buell s1 lightning '97 Manuel

 

1.

Thoroughly clean and inspect all parts. Replace any
parts that are bent, broken or damaged.

2.

Inspect the O-rings for damage, wear or general deterio-
ration; replace as necessary. Replace all other removed
seals.

3.

See 

 Check inner tube (18). Tube surface

should be shiny, smooth and free of scoring or abrasions.

 

1.

Install 

 

 fork seal retaining ring (14) and spacer ring

(13) on inner tube.

2.

See 

 Using

 

 fork oil seal

on inner tube. External spring on fork oil seal faces bot-
tom of fork leg.

3.

 Install 

 

support ring (11). 

4.

Install upper DU bushing (16) with large end towards the
bottom of the fork leg. Install washer (17) and lower DU
bushing (10). Install red retaining cap (15).

 

NOTE

Inspect both DU bushings upon assembly. Bushings are
bronze with a Teflon layer. A DU bushing should be replaced
when 20-30% of the Teflon layer has been worn through. In
this circumstance, a visual inspection will show 20-30% of the
bronze base. Also replace bushings if bushing interiors show
any small grooves. Such grooves will damage the outside sur-
face of the inner tubes.

 

5.

6.

See 

 Place inner tube assembly inside outer

tube. Using 

 

, drive in DU bush-

ings until fully seated. 

7.

Reverse 

. Seat fork oil seal with 

 

 side of

tool. Drop seal retaining ring in place. Fully seat retaining
ring.

8.

See 

 Clamp fork in a horizontal position.

Install damper assembly (22) using bolt (20) (metric) and
a 

 

 copper washer (19). Tighten bolt to 18-23 ft-lbs

(24.4-31.2 Nm).

9.

Clamp fork upright in the fully compressed stage. 

10. Fill fork with oil. See 

 in Section 1.

11. Install fork spring (8).

12. Pull damper assembly above fork spring. Place steel

washer (7) and preload shim(s) (6) on top of spring.

13. Installing the retaining clips (5) requires two people.

Have one person compress the spring, steel washer and
preload shim(s). At the same time, have the second per-
son install both retaining clips.

14. Install washer (4), 

 

 O-ring (3) and fork cap (2) (metric). 

5759