Clutch Cable - Buell 2007 LIGHTNING Service Manual

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ASSEMBLY/INSTALLATION

Clutch Cable

1. Install new o-ring on the clutch cable fitting before install-
ing.
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 Nm).
3. See Figure 2-102. 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 2-104. Install rubber washer and engine shift
lever assembly (1).
5. See Figure 2-101. Install (9) bearings and (8) sleeve into
the shift lever.
6. After applying LOCTITE 271, install flange bolt (6) and
shift pedal to primary cover, and tighten to 22-24 ft-lbs
(30-32.5Nm).
7. After applying LOCTITE 271 (red), tighten engine shift
lever pinch screw to 48-60 in-lbs (5.4-6.8 Nm).
8. See Figure 2-104. If the shift linkage assembly (7) was
removed for any reason, apply Loctite 271 to fasteners
and tighten to 36-60 in-lbs (4-6.8 Nm). Adjust to rider
comfort.
NOTE
See D.1 HOSE AND WIRE ROUTING
9. Route clutch cable through clutch cable wire form and
upper triple clamp.
6.3 CLUTCH
in Appendix D.
12257
1
7
4
6
5
1. Engine shift lever
2. Primary cover
3. Clutch inspection cover
4. Flange head bolt
5. Chain adjuster screw
6. Locknut
7. Shift linkage assembly
Figure 2-104. Installing Shift Linkage
2007 Buell Lightning: Chassis
2
3
2-71