buell s1 lightning '97 Manual

 

3.

Insert needle jet holder (10) into main jet passage with
needle inserted into center of holder. Thread holder into
passage and tighten. Thread and tighten main jet (11) in
tapped hole in needle jet holder (10).

4.

Place float assembly (16) into position with fuel inlet
valve (13) inserted into valve seat and with pivot arm
aligned with holes in mounting posts (at bottom of carbu-
retor body). Insert pin (14) through float pivot arm and
float mounting posts.

5.

Check float level setting and adjust if necessary. See

on 

.

6.

Place float bowl (38) over float and onto carburetor body
flange. Bowl will only fit in one position. Install and tighten
screws and lockwashers (18).

 

Install diaphragm (44), spring (43), O-ring (45) and pump
housing (42). Secure with screws (49) and lockwashers (48).

 

1.

See 

 Place mounting flanges (1, rear and 2,

front) on aluminum manifold (5).

2.

Place intake manifold seals (3) on each spigot of manifold
with chamfered edge against mounting flanges (1, 2).

3.

Place channel of seal ring (6) over inlet end of manifold.

4.

Position manifold against intake ports of cylinder head,
with slotted and round holes in flanges (1, 2) aligned with
holes in cylinder head. Manifold should slide over screws
on primary side of engine. Insert two screws (4) through
manifold flanges on gearcase side and loosely thread
into tapped holes in cylinder head. Tighten intake mani-
fold screws (4) to 6-10 ft-lbs (8.1-13.6 Nm).

5.

Install ignition key switch bracket.

a.  Fasten bracket to cylinder heads with two TORX

screws and washers. Tighten to 25-30 ft-lbs (33.9-
40.7 Nm).

b.  Attach top tie bar to bracket. Tighten locknut to 30-

33 ft-lbs (40.7-44.7 Nm).

c. 

Secure ignition wires to main wiring harness using a

 

 cable strap.

 

1.

Attach throttle cables to carburetor. 

a.  Install idle control cable into longer, inboard cable

guide on carburetor.

b.  Install throttle control cable into shorter, outboard

cable guide on carburetor.

 

NOTE

The fit between the carburetor and the seal ring is tight. For
ease of installation, lubricate the mating surfaces, carburetor
body and seal ring with liquid dish soap or tire mounting lube
prior to assembly.

 

2.

See 

 Connect fuel drain hose to drain fitting.

Connect vacuum hose to V.O.E.S. fitting. On California
models, connect canister hose to carburetor.

3.

Lubricate only the inside surface of seal ring that will be
in contact with the carburetor. Also apply a light coat of
lubricant to the spigot of the carburetor body. Push car-
buretor body into seal ring.

4.

Attach fuel hose to carburetor with a 

 

 clamp.

5.

Install enrichener cable on bracket and adjust. See

. 

6.

Adjust throttle cables. See 

in Section 1.

7.

Install air cleaner components. See 

.

8.

Install fuel tank. See 

on

.

 

Route fuel drain hose from the carburetor drain fitting down-
ward and forward through the space between the engine rear
cylinder and the rear cylinder push rod covers (intake and
exhaust), and then downward through the space between the
engine crankcase and the oil pump.