buell s1 lightning '97 Manual

If only cylinder head work was needed, reinstall cylinder head
following these instructions. If further repair is required, see

.

1.

See 

 Coat mating surfaces of cylinder studs

(12) and head screws (1, 2) with parts cleaning solution.

2.

Scrape old oil and any carbon deposits from threads by
using a back-and-forth motion, threading each head
screw onto its mating cylinder stud.

3.

Remove head screws from studs. Wipe or blow dry
thread surfaces.

4.

Apply oil to stud threads and to the underside of the head
screw shoulder.

1

5.

Blow or wipe off excess oil from head screws.

6.

Thoroughly clean and dry the gasket surfaces of cylinder
(19) and cylinder head (18).

7.

Install a new O-ring (14) on each dowel (15).

1

8.

Install a new head gasket (4) to cylinder.

9.

Carefully lower cylinder head over studs and position on
dowels. Use great care so as not to disturb head gasket.

10. Install head screws (1, 2) finger tight.

1

11. See 

 For each cylinder head, start with screw

numbered one, as shown. In increasing numerical
sequence (i.e. – 1, 2, 3 and 4), tighten head screws in
three stages:

FIRST 

STAGE: 

Tighten each screw to 7-9 ft-lbs
(9-12 Nm).

SECOND STAGE: 

Tighten each screw to 12-14 ft-lbs
(16-19 Nm).

THIRD STAGE: 

See 

 Mark cylinder head

and head screw shoulder with a line as
shown (View A). Tighten each screw a
1/4-turn (90

°

) (View B).

12. See 

 Rotate engine so that both tappets (6),

from the cylinder being serviced, will be installed on the
base circle (lowest position) of the cam.

13. Apply a liberal amount of engine oil to tappet assembly

(especially roller needles) for smooth initial operation.

14. Insert tappet (6) into bore in crankcase (1). Rotate tappet

so that flats at upper end of tappet face the front and rear
of the engine. If the tappet is installed incorrectly, pins (2)
cannot be inserted.

15. Insert pins (2) in the holes in crankcase. Place new O-

rings (3) over ends of pins. Install plate (4) using screw
(5) with washer (14). Tighten screw (5) to 80-110 in-lbs.
(9.0-12.4 Nm).

16. Slide  new seal (8), and place retainer (9), over top of

push rod cover (7). Position new O-ring (10) at top of
push rod cover. Hold cover at an angle and insert top
through hole in cylinder head. Push up on cover while
aligning bottom of cover with tappet bore in crankcase.
Lower retainer (9) with seal (8) onto crankcase, aligning
locating pin (15) with hole in retainer.

17. Insert screw (11) with washer (13) through hole in

retainer (9), and thread into tapped hole in crankcase.
Tighten screw (11) to 15-18 ft-lbs (20-24 Nm).

18. Identify push rod color coding, length and respective push

rod positions in engine. See 

 Place intake and

exhaust push rods (1, 2) onto seat at top of tappet (6).

19. See 

 Install new gaskets (16, 17) with the

bead facing up. Place lower rocker box assembly (with
rocker arms and shafts) into position. Place push rods in
rocker arm sockets.

Exhaust (Front & Rear)

3 Band - Pink,

17904-89,

10.800 in.

Intake (Front & Rear)

1 Band - Brown,

17897-89,

10.746 in.

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