Handlebars - Buell 2007 LIGHTNING Service Manual

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HANDLEBARS

REMOVAL
1. Remove seat. See 2.44
11 1
WARNING
To prevent accidental vehicle start-up, which could
cause death or serious injury, disconnect negative (-)
battery cable before proceeding. (00048a)
2. Disconnect battery negative cable.
3. On XB9SX models, remove deflectors. See
DEFLECTORS/HANDLEBARS
4. Remove left handlebar switch housing. See
DLEBAR SWITCHES. Cut left handlebar grip and
remove.
5. Detach clutch hand control from handlebars. See
CLUTCH CONTROL/CABLE.
6. Remove front brake master cylinder. See
BRAKE MASTER CYLINDER AND HAND
7. Loosen screws on right handlebar switch housing, but do
not detach throttle grip assembly from handlebar. See
2.24 THROTTLE CONTROL.
8. Remove clutch lever assembly. See
TROL/CABLE.
9. See Figure 2-112. Remove the four screws holding
upper handlebar clamp.
NOTE
Right hand control assembly may now be removed from
detached handlebar.
10. Remove handlebars without stretching throttle cables.
11. See Figure 2-112. Remove endcaps.
INSTALLATION
1. Slide handlebars into throttle grip assembly. Fasten right
handlebar switch housing to handlebar. See
THROTTLE CONTROL.
2. See Figure 2-112. Attach handlebars.
a. Position handlebar on lower clamp.
b. Place the upper handlebar clamp in position and
thread the four screws in place after applying Loctite
271 (Red).
c. Tighten both front screws to 10-12 ft-lbs (14-16 Nm).
d. Then tighten both rear screws (2) 10-12 ft-lbs (14-16
Nm).
2-80 2007 Buell Lightning: Chassis
SEAT.
WARNING
(XB9SX).
7.17 HAN-
2.10 FRONT
LEVER.
2.26 CLUTCH CON-
3. Install clutch hand control. Tighten but do not torque. See
2.26 CLUTCH
4. Install left switch housing. See
SWITCHES.
5. Check control wire routings. See
ROUTING.
a. Route right hand control wires between the lower
clamp and fork tube and on the outside of the clutch
cable.
b. Route left hand control wires between the lower
clamp and fork tube.
6. Install a new left hand grip.
2.25 7. Position clutch hand lever to rider preferences and
tighten fastener (1) to 60-84 in-lbs (6.8-9.5 Nm). See
2.26 CLUTCH
8. Install front brake master cylinder. See
BRAKE MASTER CYLINDER AND HAND
9. On XB9SX models, install end caps and deflectors. See
2.26
2.25 DEFLECTORS/HANDLEBARS
10. Check steering motion range to both fork stops.
Connect positive (+) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explo-
sion, which could result in death or serious injury.
(00068a)
11. Install battery by threading positive cable (red) into
threaded hole first tightening to 72-96 in-lbs (8-11 Nm).
See 1.4 BATTERY
After installing seat, pull upward on front of seat to be
sure it is in locked position. While riding, a loose seat can
shift causing loss of control, which could result in death
or serious injury. (00070a)
12. Install seat. See
2.24
CONTROL/CABLE.
7.17 HANDLEBAR
D.1 HOSE AND WIRE
CONTROL/CABLE.
(XB9SX).
11 1
WARNING WARNING
MAINTENANCE.
11 1
WARNING WARNING
2.44 SEAT.
2.30
2.10 FRONT
LEVER.