Handlebar Switches - Buell S1 Lightning Workshop Manual

REMOVAL
1. Remove front brake master cylinder. See
BRAKE MASTER CYLINDER, REMOVAL
2. Remove left and right handlebar switch housings. See

HANDLEBAR SWITCHES

3. Cut left handlebar grip and remove.
4. Remove instrument support. See
TACHOMETER on page
5. Loosen four screws (1) on upper handlebar clamp (2).
6. Move handlebar towards the air cleaner to increase clutch
cable freeplay. Remove clutch control. See
CONTROL, REMOVAL/DISASSEMBLY
7. Remove four screws (1), upper handlebar clamp (2) and
handlebars (3).
8. Remove four bolts (8), lockwashers (7) and washers (6)
to detach lower handlebar clamps (4, 5) from upper triple
clamp.
INSTALLATION
1. Install lower handlebar clamps (4, 5) with four bolts (8),
lockwashers (7) and washers (6). Tighten to 30-33 ft-lbs
(40.7-44.7 Nm).
2. Install clutch control. See
BLY/INSTALLATION on page
3. Install handlebar (3) using upper handlebar clamp (2)
and four screws (1). Tighten screws to 10-12 ft-lbs (13.6-
16.2 Nm).
4. Install instrument support. See
TACHOMETER on page
5. Install left and right handlebar switch housings. See
HANDLEBAR SWITCHES
6. Install a new left handgrip.
a. Clean end of handlebar with M600.
b. Place LOCTITE 411 ADHESIVE around inside of
grip.
c. Push grip onto handlebar end. Twist grip on bar until
end touches left switchgear housing.
d. Wipe off excess adhesive with a rag.
7. Install front brake master cylinder. See
MASTER CYLINDER, INSTALLATION
HANDLEBAR
FRONT
on page 2-19.
in Section 7.
SPEEDOMETER AND
2-46.
CLUTCH
on page 2-44.
CLUTCH CONTROL, ASSEM-
2-45.
SPEEDOMETER AND
2-46.
in Section 7.
FRONT BRAKE
on page 2-19.
b0220x2x
1
2
3
4
6
8
1. Screw (4)
2. Upper handlebar
clamp
3. Handlebar
4. Lower right handlebar
clamp
Figure 2-57. Handlebars
5
7
5. Lower left handlebar
clamp
6. Washer (4)
7. Lockwasher (4)
8. Bolt (4)
2-49