Assembly And Installation; Clutch Cable - Buell 2009 XB Series Service Manual

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3
1. Outer ramp and hook
2. Coupling
3. Cable end
Figure 2-135. Clutch Release Mechanism (Typical)
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Figure 2-136. Clutch Cable and Fitting

ASSEMBLY AND INSTALLATION

Clutch Cable

1. Install new o-ring on the clutch cable fitting before
installing.
2. Apply 565 THREAD SEALER to fitting on clutch cable and
screw the clutch cable fitting into the primary cover and
tighten to 36-108 in-lbs (4-12.2 Nm).
3. See Figure 2-135. Install cable end into slot in coupling.
Install the outer ramp and hook (1) onto the cable end (3)
and coupling (2) and place assembly back into the clutch
inspection area in the primary cover. See
RELEASE MECHANISM.
4. See Figure 2-134. Install oil seal (rubber washer) and
engine shift lever assembly (10, 3).
2-104 2009 XB Service: Chassis
5.
6.
1
7.
2
8.
See
9.
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10. See
11. Adjust clutch adjusting screw. See
12. Add FORMULA+ TRANSMISSION AND PRIMARY
Each time the clutch inspection cover is removed the gasket
must be replaced.
5.4 CLUTCH
13. Install new clutch cover gasket.
14. See
See Figure 2-134. Install (7) bearings and (8) sleeve into
the shift lever.
After applying LOCTITE 271 (red), install flange bolt (6)
and shift pedal (4) to primary cover, and tighten to 22-24
ft-lbs (30-32.5 Nm).
After applying LOCTITE 271 (red), tighten engine shift
lever pinch screw to 48-60 in-lbs (5.4-7 Nm).
See Figure 2-137. If the shift linkage assembly (8) was
removed for any reason, apply LOCTITE 271 to fasteners
and tighten to 36-60 in-lbs (4-7 Nm). Adjust to rider com-
fort.
NOTE
D.1 APPENDIX D: HOSE AND WIRE
Route clutch cable through upper triple clamp.
1
8
7
6
1. Lever, engine
2. Primary cover
3. Clutch inspection cover
4. Drain plug
5. Flange head bolt
6. Chain adjuster screw
7. Locknut
8. Shift linkage assembly
Figure 2-137. Installing Shift Linkage (Typical)
Figure 2-133. Connect clutch cable ferrule (7) to hand
lever (4).
MISSION/PRIMARY FLUID.
CHAINCASE LUBRICANT (Part No. 99851-05) if needed
as required until fluid level is even with bottom of clutch
diaphragm spring. See
SION/PRIMARY FLUID, Transmission
NOTE
Figure 2-134. Install clutch inspection cover (2) with
three TORX screws with washers. Tighten screws in a
crosswise pattern to 84-108 in-lbs (9.5-12 Nm).
ROUTING.
2
3
5
4
1.9 CLUTCH/TRANS-
1.9 CLUTCH/TRANSMIS-
Fluid.