buell s1 lightning '97 Manual

1.

Remove front brake master cylinder. See 

.

2.

Remove left and right handlebar switch housings. See

 in Section 7.

3.

Cut left handlebar grip and remove.

4.

Remove instrument support. See 

.

5.

Loosen four screws (1) on upper handlebar clamp (2). 

6.

Move handlebar towards the air cleaner to increase clutch
cable freeplay. Remove clutch control. See 

.

7.

Remove four screws (1), upper handlebar clamp (2) and
handlebars (3).

8.

Remove four bolts (8), lockwashers (7) and washers (6)
to detach lower handlebar clamps (4, 5) from upper triple
clamp.

1.

Install lower handlebar clamps (4, 5) with four bolts (8),
lockwashers (7) and washers (6). Tighten to 30-33 ft-lbs
(40.7-44.7 Nm).

2.

Install clutch control. See 

3.

Install handlebar (3) using upper handlebar clamp (2)
and four screws (1). Tighten screws to 10-12 ft-lbs (13.6-
16.2 Nm).

4.

Install instrument support. See 

.

5.

Install left and right handlebar switch housings. See

 in Section 7.

6.

Install a new left handgrip.

a. 

Clean end of handlebar with M600.

b.  Place LOCTITE 411 ADHESIVE around inside of

grip.

c. 

Push grip onto handlebar end. Twist grip on bar until
end touches left switchgear housing.

d. 

Wipe off excess adhesive with a rag.

7.

Install front brake master cylinder. See 

.

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