Clutch Hand Lever - Buell 2003XB9S Service Manual

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CLUTCH HAND LEVER

REMOVAL/DISASSEMBLY
NOTE
For clutch adjustment, see 1.9
1. See Figure 2-90. Remove p-clamp from front isolator.
2. See Figure 2-91. Slide clutch cable adjuster boot (8) up
to access clutch adjuster (7).
3. Loosen clutch adjuster (7) to release tension from hand
lever (4).
4. Remove clutch cable ferrule (9) from hand lever (4).
5. Remove hand lever pinch bolt (3).
6. Remove hand lever (4) from hand lever clamp (2).
7. Remove safety interlock switch (5).
a. Remove hand lever clamp fastener (1) and spin
clamp (2) to access safety interlock switch (5).
b. Disconnect safety interlock switch connector (5) and
remove switch fastener (6) and switch (5).
NOTE
The individual parts of the clutch switch are not serviceable.
Replace switch upon failure.
8. Remove left handlebar grip.
9. Slide clutch lever bracket off of handlebar.
ASSEMBLY/INSTALLATION
1. See Figure 2-91. Slide hand lever clutch clamp (2) over
left handlebar. Loosely tighten hand lever pinch fastener
and nut (3).
2. Connect safety interlock connector and switch (5).
3. Install safety interlock switch (5) with fastener (6) tighten-
ing to 7-10 in-lbs (0.8-1.0 Nm).
NOTE
Apply small amount of LOCTITE ANTI-SEIZE LUBRICANT to
bolt (3).
4. Install clutch hand lever (4) in hand lever clamp (2) and
tighten hand lever pinch fastener (3) to 39-48 in-lbs (4-
5 Nm).
5. Position hand lever (4) to rider preference and tighten
hand lever clamp pivot fastener (1) to 36-60 in-lbs (4-
7 Nm).
6. Connect clutch cable ferrule (9) to hand lever clamp (2).
7. Install cable strap holding safety interlock switch and left
switch housing on left upper fork. Do not over tighten
cable strap.
8. Adjust clutch cable. See
2-64 2003 Buell XB9S: Chassis
CLUTCH.
1.9 CLUTCH.
8740
Figure 2-90. Clutch Cable P-clamp
b0939x2x
1
9
5
8
7
1. Hand lever clamp pinch fastener
2. Hand lever clamp
3. Hand lever pinch fastener and nut
4. Clutch hand lever
5. Safety interlock connector and switch
6. Safety interlock switch fastener
7. Clutch adjuster
8. Clutch cable adjuster boot
9. Clutch cable ferrule
Figure 2-91. Clutch Hand Control Assembly
2.24
3
2
4
3
6