Buell S1 Lightning 1996 Manual page 210

4. See Figure 5-15. Use a wire hook to pull upward on
brush springs, and lift brushes out of holder. Remove
brush holder.
5. Check brush length. Replace all four brushes if length of
any one brush is less than 0.433 in. (11.0 mm).
Replace brushes in sets of four only.
6. See Figure 5-14. Remove armature (6) and field frame (7).
7. Place armature in lathe or truing stand and check runout
of commutator. Commutators with more than 0.016 in.
(0.41 mm) of runout should be replaced, or machined on
a lathe. Commutators should be replaced when diameter
is less than 1.141 in. (28.98 mm).
b0136x5x
Undercutting mica with piece
5-14
Starting groove in mica
with 3 cornered file
Commutator
of hacksaw blade
Figure 5-16. Undercutting Mica Separators
www.PlanDeGraissage.org
3540a
Figure 5-15. Removing Brush Holder
Mica must not be left with a
thin edge next to segments
Segments
Wrong way
Mica must be cut away
clean between segments
Segments
Right way
Brush holder
Mica
Mica