Warning - Buell S1 Lightning Workshop Manual

REMOVAL
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.
NOTE
See Figure 6-9. If replacement of clutch pack (friction plates
[18], steel plates [19], and spring plate [20]) is the only ser-
vice work to be performed, perform REMOVAL Step 1 only,
and then proceed to DISASSEMBLY, NOTE.
1. Remove primary cover. See
page 6-3.
2. Install SPROCKET LOCKING LINK (Part No. HD-
38362). Remove the engine sprocket nut. Loosen, but do
not remove, engine sprocket. If necessary, use the slot-
ted portion of TWO CLAW PULLER (Part No. HD-97292-
61) and two bolts to loosen the engine sprocket.
3. Remove retaining ring (12). Remove adjusting screw
assembly (13, 14, 15 and 16) from pressure plate (17).
1
CAUTION
Clutch hub nut (21) has left-hand threads. To prevent
damage, turn nut clockwise to loosen and remove from
mainshaft.
4. Remove nut (21) and washer (22). Remove the clutch
assembly, primary chain, and engine sprocket as an
assembly from the vehicle.
5. If primary chain is damaged or excessively worn, remove
it from engine sprocket and clutch assembly; replace
original primary chain with a new one.
DISASSEMBLY
NOTE
See Figure 6-9. If replacement of clutch pack (friction plates
[18], steel plates [19], and spring plate [20]) is the only ser-
vice work to be performed, perform DISASSEMBLY Steps 2,
3, 4, 5 and 7 only, and then proceed to INSPECTION AND
REPAIR, NOTE. Observe
1
CAUTION statements which apply to the steps speci-
fied.
1. See Figure 6-9. With clutch assembly removed from pri-
mary chaincase, reinstall adjusting screw assembly (13,
14, 15 and 16) into pressure plate (17), noting that two
tabs on perimeter of release plate (13) must be inserted
into corresponding recesses in pressure plate (17).
Secure the adjusting screw assembly with retaining ring
(12).
6-10
PRIMARY DRIVE/CLUTCH
PRIMARY CHAIN on
1
all WARNING and
1
WARNING
See Figure 6-10. Do not attempt to disassemble the
clutch without SPRING COMPRESSING TOOL (Part No.
HD-38515-A), CLUTCH SPRING FORCING SCREW (Part
No. HD-38515-91) and proper eye protection. Otherwise,
the highly compressed diaphragm spring could fly out
with great force, possibly causing personal injury.
2. Thread the CLUTCH SPRING FORCING SCREW (Part
No. HD-38515-91) (item 1,
adjusting screw (item 16,
(item 2, Figure 6-10.) of SPRING COMPRESSING TOOL
(Part No. HD-38515-A) against diaphragm spring (item
10, Figure 6-9.) Thread the tool handle (item 3,
10.) onto end of forcing screw.
1
CAUTION
See Figure 6-9. Turn compressing tool handle only the
amount required to remove spring seat (10) and snap
ring (9). Excessive compression of diaphragm spring
could damage clutch pressure plate.
3. See Figure 6-10. With a wrench on the clutch spring forc-
ing screw flats to prevent the forcing screw from turning,
turn handle clockwise until tool relieves pressure on snap
ring (9) and spring seat (10).
4. Remove snap ring (9) and spring seat (10) from the
groove in clutch hub (23) prongs. Remove the assembly
of diaphragm spring (11), pressure plate (17), adjusting
screw components, and compressing tool.
5. Turn the compressing tool handle counterclockwise until
the clutch spring forcing screw disconnects from the
clutch adjusting screw (16). Remove snap ring (9), spring
seat (10), and diaphragm spring (11) from pressure plate
(17) assembly.
6. Remove retaining ring (12) and adjusting screw assem-
bly (13, 14, 15 and 16) from pressure plate (17). If neces-
sary, disassemble adjusting screw assembly by removing
retaining ring (14), and then separating the remaining
adjusting screw components (13, 15 and 16).
7. Remove the clutch pack, which consists of eight friction
plates (18), six steel plates (19), and a spring plate (20),
from the clutch hub (23).
1
CAUTION
Due to the possible damage to the bearing (25), the
clutch hub (23) and shell (26) assembly should not be
disassembled unless the bearing, hub, or shell require
replacement. If the assembly is pressed apart, the bear-
ing must be replaced.
8. Remove retaining ring (27) from inboard end of clutch
hub (23). Using an arbor press, separate clutch hub (23)
from assembly of clutch shell (26), bearing (25), and
retaining ring (24).
9. Remove retaining ring (24) from groove in clutch shell
(26). Press on the inboard side of bearing (25) outer race
to remove bearing from clutch shell.
Figure 6-10.) onto the clutch
Figure 6-9.) Place the bridge
Figure 6-