MAINTENANCE General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1996 S1-Lightning Specifications . . . . . . . . . . . . . . . . . . . Side Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regular Maintenance Intervals (table) . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Belt Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Primary Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1 1-5 1-6 1-8 1-9 1-13 1-15 1-17 1-18 1-19 1-21 1-22
Rear Preload Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum-Operated Electrical Switch (V.O.E.S.) . . . . . . . . Handlebars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-23 1-24 1-25 1-27 1-28 1-29 1-30 1-32 1-33 1-34 1-35 1-36
CHASSIS Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle Identification Number . . . . . . . . . . . . . . . . . . . . . Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Cast Rim Runout . . . . . . . . . . . . . . . . . . . . . . . Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . Front Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Brake Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . Rear Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Brake Line and Switch . . . . . . . . . . . . . . . . . . . . . . Front Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fork Stem and Bracket Assembly . . . . . . . . . . . . . . . . . .
2-1 2-4 2-5 2-6 2-8 2-11 2-14 2-15 2-18 2-19 2-20 2-22 2-23 2-25 2-27 2-28 2-32
Swingarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . Suspension Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suspension Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . Throttle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speedometer and Tachometer . . . . . . . . . . . . . . . . . . . . Handlebars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sprocket Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tail Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Side Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-33 2-36 2-38 2-39 2-43 2-44 2-46 2-49 2-50 2-52 2-53 2-54 2-55 2-56 2-57 2-58
ENGINE Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stripping Motorcycle For Engine Repair . . . . . . . . . . . . . Installing The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder and Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1 3-5 3-8 3-10 3-11 3-22 3-28 3-29 3-30
Oil Pressure Signal Light Switch . . . . . . . . . . . . . . . . . . . Crankcase Breathing System . . . . . . . . . . . . . . . . . . . . . Oiling System (Color Foldout) . . . . . . . . . . . . . . . . . . . . . Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Filter Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Valve Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gearcase Cover and Cam Gears . . . . . . . . . . . . . . . . . . Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-31 3-32 3-33 3-34 3-37 3-38 3-40 3-48
FUEL SYSTEM Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Fuel Supply Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Evaporative Emissions Control-California Models . . . . . 4-23
ELECTRIC STARTER Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Electric Starter System . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Diagnostics/Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 5-9
Starter System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Starter Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
DRIVE/TRANSMISSION Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Primary Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Secondary Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Release Mechanism . . . . . . . . . . . . . . . . . . . . . . . Primary Drive/Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1 6-3 6-6 6-8 6-9 6-10 6-14
Transmission Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shifter Forks and Drum . . . . . . . . . . . . . . . . . . . . . . . . . . Mainshaft and Countershaft . . . . . . . . . . . . . . . . . . . . . . Main Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Access Door Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . Right Transmission Case Bearings . . . . . . . . . . . . . . . . . Transmission Installation and Shifter Pawl Adjustment .
6-16 6-18 6-20 6-26 6-28 6-29 6-30
ELECTRICAL Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vacuum-Operated Electrical Switch (V.O.E.S.) . . . . . . . . Ignition/Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Sensor Plate and Rotor . . . . . . . . . . . . . . . . . . . . Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark Plug Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1 7-3 7-10 7-11 7-13 7-14 7-16 7-18 7-19 7-23 7-29 7-31
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tail Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turn Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turn Signal Flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handlebar Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Neutral Indicator Switch . . . . . . . . . . . . . . . . . . . . . . . . . Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . Deutsch Electrical Connectors . . . . . . . . . . . . . . . . . . . . Amp Multilock Electrical Connectors . . . . . . . . . . . . . . . .
7-32 7-33 7-35 7-37 7-38 7-39 7-41 7-42 7-43 7-44 7-46 7-48
1997 INFORMATION Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 11 17 19
Electric Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive/transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 29 31
APPENDIX Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Metric Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
FOREWORD GENERAL
PREPARATION FOR SERVICE
This Service Manual Supplement has been prepared with two purposes in mind. First, it will acquaint the user with the construction of the 1997 Buell S1 Lightning and assist in the performance of basic maintenance and repair. Secondly, it will introduce to the professional Buell Technician the latest field-tested and factory-approved major repair methods. We sincerely believe that this Service Manual Supplement will make your association with Buell products more pleasant and profitable.
HOW TO USE YOUR SERVICE MANUAL SUPPLEMENT 1.
Check the TABLE OF CONTENTS following this FORWORD to find the desired subject.
2.
If the information you seek is not in this supplement, refer to the corresponding section in the Buell 1996 S1 Lightning Service Manual (Part No. 99490-96Y). Check the TABLE OF CONTENTS or INDEX to find the desired subject.
3.
Information is presented in a definite order as follows: Specifications General/Model Year Change Adjustment/Testing Removal/Disassembly Cleaning, Inspection, and Repair Assembly/Installation
In figure legends, the number which follows the name of a part indicates the quantity necessary for one complete assembly.
NOTE To avoid needless disassembly, carefully read all relative service information before repair work is started.
1WARNING Gasoline is extremely flammable and highly explosive. Always stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near the work site. Inadequate safety precautions may result in personal injury. Good preparation is very important for efficient service work. A clean work area at the start of each job will allow you to perform the repair as easily and quickly as possible, and will reduce the incidence of misplaced tools and parts. A motorcycle that is excessively dirty should be cleaned before work starts. Cleaning will occasionally uncover sources of trouble. Tools, instruments and any parts needed for the job should be gathered before work is started. Interrupting a job to locate tools or parts is an unnecessary distraction and causes needless delay.
SERVICE BULLETINS In addition to the information presented in this Service Supplement, Buell Distribution Corporation will periodically issue Service Bulletins to Buell dealers. Service Bulletins cover interim engineering changes and supplementary information.
USE GENUINE REPLACEMENT PARTS 1WARNING When replacement parts are required, use only genuine Buell parts or parts with equivalent characteristics (which include type, strength and material). Failure to do so may result in product malfunction and possible injury to the operator and/or passenger. To ensure satisfactory and lasting repairs, carefully follow the instructions and use only genuine Buell replacement parts. This is your assurance that the parts you are using will fit right, operate properly and last longer.
i.
PRODUCT REFERENCES 1WARNING Follow the directions listed on all products. Carefully read all labels, warnings and cautions before use. Inadequate safety precautions may result in personal injury. When reference is made in this Service Manual Supplement to a specific brand name product, tool or instrument, an equivalent product, tool or instrument may be substituted.
WARNINGS AND CAUTIONS Statements in this supplement preceded by the word “1WARNING” or “1CAUTION” are very important. Since these items alert you to situations where the possibility of personal injury or vehicle damage exists, please take special notice of them.
1WARNING A “WARNING” indicates the potential for personal injury, whether to yourself or others.
1CAUTION A “CAUTION” indicates that vehicle damage can occur.
Kent-Moore Products All tools mentioned in this supplement with an “HD”, “J” or “B” preface must be ordered through:
1WARNING ●
Proper service and repair is important for the safe, reliable operation of all mechanical products. The service procedures recommended and described in this Service Manual are effective methods for performing service operations. Some of these service operations require the use of tools specially designed for the purpose. These special tools should be used when and as recommended. It is important to note that some warnings against the use of specific service methods, which could damage the motorcycle or render it unsafe, are stated in this Service Manual. However, please remember that these warnings are not all-inclusive.
●
Since Buell could not possibly know, evaluate or advise the service trade of all possible ways in which service might be performed, or of the possible hazardous consequences of each method, we have not undertaken any such broad evaluation. Accordingly, anyone who uses a service procedure or tool which is not recommended by Buell must first thoroughly satisfy himself that neither his nor the operator’s safety will be jeopardized as a result.
●
Wear eye protection when using hammers, arbor or hydraulic presses, gear pullers, spring compressors, slide hammers and similar tools. Be especially cautious when using pulling, pressing or compressing equipment. The forces involved can cause parts to fly outward with considerable force, possibly resulting in personal injury.
Kent-Moore SPX Corporation 29784 Little Mack Roseville, Michigan 48066-2298 Telephone: 1-800-345-2233
Sealing and Threadlocking Products LOCTITE PRODUCTS Some procedures call for the use of Loctite® products. If you have any questions regarding Loctite product usage or retailer/wholesaler locations, please call Loctite Corp. at 1800-323-5106.
CONTENTS All photographs and illustrations may not necessarily depict the most current model or component, but are based on the latest production information available at the time of publication. Since product improvement is our continual goal, Buell reserves the right to change specifications, equipment or designs at any time without notice and without incurring obligation.
Buell products are manufactured under one or more of the following patents: U.S. Patents – 2986161, 2987934, 2998809, 3116089, 3144531, 3144860, 3226994, 3229792, 3434887, 3559773, 3673359, 3709317, Des. 225 626.
ii.
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SECTION I–MAINTENANCE SUBJECT 1. 2. 3. 4. 5. 6.
PAGE NO.
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Side Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Preload Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 4 6 7 8 9
This section explains procedures unique to 1997 model S1 Lightnings. Any procedures not found in this supplement are covered in the 1996 S1 Lightning Service Manual (Part No. 99490-96Y).
1