buell s1 lightning '97 Manual
6-9
CLUTCH RELEASE MECHANISM
ADJUSTMENT
See
CLUTCH, ADJUSTMENT
in Section 1.
DISASSEMBLY
1
WARNING
To avoid accidental start-up of vehicle and possible per-
sonal injury, disconnect the battery cables before pro-
ceeding. Always disconnect the negative cable first. If
the positive cable should contact ground with the nega-
tive cable installed, the resulting sparks may cause a bat-
tery explosion producing personal injury.
sonal injury, disconnect the battery cables before pro-
ceeding. Always disconnect the negative cable first. If
the positive cable should contact ground with the nega-
tive cable installed, the resulting sparks may cause a bat-
tery explosion producing personal injury.
1.
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 (1.6-3.2 mm). Adjust freeplay
by turning cable adjuster.
clutch hand lever bracket. Gap between ferrule and
bracket should be 1/16-1/8 (1.6-3.2 mm). Adjust freeplay
by turning cable adjuster.
2.
Remove four TORX screws with washers
(1) and clutch inspection cover (2).
3.
Slide spring (3) with attached screw lockplate (4) from
flats of adjusting screw (12).
flats of adjusting screw (12).
4.
Turn adjusting screw (12) clockwise to release ramp and
coupling mechanism. As the adjusting screw is turned,
ramp assembly moves forward. Unscrew nut (5) from end
of adjusting screw.
coupling mechanism. As the adjusting screw is turned,
ramp assembly moves forward. Unscrew nut (5) from end
of adjusting screw.
5.
Remove hook of ramp from cable end coupling (16).
Remove cable end (10) from slot in coupling.
Remove cable end (10) from slot in coupling.
6.
Remove retaining ring (13) from ramp assembly to sepa-
rate inner and outer halves. Remove three balls (7) from
ramp sockets.
rate inner and outer halves. Remove three balls (7) from
ramp sockets.
CLEANING, INSPECTION
AND REPAIR
AND REPAIR
1.
Thoroughly clean all parts in cleaning solvent.
2.
nism and ball socket surfaces of inner and outer ramps
for wear, pitting, surface breakdown and other damage.
Replace parts as necessary.
for wear, pitting, surface breakdown and other damage.
Replace parts as necessary.
3.
Check hub fit of inner (15) and outer (6) ramps. Replace
ramps if excessively worn.
ramps if excessively worn.
4.
Check clutch cable for frayed or worn ends. Replace
cable if damaged or worn.
cable if damaged or worn.
5.
Change or add transmission fluid if necessary. See
CLUTCH, TRANSMISSION FLUID
in Section 1.
ASSEMBLY
1.
See
Apply multi-purpose grease to balls (7)
and ramps (6, 15). Insert balls in sockets of outer ramp.
Install inner ramp on hub of outer ramp with tang 180
Install inner ramp on hub of outer ramp with tang 180
°
from hook of outer ramp. Install retaining ring in groove of
outer ramp hub.
outer ramp hub.
2.
Fit coupling (16) over cable end. Place hook of ramp
around coupling button and rotate assembly counter-
clockwise until tang on inner ramp fits in slot of primary
cover (11).
around coupling button and rotate assembly counter-
clockwise until tang on inner ramp fits in slot of primary
cover (11).
3.
Thread nut (5) on adjusting screw (12) until slot of screw
is accessible with a screwdriver. Fit nut hex into recess of
outer ramp and turn adjusting screw counterclockwise
until resistance is felt.
is accessible with a screwdriver. Fit nut hex into recess of
outer ramp and turn adjusting screw counterclockwise
until resistance is felt.
4.
Adjust clutch release mechanism. See
CLUTCH,
ADJUSTMENT
in Section 1.
Figure 6-8. Clutch Release Mechanism
1.
TORX screw with washer (4)
2.
Clutch inspection cover
3.
Spring
4.
Adjusting screw lockplate
5.
Nut
6.
Outer ramp
7.
Ball (3)
8.
O-ring
9.
Cable end fitting
10. Clutch cable end
11. Primary cover
12. Clutch adjusting screw
11. Primary cover
12. Clutch adjusting screw
assembly
13. Retaining ring
14. Quad ring
15. Inner ramp
16. Coupling
14. Quad ring
15. Inner ramp
16. Coupling
b0131x6x
1
2
3
4
5
6
7
16
15
8
9
10
11
12
13
14
NOTE
Depending upon vehicle production date,
configuration of items 6 and 16 may vary.
See CLUTCH in Section 1.
configuration of items 6 and 16 may vary.
See CLUTCH in Section 1.