Warning - Buell S1 Lightning Workshop Manual

Primary Cover
1. Remove foreign material from magnetic drain plug. Install
plug and tighten to 14-21 ft-lbs (19-28 Nm).
2. Wipe gasket surface clean. Install new gasket on primary
cover.
3. See Figure 6-4. Install primary cover and gasket onto left
crankcase half using mounting bolts. Tighten bolts to 80-
110 in-lbs (9.0-12.4 Nm).
4. See Figure 6-1. Install new shift lever oil seal (14).
5. Fit coupling (6) over clutch cable end. Place hook of
ramp (7) around coupling button and rotate assembly
counterclockwise until tang on inner ramp fits in slot of
primary cover.
6. Thread nut (5) on adjusting screw (17) until slot of screw
is accessible with a screwdriver. Fit nut hex into recess of
outer ramp and turn adjusting screw counterclockwise.
7. Fill transmission to proper level with fresh lubricant. See
CLUTCH, TRANSMISSION FLUID
8. Adjust clutch. See CLUTCH, ADJUSTMENT
9. Adjust primary chain tension. See
ADJUSTMENT in Section 1.
10. Install rubber washer (13) and shift lever assembly (12).
Shift lever must bisect primary chain inspection cover.
See Figure 6-5. Tighten pinch screw to 100-120 in-lbs
(11.3-13.6 Nm).
11. Install muffler. See EXHAUST SYSTEM
1

WARNING

Always connect positive battery cable first. If the positive
cable should contact ground with the negative cable
installed, the resulting sparks may cause a battery explo-
sion producing personal injury.
1
CAUTION
Hold battery cable when tightening battery terminal hard-
ware. Failure to hold cable may cause battery damage.
12. Connect battery cables, positive cable first.
x0023a6x
1.
2.
3.
5583
in Section 1.
in Section 1.
PRIMARY CHAIN,
in Section 2.
2
1
2
1
3
1/4-20 x 1-3/4 in. bolt with washers (7)
1/4-20 x 2-1/4 in. bolt with washers (4)
5/16-18 x 3-1/2 in. bolt with washers (2)
Figure 6-4. Install Primary Cover Bolts
Primary chain
inspection cover
Shift lever
Figure 6-5. Shift Lever
1
2
1
6-5