Clutch - Buell 2006LIGHTNING MODELS Service Manual

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CLUTCH

GENERAL
Transmission fluid capacity is approximately 1.0 quart
(0.95 liter). For best results, drain fluid while hot.
TRANSMISSION FLUID
1. When the engine reaches normal operating temperature,
turn the engine off and position motorcycle on jiffy stand.
this will allow the chaincase lubricant to drain out of the
transmission.
CAUTION
When draining or adding lubricant, do not allow dirt,
debris or other contaminants to enter the engine.
(00198a)
2. See Figure 1-21. Position a suitable container under
drain plug. Remove plug and drain fluid.
3. Position the motorcycle STRAIGHT UP and LEVEL. This
allows additional fluid to be drained from clutch compart-
ment and will prevent chaincase lubricant from draining
out of clutch cover opening when refilled.
4. Inspect and replace the drain plug o-ring.
5. Wipe any foreign material from the magnetic drain plug
and apply LOCTITE 565 THREAD SEALANT. Reinstall
plug and tighten to 14-30 ft-lbs (19-41 Nm).
6. Remove three fasteners and washers from clutch inspec-
tion cover. Remove clutch inspection cover with gasket
from primary cover.
CAUTION
Do not overfill the primary chaincase/transmission with
lubricant. Overfilling can cause rough clutch engage-
ment, incomplete disengagement, clutch drag and/or dif-
ficulty in finding neutral at engine idle. (00199b)
NOTE
Make certain primary chaincase is filled with proper amount
of lubricant with motorcycle upright. If under filled, transmis-
sion can be damaged during vehicle operation.
7. See Figure 1-22. Add FORMULA+ TRANSMISSION
AND PRIMARY CHAINCASE LUBRICANT (Part No.
99851-05) quart size as required until fluid level (4) is
even with bottom of clutch diaphragm spring (1).
NOTE
Each time the clutch inspection cover is removed the gasket
must be replaced.
8. Install new clutch cover gasket.
9. See Figure 1-20. Install clutch inspection cover tighten-
ing three fasteners and washers to 84-108 in-lbs (10-
12 Nm).
10. Clean up any fluid that may have spilled on muffler.
1-24 2006 Buell Lightning: Maintenance
12045
Figure 1-20. Clutch Inspection Cover
12257
Figure 1-21. Primary Drain Plug
b1144x1x
2
1
1. Clutch diaphragm spring
2. Clutch adjusting screw
3. Primary cover
4. Correct chaincase lubricant level
Figure 1-22. Fluid Level
1.8
3
4