. 99896-88 quart size; Part No. 99895-88 gallon siz e) as required until fluid l vel (3) is e ven with bottom of clutch diaphragm spring (2).

NOTE Each time the clutch inspection cover is removed the gasket must be replaced.

6. Install new clutch cover gasket.

7. See Figure 1-19. Install clutch inspection co ver tighten-

ing three f asteners and w ashers to 84-108 in-lbs (10- 12 Nm).

8. Clean up any fluid that m y have spilled on muffle .

Figure 1-20. Primary Drain Plug

Figure 1-21. Fluid Level

2004 Buell Lightning: Maintenance 1-23

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ADJUSTMENT

If clutch slips under load or dr ags when released, first che k control cable adjustment. If cable adjustment is within specifi cations, 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 wheel off floor using REAR WHEEL SUPPORT STAND (Part No. B-41174).

2. See Figure 1-22. Slide rubber boot (1) upward to expose adjuster mechanism. Loosen jam n ut (3) from adjuster (4). Turn adjuster to shorten cable housing until there is a large amount of free play at clutch hand lever.

3. See Figure 1-19. Remove three f asteners and washers from clutch inspection co ver. Remove clutch inspection cover and gasket from primary cover.

4. See Figure 1-23. Remove spring (1) and loc kplate (2). Using a flat tip scr wdriver, turn adjusting scre w (3) counterclockwise until it lightly bottoms.

5. Turn adjusting screw clockwise 1/4-1/2 turn. Install loc kplate and spring on adjusting scre w flat . If hex on lockplate does not align with recess in outer r amp, rotate adjusting screw clockwise until it aligns.

NOTE

Spring installs on outboard side of hex lockplate.

1. Rubber boot

2. Cable end

3. Jam nut

4. Adjuster

8411

Figure 1-22. Clutch Cable Adjuster Mechanism

8405

1. Diaphragm spring

2. Lockplate

3. Adjusting screw

Figure 1-23. Clutch Adjustment

1-24 2004 Buell Lightning: Maintenance

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b0289x6x

Bracket

Ferrule

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

6. Squeeze clutch hand lever to maximum limit three times. This sets the ball and r amp mechanism. Pull outer cable conduit and at the same time adjust cab le adjuster to provide 1/16-1/8 in. (1.6-3.2 mm) free play at clutch hand lever. Adjust as follows:

a. See Figure 1-24. Pull ferrule (end of cable housing)

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

b. See Figure 1-22. Set free pla y by turning 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 necessa y.

NOTE Each time the clutch inspection cover is removed the gasket must be replaced.

8. See Figure 1-19. Install clutch inspection cover and new

gasket using three fasteners and washers and tighten to 84-108 in-lbs (10-12 Nm).

9. Check clutch cable free play. See Step 6 above.

Figure 1-24. Adjusting Clutch Free Play

2004 Buell Lightning: Maintenance 1-25

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DRIVE BELT 1.10

GENERAL

The drive belt tension on a ne w belt will be considerably tight and will loosen after appro ximately 1000 miles (1600 km). The drive belt tension is automatically maintained by the idler pulley. Axle alignment is not adjustable.

Replace drive belt and idler pulley assembly:

● At every 25,000 mile (40,000 km) service interval.

INSPECTION

Rear Sprocket

NOTE If chrome chips or gouges to rear sprocket are large enough to be harmful, they will leave a pattern on the belt face.

1. Inspect each tooth of rear sprocket for:

a. Major tooth damage.

b. Large chrome chips with sharp edges.

c. Gouges caused by hard objects.

d. Excessive loss of chrome plating (see Step 2).

2. To check if chrome plating has w orn off, drag a scribe or

sharp knife point across the bottom of a g roove (2) (between two teeth) with medium pressure.

a. If scribe or knife point slides across g roove without

digging in or lea ving a visible mark, chrome plating is still good.

b. If scribe or knif e point digs in and lea ves a visib le

mark, it is cutting the bare alumin um. A knife point will not penetrate the chrome plating.

3. Replace rear sproc ket if major tooth damage or loss of

chrome exists.

Drive Belt

Refer toTa ble 1-7. Inspect drive belt for:

● Cuts or unusual wear patterns on both sides of belt.

● Outside edge be velling (8). Some bevelling is common,

but it indicates that sprockets are misaligned.

● Outside surface for signs of stone puncture (7). If cracks/

damage exists near edge of belt, replace belt immediately. Damage to center of belt will require belt replacement eventually, but when cracks extend to edge of belt, belt failure is imminent.

● Inside (toothed portion) of belt for exposed tensile cords

(normally covered by nylon layer and polyethylene layer). This condition will result in belt failure and indicates worn transmission sprocket teeth. Replace belt and tr ansmission sprocket.

● Signs of puncture or cr acking at the base of the belt

teeth. Replace belt if either condition exists.

Idler Pulley

See Figure 1-25. Inspect idler pulley for signs of uneven wear. Excessive lateral side play of 0.020 in. (0.5 mm) or roughness indicates worn bearings. Replace idler pulley as an assembly. See 6.6 DRIVE BELT SYSTEM.

10124

1-26 2004 Buell Lightning: Maintenance

Figure 1-25. Checking Lateral Side Play on Idler Pulley

with a Dial Indicator

CLEANING

Keep dirt, grease, oil, and debr is off the belt, idler pulle y and sprockets. Clean the dr ive belt with a mild soap and w ater spray solution as required. Dry thoroughly. Do not immerse belt in solution.

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Table 1-7. Potential Limits to Belt Drive Service Life

CONDITION ROOT CAUSE REQUIRED ACTION

Misalignment or bent drive structure Check structure (bad bearing, bent members, etc.)

Bent or rough flang Repair flange/replace spro ket

Damage due to handling (pry on, etc.) Follow proper handling/installation procedure

Inspect/replace belt

Inspect for damaged or missing guards

Check structure (bad bearing, bent members, etc.)

Inspect for loose/missing fasteners

Inspect for damaged or missing guards

Replace idler assembly

Inspect for loose/missing fasteners

Check structure (bad bearing, bent members, etc.)

Inspect for loose/missing fasteners

Inspect for damaged or missing guards

Clean and protect drive

Inspect for damaged or missing guards

Eliminate or control exposure

Inspect for damaged or missing guards

Clean and protect drive

Inspect for damaged or missing guards

Eliminate or control exposure

Clean and protect drive

Eliminate or control exposure

Clean and protect drive

Inspect/replace sprocket

Continue to run but monitor condition frequently

Inspect/replace sprocket

Inspect/replace belt

Excessive Edge Wear (mistracking)

Excessive tooth wear

Apparent belt stretch

Cracks in back of belt

Debris damage to edge of belt

Belt hitting obstruction

Bent or loose idler bracket

Broken or loose guards

Rough or damaged sprocket Inspect/replace sprocket

Worn sprocket Inspect/replace sprocket

Debris in sprocket

Abrasive environment

Worn sprocket Inspect/replace sprocket

Debris in sprocket

Idler bearing failure Replace idler assembly

Aggressive riding/hard use Riding practice/operator choice

Exposure to oils, solvents, harsh chemicals

Idler/bearing binding Replace idler assembly

Exposure to oils, solvents, harsh chemicals

Cut by sharp debris (not at belt edge)

Cut by sharp debris at belt edge

2004 Buell Lightning: Maintenance 1-27

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Table 1-7. Potential Limits to Belt Drive Service Life

CONDITION ROOT CAUSE REQUIRED ACTION

To oth shear/cracks

Belt breakage

Excessive drive noise

Excessive load/shock load

Worn sprocket Inspect/replace sprocket

Debris damage

Excessive load/Shock load

Damage due to handling (pry-on, etc.) Follow proper handling/installation procedure

Debris in sprocket or belt

Worn/damaged sprocket Inspect/replace sprocket

Damaged flang Repair flange/replace spro ket

Damaged idler

Damaged belt

Debris stuck in belt

Debris stuck in sprocket

Inspect/replace belt

Riding practice/operator choice

Inspect/replace sprocket

Clean and protect drive

Inspect/replace belt

Continue to run but monitor condition frequently

Inspect for damaged or missing guards

Inspect/replace belt

Riding practice/operator choice

Inspect/replace sprocket

Clean and protect drive

Inspect/replace belt

Check structure (bad bearing, bent members, etc.)

Replace idler assembly

Follow proper handling/installation procedure

Inspect/replace belt

Inspect/replace sprocket

Clean and protect drive

Inspect/replace belt

Inspect/replace sprocket

Follow proper handling/installation procedure

Inspect/replace belt

1-28 2004 Buell Lightning: Maintenance

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PRIMARY CHAIN 1.11

INSPECTION

See Figure 1-26. Measure primary chain tension through the inspection cover opening. Adjust primary chains not meeting vertical free play specification .

1. See Figure 1-26. Remove two fasteners with captiv e washers and primary chain inspection cover with gasket from primary cover.

2. See Figure 1-27. Check primary chain tension b y measuring vertical free play.

a. Measure vertical free play through chain inspection

cover opening.

b. Rotate engine to mo ve primary chain to a diff erent

position on sprockets.

c. Measure vertical free pla y several times, each time

with primary chain moved so that the measurement is taken with sprockets rotated to the tightest chain position.

3. The tightest measurement taken in Step 2 must be within the specifications listed in Ta bl e 1-8. If necessary, adjust as described under 1.11 PRIMARY CHAIN in ADJUST-

MENT.

Figure 1-26. Primary Chain Inspection Cover

NOTE

The initial primary chain vertical free play speciﬁcation used at the assembly plant is 1/4-1/2 in. (6.4-12.7 mm) with a cold engine. The 1/4 in. (6.4 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. (6.4 mm) vertical free play (with a cold engine), adjust free play to the “ﬁeld” speciﬁcation of 3/8-1/2 in. (9.5-12.7 mm). The looser speciﬁcation will avoid ov ertightening, which might otherwise occur during adjustment using “non-factory” equipment and methods.

4. See Figure 1-26. Install primary chain inspection co ver and

new

gasket to pr imary cover using tw o fasteners with captive washers. Tighten fasteners to 40-60 (5-7 Nm).

in-lbs

Figure 1-27. Measuring Primary Chain Free Play

Table 1-8. Primary Chain Free Play

ENGINE

TEMPERATURE

Cold 3/8-1/2 9.5-12.7

Hot (normal running temperature)

in. mm

1/4-3/8 6.4-9.5

2004 Buell Lightning: Maintenance 1-29

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ADJUSTMENT

NOTE If vertical free play cannot be set within the limits speciﬁed, then primary chain and/or chain adjuster are worn beyond adjustment limits. Replace parts as necessary. See 6.5 PRI-

MARY CHAIN.

1. See Figure 1-28. Loosen locknut (1).

2. Turn adjusting fastener (2):

a. Clockwise (inward) to reduce free play.

b. Counterclockwise (outward) to increase free play.

3. Tighten locknut (1) to 20-25 ft-lbs (27-34 Nm).

8403

1. Locknut

2. Adjusting Fastener

Figure 1-28. Chain Tension Adjusting Fastener

1-30 2004 Buell Lightning: Maintenance

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SUSPENSION DAMPING ADJUSTMENTS 1.12

GENERAL

1WARNING1WARNING

Before evaluating and adjusting suspension settings, check the motorcycle’s tires. Tires must be in good condition and pr operly inflated Failure to c heck the tires could result in death or serious injury.

ments. Adjusting more than one or tw o clicks at a time ma y cause you to skip the best adjustment. Test ride after each adjustment. When an adjustment makes no difference, return to the previous adjustment and try a different approach.

Table 1-9. Recommended Suspension Settings for Rider Weight (XB9S, XB12S)

RIDER AND CARGO

WEIGHT

PRELOAD

LB. KG

Less than 130 59 7 2 1.75 1 2.50 2

130-150 59-68 6.5 1.75 1.75 2 2.25 1.75

# OF

LINES

FRONT FORK REAR SHOCK

*COMPRESSION *REBOUND

If both preload adjustments are correct, and y ou have the rebound and compression damping set at the f actory recommended points, the motorcycle should handle and r ide properly. If y ou wish to fine tune these settings th y can be changed according to the following procedures.

NOTE

Evaluating and changing the rebound and compression damping is a very subjective process. Many variables affect motorcycle handling under different circumstances. Approach all changes carefully and consult Table 1-9.

PRELOAD POSITION

*COMPRESSION *REBOUND

150-170 68-77 6 1.50 1.625 3 2 1.50

170-190 77-86 5.5 1.50 1.50 4 1.75 1.50

190-210 86-95 5 1.25 1.50 5 1.50 1.25

210-230 95-104 4.5 1.25 1.50 6 1.25 1

230-GVWR 104-GVWR 4 1 1.25 7 1.25 1

* Note all compression and rebound settings are number of turns out from maximum.

Table 1-10. Recommended Suspension Settings For Rider Weight (XB9SL)

RIDER AND CARGO WEIGHT FRONT FORK REAR SHOCK

PRELOAD

LB. KG

Less than 150 68 6 1.75 1.75 1 3 1.5

150-170 68-77 5.5 1.75 1.5 2 2.5 1.25

170-190 77-86 5 1.5 1.5 3 2.25 1.25

190-210 86-95 4.5 1.5 1.25 4 2 1

210-230 95-104 4 1.25 1.25 5 1.75 1

# OF

LINES

*COMPRESSION *REBOUND

PRELOAD POSITION

*COMPRESSION *REBOUND

230-250 104-113 3.5 1.25 1 6 1.5 0.75

250-GVWR 113-GVWR 3 1 1 7 1.25 0.75

* Note all compression and rebound settings are number of turns out from maximum.

2004 Buell Lightning: Maintenance 1-31

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SUSPENSION ADJUSTMENTS

1WARNING1WARNING

Always adjust each fork leg to the same settings. Uneven adjustment between left and right f orks may lead to a loss of contr ol which could result in death or serious injury.

NOTE All “turn settings” in Table 1-9. and Table 1-10. are “turns out

from maximum”. That is, first gently turn adjustment screws fully clockwise (until they stop), then turn adjustment screws counterclockwise the amount specified.

The recommended rebound and compression damping settings for various road and riding conditions are given in Table

1-10. and Table 1-10.

Setting Front Fork Preload

1. Check number of lines (3) to be showing for your load

condition. Refer to Table 1-9. or Table 1-10.

2. See Figure 1-29. Adjust preload by turning the adjuster

nut (2) with a wrench.

Setting Front Fork Rebound Damping

1. See Figure 1-29. Using a screwdriver, turn the slotted dial

(1) clockwise until it stops. This is the maximum rebound damping setting.

2. Then turn the dial counterclockwise the recommended

amount specified in Table 1-9. or Table 1-10.

9957

1. Rebound adjuster screw

2. Preload adjuster nut

3. Four lines visible (factory setting)

Figure 1-29. Front Fork Preload And Rebound Adjuster

8361

Setting Front Fork Compression Damping

1. See Figure 1-30. Using a screwdriver, turn the slotted dial

clockwise until it stops. This is the maximum compression damping setting.

2. Then turn the dial counterclockwise the recommended

amount specified in Table 1-9. or Table 1-10.

Figure 1-30. Front Fork Compression Damping Adjuster

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8388

Maximum preload adjustment (ramp number 7) Minimum preload adjustment (ramp number 1)

b0954x1x

8416

Setting Rear Shock Preload

The factory setting is ramp number 2 position (ramp number 7 position being the tallest ramp and maximum preload). For recommended spring preload refer to Table 1-9. or Table 1-

10.

1. Remove seat. See 2.41 SEAT.

2. See Figure 1-31. Change the spring preload by turning the preload adjuster at the upper par t of the shoc k with the SHOCK SP ANNER WRENCH (HD-94700-52C) or the wrench included in the tool kit.

a. Turn adjuster to setting specified in Table 1-9. or

Table 1-10. Rotate adjuster cloc kwise to increase

preload.

b. Rotate adjuster countercloc kwise to decrease pre-

load.

1WARNING1WARNING

3. Install seat. See 2.41 SEAT.

Figure 1-31. Rear Shock Preload Adjuster

Setting Rear Shock Rebound Damping

1. See Figure 1-32. Using a screwdriver, turn the slotted dial clockwise until it stops. This is the maximum rebound damping setting.

2. Then turn the dial countercloc kwise the recommended amount specified in Table 1-9. or Table 1-10.

Figure 1-32. Rear Shock Rebound Adjustment

2004 Buell Lightning: Maintenance 1-33

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Setting Rear Shock Compression Damping

1. Remove seat. See 2.41 SEAT.

2. See Figure 1-33. Using a scre wdriver, turn the slotted dial clockwise until it stops . This is the maxim um compression damping setting.

3. Then turn the dial counterclockwise the recommended amount specified in Table 1-9. or Table 1-10.

1WARNING1WARNING

4. Install seat.

8976a

Figure 1-33. Rear Shock Compression Adjustment

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8421

STEERING HEAD BEARINGS 1.13

GENERAL

The steering head bearings are sealed, angular contact bearings and do not require additional lubrication.

Check steering head bearing resistance:

At every 5000 mile (8000 km) service interval.

●

When storing or removing the motorcycle for the season.

INSPECTION

NOTES

Check that throttle cables do not bind when measuring

●

bearing resistance. Steering head bearings are sealed and do not require

●

additional lubrication. Steering head bearing resistance is not adjustable.

●

Replace bearings that do not meet resistance speciﬁcations.

1. Detach clutch cable at handlebar.

2. Place a scissor jac k under jacking point and r aise front wheel off g round. For location of jac king point see 2.29

EXHAUST SYSTEM.

1WARNING1WARNING

Steering must be smooth and free with no binding or interference. Anything interfering with steering system operation may cause loss of vehicle control, which could result in death or serious injury.

3. Check steering stem bear ings for notches b y turning front wheel full right and then left. Repeat if necessary.

4. Next place wheel f acing straight ahead and g rabbing both fork sides at the bottom move front-end forward and back to check for steering head play.

5. To inspect for correct steering head resistance turn front wheel all the way to the right.

6. See Figure 1-34. Hook a spring scale into the hole in the front axle. With scale 90 degrees from fork leg, pull front wheel to center position.

a. The desired resistance to pull front wheel to center

is between 1-7 lbs (0.5-3.2 kg).

Figure 1-34. Measuring Steering Head Bearing

Resistance

DETERMINING PROPER RESISTANCE

1. Detach clutch cable at handlebar and ensure that throttle cables do not bind before measuring steering head bearing resistance.

2. Remove steering stem pinch f astener at upper tr iple clamp.

3. Loosen steering stem capnut and back off several turns.

4. Remove lower triple clamp pinch fasteners, two per side.

5. Tighten steering stem capnut to 38-42 ft-lbs (52-57 Nm).

6. Turn front wheel all the way to the right.

7. See Figure 1-34. Hook a spring scale into the hole in the front axle. With scale 90 degrees from fork leg, pull front wheel to center position.

8. The desired resistance is between 1-7 lbs (0.5-3.2 kg).

NOTE

If the correct speciﬁcation cannot be achieved, the steering head bearings must be replaced. See 2.18 STEERING

HEAD BEARINGS.

9. Once correct steering head resistance has been verified apply LOCTITE 272 to steer ing stem pinch bolt, install and tighten to 17-19 ft-lbs (23-26 Nm).

b. If steering head resistance measurement is not

within specification, see DETERMINING PROPER

RESISTANCE.

7. When adjustment is complete , attach clutch cab le and adjust. See 1.9 CLUTCH.

10. Apply LOCTITE 272 to lo wer triple clamp f asteners, install and tighten to 13-15 ft-lbs (18-20 Nm).

11. When adjustment is complete , attach clutch cab le and adjust. See 1.9 CLUTCH.

12. Remove scissor jack.

2004 Buell Lightning: Maintenance 1-35

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SPARK PLUGS 1.14

INSPECTION

Check spark plugs:

●

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

Use only Harley-Davidson 10R12A spark plugs.

●

1. Remove left side air scoop to access front cylinder spar k plug. See 2.36 AIR SCOOPS.

2. Disconnect spark plug wire from front spark plug.

3. Using a 5/8 in. box end wrench and 5/8 in. spark plug socket, remove front spark plug.

4. Remove seat. See 2.41 SEAT.

5. Remove airbox assembly. See 4.30 AIRBOX.

6. Disconnect spark plug wire from rear spar k plug (use automotive spark plug boot remover/installer if required).

7. Using a 5/8 in. wobble socket and 12 in. extension, remove rear spark plug.

8. See Figure 1-35. Compare your observations of the plug deposits with the descriptions provided below.

4636

Figure 1-35. Typical Spark Plug Deposits

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

trodes and cer amic insulator tip indicates an oil fouled plug. The condition may be caused by one or more of the f ollowing: 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 lack deposit indicates an air-

fuel mixture that is too r ich and/or engine idling f or excessive periods.

c. A light bro wn, glassy deposit indicates an o ver-

heated plug. This condition may be accompanied by cracks in the insulator or b y erosion of the electrodes and is caused b y 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 ma y cause high-speed misfi ing. A plug with eroded electrodes , heavy deposits or a cr acked insulator m ust be replaced.

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

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

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8389

1WARNING1WARNING

Low pressure compressed air can b low debris into your face and e yes. Always wear e ye protection or a face shield when using pressuriz ed air. Failure to take adequate safety precautions could result in death or serious injury.

9. If the plugs require cleaning betw een tune-ups and replacement plugs are not available, proceed as follows:

a. Degrease fi ing end of spar k plug using ELECTRI-

CAL CONTACT CLEANER. Dry plug with compressed air.

b. Use a thin file to flatten sp k plug electrodes . A

spark plug with shar p edges on its electrodes requires 25-40% less fi ing voltage than one with rounded edges.

10. If the plugs cannot be cleaned, replace with 10R12A spark plugs.

11. Check electrode gap with a wire-type f eeler gauge. Gap should be 0.035 in. (0.9 mm).

Figure 1-36. Rear Spark Plug Access

12. Apply LOCTITE ANTI-SEIZE to threads of spar k plugs. Install and tighten spar k plugs to 11-18 ft-lbs (1524 Nm).

NOTES

●

Start threading rear spark plug with 3/8” fuel hose being careful not to cross thread spark plug.

Start front spark plug with ﬁngers.

●

An extension may be needed to push on rear spark plug

●

boot to ensure it is seated properly.

13. Connect spark plug wires. Verify that wires are securely connected to coil and spar k plugs. See 7.4 SPARK

PLUG CABLES.

14. Install left side air scoop. See 2.36 AIR SCOOPS.

15. Install airbox assembly. See 4.30 AIRBOX.

1WARNING1WARNING

16. Install seat. See 2.41 SEAT.

2004 Buell Lightning: Maintenance 1-37

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AIR CLEANER FILTER 1.15

REMOVAL

CAUTION

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

Check air cleaner filter element

●

Inspect at the 1000 mile (1600 km) ser vice interval and at every 5000 mile (8000 km) service interval thereafter.

●

Replace at every 20,000 mile (32,000 km) service interval.

NOTE

Inspect and replace air cleaner ﬁlter element more often if the motorcycle is run in a dusty environment.

1. Remove seat. See 2.41 SEAT.

2. Remove four fasteners, nylon washers and intake cover assembly. See 2.35 INTAKE COVER ASSEMBLY.

3. See Figure 1-37. Remove fuel vent tube (4) from v apor valve at front of air cleaner cover and groove on top of air cleaner cover (1).

NOTE

The following steps are for the XB12S with the interactive exhaust system.

4. See Figure 1-37. Remove upper isolator (2) and actuator (3) along with cab le (5) and har ness (6) from top of air cleaner cover and lay to one side.

5. Unlatch six latching tabs (7) and remo ve air cleaner cover from baseplate.

6. See Figure 1-39. Remove the filter element (1) fro baseplate (2). Inspect and replace if necessary.

10494

1. Air cleaner cover

2. Upper isolator

3. Actuator (interactive exhaust)

4. Fuel vent tube

5. Cable (interactive exhaust)

6. Harness (interactive exhaust)

7. Air cleaner cover latch tabs

Figure 1-37. Air cleaner cover, Fuel Vent Tube and Fuel

Vapor Valve (XB12)

8372

CAUTION

See Figure 1-39. Cover the velocity stack so nothing can drop into the motor.

CLEANING AND INSPECTION

1WARNING1WARNING

Do not use gasoline or solvents to c lean the filter ele ment. Volatile/flamma le cleaning agents may cause an intake system fire whi h could result in death or serious injury.

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

2. Thoroughly clean baseplate and inside of air cleaner cover.

3. See Figure 1-40. Make sure tw o crankcase breather hoses (1) and intake air sensor (2) are captured in baseplate behind velocity stack (3).

1-38 2004 Buell Lightning: Maintenance

1. Air cleaner cover

2. Fuel vent tube

3. Vapor valve

4. Air cleaner cover latch tabs

Figure 1-38. Air Cleaner Cover, Fuel Vent Tube and Fuel

Vapor Valve (XB9)

Page 87

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8373

1. Breather hoses (2)

2. Intake air sensor

3. Velocity stack

8371

1. Filter element

2. Baseplate assembly

3. Air cleaner cover latch tabs (6)

4. Velocity stack

Figure 1-39. Installed Air Cleaner Filter Element

INSTALLATION

1. See Figure 1-39. Place filter element (1) on baseplat (2).

2. See Figure 1-37. Position air cleaner co ver (1) o ver baseplate. Make sure air filter remains correctly posi tioned.

3. Install air cleaner co ver by latching six latch tabs (4) to baseplate.

4. Install actuator and position cab le and har ness in grooves on air cleaner cover.

5. Position fuel vent tube (2) in g roove on top of air cleaner cover and connect to fuel v ent valve (3). Secure vent tube to vent valve with

6. Adjust interactive exhaust cable. See 1.17 INTERAC-

TIVE EXHAUST CABLE (XB12S).

7. Install intake cover assembly with f our fasteners and nylon washers. Tighten fasteners to 12-36 4 Nm).

new

cable strap.

in-lbs

(4-

Figure 1-40. Air Cleaner Baseplate Assembly

8. Install seat. See 2.41 SEAT.

1WARNING1WARNING

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THROTTLE CABLE AND IDLE SPEED ADJUSTMENT 1.16

THROTTLE CABLE

1WARNING1WARNING

Throttle cables must not pull tight when handlebar s are turned fully to left or right f ork stops. Be sure wires and throttle cables are clear of fork stops at steering head so they will not be pinc hed when f ork is turned a gainst stops. Steering must be smooth and free with no binding or interference. Anything interfering with steering system operation ma y cause loss of vehic le control, which could result in death or serious injury.

Check throttle cable adjustment:

●

Before every ride.

At every scheduled service interval.

●

With engine r unning, turn handlebars through full r ange of travel. If engine speed changes dur ing this maneuv er, turn engine OFF and adjust throttle cables as follows:

1. Remove airbox and baseplate. See 4.30 AIRBOX.

6853

1. Rubber boot

2. Throttle control cable

3. Idle control cable

4. Cable adjuster

5. Cable adjuster lock

Figure 1-41. Throttle Control Cables

8390

2. See Figure 1-41. Loosen cable adjuster lock (5) on each.

3. Turn adjusters (4) in direction which will shor ten cable housings to minimum length.

4. Point front wheel str aight ahead. Twist throttle control grip to fully open position; hold in position.

5. Turn adjuster on throttle control cab le (2) until throttle cam stop touches stop plate . Tighten cable adjuster lock on throttle control cab le adjuster; release throttle control grip.

6. Turn handlebars fully to r ight. Turn adjuster on idle control cable (3) until end of cab le housing just touches the cable guide.

7. Twist and release throttle control g rip a few times. Throttle plate m ust return to idle position each time throttle grip is released. If this is not the case , turn adjuster on idle control cable (shortening cable housing) until throttle control functions properly.

8. Tighten cable adjuster loc k on idle control cab le. Recheck operation of throttle control.

9. Recheck engine slow idle speed; adjust if required.

Figure 1-42. Idle Adjuster (behind left fork)

IDLE SPEED

See Figure 1-42. Regular idle speed is 1050 - 1150 RPM. Set idle speed using idle adjuster . Turn adjuster cloc kwise to increase idle speed or countercloc kwise to decrease idle speed.

10. Install airbox, baseplate and intake cover assembly. See

4.30 AIRBOX.

1-40 2004 Buell Lightning: Maintenance

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CAUTION

10512

INTERACTIVE EXHAUST CABLE (XB12S) 1.17

ADJUSTMENT

1. Remove four fasteners, nylon washers and intake cover assembly. See 2.35 INTAKE COVER ASSEMBLY.

NOTE

When the ignition/light switch is turned off with the interactive exhaust valve in motion, the valve will stop partially open which will cause an inaccurate adjustment. For a description of the inactive exhaust operation, see 7.6 INTERACTIVE

EXHAUST SYSTEM (XB12S).

2. To close the valve in the muffle , cycle the actuator:

a. Hold the throttle wide open.

b. Tu rn the engine cut-off switch to RUN.

c. Turn the ignition/light key switch ON.

d. Watch the actuator cycle close/open/close.

10513

5. Using a pair of pliers , fully open the exhaust valve in the muffler by pulling the cab le core b y the ferule that w as disconnected from the cab le wheel in the pre vious step until resistance is felt. Be careful not to damage the cable core.

6. Mark the cable core with the mar ker all the way around where it comes out of the housing.

7. Release the cab le core and reattach the cab le to the cable wheel and bracket.

8. Tighten jam nut.

Do not overtighten jam nut on interactive exhaust cable.

10512

1. Adjuster

2. Interactive exhaust cable

3. Jam nut

4. Cable wheel

Figure 1-43. Interactive Exhaust Cable

3. See Figure 1-43. Loosen jam nut (3).

4. Remove cable (2) from bracket and cable wheel (4).

NOTE

For the next step in the procedure it will be necessary to obtain a permanent marker.

Figure 1-44. Checking For 1/8 in. (3.2 mm) Maximum Free

Play In Either Direction For Proper Adjustment

9. See Figure 1-44. Adjust interactive exhaust cable as follows:

a. See Figure 1-43. Move cable with your fingers fro

side to side . There should be no more than 1/8 in. (3.2 mm) side play in cable in either direction with 1/ 4 in. (6.4 mm) maximum overall side play.

b. Adjust cable as needed using cable adjuster (1).

10. Cycle the actuator to verify cable and valve operation:

a. Hold the throttle wide open.

b. Tu rn the engine cut-off switch to RUN.

c. Turn the ignition/light key switch ON.

d. Watch the actuator cycle close/open/close.

DO NOT start vehicle in this mode.

NOTE In this mode the exhaust valve in the interactive mufﬂer should cycle from the closed position to the wide open position and back to the closed. When the exhaust valve moves to the open position, you should see the mark on the cable core made previously. This ensures the system is working properly. If you do not see the mark, verify previous cable adjustment.

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10514a

1. Interactive exhaust cable

2. Frame lug

Figure 1-45. Correct Cable Routing Behind Frame Lug

11. See Figure 1-45. Ver ify that the interactive exhaust cable (1) is routed behind the frame lug (2) before installing air intake cover.

CAUTION

If cable is routed in front of the frame lug it will cause the muffler valve to sta y open not allo wing it to w ork properly.

12. Install air intake cover.

1-42 2004 Buell Lightning: Maintenance

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8351

b0965x1x

IGNITION TIMING 1.18

INSPECTION

Check ignition timing: after each removal of the cam position sensor.

CHECKING STATIC TIMING

1CAUTION

Always wear proper eye protection when drilling. Flying debris may result in minor or moderate injury.

CAUTION

Carefully drill hole , applying minimum pressure to drill out timer plate cover rivets. Applying too much pressure will damage cam position sensor and/or timer plate and cover.

NOTES

●

It is not necessary to remove the spark plug to determine TDC compression stroke of the front cylinder in the following procedure.

11. If engine is coming up on the compression strok e for the REAR (incorrect) cylinder, the screen will be displa ying HIGH - 5 volts as timing mar k is just coming into vie w at left edge of windo w and will s witch to LO W - 0 v olts at same point as the timing mar k continues through the window. (If this is obser ved, turn flywheel orward one revolution to bring engine to compression stroke for front cylinder.)

NOTES

If timing mark check point is overshot, bump ﬂywheel

●

backwards till TDC mark is at left edge of inspection window and repeat test bumping ﬂywheel in forward (normal) direction.

Never conﬁrm timing while bumping ﬂywheel backwards.

●

This will give you an incorrect reading.

12. If timing is correct, install timing inspection plug and tighten to 120-180 rect, see ADJUST TIMING in this section.

in-lbs

(14-20 Nm). If timing is not cor-

Do not remove the timing inspection cover to check the

●

static timing. If timing must be corrected, the inspection plate will then be removed.

1. Raise rear wheel using a lift or jac king point. Tie down motorcycle for additional support.

2. Remove timing inspection plug.

3. Place transmission in 5th gear.

4. Raise sidestand.

5. Connect Digital Technician to data por t on motorcycle and select the Static Timing procedure screen.

6. Turn on ignition and mo ve handlebar stop s witch to the run position. Listen for fuel pump cycling to confi m ignition is active.

7. Turn or gently b ump the flywheel in a orward direction using the rear wheel. Position the flywheel TDC mark at the very left edge of the inspection hole.

8. If the engine is coming up on the compression strok e for the FRONT (correct) cylinder, the screen will be displaying LOW - 0 volts with timing mark at left edge of window.

9. Gently bump flywheel orward in tiny increments.

Figure 1-46. Timing Plug

Figure 1-47. Correct Timing

10. See Figure 1-47. If the static timing is correct, the screen will switch to HIGH - 5 v olts at the precise moment the timing mark exactly centers in the inspection window.

2004 Buell Lightning: Maintenance 1-43

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ADJUST TIMING

1. See Figure 1-48. Remove timing plate cover.

a. Drill rivets holding the timing plate cover.

b. Using a hook, remove timing plate cover.

2. See Figure 1-50. If timing is advanced (mark appears on left side of window) rotate timing plate counterclockwise.

3. Check timing. See CHECKING STATIC TIMING.

4. See Figure 1-51. If timing is retarded (mar k appears on right side of window) rotate timing plate clockwise.

5. Recheck timing.

8363

Figure 1-48. Timer Cover

8391

b0964x1x

b0963x1x

Figure 1-49. Cam Position Sensor

Figure 1-50. Advanced Timing

1-44 2004 Buell Lightning: Maintenance

Figure 1-51. Retard Timing

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Position

Motorcycle

25 ft (7.6 m)

b0949x1x

Horizontal Line

29-31 in.

(74-79 cm)

High Beam

Low Beam

Horizontal Line

29-31 in.

(74-79 cm)

Position

Motorcycle

25 ft (7.6 m)

9960

1. High beam

2. Low beam

HEADLIGHTS 1.19

INSPECTION

1WARNING1WARNING

Do not modify ignition/light s witch wiring to cir cumvent the automatic-on headlight f eature. High visibility is an important consideration for motorcycle riders. Failure to have headlight on at all times could cause an accident, resulting in death or serious injury.

Check headlights for proper alignment:

●

When the new owner takes delivery of the motorcycle.

●

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

1. In a location with lo w light, dr aw a hor izontal line on a screen or wall that measures 29-31 in. (74-79 cm) above floo .

2. See Figure 1-52. Position motorcycle 25 ft (7.6 m) a way from a screen or wall by measuring the distance from the front axle to the screen/wall.

3. Verify correct front and rear tire pressure. See 1.8 TIRES

AND WHEELS.

4. Load vehicle with r ider/passenger/cargo/accessories. Weight will compress vehicle suspension slightly.

5. Stand motorcycle upr ight with headlights aimed str aight forward.

6. Check LOW beam (right lens) for alignment.

a. See Figure 1-53. Tu rn ignition switch to IGN. Set

b. Check that the correct patter n of light is a doub le

c. Adjust headlight alignment. See ADJUSTMENT

7. Check HIGH beam (left) for alignment.

a. See Figure 1-53. Set handlebar headlamp switch to

Low beam lamp will not stay illuminated when high beam is activated.

b. Check that the correct patter n of light is a circular

c. Adjust headlamp alignment. See ADJUSTMENT

handlebar headlamp switch to LOW beam position.

rectangular pattern and is aligned with the horizontal line as shown in Figure 1-52.

which follows.

HIGH beam position.

pattern and is centered on the hor izontal line as shown in Figure 1-52.

NOTE

section.

Figure 1-52. Checking Headlight Alignment

Figure 1-53. Headlamp Switch

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ADJUSTMENT

Horizontal Alignment

See Figure 1-54. Loosen fasteners on r ight and left side of headlight housing to adjust the horizontal alignment.

Vertical Alignment

See Figure 1-55. Loosen fastener on the bottom of headlight housing to adjust the vertical alignment.

NOTE

Only loosen headlamp alignment fasteners enough to adjust headlamp. Once headlights are aligned, tighten fasteners to 48-72

in-lbs

(5-8 Nm).

9949

9950

Figure 1-54. Horizontal Headlamp Adjustment

9951

1-46 2004 Buell Lightning: Maintenance

Figure 1-55. Vertical Headlamp Adjustment

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8390

THROTTLE POSITION SENSOR (TPS) 1.20

INSPECTION

1. Connect vehicle to Digital Technician.

2. Select data monitor screen.

3. Select TP degrees on screen.

4. Ignition and run switch should be in the on position with engine off and throttle in the closed position.

NOTE If closed throttle TP degree reading is not between 5.1° - 6.2°, TPS should be re-calibrated. See ADJUSTMENT below.

ADJUSTMENT

1. Connect vehicle to Digital Technician.

2. Select calibrations screen/TPS Function.

3. Select Buell TPS zero tab.

4. Select TP volts on screen.

5. See Figure 1-56. Back off idle adjustment until TP volts

and then contin ue to back out one full

stop decreasing turn.

6. Open and

This is to ensure that the throttle plate is completely closed before beginning recalibration.

7. With ignition and r un switch in the on position with

engine off and throttle in the closed position press the TPS zero button at the bottom of the screen.

8. Select TPS zero button and perform TPS zero.

When calibration is complete, dialogue box will appear on Digital Tech screen with message display “Command Sent Successfully”. Press OK.

9. Turn idle adjustment cab le screw clockwise until TPS

degrees read 5.2-5.6 degrees.

10. Run vehicle until engine temperature is at 285

C).

11. Set idle to 1050-1150 RPM.

snap shut

throttle control grip 2-3 times.

NOTE

F (140°

Figure 1-56. Idle Adjuster (behind left fork)

2004 Buell Lightning: Maintenance 1-47

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STORAGE 1.21

GENERAL

1WARNING1WARNING

Gasoline is flamma le. Do not store motor cycle having gasoline in tank within the home or gara ge where open flames pilot lights, sparks or electric motors are present. Inadequate safety precautions ma y cause an accident which could result in death or serious injury.

If the motorcycle will not be oper ated for several months, such as dur ing the winter season, there are se veral things which should be done to protect par ts against corrosion, to preserve the batter y and to pre vent the b uildup of gum and varnish in the fuel system.

1. Fill fuel tank and add a gasoline stabilizer. Use one of the commercially available gasoline stabiliz ers following the manufacturer’s instructions. Run engine until treated gasoline has had a chance to reach fuel injectors.

2. Remove battery and charge as needed to maintain the correct voltage. See 1.5 BATTERY MAINTENANCE.

3. Remove the spark plugs, inject a few squirts of engine oil into each cylinder and cr ank the engine 5-6 re volutions. Reinstall spark plugs. See 1.14 SPARK PLUGS.

4. Adjust primary chain. See 1.11 PRIMARY CHAIN.

5. Check tire inflation See 1.8 TIRES AND WHEELS. If the motorcycle will be stored f or an extended period of time, securely support the motorcycle so that all w eight is off the tires.

REMOVAL FROM STORAGE

1WARNING1WARNING

After extended periods of stora ge and prior to star ting vehicle, place transmission in g ear, disengage clutch and push vehic le back and f orth a f ew times to ensure proper clutch disengagement. Improper clutch disengagement could result in death or serious injury.

1. Charge and install batter y. See 1.5 BATTERY MAINTE-

NANCE.

2. Remove and inspect spar k plugs. Replace if necessar y. See 1.14 SPARK PLUGS.

3. Inspect air filter element Replace if necessary. See 1.15

AIR CLEANER FILTER.

4. If fuel tank was drained, fill fuel tank with fresh gasolin .

5. Start the engine and r un until it reaches nor mal operating temperature. Check fluids and refill to proper vels if required.

a. Check engine oil le vel. See 1.6 ENGINE LUBRICA-

TION SYSTEM.

b. Check transmission fluid l vel. See 1.9 CLUTCH.

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

1WARNING1WARNING

Do not apply any oil to brake rotors or brake pads. Oil on brake pads degrades braking efficien y and can result in an accident which could result in death or serious injury.

6. Wash molded-in-color and chrome-plated surf aces. Apply a light film of oil to xposed uncoated metal surfaces.

7. If motorcycle is to be co vered, use a mater ial that will breathe, such as light can vas. Plastic mater ials that do not breathe promote the formation of condensation.

1-48 2004 Buell Lightning: Maintenance

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TROUBLESHOOTING 1.22

GENERAL

The following check list can be helpful in locating most operating troubles. Refer to the appropr iate 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 o verrunning clutch slipping.

6. Clutch lever not pulled in. Vehicle in gear.

7. Starter interlock circuit malfunction.

Engine Turns Over But Does Not Start

NOTE

See 4.11 ENGINE CRANKS BUT WILL NOT START for spe- ciﬁc tests.

1. Fuel tank empty.

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

3. Fouled spark plugs.

4. Loose or shorting spark plug cables or connections.

5. Ignition timing badly out of adjustment.

6. Loose wire connection at coil or batter y connection or plug between ignition sensor and module. See Section 4.

7. Ignition coil not functioning.

8. Ignition module not functioning.

9. Ignition sensor not functioning.

10. Sticking or damaged valve or valves.

11. Engine oil too heavy (winter operation).

12. Ignition circuit interlock malfunction.

13. No output from the ECM. See dealer.

14. Inadequate fuel pressure in fuel lines (possib le leak). See dealer.

15. Clogged fuel filte . See dealer.

16. Clogged fuel injectors. See dealer.

17. Tripped bank angle sensor. Turn key to OFF, wait 15 seconds, and then back to IGN again to start bike.

18. TP Sensor/fast idle screw not set properly. See dealer.

19. No output from CMP sensor. See dealer.

20. Inoperative fuel pump. See dealer.

Starts Hard

1. Spark plugs in bad condition, ha ve 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 batter y terminals, at coil or at plug between ignition sensor and module.

5. Throttle 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 fuel line closed off restricting fuel fl w.

10. Water or dirt in fuel system.

11. Air leak at intake manifold.

12. Valves sticking.

13. TP Sensor and/or f ast idle scre w not set proper ly. See dealer.

14. Oxygen, IAT or ET sensors damaged or malfunctioning. See dealer.

Starts But Runs Irregularly or Misses

NOTE

See 4.15 MISFIRE for speciﬁc tests.

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 batter y terminals or coil.

9. Intermittent short circuit due to damaged wire insulation.

10. Water or dirt in fuel system and throttle body or filte .

11. Vapor vent valve plugged.

12. Throttle controls improperly adjusted.

13. Air leak at intake manifold or air filte .

14. Damaged intake or exhaust valve.

15. Weak or broken valve springs.

16. Incorrect valve timing.

17. Oxygen, IAT or ET sensors damaged or malfunctioning. See dealer.

18. TP Sensor not set properly. See dealer.

19. Fuel level too low. Add gasoline.

20. Inoperative fuel injector. See dealer.

21. Obstructed fuel tank v ent valve or pinched v ent tube. See dealer.

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Spark Plug Fouls Repeatedly

1. Incorrect spark plug.

2. Piston rings badly worn or broken.

3. Valve stem seals worn or damaged.

4. Valve guides badly worn.

5. Sensors damaged.

Pre-Ignition or Detonation (Knocks or Pings)

1. Excessive carbon deposit on piston head or comb ustion chamber.

2. Incorrect heat range spark plug.

3. Spark plugs not fi ing.

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. Clogged or damaged fins on oil coole .

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 fitting .

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.

Engine Leaks Oil From Cases, Push Rods, Hoses

1. Loose parts.

2. Imperfect seal at gaskets, push rod co ver, 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.

3. Cooling fan not operating properly.

4. Leaking valves.

5. Heavy carbon deposit.

6. Ignition timing retarded.

Valve Train 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.

Excessive Vibration

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

2. Isolator mounting fasteners loose.

3. Broken frame.

4. Primary chain badly w orn or links tight as a result of insufficient lub ication.

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.

FUEL SYSTEM

5. Wheels not aligned and/or tires worn.

6. Internal engine problem.

7. Wheels not balanced correctly.

1-50 2004 Buell Lightning: Maintenance

Poor Fuel Economy

1. Oxygen sensor damaged or malfunctioning (bike running rich). See dealer.

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TRANSMISSION

Shifts Hard

1. Clutch dragging slightly.

2. Shifter forks (inside transmission) damaged.

3. Corners worn off shifter clutch dogs (inside tr ansmission).

Jumps Out of Gear

1. Shifter engaging par ts (inside tr ansmission) badly worn and rounded.

2. Shifter forks bent.

3. Damaged gears.

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 or moisture.

3. Master or wheel cylinder piston worn.

4. Brake pads covered with grease or oil.

5. Brake pads badly worn to minimum lining thickness.

6. Brake rotor badly worn or warped.

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

8. Insufficient brake pedal or hand le ver free pla y (brake drags).

Handling Irregularities

1. Tires improperly inflated See 1.8 TIRES AND WHEELS. Do not overinflat .

2. Loose wheel axle . Tighten front axle to 39-41 ft-lbs (5356 Nm). Tighten rear axle to 48-52 ft-lbs (65-70 Nm).

3. Excessive wheel hub bearing play.

4. Rims and tires out-of-tr ue sideways (tire r unout should not be more than 0.080 in. (2.03 mm)).

5. Rims and tires out-of-round or eccentr ic with hub (tire runout should not be more than 0.060 in. (1.5 mm)).

6. Irregular or peaked front tire tread wear.

7. Tire and wheel unbalanced or w eights on wrong side of wheel. (Front wheel weights must be on the br ake rotor side.)

8. Steering head bear ings improperly tightened or w orn. See 1.13 STEERING HEAD BEARINGS . Check for proper torque and replace w orn bearings. See 2.17

FORK CLAMPS, UPPER AND LOWER.

9. Shock absorber or front f orks not functioning nor mally due to incorrect adjustment. See 1.12 SUSPENSION

DAMPING ADJUSTMENTS.

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

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SUSPENSION

When making adjustments , remember there are tw o mediums in setting up a bik e, geometry and suspension. Both components work together because suspension is a par t of geometry. In order to solv e handling problems, it is important to diagnose the problem’s true nature.

Table 1-11. General Suspension Problems

TROUBLESHOOTING CONDITION ADJUSTMENT SOLUTION

Chattering, sliding or an uncomf ortable feeling are suspension-related. Handling and a s winging fork are geometr yrelated, but often these unw anted characteristics can be solved by suspension adjustments.

The following tables list possib le suspension and oper ating troubles and their probable causes.

Bike wallows through turns. Feels loose or vague after bumps. Wheel tends to “pogo” after passing over a bump. This is noticeable by watching the bike continue to bounce as it travels over multiple bumps.

Wheel responds to bump, but doesn’t return to ground quickly after bumps. This is more pronounced over a series of bumps and is often referred to as “packing down.”

The bike bottoms out or dips while cornering. Bike has excessive brake dive.

Harsh ride particularly over washboard surfaces. Bumps kick through handlebars or seat. Suspension seems not to respond to bumps. This is evidenced by tire chattering (a movement with short stroke and high frequency) through corners or by jolting the rider over rough roads.

Increase rebound damping.

Reduce rebound damping.

Increase compression damping.

Reduce compression damping.

Table 1-12. Rear Suspension Problems

TROUBLESHOOTING CONDITION ADJUSTMENT SOLUTION

“Pumping on the Rear” occurs when you are accelerating out of a corner. This problems occurs in two varieties.

1. The first type has a m vement with a long stroke and a high frequency.

2. The second version has a movement with a short stroke and high frequency.

Chattering during braking. Decrease the compression damping. If the problem persists,

Lack of tire feedback. The suspension is too soft. Increase compression damping.

Sliding during cornering. Sliding may occur going into the corner or accelerating out of the corner.

1. The shock is too soft. Increase compression damping. If the adjuster is already set to the maxim um, add more preload to the spring (one turn maximum).

2. In this case the shoc k is too hard. Decrease compression damping.

decrease rebound damping for a faster rebound rate. Less spring preload may also help.

The suspension is too hard. Decrease compression damping.

Table 1-13. Front Suspension Problems

TROUBLESHOOTING CONDITION ADJUSTMENT SOLUTION

Not absorbing bumps. A good suspension is a balance between damping

and track condition. Finding this balance requires exploring all possible compression settings.

Lack of tire feedback. Increase compression damping.

Tire slides. Decrease compression damping.

1-52 2004 Buell Lightning: Maintenance