buell s1 lightning '97 Manuel

 

The front fork consists of two telescoping outer tube/inner
slider assemblies. Each tube/slider assembly has an internal
compression spring which supports the forward weight of the
vehicle/rider. The compression spring extends and retracts to
cushion the ride over rough or irregular road surfaces. An oil-
filled damping mechanism controls the telescoping action of
each tube/slider assembly.

 in Section 1 for fork oil change procedure.

 

1.

2.

Remove front brake caliper. See 

on 

.

3.

Remove front wheel. See 

4.

Remove front fender. See 

.

5.

Loosen left and right headlamp brackets. See 

in Section 7.

6.

Loosen all five pinch screws on both the upper and lower
triple clamps.

7.

Remove front forks.

 

1.

See 

 Clamp the fork vertically in a vise using

2.

 Turn adjuster to full slow position (com-

pletely clockwise).

3.

 Remove fork cap (2) (metric), O-ring (3)

and washer (4).

4.

Reduce spring pressure and remove both retaining
clips (5).

5.

Remove preload shim(s) (6) and steel washer (7).

6.

Remove fork spring (8).

7.

Invert fork and drain fork oil.

8.

seal retaining ring (14) and spacer ring (13).

9.

Using

bottom of outer tube. When the tube has sufficiently
expanded, drive inner tube (18) from outer tube with a
slide hammer action. Inner tube will retain fork oil seal
(12) and support ring (11) in place.

10. Spread red retaining cap (15) and remove. Remove

upper DU bushing (16) and washer (17).

11. Remove retaining ring (14) and spacer ring (13).

12. Remove lower DU bushing (10), support ring (11) and

fork oil seal (12). Discard fork oil seal and support ring.

13. Invert fork. Hold damper assembly and remove bolt (20)

(metric) and copper washer (19). Discard copper washer. 

14. Remove damper assembly (22). 

 

NOTE

The damper assembly (22) contains no user serviceable
parts.

5761

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