Buell S1 Lightning Workshop Manual page 123

ASSEMBLY/INSTALLATION
Clutch Cable – Lower
1. See Figure 2-52. 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).
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).
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.
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.
5. With clutch cable upper section connected to clutch
lever, adjust primary chain tension. See
CHAIN in Section 1.
6. Adjust clutch. See CLUTCH
Clutch Hand Control
1. See Figure 2-53. Attach clutch clamp (5) as follows.
a. Slide clamp over handlebar.
b. Install left switchgear housing. See
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).
d. Install mirror parallel to handlebars. Mirror mount
has metric, left hand threads.
e. Install a new left handgrip. See
INSTALLATION on page
2. Connect end of clutch cable upper section to clutch han-
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).
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.
6. With clutch cable lower section connected to primary
cover, adjust clutch. See
PRIMARY
in Section 1.
HANDLEBAR
HANDLEBAR,
2-49.
CLUTCH in Section 1.
b0221x2x
3
4
5
9
7
8
10
1. Clutch handlever
2. Bolt (metric)
3. Mirror assembly
4. Screw (metric)
5. Clutch clamp
6. Nut (metric)
Figure 2-53. Clutch Hand Control
1
2
6
11
7. Clutch switch
8. Screw
9. Clutch cable
10. Wire guide
11. Cable clamp
2-45