Buell S1 Lightning 1996 Manual page 76

2
GENERAL
The front fork consists of two telescoping outer tube/inner
slider assemblies. Each tube/slider assembly has an internal
compression spring which supports the forward weight of the
vehicle/rider. The compression spring extends and retracts to
cushion the ride over rough or irregular road surfaces. An oil-
filled damping mechanism controls the telescoping action of
each tube/slider assembly.
See FRONT FORK in Section 1 for fork oil change procedure.
REMOVAL
1. Raise front wheel off floor using
PORT STAND (Part No. B-41395)
ADAPTER (Part No.
2. Remove front brake caliper. See
PER, REMOVAL/DISASSEMBLY
3. Remove front wheel. See
on page 2-8.
4. Remove front fender. See
INSTALLATION on
5. Loosen left and right headlamp brackets. See
LAMP, REMOVAL in Section 7.
6. Loosen all five pinch screws on both the upper and lower
triple clamps.
7. Remove front forks.
DISASSEMBLY
1. See Figure 2-30. Clamp the fork vertically in a vise using
FRONT FORK HOLDING TOOL (Part No.
2. See Figure 2-31. Turn adjuster to full slow position (com-
pletely clockwise).
3. See Figure 2-32. Remove fork cap (2) (metric), O-ring (3)
and washer (4).
4. Reduce spring pressure and remove both retaining
clips (5).
5. Remove preload shim(s) (6) and steel washer (7).
6. Remove fork spring (8).
7. Invert fork and drain fork oil.
8. Clamp fork outer tube (9) horizontally using
FORK HOLDING TOOL (Part No.
seal retaining ring (14) and spacer ring (13).
9. Using ROBINAIR HEAT GUN (Part No. HD-25070)
bottom of outer tube. When the tube has sufficiently
expanded, drive inner tube (18) from outer tube with a
slide hammer action. Inner tube will retain fork oil seal
(12) and support ring (11) in place.
10. Spread red retaining cap (15) and remove. Remove
upper DU bushing (16) and washer (17).
11. Remove retaining ring (14) and spacer ring (13).
2-28
FRONT FORK
FRONT WHEEL SUP-
and S1 LIFT
B-41686).
FRONT BRAKE CALI-
on page 2-20.
FRONT WHEEL, REMOVAL
FENDERS, REMOVAL/
page 2-54.
B-41177).
B-41177). Loosen fork
www.PlanDeGraissage.org
5761
Front Fork Holding Tool,
(Part No. B-41177)
Figure 2-30. Front Fork Holding Tool
HEAD-
b0206x2x
Left fork leg adjuster-
Rebound damping
rebound/compression (slower):
Turn appropriate adjuster clockwise.
rebound/compression (faster):
Turn appropriate adjuster counterclockwise.
Figure 2-31. Fork Adjusters
FRONT
12. Remove lower DU bushing (10), support ring (11) and
fork oil seal (12). Discard fork oil seal and support ring.
heat
13. Invert fork. Hold damper assembly and remove bolt (20)
(metric) and copper washer (19). Discard copper washer.
14. Remove damper assembly (22).
Right fork leg adjuster-
Compression damping
FORK ADJUSTMENTS