Warning - Buell S1 Lightning Workshop Manual

REMOVAL
NOTE
Mark all hardware as it is removed so that it may be returned
to its original location.
1. Swingarm removal requires motorcycle to be supported
in several areas. First, secure front wheel and then raise
rear wheel off ground with
STAND (Part No. B-41174).
1

WARNING

To avoid accidental start-up of vehicle and possible per-
sonal injury, disconnect the battery cables before pro-
ceeding. Always disconnect the negative cable first. If
the positive cable should contact ground with the nega-
tive cable installed, the resulting sparks may cause a bat-
tery explosion producing personal injury.
1
CAUTION
Hold battery cable when loosening battery terminal hard-
ware. Failure to hold cable may cause battery damage.
2. Disconnect both battery cables, negative cable first.
3. Remove seat, fuel tank and tail section. See
TION, REMOVAL on page
4. Drain oil tank and remove filter. Detach feed, vent and
return hoses from oil tank. See
SYSTEM in Section 1.
5. Support motorcycle frame with a floor hoist such as the
CENTRAL HYDRAULICS FOLDING CRANE (Model T-
5466).
6. Remove rear fender. See
INSTALLATION on page
7. Remove rear brake caliper assembly from swingarm.
See REAR BRAKE CALIPER, REMOVAL/DISASSEM-
BLY on page 2-25.
8. Remove rear wheel. See
page 2-11.
9. Remove rear shock. See
REMOVAL on page 2-36.
10. Remove rider footrests. See
on page 2-52.
11. Remove air cleaner assembly. See
REMOVAL in Section 4.
12. Remove carburetor. See
Section 4.
13. Remove muffler and exhaust header. See
SYSTEM, REMOVAL/DISASSEMBLY
14. Support engine under crankcase. Avoid pushing tie bar
assembly upward.
15. Place a crating strap between the engine cylinders and
around the lift. Tighten crating strap until snug.
SWINGARM
REAR WHEEL SUPPORT
TAIL SEC-
2-55.
ENGINE LUBRICATION
FENDERS, REMOVAL/
2-54.
REAR WHEEL, REMOVAL
REAR SHOCK ABSORBER,
FOOTRESTS, REMOVAL
AIR CLEANER,
CARBURETOR, REMOVAL
EXHAUST
on page 2-50.
16. Detach tie bars from frame mounts in the following
sequence. Do not remove tie bars from engine.
a. Rear tie bar. Use a swivel socket.
b. Top tie bar.
c. Front tie bar and clutch cable clamp.
17. See Figure 2-37.
ers on each side.
18. Slowly raise floor hoist until rubber isolators (10) can be
removed. Frame will rise while engine and swingarm
remain secured to lift by crating strap.
19. Loosen one pinch screw (8) on the swingarm mount
block (7).
20. Remove bearing adjusting bolt (1) on that side with
PIVOT SHAFT BEARING ADJUSTER (Part No. B-
41175).
21. Loosen the remaining pinch screw. Extract pivot shaft (5)
and second adjuster as an assembly.
22. Remove swingarm.
DISASSEMBLY
Carefully mark all bearing components as they are
removed, so that they may be returned to their original
locations. Do not intermix bearing components.
1. See Figure 2-37. Remove and discard swingarm seal (2).
2. Remove roller bearings (3).
Remove roller bearing cups (4) only if replacement is
required. The complete bearing assembly must be replaced
as a unit when replacement is necessary. Do not intermix
bearing components.
3. See Figure 2-38.
from swingarm using
on
RACE REMOVER (Part No. HD-39301A)
SAL DRIVER HANDLE (Part No.
CLEANING/INSPECTION
1. Clean all components in solvent and blow dry. Carefully
inspect all bearing components for wear and/or corro-
sion. Replace complete bearing assembly if any compo-
nent is damaged.
in
2. Check that swingarm is not bent or twisted. Replace if
damaged.
ASSEMBLY
1. See Figure 2-39.
cups (4) into swingarm using
BOLT (Part No. B-35316-5)
BEARING RACE INSTALLER (Part No.
Remove isolator screws (9) and wash-
1
CAUTION
NOTE
Carefully press roller bearing cups (4)
STEERING HEAD BEARING
and
HD-33416).
If necessary, draw new roller bearing
BEARING INSTALLATION
and STEERING HEAD
HD-39302).
UNIVER-
2-33