buell s1 lightning '97 Manual
2-45
ASSEMBLY/INSTALLATION
Clutch Cable – Lower
1.
See
Install O-ring (8) over cable end fitting
(9) of clutch cable lower section. Turn fitting clockwise to
install into primary cover (11). Tighten fitting to 3-5 ft-lbs
(4.0-6.8 Nm).
install into primary cover (11). Tighten fitting to 3-5 ft-lbs
(4.0-6.8 Nm).
2.
Fit coupling (16) over cable end. Place hook of ramp
around coupling button and rotate assembly counter-
clockwise until tang on inner ramp (15) fits in slot of pri-
mary cover (11).
around coupling button and rotate assembly counter-
clockwise until tang on inner ramp (15) fits in slot of pri-
mary 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 (6) and turn adjusting screw counter-clock-
wise.
is accessible with a screwdriver. Fit nut hex into recess of
outer ramp (6) and turn adjusting screw counter-clock-
wise.
4.
If not yet performed, route clutch cable from hand grip
across front of upper triple clamp to right side, down
between right fork leg and steering neck above lower tri-
ple clamp. Continue down to left side of bike through
clamp along primary chaincase to clutch.
across front of upper triple clamp to right side, down
between right fork leg and steering neck above lower tri-
ple clamp. Continue down to left side of bike through
clamp along primary chaincase to clutch.
5.
With clutch cable upper section connected to clutch
lever, adjust primary chain tension. See
lever, adjust primary chain tension. See
PRIMARY
CHAIN
in Section 1.
6.
Adjust clutch. See
CLUTCH
in Section 1.
Clutch Hand Control
1.
Attach clutch clamp (5) as follows.
a.
Slide clamp over handlebar.
b. Install left switchgear housing. See
HANDLEBAR
SWITCHES
in Section 7.
c. Place clamp next to switchgear housing. Fasten to
handlebar with screw (4) (metric). Tighten screw to
30-35 in-lbs (3.4-4.0 Nm).
30-35 in-lbs (3.4-4.0 Nm).
d. Install mirror parallel to handlebars. Mirror mount
has metric, left hand threads.
e. Install
a
new left handgrip. See
.
2.
Connect end of clutch cable upper section to clutch han-
dlever. Position lever within clutch clamp.
dlever. Position lever within clutch clamp.
3.
Apply small amount of LOCTITE ANTI-SEIZE LUBRI-
CANT to bolt (2). Secure handlever with bolt (2) (metric)
and nut (6) (metric).
CANT to bolt (2). Secure handlever with bolt (2) (metric)
and nut (6) (metric).
4.
Attach clutch switch (7) with screw (8).
5.
If not yet performed, route clutch cable from hand grip
across front of upper triple clamp to right side, down
between right fork leg and steering neck above lower tri-
ple clamp. Continue down to left side of bike through
clamp along primary chaincase to clutch.
across front of upper triple clamp to right side, down
between right fork leg and steering neck above lower tri-
ple clamp. Continue down to left side of bike through
clamp along primary chaincase to clutch.
6.
With clutch cable lower section connected to primary
cover, adjust clutch. See
cover, adjust clutch. See
CLUTCH
in Section 1.
Figure 2-53. Clutch Hand Control
b0221x2x
3
1.
Clutch handlever
2.
Bolt (metric)
3.
Mirror assembly
4.
Screw (metric)
5.
Clutch clamp
6.
Nut (metric)
7.
Clutch switch
8.
Screw
9.
Clutch cable
10. Wire guide
11. Cable clamp
11. Cable clamp
1
2
4
9
8
7
6
11
10
Remove switch (7)
5