buell s1 lightning '97 Manual
1-20
ADJUSTMENT
Check clutch adjustment:
●
At the 500 mile (800 km) service interval.
●
At every 5000 mile (8000 km) service interval thereafter.
If clutch slips under load or drags when released, first check
control cable adjustment. If cable adjustment is within specifi-
cations, adjust clutch mechanism as described below.
control cable adjustment. If cable adjustment is within specifi-
cations, adjust clutch mechanism as described below.
When necessary, lubricate cable with LUBIT-8 TUFOIL
®
CHAIN AND CABLE LUBE (Part No. HD-94968-85TV).
1.
Raise rear of vehicle off the floor using
REAR WHEEL
SUPPORT STAND (Part No. B-41174)
.
2.
See
Slide rubber boot (1) upward to expose
adjuster mechanism. Loosen jam nut (3) from adjuster
(4). Turn adjuster to shorten cable housing until there is a
large amount of freeplay at clutch hand lever.
(4). Turn adjuster to shorten cable housing until there is a
large amount of freeplay at clutch hand lever.
3.
Remove TORX screws with washers (1)
from clutch inspection cover (2). Remove clutch inspec-
tion cover from primary cover, but leave Quad ring (3) in
place.
tion cover from primary cover, but leave Quad ring (3) in
place.
NOTE
Quad ring removed from primary cover for illustrative pur-
poses only in
poses only in
4.
Remove spring (4) and adjusting screw lockplate (5).
Turn adjusting screw counterclockwise until it lightly bot-
toms.
Turn adjusting screw counterclockwise until it lightly bot-
toms.
5.
Turn clutch adjusting screw (6) clockwise 1/4 turn. Install
lockplate (5) and spring (4) on adjusting screw flats. If
hex on lockplate does not align with recess in outer ramp,
rotate adjusting screw clockwise until it aligns.
lockplate (5) and spring (4) on adjusting screw flats. If
hex on lockplate does not align with recess in outer ramp,
rotate adjusting screw clockwise until it aligns.
6.
Squeeze clutch lever to maximum limit three times to set
ball and ramp mechanism. Pull outer cable conduit and at
the same time adjust cable adjuster to provide 1/16-1/8 in.
(1.6-3.2 mm) freeplay at hand lever. Adjust as follows.
ball and ramp mechanism. Pull outer cable conduit and at
the same time adjust cable adjuster to provide 1/16-1/8 in.
(1.6-3.2 mm) freeplay at hand lever. Adjust as follows.
a. See
Pull clutch cable ferrule (end of
cable housing) away from clutch hand lever bracket.
Gap between ferrule and bracket should be 1/16-1/8
in. (1.6-3.2 mm).
Gap between ferrule and bracket should be 1/16-1/8
in. (1.6-3.2 mm).
b. See
Adjust freeplay by turning cable
adjuster (4).
c.
Tighten jam nut (3) against adjuster (4).
d.
Slide boot (1) over cable adjuster mechanism.
7.
Change or add transmission fluid if necessary.
8.
Install clutch inspection cover (2). Tighten TORX screws
with washers (1) in a crosswise pattern to 7-9 ft-lbs (9-
12 Nm).
with washers (1) in a crosswise pattern to 7-9 ft-lbs (9-
12 Nm).
9.
Check clutch cable freeplay. See Step 6 above.
Figure 1-18. Clutch Cable Adjuster Mechanism
Figure 1-19. Clutch Release Mechanism
Figure 1-20. Adjusting Clutch Freeplay
1.
Rubber boot
2.
Cable end
3.
Jam nut
4.
Adjuster
1
5594
2
3
4
1.
Torx screw with washer
2.
Clutch inspection cover
3.
Quad ring
4
5
1
2
3
6
4.
Spring
5.
Lockplate
6.
Adjusting screw
b0152x6x
5595
Adjust for 1/16-1/8 in. (1.6-3.2 mm)
gap between ferrule and bracket
gap between ferrule and bracket