buell s1 lightning '97 Manuel

 

1.

Remove fork assemblies. See 

.

2.

See 

 Remove fork stem bolt (1) and upper

triple clamp (2).

3.

Remove upper dust shield (3) and upper roller
bearing (4). 

4.

Lower the lower triple clamp (6). The lower bearing cone
is a press fit on fork stem. Chisel through outer bearing
cage to allow rollers to fall free. Apply heat to remove the
remaining portion of bearing cone. Continuously move
flame around its entire circumference until bearing falls
free. Remove lower dust shield (3).

5.

If replacement of bearing cups (5) is necessary, drive
cups from steering head using 

 

 in Section 1 for adjustment procedures.

1.

See 

 Clean the dust shields (3), bearing

cups (5), fork stem and lower triple clamp (6) and frame
with solvent. 

2.

Carefully inspect bearing races and assemblies for pit-
ting, scoring, wear and other damage. Replace damaged
bearing as a set. 

3.

Check the fork stem and lower triple clamp (6) for dam-
age. Replace damaged fork stem.

 

1.

 If removed, install 

 

 bearing cups (5)

2.

Liberally coat the bearing cones (4) with grease using

Work the grease into the rollers.

3.

Place lower bearing dust shield (3) over fork stem. Find a
section of pipe having an inside diameter slightly larger
than the outside diameter of the fork stem. Press bearing
cone (4) onto fork stem and bracket (1) using the pipe as
a press on tool.

4.

Insert lower triple clamp (6) through the steering head.
Install the upper bracket bearing (4) and dust shield (3)
onto fork stem.

5.

Install the upper triple clamp (2) and loosely install fork
stem bolt (11).

6.

Install fork assemblies. See 

.

7.

Tighten the fork stem bolt (1) until the bearings have no
freeplay. Make sure the fork stem turns freely, then
tighten the fork stem clamp screw (rearmost pinch screw
on upper triple clamp). 

8.

Check bearing adjustment. See 

in Section 1.