buell s1 lightning '97 Manual

1.

Secure right and left crankcase halves with three crank-
case stud bolts (top center and bottom left and right). The
sprocket shaft bearing outer races and large spacer must
be installed in left crankcase.

2.

See 

. Assemble

sprocket shaft bearing bushing. Sleeves, for use with
tapered bearing, are assembled to case with bearings
and small spacer collar. Finger-tighten the sleeve parts.

3.

Insert lap shaft with arbor assembled through pinion
bearing bushing and into guide sleeve. Tighten arbor
expansion collars using a length of 0.156 in. (3.96 mm)
rod as spanner until arbor begins to drag. Do not adjust
arbor snug in bushing or bushing will “bell,” a condition
where hole is larger at ends than it is in the center.

4.

Withdraw arbor far enough to coat lightly with 220 grit
lapping compound. Do not apply a heavy coat. Reposi-
tion lap in bushing and turn handle at moderate hand
speed. Work lap back and forth in bushing, as it is
revolved, to avoid grooving and tapering.

5.

At frequent intervals, remove lap from crankcase wash
and inspect bushing. Lapping is completed when entire

bushing surface has a dull, satin finish rather than a
glossy, smooth appearance. If necessary, flush off lap in
cleaning solvent, air dry and apply fresh, light coat of fine
lapping compound.

After correct connecting rod bearing fit has been attained,
clean and assemble parts as follows:

1.

Carefully clean all flywheel components using a non-
petroleum-based solvent, such as LOCTITE CLEANING
SOLVENT or electrical contact cleaner. Thoroughly dry
all components.

2.

See 

 Apply two drops of LOCTITE 620

RETAINING COMPOUND to the crank pin threads, and
apply no more than two drops to the nut bearing faces.

1

3.

Assemble crank pin (6) to gear-side flywheel (5) making
sure that key (7) is in proper position. Tighten crank pin
nut. See 

 for proper torque.

4.

Position gear-side flywheel assembly in a flywheel fixture
with crank pin pointing up. Wipe crank pin taper clean.

5.

 Slip bearings, and connecting rods over

crank pin. Assemble angular boss of the female rod adja-
cent to large radius side of the male rod as shown. The
side of the male rod with the larger radius is narrower in
the area where it fits between the forks of the female rod.

6.

Verify that oil passages through pinion shaft, gear-side
flywheel and crank pin are clear by blowing compressed
air into oil galley at end of pinion shaft.

7.

Install sprocket-side flywheel. Lightly tighten nut.

8.

 Hold steel straightedge along outer face

of wheel rims at 90

°

 from crank pin as shown. Tap outer

.187" (4.75 mm)

2.00"

(50.8 mm)

1.00

(25.4 mm)

1.00"

(25.4 mm)

1.560"

(39.62 mm)

1.560"

(39.62 mm)

.187" (4.75 mm)

5/16"

(7.94 mm)

DRILL

5/16"

(7.94 mm)

DRILL

1.00"

(25.4 mm)

1.50" (38.1 mm)

1.272" (32.31 mm)
1.262" (32.05 mm)

1.145" (29.08 mm)
1.135" (28.83 mm)

5.50" (139.7 mm)

b0177x3x

3546a