buell s1 lightning '97 Manual

 

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

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

 

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

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

Replace all damaged or missing lubrication fittings.

Use Teflon pipe sealant on pipe fitting threads. 

 

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

 

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

 

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

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

Coat bearings with clean oil. Wrap bearings in clean paper.

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

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

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

 

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

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

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

 

Always discard gaskets after removal. Replace with 

 

gaskets. Never use the same gasket twice. Be sure that
gasket holes match up with holes in the mating part.

 

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

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

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

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

 

Always discard O-rings after removal. Replace with 

 

 O-

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

 

Always check gears for damaged or worn teeth.

Lubricate mating surfaces before pressing gears on shafts.

 

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

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

Clean all rust from the machined surfaces of new parts.