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buell s1 lightning '97 Manual

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6-7
 
19. Slowly raise floor hoist until rubber isolators can be
removed. Frame will rise while swingarm and engine
remain secured to lift by crating strap. 
 
NOTE
Rubber isolators align with a frame mounted metal pin.
 
20. Remove belt through gap between frame and swingarm
mount block.
 
INSTALLATION
 
1.
Install 
 
new
 
 belt over sprockets.
2.
Install rubber isolators.
a. 
Align metal pin on frame with hole in isolator. 
b.  Slowly lower floor hoist to drop frame and isolators
around swingarm mount block.
 
NOTE
If isolator fit is troublesome, place a flat tool such a disposable
putty knife between swingarm mount block and isolator. As
frame lowers, withdraw tool when edge of isolator slides
around edge of mount block.
 
3.
Apply LOCTITE THREADLOCKER 262 (red) to isolator
bolts. Install isolator bolts and washers through isolators
and into swingarm mount block. Tighten bolts to 100-110
ft-lbs (135.6-149.1 Nm).
4.
Attach tie bars to frame in the following order.
a. 
Place clutch cable clamp on front tie bar bolt. Clamp
should hold cable on air cleaner side of motor. Insert
bolt from front through frame and tie bar. Fasten with
flat washer and nut. Tighten to 30-33 ft-lbs (40.7-
44.7 Nm). 
b. Insert 
bolt through top tie bar, washer, spacer and
frame tab. Secure with locknut. Tighten to 30-33 ft-
lbs (40.7-44.7 Nm).
c. 
Rear tie bar must be horizontal and below frame tab.
Insert bolt upwards through tie bar and frame. Fas-
ten with nut. Tighten to 30-33 ft-lbs (40.7-44.7 Nm).
5.
Remove crating strap from lift and swingarm.
6.
Remove jacks from underneath swingarm and crank-
case.
7.
Attach rear shock to swingarm with bolt (metric) and nut.
Tighten to 40-45 ft-lbs (47.5-61.0 Nm).
8.
Remove floor hoist straps from frame.
9.
Connect and fill lubrication system. See 
ENGINE LUBRI-
CATION SYSTEM
 in Section 1.
10. Install muffer and exhaust header. See 
EXHAUST SYS-
TEM
 in Section 2.
11. Align belt and rear wheel. See 
REAR BELT DEFLEC-
TION
 in Section 1.
12. Install rider footrests. See 
FOOTRESTS, INSTALLATION
in Section 2.
13. Install air cleaner. See 
AIR CLEANER, INSTALLATION 
in
Section 4.
14. Install sprocket cover and rear belt guard. See
SPROCKET COVER
 and 
FENDERS
 in Section 2.
15. Install rear fender. See 
FENDERS, REMOVAL/INSTAL-
LATION 
in Section 2.
16. Install rear caliper. See 
REAR BRAKE CALIPER, INSTAL-
LATION 
in Section 2.
1
 
WARNING
After installing seat, pull upward on front of seat to be
sure it is locked in position. If seat is loose, it could shift
during vehicle operation and startle the rider, causing
loss of control and personal injury.
 
17. Install tail section, fuel tank and seat. See 
TAIL SEC-
TION, INSTALLATION 
in Section 2.
1
 
WARNING
Always connect positive battery cable first. If the positive
cable should contact ground with the negative cable
installed, the resulting sparks may cause a battery explo-
sion resulting in personal injury.
1
 
CAUTION
Hold battery cable when tightening battery terminal hard-
ware. Failure to hold cable may cause battery damage.
 
18. Connect 
 
both
 
 battery cables, positive cable first.
19. Perform the following tests.
a. 
Check license plate lamp illumination.
b.  Check oil level after starting vehicle and allowing
motorcycle to reach normal operating temperature. 
20. Remove supports.
a. 
Remove REAR WHEEL SUPPORT STAND.
b. 
Free front wheel and remove motorcycle from lift.