Werkstatthandbuch Buell S1 Lightning Englisch

SECTION I–MAINTENANCE
SUBJECT PAGE NO.

1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2. Side Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. Fluid Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4. Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5. Rear Preload Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6. Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
NOTES
2
SPECIFICATIONS
I
DIMENSIONS IN. MM IGNITION SYSTEM
Wheel base 55 1397 Spark plugs No. 6R12

Overall length 79.5 2019 Size 12 mm
Overall width 30 762 Gap 0.038-0.045 in. 0.97-1.14 mm
Road clearance 5.2 132
Seat height 29.5 749 TRANSMISSION
Type Constant Mesh, Foot Shift

Speeds 5 Forward
CAPACITIES U.S. LITERS
Fuel tank (including reserve) 4.0 gallons 15.14 NUMBER OF SPROCKET TEETH
Reserve 0.6 gallons 2.27 Engine 35
Oil tank 2.0 quarts 1.89 Clutch 56
Transmission 1.0 quart 0.95 Transmission 27
Rear wheel 61
Belt 128
WEIGHT LBS. KG
S1 shipping weight 446 202 TRANSMISSION GEAR RATIOS FINAL* OVERALL**

GVWR 820 372 First (low) gear 2.69 9.717
GAWR - Front 340 154 Second gear 1.97 7.118
GAWR - Rear 480 218 Third gear 1.43 5.180
Fourth gear 1.18 4.269
NOTE Fifth (high) gear 1.00 3.615
Gross Vehicle Weight Rating (GVWR) (maximum allowable
*Final gear ratios indicate number of mainshaft revolutions
loaded vehicle weight) and corresponding Gross Axle Weight
required to drive output sprocket one revolution.
Ratings (GAWR) are given on an information decal located on
**Overall gear ratios indicate number of engine revolutions
the front frame steering head.
required to drive rear wheel one revolution.
PRESSURE
ENGINE PRESSURE
TIRE AND POSITION FOR SOLO
AT GVWR
Number of cylinders 2 RIDING
Type 4-Cycle, 45 Degree V-Type Front-Dunlop Sportmax 32 PSI 36 PSI

Radial II 120/70 ZR 17 (2.2 bar) (2.5 bar)
Bore 3.498 in. 88.849 mm
Rear-Dunlop Sportmax 36 PSI 38 PSI
Stroke 3.8125 in. 96.838 mm Radial II 170/60 ZR 17 (2.5 bar) (2.8 bar)
Piston displacement 73.4 cu. in. 1203 cc
Compression ratio 10.0 to 1 1WARNING
Horsepower @ RPM 91 @ 5800 Do not inflate any tire beyond its maximum inflation
pressure as specified on tire sidewall. Overinflation may
Torque ft-lb @ RPM 87 @ 5200 cause tire to suddenly deflate leading to personal injury.
3
SIDE VIEWS
5806
6
2 3 4 5 7
8
1
9
10
16
15 14 13 12 11
1. Right rear turn signal 6. Front brake master cylinder 12. Rear shock absorber
2. Tail/stop lamp 7. Front brake hand lever 13. Rear brake pedal
3. Rear brake master cylinder/ 8. Right front turn signal 14. Rider footrest
reservoir 9. Headlamp 15. Belt guard(s)
4. Air cleaner cover 10. Front brake caliper 16. License plate light
5. Fuel filler cap 11. Timer cover
Figure 1. 1997 S1 Lightning, Right Side View
5808
6 8
3 4 5
2
1 9
14 13 12 11 10
1. Rear axle adjuster nut 5. Turn signal flasher 10. Oil pump
2. Rear sprocket and secondary 6. Remote idle adjuster 11. Battery
drive belt 7. Front brake master cylinder 12. Voltage regulator
3. Ignition module 8. Front brake hand lever 13. Rider footrest
4. Fuse block and spare fuse 9. Front brake caliper 14. Passenger footrest
Figure 2. 1997 S1 Lightning, Right Side View (Body Removed)
4
5807
3 4 5 6 7 8
2
9
10
15 14 13 12 11
1. Left front turn signal 6. Ignition/headlamp key switch 11. Passenger footrest
2. Headlamp 7. Fuel supply valve 12. Rider footrest
3. Clutch hand lever 8. Tail/stop lamp 13. Gear shift lever
4. Fuel filler cap 9. Left rear turn signal 14. Exhaust muffler
5. Horn 10. Rear brake caliper 15. Oil filter
Figure 3. 1997 S1 Lightning, Left Side View
5809
1 2 3
4 5 6 7 8 9
10
15 14 13 12 11
1. Steering head lock 6. Starter relay 11. Oil tank drain hose
2. Instruments 7. Oil filler plug/dipstick 12. Gear shift lever
3. Clutch hand lever 8. Oil tank 13. Exhaust muffler
4. Ignition coil 9. Rear brake caliper 14. Oil filter
5. Enrichener knob 10. Rear axle adjuster nut 15. Speedometer drive
Figure 4. 1997 S1 Lightning, Left Side View (Body Removed)
5
FLUID REQUIREMENTS
GENERAL FRONT FORK OIL

Use only WP FORK OIL, 5 WEIGHT.
United States System
Unless otherwise specified, all fluid volume measurements FUEL
in this Service Manual are expressed in United States
Use a good quality leaded or unleaded gasoline (91 pump
(U.S.) units-of-measure. See below:
octane or higher). Pump octane is the octane number usually
● 1 pint (U.S.) = 16 fluid ounces (U.S.) shown on the gas pump.
● 1 quart (U.S.) = 2 pints (U.S.) = 32 fl. oz. (U.S.)
● 1 gallon (U.S.) = 4 quarts (U.S.) = 128 fl. oz. (U.S.)
ENGINE OIL
Metric System Use the proper grade of oil for the lowest temperature
expected before the next oil change.
Fluid volume measurements in this Service Manual include
the metric system equivalents. In the metric system, 1 liter
(L) = 1,000 milliliters (mL). Should you need to convert from
Table 1. Recommended Oil Grades
U.S. units-of-measure to metric units-of-measure (or vice COLD
versa), refer to the following: HARLEY- LOWEST WEATHER
HARLEY-
VISCOSITY DAVIDSON AMBIENT STARTS
DAVIDSON TYPE
● fluid ounces (U.S.) x 29.574 = milliliters RATING TEMP. BELOW
● pints (U.S.) x 0.473 = liters 50° F
● quarts (U.S.) x 0.946 = liters SAE Below 40°F
H.D. Multi-Grade HD 240 Excellent
● gallons (U.S.) x 3.785 = liters 10W40 (4°C)
● milliliters x 0.0338 = fluid ounces (U.S.) SAE Above 40°

H.D. Multi-Grade HD 240 Good
20W50 (4°C)
● liters x 2.114 = pints (U.S.)
SAE °
● liters x 1.057 = quarts (U.S.) Above 60
H.D. Regular Heavy HD 240 Poor
50 (16°C)
● liters x 0.264 = gallons (U.S.) °
SAE Above 80
H.D. Extra Heavy HD 240 Poor
60 (27°C)
STEERING HEAD BEARING
GREASE PRIMARY DRIVE/TRANSMISSION
Use WHEEL BEARING GREASE (Part No. 99855-89). LUBRICANT
Use only SPORT-TRANS FLUID (Part No. 98854-96 quart
BRAKE FLUID size or Part No. 98855-96 gallon size).
1WARNING
D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID can cause
eye irritation. In case of contact with eyes, flush with
plenty of water and get medical attention. KEEP BRAKE
FLUID OUT OF THE REACH OF CHILDREN!
Use only D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID
(Part No. 99902-77).
6
CLUTCH
MODEL YEAR CHANGE

5671
See Figure 5. All 1997 model year motorcycles use the new
New style Old style
style clutch release ramp introduced on late 1996 vehicles.
The clutch adjustment and lever freeplay procedures remain
the same. The change was made to provide additional clear-
ance between the coupler and the primary cover.
Figure 5. Ramp Change
7
REAR PRELOAD ADJUSTMENT
GENERAL b0269xox
Rear suspension spring preload must be adjusted before any
other adjustments can be attempted. This adjustment assures Rear turn signal
that the rear suspension has the proper amount of travel. mounting bolt
Spring preload is the most important suspension adjustment
on the S1 Lightning. Improper preload will adversely affect
both the handling and motorcycle ride. Correct preload set-
ting will result in motorcycle handling that suits the rider’s size
and weight.
Rear axle nut

ADJUSTMENT
You will need three people to carry out this adjustment.
1. Verify correct front and rear tire pressure. See SPECIFI-
CATIONS on page 3.
2. Remove all accessories from motorcycle including tank
bag and/or saddlebags. Figure 6. Checking Rear Preload
3. Take the motorcycle off the side stand and bounce the
rear up and down a few times to be sure the suspension
is free and not binding. 2 3 b0283x2x
4. See Figure 6. Measure the distance from the center of the 1

rear axle nut to the rear turn signal mounting bolt without
rider/passenger/cargo/accessories on the motorcycle.
5. Install items removed in Step 2. Load all cargo.
6. Bounce a few times on the seat to be sure the suspen-
sion is free and not binding.
7. With the help of an assistant, take the same measure-
ment with the vehicle fully loaded (rider/passenger/lug-
gage/cargo). The assistant should help balance the
motorcycle so the rider can keep both feet on the foot-
rests.
8. Subtract the second measurement from the first. The dif-
ference, which is the squat, should be 0.25-0.75 in. (6.4-
19.1 mm). If it is not, you will have to adjust the spring 1. Preload adjusting nut (2) (metric)
preload. 2. Rear drawing ring
3. Adjustment rod (2)
1CAUTION
● Be sure to apply the same number of turns to each Figure 7. Adjusting Rear Preload
preload adjusting nut to ensure that the drawing
rings do not become misaligned. Misaligned drawing
rings will cause the shock absorber spring to bind
against the adjustment rods
● Be sure the drawing rings are parallel within 1/64 in.
(0.4 mm). Misaligned drawing rings will cause the
shock absorber spring to bind against the adjust-
ment rods.
9. See Figure 7. Change the spring preload by adjusting
both preload adjusting nuts (1) (metric) behind the rear
drawing ring (2).
a. Increase the preload by tightening the nuts.
b. Decrease the preload by loosening the nuts.
8
IGNITION TIMING
MODEL YEAR CHANGE 5853

See Figure 8. All 1997 model year motorcycles have the
remote idle adjuster introduced on late 1996 vehicles. Using
this adjuster, it is no longer necessary to use the CARBURE-
TOR IDLE ADJUSTMENT TOOL (Part No. HD-33413) and
TIP (SNAP-ON Part No. TMP23A) to adjust engine idle
speed.
NOTE
The new idle adjuster changes Step 4 of IGNITION TIMING,
INSPECTION in Section 1 the 1996 manual.
See REMOTE IDLE ADJUSTER on page 21 for more infor-
mation.
Figure 8. Remote Idle Adjuster
9
NOTES
10
SECTION II–CHASSIS
SUBJECT PAGE NO.

1. Vehicle Identification Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2. Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3. Front Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4. Swingarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
11
NOTES
12
VEHICLE IDENTIFICATION NUMBER
MODEL YEAR CHANGE An abbreviated V.I.N. is stamped on the front left side of the
crankcase.
See Figure 9. A 17-digit serial number, or Vehicle Identifica-
tion Number (V.I.N.), is stamped on the right side of the steer- NOTE
ing head (ex., 4MZSS11J1V3200001). Also affixed to the Always give the V.I.N. or abbreviated V.I.N. when ordering
steering head at this location is an information decal bearing parts or making inquiries about your Buell motorcycle.
the V.I.N. code.
Manufacturer: Buell Motorcycle Company

Type Designation
11 = World
Engine
56 = California
Horsepower Code
Model Year - 1997
Sequential Number 00001-20000 = World
20001-25000 = California
4 MZ SS 11 J * V 32 00001
*Varies - can be 0 thru 9 or X
Sample V.I.N. as it appears on the steering head - 4MZSS11J1V3200001

Sample abbreviated V.I.N. as it appears on the left side crankcase- SS11V200001
Figure 9. Vehicle Identification Number (V.I.N.)
13
FRONT WHEEL

See Figure 10. All 1997 model year motorcycles have new
fasteners on the front brake rotor/carrier assembly. 5
Separate the carrier from the rotor only when necessary. Use 2
new clips when reassembling.
NOTE
The new rotor/carrier assembly changes Step 4 of FRONT 1 4
WHEEL, REMOVAL and Step 2 of FRONT WHEEL, ASSEM-
BLY in the 1996 manual.
REMOVAL/INSTALLATION 3
1. See Figure 10. Remove and discard the clip (2).
2. Remove the wave washer (3).
3. Remove the drive pin (1). Repeat this procedure for the
other five fasteners to separate the carrier (4) from the
rotor (5). 1. Drive pin (6) 4. Carrier
4. Assemble in reverse order. Use new clips upon assembly. 2. Clip (6) 5. Rotor
3. Wave washer (6)
Figure 10. 1997 Rotor to Carrier Fastener
14
FRONT BRAKE CALIPER
TOOL INFORMATION b0265x2x
Use the BRAKE CALIPER PISTON REMOVER (Part No. B-

42079) to simplify front caliper piston removal. Banjo bolt hole
NOTE
The following instructions expand upon Step 9 of FRONT
BRAKE CALIPER, REMOVAL/DISASSEMBLY in the 1996
manual.
1. Attach caliper half to tool.
a. See Figure 11. Attach outside caliper half using two
screws.
b. See Figure 12. Attach inside caliper half using two
screws and two nuts.
1WARNING
When using air pressure to remove pistons from caliper,
pistons may be ejected with considerable force. Wear
safety glasses and heavy gloves to prevent personal Figure 11. Outside Caliper Half
injury.
1CAUTION b0266x2x
Exercise care to avoid dropping piston on hard surface.

Any damage requires piston replacement.
2. If removing pistons from outside caliper half, place a
gloved finger over the banjo bolt hole.
3. See Figure 13. Apply low pressure air to force the pistons
from the caliper bores.
Figure 12. Inside Caliper Half
b0297x2x
Figure 13. Using Air Pressure to Remove Pistons
15
SWINGARM
MODEL YEAR CHANGE b0290a2x
All 1997 model year motorcycles use a revised swingarm

Threads
pivot assembly. The modifications allow preload to be
adjusted without using the PIVOT SHAFT BEARING
ADJUSTER (Part No. B-41175).
NOTE
See Figure 14. The threaded rod (1) replaces a pivot shaft
used on 1996 models. This new part changes the SWING-
ARM, ASSEMBLY and SWINGARM, INSTALLATION proce-
dures in the 1996 manual. 6
3
ASSEMBLY 2
1. See Figure 14. If necessary, draw new roller bearing
1 5
cups (5) into swingarm using BEARING INSTALLATION
BOLT (Part No. B-35316-5) and STEERING HEAD 4
BEARING RACE INSTALLER (Part No. HD-39302).
NOTE
Timkin roller bearing assemblies should be replaced as a 1. Threaded rod 4. Roller bearing (2)
unit. Do not intermix components. Mark all components so 2. Bearing adjustment 5. Bearing cup (2)
they may be correctly installed. bolt, right 6. Bearing adjustment
2. Coat bearing components with WHEEL BEARING 3. Swingarm seal (2) bolt, left
GREASE (Part No. HD-99855-89) and assemble.
Figure 14. Swingarm
3. Install a new swingarm seal (3) flush to the swingarm.
4. Slide swingarm assembly into position. b0294x2x
NOTE
See Figure 14. The left side bearing adjustment bolt (6) has
additional internal threads.
5. Install both bearing adjustment bolts (2, 6) and the
threaded rod (1). Insert the rod from the air cleaner side
of the motorcycle.
6. Tighten the left pinch screw on the swingarm mount
block. Do not tighten the right side pinch screw at this
time.
INSTALLATION
1. See Figure 15. Adjust swingarm preload by tightening
the threaded rod. Preload should measure 3.5-5.5 lbs
(1.6-2.5 kg).
2. Follow the remaining installation instructions in the 1996
manual.
Figure 15. Adjusting Preload
16
SECTION III–ENGINE
All engine procedures in the 1996 S1 Lightning Service Manual (Part No. 99490-96Y) apply to
1997 models.
17
NOTES
18
SECTION IV–FUEL SYSTEM
SUBJECT PAGE NO.

1. Remote Idle Adjuster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2. Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
19
NOTES
20
REMOTE IDLE ADJUSTER
GENERAL b0291xox
See Figure 16. The remote idle adjuster allows idle adjust-
ments without use of tools. Idle speeds are listed in Table 2. Increase
idle speed
REMOVAL
1. Remove seat and fuel tank. See FUEL TANK, REMOVAL
in Section 4 of the 1996 manual.
2. Remove cable strap holding adjuster to frame. Adjuster
3. See Figure 17. Unthread adjuster assembly from bracket Decrease
(4). Remove spring (3) and washer (2). idle speed
NOTE
If remote idle adjuster is permanently removed, install idle
adjuster screw, spring and two washers. See the 1996 S1
LIGHTNING PARTS CATALOG (Part No. 99571-96Y). Figure 16. Idle Speed Adjuster
INSTALLATION 5900
1. See Figure 17. Thread remote adjuster (1), spring (3)

and washer (2) into bracket (4). Adjuster shaft (5) must 1
touch stop plate (6).
2
2. See Figure 18. Secure adjuster to frame with a figure-8
cable strap. 4
a. Wrap cable strap around inside of frame, then up
and through the slot. 3 5
b. Contine cable strap over adjuster.
c. Run cable strap through the other side of the slot.
Strap should be tight enough that the adjuster turns 6
easily.
1WARNING
After installing seat, pull upward on front of seat to be 1. Remote adjuster 4. Bracket
sure it is locked in position. If seat is loose, it could shift 2. Washer 5. Shaft
during vehicle operation and startle the rider, causing 3. Spring 6. Stop plate
loss of control and personal injury.
Figure 17. Removal/Installation
3. Install fuel tank and seat. See FUEL TANK, INSTALLA-
TION in Section 4 of the 1996 manual.
b0302x4x
4. Start vehicle and warm engine to normal operating tem-
perature.
5. See Figure 16. Set idle speed by turning adjuster. See
Table 2.
a. Turn clockwise to increase idle speed.
a. Turn counterclockwise to decrease idle speed.
Table 2. Engine Idle Speed
MODEL REGULAR IDLE FAST IDLE
World Model 950-1050 RPM Figure 18. Cable Strap

2000 RPM
California 1150-1250 RPM
21
AIR CLEANER
All 1997 model year motorcycles use a modified air cleaner

1
assembly. The new design increases serviceability.
REMOVAL
1CAUTION
Do not run engine without filter element in place. Debris
could be drawn into the engine causing damage.
1. See Figure 19. Remove screw and nylon washer (1) on

top of air cleaner cover.
2
2. Remove screw and locknut (2) at rear of air cleaner cover.
1. Screw and nylon washer
3. See Figure 20. Remove cover (3) with attached filter box
2. Screw and locknut
(2) and filter (1).
4. See Figure 21. Remove backplate hoses. Figure 19. Air Cleaner Cover
a. Detach rear breather hose (4) from tee fitting (3).

5883
b. Detach snorkel breather hose (2) at snorkel (1). 2 3
c. Remove hoses (2, 5) and tee fitting (3) from front
breather bolt (6).
d. On California models, slide fresh air hose from can-
ister through backplate.
5. See Figure 22. Remove two screws and snorkel plate.
6. Remove snorkel. 1
7. See Figure 23. Remove screw with spacer and gasket. 4
8. Remove backplate.
1. Filter 3. Cover
a. See Figure 24. Remove two bolts (1), washers (2) 2. Filter box 4. Rear mount
and nuts (3).
Figure 20. Inside of Air Cleaner Cover
b. Draw rear breather hose through backplate.
c. Remove front breather bolt. Detach backplate from
5881
motorcycle.
9. If necessary, remove air cleaner support ring.
1
a. Detach breather hose from rear cylinder head 2 4 5
breather bolt.
b. Loosen rear bolt.
c. Slide air cleaner support ring upward and remove.
NOTE
3 6
Air cleaner support ring fits around breather bolts. Fitting on
rear breather bolt may not clear the frame if bolt removal is
attempted. Do not remove rear breather bolt unless abso- 1. Snorkel 4. Rear head breather
lutely necessary. 2. Snorkel breather 5. Front head breather
3. Tee fitting 6. Front breather bolt
Figure 21. Breather Hoses
22
INSTALLATION 5884
1. Install backplate.
a. Apply HYLOMAR to threads of breather bolts.
b. Install air cleaner support ring and backplate using 1

breather bolts. Tighten breather bolts to 10-15 ft-lbs
(13.6-20.3 Nm).
c. Attach rear breather hose to rear breather bolt. 1 3

2
d. See Figure 24. Install two bolts (1), washers (2) and
nuts (3) through backplate into isolator mount.
1. Screw (2) 3. Snorkel
2. See Figure 21. Install breather hoses. 2. Snorkel plate
Figure 22. Snorkel Ring

a. Slide rear breather hose through backplate.
b. Attach front breather hose (5, with attached tee and

5897
snorkel breather hose) to front breather bolt (6).
c. Connect rear breather hose (4) to tee fitting (3).

2
d. On California models, insert fresh air hose from can-
1
3. See Figure 23. Apply LOCTITE THREADLOCKER 242
(blue) to screw. Install ring with screw through backplate.
Tighten to 7-9 ft-lbs (9.5-12.2 Nm).
4. See Figure 22. Apply LOCTITE THREADLOCKER 242

(blue) to screws. Fasten snorkel tube with ring and two
screws. Tighten to 6-8 ft-lbs (8.1-10.8 Nm).
1. Air cleaner spacer with gasket
5. Connect snorkel hose to snorkel tube. 2. Screw
6. See Figure 20. Check air cleaner filter. Place filter inside Figure 23. Air Cleaner Spacer
filter box. Place cover assembly over backplate.
7. See Figure 19. Install screw and washer into top well nut. 5898
8. Install screw and locknut at rear mount. Tighten to 6-8 ft-

lbs (8.1-10.8 Nm).
1
2
3 5
4
1. Bolt (2) 4. Backplate
2. Washer (2) 5. Isolator mount
3. Nut (2)
Figure 24. Front Isolator Mount Attachment
23
NOTES
24
SECTION V–ELECTRIC STARTER
SUBJECT PAGE NO.

1. Starting System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
25
NOTES
26
STARTING SYSTEM DIAGNOSIS
— BATTERY TESTS —
● VISUAL ● VOLTAGE ● LOAD
Check Connections at Battery

and Starter Components. Continued on
Next Page
Solenoid Clicks. INOPERATIVE Nothing Clicks.
Relay
Clicks.
Perform Voltage Drop Tests
Between Battery and Test for Voltage at
“Relay” Terminal on Solenoid Terminal. Is
Solenoid. Less Than 1 Volt? 12V Present When
Starter Button is
Pressed?
YES NO
YES NO
2 Perform Voltage Drop 2 Backtrack to
Tests from Battery Pinpoint Poor Test for Voltage
(Pos. +) to Starter Connections or to Relay. Is 12V
“Motor”Terminal. Relay Contact Present on
1
Crank Engine. Is Problems Using Does Starter Relay Terminal
Voltage Greater than Voltage Drop Motor Turn if
1 Volt? Tests. Jumped?
YES NO
YES NO YES NO
Test for Voltage Repair Open on
2 Perform Voltage 2 Perform Voltage Replace Test Starter from Relay. Is 12V R/BK Wire Feeding
Drop Tests from Drop Test Solenoid. Motor for Present on Relay Terminal 30 on
Battery (Pos. +) Between Battery Opens, Terminal 87 When Starter Relay.
to Starter Motor (Neg. -) and Starter Shorts or Starter Button is
“M” (Battery) Studs or Bolts. Grounds. Pressed?
Terminal. Crank Is Voltage Greater
Engine. Is than 1 Volt? NO
YES
Voltage Greater
than 1 Volt? NO
YES Repair Open Replace
on GN Wire Starter Relay.
YES NO Between Relay
Clean
and Solenoid.
Ground
Connections
Repair Repair or
Connection Replace
Between Solenoid
Battery and (Contacts). Check for Battery Voltage
Starter. at Relay Terminal 86 From
Starter Button. Battery
Voltage Present?
Relay terminal
YES NO
Check for Check for Battery Voltage from Starter

Ground at Relay Button BK/R Wire. Battery Voltage
Terminal 85. Present With Starter Button Pressed?
Ground Present?
YES NO 5
YES NO
Substitute Inspect Starter Repair Wiring Check for Battery Voltage to

Good Relay Interlock From Starter Starter Button W/BK Wire.
or Test Relay. Circuit or Button to Relay. Battery Voltage Present?
Correct Relay
Ground.
YES NO
Motor terminal Replace Repair Wiring to

Battery terminal Starter Button. Starter Button.
27
Continued from
Previous Page
RUN-ON STARTER SPINS, BUT

DOES NOT ENGAGE
Disconnect Solenoid
“Relay” Terminal from
Solenoid. Is 12V Present
at GN Wire Terminal with
Starter Button NOT Remove Starter.
Pressed? Disassemble Drive
Housing Assembly.
Inspect for Damage
to Armature Gear or
YES NO
Idler Gear. Damage
Present?
Is 12V Present on Replace
Starter Relay Terminal Solenoid.
86 with Starter Button
NOT Pressed?
YES NO
YES NO
Replace Starter Replace Starter

Replace Starter Clutch
Button. Relay.
Damaged Gear Failure. Replace
and Armature. Starter Clutch.
STARTER STALLS OR
SPINS TOO SLOWLY
2 Perform Voltage Drop

Tests from Battery (Pos. +)
to Starter “Motor” Terminal.
Crank Engine. Is Voltage Greater
than 1 Volt?
YES NO
2
Perform Voltage Drop Perform Voltage Drop Test
Tests from Battery (Pos. +) Between Battery
to Starter “Battery” Terminal. (Neg. -) and Starter Studs
Crank Engine. Is Voltage Greater or Bolts. Is Voltage Greater
than 1 Volt? than 1 Volt?
YES NO
YES NO
Clean Ground 3 Perform Starter Motor
Connections. Current Draw Test (on
Repair Connection Repair or Vehicle).
Between Battery Replace
and Starter. Solenoid
(Contacts).
4 Perform Starter Motor
Free Draw Bench Test. Are
Test Results in Range?
NOTES
1 Remove starter motor and connect jumper wires as YES NO
described in Free Running Current Draw Test.
2 See Troubleshooting/Diagnostics- Voltage drops. Inspect Engine or Test Starter
Primary Drive. Motor
3 See Starter Current Draw Test. for Opens,
4 See Free Running Current Draw Test. Shorts or
Grounds.
5 See Starter Interlock Circuit Test
28
SECTION VI–DRIVE/TRANSMISSION
All drive/transmission procedures in the 1996 S1 Lightning Service Manual (Part No. 99490-96Y)
apply to 1997 models.
29
NOTES
30
SECTION VII–ELECTRICAL
SUBJECT PAGE NO.

1. Handlebar Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2. Starter Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3. Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4. Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
31
NOTES
32
HANDLEBAR SWITCHES
MODEL YEAR CHANGE b0279x7x
All 1997 model year motorcycles use new handlebar

switches. The switches feature new icons, connectors and a
different pin numbering sequence.
Ignition ON
NOTE
All HANDLEBAR SWITCHES, REMOVAL and HANDLEBAR Ignition OFF
SWITCHES, INSTALLATION procedures remain the same.
The new switch assemblies are interchangeable between
1996 and 1997 models if the corresponding connector on the
Electric starter
wiring harness is changed.
See WIRING HARNESS on page 37 for more information.

RIGHT HANDLEBAR
SWITCH CONNECTOR
Right Handlebar Switch IGN POWER BE
P1
GY
4
IGN MODULE W/R 3 W/BK
See Figure 25. The right handlebar switch [P1] contains: FROM (2)
TO STARTER
GN/BK
Y/R
2
1
W/BK
BK/R
P2
● Engine stop switch (ignition ON or OFF) ACC POWER O/W 1 O/W
TO STOPLIGHT R/Y 2 R/Y
● Electric starter switch BRAKE SWITCH
Left Handlebar Switch

See Figure 26. The left handlebar switch [P6] contains: Figure 25. Right Handlebar Switch [P1]
● Passing lamp switch
b0274x7x
● Headlamp dimmer switch (headlamp HIGH or LOW LEFT HANDLEBAR
beam) SWITCH CONNECTOR
P6
LOW BEAM W 1 Y
● Turn signal switch LIGHT POWER BN 2 BE
HIGH BEAM BK 3 W
4
● Horn switch HORN GN 5 Y/BK
FROM FLASHER BE 6 V/BN
LEFT TURN O 7 V
RIGHT TURN LT.BE 8 BN
HORN POWER GY 9 O/W
P5
FROM IGN RLY R/BE 1 TN/GN
TO GROUND BK 2 BK
CLUTCH SWITCH
Passing lamp
HIGH beam
LOW beam
Turn signals
Horn
Figure 26. Left Handlebar Switch [P6]
33
STARTER INTERLOCK SYSTEM
INSPECTION NOTE
The starter interlock system is designed to prevent unin- The STARTER CIRCUIT and IGNITION CIRCUIT tests
tended start-up and/or forward motion of the motorcycle with should be performed in one continuous operation. Conduct
the vehicle’s side stand not retracted. Use the following two both tests one after the other in the sequence given without
tests to check the system for proper operation. interruption
Starter Circuit
Raise rear wheel off floor using REAR WHEEL SUPPORT STAND (Part No. B-41174).
Remove GN wire from starter motor.
Connect a test light or voltmeter to the vehicle in series.
a. Attach one end to starter wire terminal.
b. Attach the other end to vehicle ground.
Set engine stop switch to RUN.
Turn ignition switch to IGN.
Place motorcycle in neutral.
Press starter button on right handlebar.
Is current present? (Current is present if test light illuminates or if voltmeter shows 12 VDC ± 1.0 VDC.)
Check neutral switch and circuit. See NEUTRAL INDI-

YES NO CATOR SWITCH in Section 7 of the 1996 manual.
Repeat entire interlock circuit test when finished.
Place motorcycle in first gear. Check neutral switch. See NEUTRAL INDICATOR
Press starter button on right handlebar. YES SWITCH in Section 7 of the 1996 manual. Repeat
Is current present? entire interlock circuit test when finished.
NO
Disengage clutch lever by pulling lever in fully. Check clutch switch. See STARTER INTERLOCK in
NO Section 7 of the 1996 manual. Repeat entire interlock
circuit test when finished.
Is current present?
YES
Release clutch lever. Check clutch switch. See STARTER INTERLOCK in

YES Section 7 of the 1996 manual. Repeat entire interlock
circuit test when finished.
Is current present?
Starter circuit operating properly.

a. Turn ignition switch to LOCK. Proceed to IGNITION CIRCUIT
No
b. Remove test light or voltmeter. on page 35.
c. Reattach starter motor wire.
34
Ignition Circuit
Remove W/BK wire from ignition coil.
Connect a test light or voltmeter to the vehicle.
a. Attach one end to W/BK wire terminal.
b. Attach the other end to vehicle ground.
Turn ignition switch to IGN.
Set engine stop switch to RUN.
Place motorcycle in neutral. Is current present?
Check neutral switch and circuit. See NEUTRAL INDI-

YES NO CATOR SWITCH in Section 7 of the 1996 manual.
Repeat entire ignition portion of interlock circuit test
when finished.
Check neutral switch. See NEUTRAL INDICATOR

Place motorcycle in first gear.
YES SWITCH in Section 7 of the 1996 manual. Repeat
Is current present?
entire ignition portion of interlock circuit test when fin-
ished.
NO
Retract side stand. Check side stand switch. See STARTER INTERLOCK
Is current present? NO in Section 7 of the 1996 manual. Repeat entire ignition
portion of interlock circuit test when finished.
YES
Extend side stand. Check clutch switch. See STARTER INTERLOCK in

NO Section 7 of the 1996 manual. Repeat entire ignition
Pull-in clutch lever. Is current present?
portion of interlock circuit test when finished.
YES
Ignition circuit operating properly.

a. Turn ignition switch to LOCK.
a. Set engine stop switch to OFF.
b. Remove test light or voltmeter.
c. Reconnect W/BK wire to ignition coil.
d. Remove REAR WHEEL SUPPORT STAND.
35
HORN

See Figure 27. All 1997 model year motorcycles have a new
horn in a new location.
NOTE
For troubleshooting information, see HORN, TROUBLE-
SHOOTING in Section 7 in the 1996 manual.
REMOVAL
in Section 4 of the 1996 manual.
2. See Figure 28. Detach horn wires.
a. Disconnect Y/BK power wire (5).
b. Disconnect BK ground wire (6).
3. Remove bolt (1), lockwasher (2) and washer (3) to Figure 27. Horn Location
detach horn and bracket from frame.
5875
INSTALLATION
1. See Figure 28. Attach horn assembly to frame using 2
bolt (1), lockwasher (2) and washer (3). 3
2. Connect horn wires.
a. Attach Y/BK power wire (5). 1
4
b. Attach BK ground wire (6).
1WARNING 6
After installing seat, pull upward on front of seat to be
5
sure it is locked in position. If seat is loose, it could shift
during vehicle operation and startle the rider, causing

TION in Section 4 of the 1996 manual. 1. Bolt 4. Adjuster
2. Lockwasher 5. Power wire (Y/BK)
3. Washer 6. Ground wire (BK)
Figure 28. Horn Attachment
36
WIRING HARNESS
MODEL YEAR CHANGE

The following changes were made to the wiring harness for
1997 model year motorcycles.
● New connectors and a different pin numbering sequence
for the right handlebar switch [P1] and the left handlebar
switch [P6]. See HANDLEBAR SWITCHES on page 33.
● Longer wires leading to the horn to accommodate the
new mounting position.
Table 3. Electrical Connectors

CONNECTOR
DESCRIPTION COMPONENT(S)
NUMBER
[P1] 4-place connector right handlebar switch housing-ignition power, module and starter
[P2] 2-place Amp Multilock front brake switch
[P3] 12-place Amp Multilock instruments and indicator lamps
[P4] 4-place Amp Multilock headlamp
[P5] 2-place Amp Multilock clutch switch
[P6] 8-place connector left handlebar switch housing-horn, turn signals, lights
[P7] 2-place Deutsch vacuum-operated electric switch
[P8] 4-place PED ignition/headlamp switch
[P9] 4-slot fuse block four 15 amp fuses-ignition, instruments, lights and accessories
[P10] 8-place Deutsch ignition module
[P11] 8-place Amp Multilock tail lamp and rear turn signals
[P12] 4-place relay ignition relay
[P13] 4-place relay starter relay
[P14] 2-place Amp Multilock side stand switch
[P15] 2-place Amp Multilock license plate light
[P16] 3-place Deutsch timer and pickup
[P17] 2-place plug voltage regulator
37
38
b0245a7x
BN
RIGHT BK ELECTRONIC IGNITION
TURN FLASHER
VACUUM SWITCH
OIL GN/Y
O
TIMER AND PICKUP BK
BK
PRESSURE O/W
SPEEDOMETER NEUTRAL
TN
O
P7 2 1 BK
Y/BK
HORN
V/W
BK
W
V/BN
HIGH BEAM BK
GN/W
BK/W
W/BK
O/W
BK
PK
V/W
R/W
R/W BK/W
R/Y
TN GN/Y
GN/W
V R/Y
LEFT TURN BK P10 8 7 6 5 4 3 2 1
P1
IGN POWER BE 4 GY
GN/W
BK/W
W/BK
BK
PK
V/W
R/W
IGN MODULE W/R 3 W/BK O/W
FROM (2) GN/BK 2 W/BK W/GN A B C P16
TO STARTER Y/R 1 BK/R BK
O
P2 TACHOMETER PK
ACC POWER O/W 1 O/W NEUTRAL OIL PRESSURE REAR
TO STOPLIGHT R/Y R/Y
2
12 11 10 9 8 7 6 5 4 3 2 1 P3 SWITCH SWITCH STOPLIGHT
BRAKE SWITCH SWITCH
GN/Y
O/W
BK
BK
TN
PK
BN
O
O
V
W
S8
BK TN/W
P14 2 1
BK W
RIGHT FRONT R/BK BN
TURN SIGNAL
BE BK
S6 BN LT.BE RIGHT REAR
BK BE
TURN SIGNAL
SIDE STAND
SWITCH
BN 1 BN
O/W 2 O/W
P4
V
BK
3
4
V
BK
TAIL LAMP
BK 5 BK
POSITION LMP O/W 1 O/W R/Y 6 R/Y
HIGH BEAM
LOW BEAM
W
Y
2
3
W
Y
S9 BK
7
8 BK
R/Y
LMP GROUND BK 4 BK
P11 BK
O/W
S2
P15
BE 1 BE Y
HEADLAMP S4 BK 2 BK BK
LICENSE PLATE
LIGHT
S1
LEFT FRONT LT.BE V S5 S3
TN
TURN SIGNAL
V
BK
R/BK
BE
LEFT REAR
BE BK TURN SIGNAL
S13 S12
MAIN CHASSIS GROUND
S11 TN/GN TN
S10 R BK
TN/GN TN/GN
MASTER
30A CIRCUIT
P6 BREAKER
LOW BEAM W 1 Y BK
LIGHT POWER BN 2 BE
HIGH BEAM BK 3 W S7
4
HORN GN 5 Y/BK
FROM FLASHER BE 6 V/BK
LEFT TURN TN/GN
O 7 V
RIGHT TURN
HORN POWER
LT.BE
GY
8
9
BN
O/W
S14 VOLTAGE REGULATOR
P5 S15 GN
R/BK
R/GY
R
FROM IGN RLY R/BE 1 TN/GN TN/W
TO GROUND BK 2 BK
GY TN/W PK
P13
P8
A
B
C
D
CLUTCH SWITCH PK
VIEW FROM FUSE BK/R TN/GN
P12
R/B K
R/GY
GN
INSERTION SIDE BK
R
W/BK
BK
COIL IGNITION BK
GY/O R/BK
15A
R/BK
COLOR CODE: LT.BE LIGHT BLUE GY/O O 1 2 P17
REAR PLUG O
INSTRUMENTS
R/BK
BE BLUE GY GRAY TN TAN GY/O 15A
BK BLACK O ORANGE V VIOLET

FRONT PLUG LIGHTS R/BK
86 85
86 85 TN/W BK/R TN/GN
BE
DIODE GY/O TN/W
15A
BK
BN BROWN PK PINK W WHITE 87
87 R/BK GN
NO CONNECTION GY/O GY
ACCESSORIES 30 KEY SWITCH
30
GN GREEN R RED Y YELLOW CONNECTION O/W R/GY
O/W 15A 87A
87A
R/BK BK
XX XX PIN CONNECTOR IGN
CABLE COLOR STRIPE COLOR SOCKET CONNECTOR IGNITION RELAY STARTER RELAY R/GY
FUSE BLOCK R OFF
P9 LOCK
BATTERY STATOR
1997 BUELL WIRING DIAGRAM
6/10/96
Figure 29. 1997 Wiring Diagram

FOREWORD
GENERAL PREPARATION FOR SERVICE

This Service Manual Supplement has been prepared with two 1WARNING
purposes in mind. First, it will acquaint the user with the
construction of the 1997 Buell S1 Lightning and assist in the Gasoline is extremely flammable and highly explosive.
performance of basic maintenance and repair. Secondly, it Always stop the engine when refueling or servicing the
will introduce to the professional Buell Technician the latest fuel system. Do not smoke or allow open flame or sparks
field-tested and factory-approved major repair methods. We near the work site. Inadequate safety precautions may
sincerely believe that this Service Manual Supplement will result in personal injury.
make your association with Buell products more pleasant and
profitable. 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
HOW TO USE YOUR SERVICE motorcycle that is excessively dirty should be cleaned before
MANUAL SUPPLEMENT 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
1. Check the TABLE OF CONTENTS following this
to locate tools or parts is an unnecessary distraction and
FORWORD to find the desired subject.
causes needless delay.
2. If the information you seek is not in this supplement, refer

to the corresponding section in the Buell 1996 SERVICE BULLETINS
S1 Lightning Service Manual (Part No. 99490-96Y). In addition to the information presented in this Service
Check the TABLE OF CONTENTS or INDEX to find the Supplement, Buell Distribution Corporation will periodically
desired subject. issue Service Bulletins to Buell dealers. Service Bulletins
cover interim engineering changes and supplementary
3. Information is presented in a definite order as follows: information.
Specifications
General/Model Year Change
USE GENUINE
Adjustment/Testing REPLACEMENT PARTS
Removal/Disassembly
Cleaning, Inspection, and Repair
Assembly/Installation
1WARNING
When replacement parts are required, use only genuine
In figure legends, the number which follows the name of a Buell parts or parts with equivalent characteristics
part indicates the quantity necessary for one complete (which include type, strength and material). Failure to do
assembly. so may result in product malfunction and possible injury
to the operator and/or passenger.
NOTE To ensure satisfactory and lasting repairs, carefully follow the

instructions and use only genuine Buell replacement parts.
To avoid needless disassembly, carefully read all relative This is your assurance that the parts you are using will fit
service information before repair work is started. right, operate properly and last longer.
i.
PRODUCT REFERENCES WARNINGS AND CAUTIONS
Statements in this supplement preceded by the word
1WARNING “1WARNING” or “1CAUTION” are very important. Since
these items alert you to situations where the possibility of
Follow the directions listed on all products. Carefully personal injury or vehicle damage exists, please take special
read all labels, warnings and cautions before use. notice of them.
Inadequate safety precautions may result in personal
injury. 1WARNING
A “WARNING” indicates the potential for personal injury,
When reference is made in this Service Manual Supplement whether to yourself or others.
to a specific brand name product, tool or instrument, an
equivalent product, tool or instrument may be substituted. 1CAUTION
A “CAUTION” indicates that vehicle damage can occur.
Kent-Moore Products
1WARNING
All tools mentioned in this supplement with an “HD”, “J” or “B” ● Proper service and repair is important for the safe,
preface must be ordered through: reliable operation of all mechanical products. The
service procedures recommended and described in
Kent-Moore this Service Manual are effective methods for
SPX Corporation performing service operations. Some of these
29784 Little Mack service operations require the use of tools specially
Roseville, Michigan 48066-2298 designed for the purpose. These special tools should
Telephone: 1-800-345-2233 be used when and as recommended. It is important
to note that some warnings against the use of
Sealing and Threadlocking Products specific service methods, which could damage the
motorcycle or render it unsafe, are stated in this
Service Manual. However, please remember that
LOCTITE PRODUCTS these warnings are not all-inclusive.
Some procedures call for the use of Loctite® products. If you ● Since Buell could not possibly know, evaluate or
have any questions regarding Loctite product usage or advise the service trade of all possible ways in which
retailer/wholesaler locations, please call Loctite Corp. at 1- service might be performed, or of the possible
800-323-5106. hazardous consequences of each method, we have
not undertaken any such broad evaluation.
Accordingly, anyone who uses a service procedure
CONTENTS or tool which is not recommended by Buell must first
thoroughly satisfy himself that neither his nor the
All photographs and illustrations may not necessarily depict operator’s safety will be jeopardized as a result.
the most current model or component, but are based on the
latest production information available at the time of ● Wear eye protection when using hammers, arbor or
publication. hydraulic presses, gear pullers, spring compressors,
slide hammers and similar tools. Be especially
Since product improvement is our continual goal, Buell cautious when using pulling, pressing or
reserves the right to change specifications, equipment or compressing equipment. The forces involved can
designs at any time without notice and without incurring cause parts to fly outward with considerable force,
obligation. possibly resulting in personal injury.
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.
1 GENERAL
SERVICING A NEW MOTORCYCLE SHOP PRACTICES

1WARNING Repair Notes
Always follow the listed service and maintenance NOTE
recommendations, since they affect the safe operation of ● General maintenance practices are given in this section.
the motorcycle and the personal welfare of the rider.
Failure to follow recommendations may cause personal ● Repair = Disassembly/Assembly.
injury.
● Replace = Removal/Installation.
Service operations to be performed before customer delivery All special tools and torque values are noted at the point of
are specified in the applicable model year PREDELIVERY use.
AND SETUP MANUAL.
All required parts or materials can be found in the appropriate
The performance of new motorcycle initial service is required PARTS CATALOG.
to keep warranty in force and to ensure proper emissions
systems operation. Safety
Safety is always the most important consideration when
After a new motorcycle has been driven its first 500 miles,
performing any job. Be sure you have a complete
and again at 2500 mile intervals, a Buell dealer should
understanding of the task to be performed. Use common
perform the service operations listed in the REGULAR
sense. Use the proper tools. Protect yourself and bystanders
MAINTENANCE INTERVALS chart on page 1-9.
with approved eye protection. Don’t just do the job – do the
job safely.
SAFE OPERATING MAINTENANCE Removing Parts
A careful check of certain equipment is necessary after Always consider the weight of a part when lifting. Use a hoist
periods of storage, and frequently between regular service whenever necessary. Do not lift heavy parts by hand. A hoist
intervals, to determine if additional maintenance is required. and adjustable lifting beam or sling are needed to remove
some parts. The lengths of chains or cables from the hoist to
1CAUTION the part should be equal and parallel and should be
● Do not attempt to retighten engine head bolts. positioned directly over the center of the part. Be sure that no
Retightening can cause engine damage. obstructions will interfere with the lifting operation. Never
leave a part suspended in mid-air.
● During the initial 500 mile (800 km) break-in period,
use only 20W50 engine oil. Failure to use the Always use blocking or proper stands to support the part that
recommended oil will result in improper break-in of has been hoisted. If a part cannot be removed, verify that all
the engine cylinders and piston rings. bolts and attaching hardware have been removed. Check to
see if any parts are in the way of the part being removed.
● Do not lubricate the enrichment cable on C.V.
carburetors. The cable requires friction to operate When removing hoses, wiring or tubes, always tag each part
properly. to ensure proper installation.
Check: Cleaning
1. Tires for abrasions, cuts and correct pressure. If you intend to reuse parts, follow good shop practice and
thoroughly clean the parts before assembly. Keep all dirt out
2. Secondary drive belt for proper tension and condition. of parts; the unit will perform better and last longer. Seals,
filters and covers are used in this vehicle to keep out
3. Brakes, steering and throttle for responsiveness. environmental dirt and dust. These items must be kept in
4. Brake fluid level and condition. Hydraulic lines and good condition to ensure satisfactory operation.
fittings for leaks. Also, check brake pads and rotors for Clean and inspect all parts as they are removed. Be sure all
wear. holes and passages are clean and open. After cleaning,
5. Cables for fraying, crimping and free operation. cover all parts with clean lint-free cloth, paper or other
material. Be sure the part is clean when it is installed.
6. Engine oil and transmission fluid levels.
Always clean around lines or covers before they are removed.
7. Headlamp, passing lamp, tail lamp, brake lamp and turn Plug, tape or cap holes and openings to keep out dirt, dust
signal operation. and debris.
1-1
Disassembly and Assembly Bushings
Always assemble or disassemble one part at a time. Do not Do not remove a bushing unless damaged, excessively worn
work on two assemblies simultaneously. Be sure to make all or loose in its bore. Press out bushings that must be replaced.
necessary adjustments. Recheck your work when finished.
Be sure that everything is done. When pressing or driving bushings, be sure to apply pressure
in line with the bushing bore. Use a bearing/bushing driver or
Operate the vehicle to perform any final check or a bar with a smooth, flat end. Never use a hammer to drive
adjustments. If all is correct, the vehicle is ready to go back to bushings.
the customer.
Inspect the bushing and the mated part for oil holes. Be sure
all oil holes are properly aligned.
REPAIR AND REPLACEMENT
PROCEDURES Gaskets
Always discard gaskets after removal. Replace with new
Hardware and Threaded Parts gaskets. Never use the same gasket twice. Be sure that
gasket holes match up with holes in the mating part.
Install helical thread inserts when inside threads in castings
are stripped, damaged or not capable of withstanding
specified torque. Lip Type Seals
Replace bolts, nuts, studs, washers, spacers and small Lip seals are used to seal oil or grease and are usually
common hardware if missing or in any way damaged. Clean installed with the sealing lip facing the contained lubricant.
up or repair minor thread damage with a suitable tap or die. Seal orientation, however, may vary under different
applications.
Replace all damaged or missing lubrication fittings.
Seals should not be removed unless necessary. Only remove
Use Teflon pipe sealant on pipe fitting threads.
seals if required to gain access to other parts or if seal
damage or wear dictates replacement.
Wiring, Hoses and Lines
Leaking oil or grease usually means that a seal is damaged.
Replace hoses, clamps, electrical wiring, electrical switches
Replace leaking seals to prevent overheated bearings.
or fuel lines if they do not meet specifications.
Always discard seals after removal. Do not use the same seal
Instruments and Gauges twice.
Replace broken or defective instruments and gauges.
Replace dials and glass that are so scratched or discolored O-Rings (Preformed Packings)
that reading is difficult.
Always discard O-rings after removal. Replace with new O-
rings. To prevent leaks, lubricate the O-rings before
Bearings installation. Apply the same type of lubricant as that being
Anti-friction bearings must be handled in a special way. To sealed. Be sure that all gasket, O-ring and seal mating
keep out dirt and abrasives, cover the bearings as soon as surfaces are thoroughly clean before installation.
they are removed from the package.
Gears
Wash bearings in a non-flammable cleaning solution. Knock
out packed lubricant inside by tapping the bearing against a Always check gears for damaged or worn teeth.
wooden block. Wash bearings again. Cover bearings with
clean material after setting them down to dry. Never use Lubricate mating surfaces before pressing gears on shafts.
compressed air to dry bearings.
Coat bearings with clean oil. Wrap bearings in clean paper.
Shafts
Be sure that the chamfered side of the bearing always faces If a shaft does not come out easily, check that all nuts, bolts or
the shoulder (when bearings installed against shoulders). retaining rings have been removed. Check to see if other
Lubricate bearings and all metal contact surfaces before parts are in the way before using force.
pressing into place. Only apply pressure on the part of the
Shafts fitted to tapered splines should be very tight. If shafts
bearing that makes direct contact with the mating part.
are not tight, disassemble and inspect tapered splines.
Always use the proper tools and fixtures for removing and Discard parts that are worn. Be sure tapered splines are
installing bearings. clean, dry and free of burrs before putting them in place.
Press mating parts together tightly.
Bearings do not usually need to be removed. Only remove
bearings if necessary. Clean all rust from the machined surfaces of new parts.
1-2
Part Replacement ● Disconnect the air supply line to an air hammer before
attaching a bit.
Always replace worn or damaged parts with new parts.
● Never point an air tool at yourself or another person.
CLEANING ● Protect bystanders with approved eye protection.
Part Protection Wrenches

Before cleaning, protect rubber parts (such as hoses, boots ● Never use an extension on a wrench handle.
and electrical insulation) from cleaning solutions. Use a
grease-proof barrier material. Remove the rubber part if it ● If possible, always pull on a wrench handle and adjust
cannot be properly protected. your stance to prevent a fall if something lets go.
Cleaning Process ● Never cock a wrench.
Any cleaning method may be used as long as it does not ● Never use a hammer on any wrench other than a
result in parts damage. Thorough cleaning is necessary for STRIKING FACE wrench.
proper parts inspection. Strip rusted paint areas to bare metal
before repainting. ● Discard any wrench with broken or battered points.
Rust or Corrosion Removal ● Never use a pipe wrench to bend, raise or lift a pipe.
Remove rust and corrosion with a wire brush, abrasive cloth,

sand blasting, vapor blasting or rust remover. Use buffing
Pliers/cutters/prybars
crocus cloth on highly polished parts that are rusted.
● Plastic- or vinyl-covered pliers handles are not intended
to act as insulation; don’t use on live electrical circuits.
Bearings
Remove shields and seals from bearings before cleaning. ● Don’t use pliers or cutters for cutting hardened wire
Clean bearings with permanent shields and seals in solution. unless they were designed for that purpose.
Clean open bearings by soaking them in a petroleum ● Always cut at right angles.
cleaning solution. Never use a solution that contains chlorine.
● Don’t use any prybar as a chisel, punch or hammer.
Let bearings stand and dry. Do not dry using compressed air.
Do not spin bearings while they are drying. Hammers
Never strike one hammer against a hardened object,
TOOL SAFETY ●
such as another hammer.
Air Tools ● Always grasp a hammer handle firmly, close to the end.
● Always use approved eye protection equipment when ● Strike the object with the full face of the hammer.
performing any task using air-operated tools.
● Never work with a hammer which has a loose head.
● On all power tools, use only recommended accessories
with proper capacity ratings. ● Discard hammer if face is chipped or mushroomed.
● Do not exceed air pressure ratings of any power tools.
● Wear approved eye protection when using striking tools.
● Bits should be placed against work surface before air
hammers are operated. ● Protect bystanders with approved eye protection.
1-3
Punches/chisels ● Always support the ratchet head when using socket
extensions, but do not put your hand on the head or you
● Never use a punch or chisel with a chipped or may interfere with the action of its reversing mechanism.
mushroomed end; dress mushroomed chisels and
punches with a file. ● When breaking loose a fastener, apply a small amount of
pressure as a test to be sure the ratchet’s gear wheel is
● Hold a chisel or a punch with a tool holder if possible.
engaged with the pawl.
● When using a chisel on a small piece, clamp the piece
firmly in a vise and chip toward the stationary jaw. Sockets
● Wear approved eye protection when using these tools.
● Never use hand sockets on power or impact wrenches.
● Protect bystanders with approved eye protection.
● Select the right size socket for the job.
Screwdrivers ● Never cock any wrench or socket.
● Don’t use a screwdriver for prying, punching, chiseling,
scoring or scraping. ● Select only impact sockets for use with air or electric
impact wrenches.
● Use the right type of screwdriver for the job; match the tip
to the fastener. ● Replace sockets showing cracks or wear.
● Don’t interchange POZIDRIV®, PHILLIPS® or REED ● Keep sockets clean.
AND PRINCE screwdrivers.
● Always use approved eye protection when using power
● Screwdriver handles are not intended to act as or impact sockets.
insulation; don’t use on live electrical circuits.
● Don’t use a screwdriver with rounded edges because it Storage Units
will slip – redress with a file.
● Don’t open more than one loaded drawer at a time. Close
Ratchets and Handles each drawer before opening up another.
● Periodically clean and lubricate ratchet mechanisms with ● Close lids and lock drawers and doors before moving
a light grade oil. Do not replace parts individually; storage units.
ratchets should be rebuilt with the entire contents of
service kit. ● Don’t pull on a tool cabinet; push it in front of you.
● Never hammer or put a pipe extension on a ratchet or ● Set the brakes on the locking casters after the cabinet
handle for added leverage. has been rolled to your work.
1-4
1996 S1 LIGHTNING SPECIFICATIONS
I
DIMENSIONS IN. MM IGNITION SYSTEM
Wheel base 55 1397 Spark plugs No. 6R12

Overall length 79.5 2019 Size 12 mm
Overall width 30 762 Gap 0.038-0.045 in. 0.97-1.14 mm
Road clearance 5.2 132
Seat height 29.5 749 TRANSMISSION
Type Constant Mesh, Foot Shift

Speeds 5 Forward
CAPACITIES U.S. LITERS
Fuel tank (including reserve) 4.0 gallons 15.14 NUMBER OF SPROCKET TEETH
Reserve 0.6 gallons 2.27
Engine 35
Oil tank 2.0 quarts 1.89
Clutch 56
Transmission 1.0 quart 0.95
Transmission 27
Rear wheel 61
Belt 128
WEIGHT LBS. KG
S1 shipping weight 446 202

TRANSMISSION GEAR RATIOS FINAL* OVERALL**
GVWR 820 372
First (low) gear 2.69 9.717
GAWR - Front 340 154
Second gear 1.97 7.118
GAWR - Rear 480 218
Third gear 1.43 5.180
Fourth gear 1.18 4.269
NOTE
Fifth (high) gear 1.00 3.615

PRESSURE
ENGINE PRESSURE
AT GVWR
RIDING
Number of cylinders 2
Type 4-Cycle, 45 Degree V-Type Front-Dunlop Sportmax 32 PSI 36 PSI
Bore 3.498 in. 88.849 mm
Rear-Dunlop Sportmax 36 PSI 38 PSI
Stroke 3.8125 in. 96.838 mm Radial II 170/60 ZR 17 (2.5 bar) (2.8 bar)
Piston displacement 73.4 cu. in. 1203 cc
Compression ratio 10.0 to 1 1WARNING
Horsepower @ RPM 91 @ 5800 Do not inflate any tire beyond its maximum inflation
pressure as specified on tire sidewall. Overinflation may
Torque ft-lb @ RPM 87 @ 5200 cause tire to suddenly deflate leading to personal injury.
1-5
SIDE VIEWS
5745
6
2 3 4 5 7
8
1
9
10
15
14 13 12 11
1. Right rear turn signal 6. Front brake master cylinder 12. Rear shock absorber
2. Tail/brake lamp 7. Front brake hand lever 13. Rear brake pedal
3. Rear brake master cylinder 8. Right front turn signal 14. Belt guard(s)
and reservoir 9. Headlamp 15. License plate light
4. Air cleaner cover 10. Front brake caliper
5. Fuel filler cap 11. Timer cover
Figure 1-1. 1996 S1 Lightning, Right Side View
5746
7
8
3 4 5 6
2
1
9
14 13 12 11 10
1. Rear axle adjuster nut 5. Turn signal flasher 10. Oil pump
2. Rear sprocket and secondary 6. Horn 11. Battery
drive belt 7. Front brake master cylinder 12. Voltage regulator
3. Ignition module 8. Front brake hand lever 13. Rider footrest
4. Fuse block and spare fuse 9. Front brake caliper 14. Passenger footrest
Figure 1-2. 1996 S1 Lightning, Right Side View (Body Removed)
1-6
5747
3 4 5 6 7 8
9
1
10
13 12 11
1. Left front turn signal 6. Ignition/headlamp key switch 11. Gear shift lever
2. Headlamp 7. Fuel supply valve 12. Exhaust muffler
3. Instruments 8. Tail/brake lamp 13. Oil filter
4. Clutch hand lever 9. Left rear turn signal
5. Fuel filler cap 10. Rear brake caliper
Figure 1-3. 1996 S1 Lightning, Left Side View
5748
1 2 3
4 5 6 7 8 9
10
15 14 13 12 11
1. Steering head lock 6. Starter relay 11. Oil tank drain hose
2. Instruments 7. Oil filler plug/dipstick 12. Gear shift lever
3. Clutch hand lever 8. Oil tank 13. Exhaust muffler
4. Ignition coil 9. Rear brake caliper 14. Oil filter
5. Enrichener knob 10. Rear axle adjuster nut 15. Speedometer drive
Figure 1-4. 1996 S1 Lightning, Left Side View (Body Removed)
1-7
FLUID REQUIREMENTS
GENERAL FRONT FORK OIL
United States System Use only WP FORK OIL, 5 WEIGHT.
Unless otherwise specified, all fluid volume measurements
in this Service Manual are expressed in United States
(U.S.) units-of-measure. See below:
FUEL
● 1 pint (U.S.) = 16 fluid ounces (U.S.)
● 1 quart (U.S.) = 2 pints (U.S.) = 32 fl. oz. (U.S.)
Use a good quality leaded or unleaded gasoline (91 pump
● 1 gallon (U.S.) = 4 quarts (U.S.) = 128 fl. oz. (U.S.)
octane or higher). Pump octane is the octane number usually
shown on the gas pump. See ENGINE in Section 3 for a
Metric System
detailed explanation of alternative fuels.
Fluid volume measurements in this Service Manual include
the metric system equivalents. In the metric system, 1 liter
(L) = 1,000 milliliters (mL). Should you need to convert from
U.S. units-of-measure to metric units-of-measure (or vice ENGINE OIL
versa), refer to the following:
● fluid ounces (U.S.) x 29.574 = milliliters Use the proper grade of oil for the lowest temperature
● pints (U.S.) x 0.473 = liters expected before the next oil change.
● quarts (U.S.) x 0.946 = liters
● gallons (U.S.) x 3.785 = liters Table 1-1. Recommended Oil Grades
● milliliters x 0.0338 = fluid ounces (U.S.) COLD
● liters x 2.114 = pints (U.S.) HARLEY- LOWEST WEATHER
HARLEY-
● liters x 1.057 = quarts (U.S.) DAVIDSON TYPE
RATING TEMP. BELOW
● liters x 0.264 = gallons (U.S.) 50° F
SAE Below 40°F
H.D. Multi-Grade HD 240 Excellent
10W40 (4°C)
STEERING HEAD BEARING SAE Above 40°
GREASE 20W50 (4°C)
SAE Above 60°
Use WHEEL BEARING GREASE (Part No. 99855-89). H.D. Regular Heavy HD 240 Poor
50 (16°C)
SAE Above 80°
60 (27°C)
BRAKE FLUID
1WARNING
D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID can cause PRIMARY DRIVE/TRANSMISSION
eye irritation. In case of contact with eyes, flush with
plenty of water and get medical attention. KEEP BRAKE LUBRICANT
FLUID OUT OF THE REACH OF CHILDREN!
Use only D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID Use only SPORT-TRANS FLUID (Part No. 98854-96 quart
(Part No. 99902-77). size or Part No. 98855-96 gallon size).
1-8
Table 1-2. Regular Maintenance Intervals
1 1 1 1 2 2 2 2 3
2 5 7 0 2 5 7 0 2 5 7 0
5 5 0 5 0 5 0 5 0 5 0 5 0
P 0 0 0 0 0 0 0 0 0 0 0 0 0
A
r 0 0 0 0 0 0 0 0 0 0 0 0 0
n
SERVICE OPERATIONS e mi mi mi mi mi mi mi mi mi mi mi mi mi
n
r SERVICE DATA
AND SPECIAL TOOLS u
i 1 1 2 2 2 3 3 4 4 4
a
d 4 8 2 6 0 4 8 2 6 0 4 8
l
e 8 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0
km km km km km km km km km km km km km
Battery connections (page 1-13) I I I I I I I I I I I I I I Torque

30-40 in-lbs (3.4-4.5 Nm)-hold cables when tightening
Engine oil (page 1-15) I R I R I R I R I R I R I R R See Recommended Oil Grades on page 1-15.
OIL FILTER WRENCH (Part No. HD-41215) Checking oil level
Check with vehicle at operating temperature, engine off, motorcycle upright
(not on side stand) on a level surface.
Oil level
Between upper and lower marks on dipstick (1/2 quart [0.47 liter] difference).
Oil capacity
2.0 quarts (1.9 liters)
Oil filter (page 1-16) R R R R R R R R Hand tighten filter 1/2-3/4 turn after gasket contacts surface.
Brake fluid level and condition (page 1-17) I I I I I I I I Fluid type

D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID
Front master cylinder level
Above LOW mark on sight glass or within 1/8 in. (3.2 mm) of molded boss
when cover is removed.
Rear master cylinder level
Between upper and lower marks on reservoir.
Rear brake pedal height adjustment and freeplay I I I I I I I I Maximum freeplay

(page 1-17) 1/8 in. (3.2 mm)
Pedal action should be smooth and not binding.
Brake pads and rotors for wear (page 1-17) I I I I I I I I I I I I I I Minimum brake pad thickness
1/16 in. (1.6 mm)
Minimum front rotor thickness
0.17 in. (4.4 mm)
Minimum rear rotor thickness
0.19 in. (4.8 mm)
Condition of rear brake caliper mounting pins and boots IL IL IL IL IL IL
Table Code:
A - Adjust. R - Replace or change.
1-9
I - Inspect, and if necessary, correct, adjust, clean or replace. T - Tighten to proper torque.
L - Lubricate with specified lubricant. X - Perform.
1-10
1 1 1 1 2 2 2 2 3
2 5 7 0 2 5 7 0 2 5 7 0
5 5 0 5 0 5 0 5 0 5 0 5 0
P 0 0 0 0 0 0 0 0 0 0 0 0 0
A
r 0 0 0 0 0 0 0 0 0 0 0 0 0
n
e mi mi mi mi mi mi mi mi mi mi mi mi mi
SERVICE OPERATIONS n
r SERVICE DATA
AND SPECIAL TOOLS u
i 1 1 2 2 2 3 3 4 4 4
a
d 4 8 2 6 0 4 8 2 6 0 4 8
l
e 8 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0
Tire pressure and inspect tire for wear/damage I I I I I I I I I I I I I I See Tire Pressures on page 1-18.
Wheel bearings (page 1-18) I I I I Check for wear and corrosion. Replace in sets only.
Primary chaincase/transmission lubricant (page 1-19) R I R I R I R I R I R I R Fluid type and amount

REAR WHEEL SUPPORT STAND (Part No. B-41174) 1.0 quart (0.95 liter) of SPORT-TRANS FLUID
(Part No. 98854-96)
Fluid level
Lubricant should reach bottom of clutch spring with motorcycle upright
(not on side stand).
Drain plug torque
14-21 ft-lbs (19-28 Nm)
Clutch adjustment (page 1-20) A A A A A A A Hand lever freeplay

1/16-1/8 in. (1.6-3.2 mm)
Clutch inspection cover screw torque
7-9 ft-lbs (9-12 Nm)
Rear belt deflection (page 1-21) I A I I I I I I Belt deflection with 10 lbs (4.5 kg) of upward force
BELT TENSION GAUGE (Part No. HD-35381) 7/8-1 in. (22.2-25.4 mm)
Rear axle nut torque
68-73 ft-lbs (89.5-98.9 Nm)
Primary chain (page 1-22) I I I I I I I Chain freeplay with hot engine

1/4-3/8 in. (6.4-9.5 mm)
Chain freeplay with cold engine
3/8-1/2 in. (9.5-12.7 mm)
Inspection screws torque
40-60 in-lbs (4.5-6.8 Nm)
Rear shock absorber (page 1-24) I I I I I I I Check for bushing wear and loose mounting hardware.
Steering head bearing adjustment (page 1-25) I I IL I IL I IL Force to pull front wheel to center
FRONT WHEEL SUPPORT STAND (Part No. B-41395) 3.5-5.5 ft-lbs (1.6-2.5 kg)
& S1 ADAPTER (B-41686) Lubricant
WHEEL BEARING GREASE (Part No. HD99855-89)
Table Code:
1 1 1 1 2 2 2 2 3
2 5 7 0 2 5 7 0 2 5 7 0
5 5 0 5 0 5 0 5 0 5 0 5 0
P 0 0 0 0 0 0 0 0 0 0 0 0 0
A
r 0 0 0 0 0 0 0 0 0 0 0 0 0
n
SERVICE OPERATIONS e mi mi mi mi mi mi mi mi mi mi mi mi mi
n
r SERVICE DATA
AND SPECIAL TOOLS u
i 1 1 2 2 2 3 3 4 4 4
a
d 4 8 2 6 0 4 8 2 6 0 4 8
l
e 8 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0
Front fork oil (page 1-26) R R R Fluid type

FRONT WHEEL SUPPORT STAND (Part No. B-41395) WP FORK OIL, 5 weight
& S1 ADAPTER (B-41686) Fluid level
PRO-LEVEL OIL GAUGE (Part No. B-59000A) 4.33 in. (110 mm) from top with fork fully compressed
Spark plugs (page 1-27) I R I R I R Spark plug type

No. 6R12
Spark plug gap
0.038-0.045 in. (0.96-1.14 mm)
Lubricant
LOCTITE ANTI-SEIZE LUBRICANT
Torque
11-18 ft-lbs (15-24 Nm)
Air cleaner filter (page 1-28) I R R R R R R Check more often in dusty conditions.
Throttle control grip sleeve, cables and speedometer cable (Section 2) I L L L L L L Check for damage and freeplay.
Front brake hand lever, throttle control cables, clutch control cable and L L L L L L L Check for damage and freeplay.
hand lever (Section 2)
Operation of throttle and enrichener controls (page 1-29) I I I I I I I I I I I I I I Controls must be smooth and not binding.
DO NOT lubricate the enrichener cable.
Engine idle speed (page 1-30) I I I I I I I I I I I I I I Fast idle-all models

CARBURETOR IDLE ADJUSTMENT TOOL 2000 RPM
(Part No. HD-33413) Regular idle-49 state models
TIP (Snap-on Part No. TMP23A) 950-1050 RPM
Regular idle-California models
1150-1250 RPM
Ignition timing (page 1-30) I I I I I I Ignition timing set at regular engine idle speed (listed above).
TIMING MARK VIEW PLUG (Part No. HD-96295-65D)
INDUCTIVE TIMING LIGHT (Part No. HD-33813)
Vacuum-operated electric switch (V.O.E.S.) (page 1-32) I I I I I I
Table Code:
1-11

1-12
1 1 1 1 2 2 2 2 3
2 5 7 0 2 5 7 0 2 5 7 0
5 5 0 5 0 5 0 5 0 5 0 5 0
P 0 0 0 0 0 0 0 0 0 0 0 0 0
A
r 0 0 0 0 0 0 0 0 0 0 0 0 0
n
e mi mi mi mi mi mi mi mi mi mi mi mi mi
SERVICE OPERATIONS n
r SERVICE DATA
AND SPECIAL TOOLS u
i 1 1 2 2 2 3 3 4 4 4
a
d 4 8 2 6 0 4 8 2 6 0 4 8
l
e 8 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0
Fuel supply valve, hoses and fittings for leaks (Section 4) I I I I I I I I I I I I I
Fuel tank filter screen (Section 4) I I I I I I

Swingarm pivot bolt (Section 2) I I I I I I Lubricant
LOCTITE ANTI-SEIZE LUBRICANT
Swingarm bearings (Section 2) I IL I IL I IL Lubricant

WHEEL BEARING GREASE (Part No. HD99855-89)
Oil and brake lines (Section 2 and 3) I I I I I I I I I I I I I I Check for leaks and loose connections.
Side stand (Section 2) I L L L L L L
Engine mounts (Section 3) I I I I I I I
Operation of all electrical equipment and switches (Section 7) I I I I I I I I I I I I I I
All fasteners except engine head bolts T T T T T T T
Road test X X X X X X X X X X X X X X
Table Code:
1
BATTERY
GENERAL 1DANGER - EXPLOSIVE GASES
1WARNING Cigarettes, flames or sparks could cause battery to
● Batteries contain sulfuric acid which can cause severe explode resulting in personal injury. Always shield
burns. Avoid contact with skin, eyes or clothing. eyes and face from battery. Do not charge without
proper instruction and training. Securely connect
● Batteries produce explosive hydrogen gas at all cables to the proper terminals.
times, especially when being charged. Keep ciga-
rettes, open flame and sparks away from the battery POISON - CAUSES SEVERE BURNS
at all times. Ventilate area when charging battery. Contains sulfuric acid. Avoid contact with skin, eyes,
Always protect hands and protect eyes with shield or and clothing. In event of accident, flush with water and
goggles when working near a battery or acid. KEEP call a physician immediately.
BATTERIES AND ACID OUT OF THE REACH OF CHIL-
DREN! KEEP OUT OF REACH OF CHILDREN
The battery is below the seat in the center of the vehicle. The Figure 1-5. Battery Warnings
battery can be removed from the left side of the motorcycle
without removing the tail section or fuel tank. b0188xox
The battery requires no additional fluid at any time. 12.9
Check the battery: 12.6

Open Circuit Volts
● At every scheduled service interval.

12.3
● When storing or removing the motorcycle for the season.
12.0
CHARGING
11.7
The sealed, low maintenance battery has a very slow dis-
charge rate. See Figure 1-6. If you suspect a battery problem,
11.4
test as described below. 0 20 40 60 80 100
1. Remove battery from motorcycle. See BATTERY, State of Charge, %
REMOVAL on page 1-14.
Figure 1-6. Open Circuit Voltage vs. State of Charge
2. Test battery voltage using a multimeter.
(No Charge Last 24 Hours)
3. If battery voltage is below 12.66 Volts, use a 1-100 Amp,
12 Volt charger on battery. See Table 1-3.
Table 1-3. Charging Rates
CHARGER OPEN CIRCUIT VOLTAGE

OUTPUT
CURRENT 12.00 to 11.40 to Less than
RATE 12.66 Volts 11.99 Volts 11.40 Volts
1 Amp 32 hours 48 hours 96 hours
2-5 Amps 16 hours 24 hours 48 hours
6-10 Amps 8 hours 12 hours 24 hours
1-13
REMOVAL 5548
1WARNING
To avoid accidental start-up of vehicle and possible per-
Locknut
sonal injury, disconnect the battery cables before pro-
ceeding. Always disconnect the negative cable first. If
the positive cable should contact ground with the nega- Battery positive
tive cable installed, the resulting sparks may cause a bat- terminal (metric)
tery explosion producing personal injury.
Battery negative
1CAUTION terminal (metric)
See Figure 1-8. Hold battery cable when loosening bat-
tery terminal hardware. Failure to hold cable will cause
battery damage.
Battery strap
1. Disconnect battery cables, negative cable first.
2. Remove battery strap locknut using 7/16 in. flex socket Figure 1-7. Battery
(SNAP-ON Part No. TMU141) and handle (SNAP-ON
Part No. TM62B).
b0189x7x
NOTE Hold cable during
removal/installation
On California models, detach carbon canister from bracket
before removing battery. Tighten to 30-40 in-lbs
(3.4-4.5 Nm)
3. Remove battery from left side.
INSTALLATION
1. Clean cable connectors and battery terminals using a
wire brush or sandpaper to remove any oxidation.
1WARNING
Always connect positive battery cable first. If the positive Figure 1-8. Checking Battery Terminals
cable should contact ground with the negative cable
installed, the resulting sparks may cause a battery explo-
sion resulting in personal injury.
1CAUTION
Connect cables to correct terminals of battery or serious
damage to motorcycle electrical system will occur.
2. Connect positive cable to positive (+) battery terminal.

Then, after positive cable has been connected to positive
terminal, connect negative cable to negative (-) battery
terminal.
1CAUTION
See Figure 1-8. Hold battery cable when tightening bat-
tery terminal hardware. Failure to hold cable will cause
battery damage.
3. Tighten battery hardware to 30-40 in-lbs (3.4-4.5 Nm).

4. Apply light coat of petroleum jelly or corrosion-retardant
material to both terminals.
NOTE
On California models, attach carbon canister to bracket after
installing battery.
1-14
ENGINE LUBRICATION SYSTEM
CHECKING ENGINE OIL LEVEL 5582
Check engine oil level:
● At least once every 500 miles (800 km).

● At every service interval.
NOTE
If engine uses more oil than normal or if vehicle is operated
under harsh conditions, check oil more frequently.
Oil pressure
When checking or changing engine oil:
switch
● Warm vehicle to normal operating temperature. Oil filter
● Turn engine off.
● Hold motorcycle upright (not leaning on side stand) on a

level surface. Figure 1-9. Oil Filter and Mount
1. Remove seat.
5545
2. See Figure 1-10. Remove filler cap/dipstick from oil tank.
Wipe dipstick clean.
3. Install filler cap onto oil tank. Make sure cap is fully
seated on tank. Lower mark
1CAUTION Upper mark

Oil tank
Do not switch oil brands indiscriminately because some
oils interact chemically when mixed. Use of inferior oils
or non-detergent oils can damage the engine.
4. Remove filler cap again and check oil level on dipstick.

Oil level should be between lower and upper dipstick
level marks. If oil level in tank is below lower mark of dip-
Figure 1-10. Checking Oil Tank Level
stick, add oil to tank. Install filler cap/dipstick.
Recommended viscosity depends upon ambient temper-
ature. See Table 1-4. Table 1-4. Recommended Oil Grades
NOTE COLD
Difference between upper and lower dipstick marks is HARLEY- LOWEST WEATHER
HARLEY-
0.5 quart (0.47 liter). DAVIDSON TYPE
RATING TEMP. BELOW
50° F
1WARNING H.D. Multi-Grade
SAE
HD 240
Below 40°F
Excellent
10W40 (4°C)
After installing seat, pull upward on front of seat to be SAE Above 40°
sure it is locked in position. If seat is loose, it could shift 20W50 (4°C)
during vehicle operation and startle the rider, causing SAE Above 60°
H.D. Regular Heavy HD 240 Poor
loss of control and personal injury. 50 (16°C)
SAE Above 80°
5. Install seat. 60 (27°C)
1-15
CHANGING ENGINE OIL AND FILTER 5547
Change engine oil:

Drain hose
● At the 500 mile (800 km) service interval. Clamp
● At every 5000 mile (8000 km) service interval thereafter. Drain plug
NOTE
The colder the weather, the shorter the recommended oil
change interval. A vehicle used only for short runs in cold
weather must have the engine oil drained more frequently.
1. Place a suitable container under the motorcycle. Figure 1-11. Oil Tank Drain Line
2. See Figure 1-11. Compress clamp. Remove hose from
drain plug by pulling hose forward. Direct hose to con- b0138aox
Apply a thin film of oil to new filter gasket
tainer and completely drain oil tank.
and crankcase mounting plate.
3. Install drain hose on drain plug. Tighten clamp.
4. Remove oil filter using OIL FILTER WRENCH (Part No.
HD-41215).
5. Clean filter gasket contact surface on crankcase. Surface
should be smooth and free of any debris or old gasket
material.
6. See Figure 1-12. Apply a thin film of oil to gasket contact
surface on crankcase mounting plate and to new oil filter.
7. Pour 4.0 ounces (0.12 liter) of clean oil into new filter
when changing oil. Figure 1-12. Oil Filter
8. Screw filter onto adapter until gasket contacts mounting
plate surface. Apply another 1/2-3/4 turn by hand.
1WARNING
Be sure no oil gets on tires when changing oil and filter.
Traction will be adversely affected which may lead to a
9. Fill oil tank with an oil from Table 1-4. Oil tank capacity is
2.0 quarts (1.90 liters) plus the 4.0 ounces (0.12 liter)
added in Step 7.
10. Install filler cap onto oil tank. Make sure filler cap is fully
seated.
1WARNING
11. Install seat.

12. Start engine. Verify that oil pressure signal light on dash
panel turns off when engine speed is 1000 RPM or
above.
13. Check for oil leaks at oil filter and drain hose.
14. Check oil level as described on page 1-15.
1-16
BRAKES
GENERAL 5565
1WARNING Bleeder valve

Brake fluid can cause irritation of eyes and skin, and may
be harmful if swallowed. If fluid is swallowed, induce
vomiting by administering two tablespoons of salt in a
glass of warm water. Call a doctor. In case of contact with
skin or eyes, flush with plenty of water. Get medical
attention for eyes. KEEP BRAKE FLUID OUT OF THE
REACH OF CHILDREN.
Check brake fluid level and condition:
● At the 500 mile (800 km) service interval.
● At every 5000 mile (8000 km) service interval thereafter.
● When storing or removing the motorcycle for the season. Figure 1-13. Front Brake Caliper Bleeder Valve
Front brake hand lever and rear brake foot pedal must have a
firm feel when brakes are applied. If not, bleed system as
5566
described. Bleeder valve
(metric)
BLEEDING BRAKES
NOTE Protective
Hydraulic brake fluid bladder-type pressure equipment can be cap removed
used to fill brake master cylinder through the bleeder valve.
Remove master cylinder reservoir cover so that system can-
not pressurize. Do not use pressure bleeding equipment
when the hydraulic system is sealed with master cylinder res-
ervoir cover and gasket in place.
1. Install end of a length of plastic tubing over caliper
bleeder valve; place other end in a clean container.
Stand motorcycle upright.
Figure 1-14. Rear Brake Caliper Bleeder Valve
a. Front brake caliper-Figure 1-13.
b. Rear brake caliper-Figure 1-14.
PADS, ROTORS AND LINKAGE
2. Add D.O.T. 5 SILICONE HYDRAULIC BRAKE FLUID to
master cylinder reservoir. Do not reuse brake fluid. Check brake pads and rotors for minimum thickness. See
Table 1-5. See Section 2 for replacement procedures.
a. Bring fluid level to within 1/8 in. (3.2 mm) of molded
boss for front master cylinder reservoir. ● At the 500 mile (800 km) service interval.
b. Bring fluid level between upper and lower marks for ● At every service interval thereafter.
rear master cylinder reservoir.
Check rear brake pedal height and freeplay. See Table 1-5.
3. Depress and hold brake lever/pedal to build up hydraulic
See Section 2 for adjustment procedures.
pressure.
4. Open bleeder valve about 1/2-turn counterclockwise; ● Before every ride.
brake fluid will flow from bleeder valve and through tub-
ing. When brake lever/pedal has moved 1/2-3/4 of its full
range of travel, close bleeder valve (clockwise). Allow ● At every 5000 mile (8000 km) service interval thereafter.
brake lever/pedal to return slowly to its released position.
5. Repeat Steps 2-4 until all air bubbles are purged.
Table 1-5. Brake System Components
6. Tighten bleeder valves.
a. Front bleeder valve to 4-6 ft-lbs (5.4-8.1 Nm). SPECIFICATION FRONT REAR
b. Rear bleeder valve to 6-9 ft-lbs (8.1-12.2 Nm). Minimum rotor thickness 0.17 in. 0.19 in.
7. Verify master cylinder fluid level as described in Step 2. (4.4 mm) (4.8 mm)
8. Tighten master cylinder reservoir cover screws to 9-13 Minimum pad thickness 1/16 in. (1.6 mm)
in-lbs (1.0-1.5 Nm). Install cover on rear reservoir. Hand lever/pedal freeplay 1/8 in. (3.2 mm) maximum
1-17
TIRES AND WHEELS
TIRE INFLATION WHEEL BEARINGS
1WARNING Check wheel bearings:
Do not inflate any tire beyond its maximum inflation pres-
sure as specified on tire sidewall. Overinflation may ● Every time the wheel is removed.
cause tire to suddenly deflate leading to personal injury.
● At every 10,000 mile (16,000 km) service interval.
Check tire pressure and tread:
● Before every ride.
● At the 500 (800 km) mile service interval. Check wheel bearings and axle spacers for wear and corro-
sion. Excessive play or roughness indicates worn bearings.
Replace bearings in sets only.
Check for proper front and rear tire pressures when tires are
cold. Compare pressure against Table 1-6.
SPEEDOMETER CABLE
Check speedometer cable:
Table 1-6. Tire Pressures
● Inspect before every ride.
PRESSURE
PRESSURE
TIRE AND POSITION FOR SOLO ● Lubricate at every 5000 mile (8000 km) service interval.
AT GVWR
RIDING
Examine speedometer cable housing (outer sheath) for kinks
Front-Dunlop Sportmax 32 PSI 36 PSI or other damage. Replace entire cable assembly if any dam-
Radial II 120/70 ZR 17 (2.2 bar) (2.5 bar) age is noted.
Rear-Dunlop Sportmax 36 PSI 38 PSI Lubricate inner cable with a good quality graphite grease.
Radial II 170/60 ZR 17 (2.5 bar) (2.8 bar) Wipe off excess grease.
1-18
CLUTCH
TRANSMISSION FLUID 5592
Check transmission fluid:
● Replace at the 500 mile (800 km) service interval.
● Inspect level at every 2500 mile (4000 km) service interval.

Torx screw with
● Replace at every 5000 mile (8000 km) service interval. washer (4)
Primary chaincase lubricant capacity is approximately 1.0

quart (0.95 liter). For best results, drain lubricant while hot.
Clutch inspection
1. Raise rear of vehicle off the floor using REAR WHEEL cover
SUPPORT STAND (Part No. B-41174) to prevent chain-
case lubricant from draining out of clutch cover opening
when refilled.
2. Remove muffler. See EXHAUST SYSTEM in Section 2.

Drain plug
3. See Figure 1-15. Position a suitable container under
transmission lubricant drain plug. Remove drain plug and
drain lubricant. Figure 1-15. Primary Cover
4. Remove foreign material from magnetic drain plug.

Reinstall plug and tighten to 14-21 ft-lbs (19-28 Nm). b0190x6x
Clutch adjusting screw
5. Remove four TORX screws with washers from clutch
inspection cover. Remove clutch inspection cover from
primary cover. Do not damage or dislodge Quad ring Quad ring
from primary cover.
Diaphragm spring
1CAUTION
Do not overfill the primary chaincase with lubricant.
Overfilling may cause rough clutch engagement and Lubricant level
incomplete disengagement (or clutch drag).
6. Add SPORT-TRANS FLUID (Part No. 98854-96 quart Figure 1-16. Lubricant Level
size; Part No. 98855-96 gallon size) as required until
lubricant is even with bottom of clutch diaphragm spring.
See Figure 1-16. 5671
New style Old style

7. Install clutch inspection cover using four TORX screws
with washers. Tighten screws in a crosswise pattern to 7-
9 ft-lbs (9-12 Nm).
8. Install muffler. See EXHAUST SYSTEM in Section 2.
PRODUCTION CHANGE
See Figure 1-17. Beginning with motorcycles built in early
January 1996, the outer clutch release ramp has been
changed. The clutch adjustment and lever freeplay proce-
dures remain the same. The change was made to prevent any Figure 1-17. Ramp Change
possible contact between the coupler and the primary cover.
1-19
ADJUSTMENT 5594
1
Check clutch adjustment:

2
● At every 5000 mile (8000 km) service interval thereafter. 3
If clutch slips under load or drags when released, first check
control cable adjustment. If cable adjustment is within specifi- 4
cations, adjust clutch mechanism as described below.
When necessary, lubricate cable with LUBIT-8 TUFOIL®

CHAIN AND CABLE LUBE (Part No. HD-94968-85TV).
1. Raise rear of vehicle off the floor using REAR WHEEL

SUPPORT STAND (Part No. B-41174).
2. See Figure 1-18. Slide rubber boot (1) upward to expose

adjuster mechanism. Loosen jam nut (3) from adjuster
1. Rubber boot 3. Jam nut
(4). Turn adjuster to shorten cable housing until there is a
2. Cable end 4. Adjuster
large amount of freeplay at clutch hand lever.
Figure 1-18. Clutch Cable Adjuster Mechanism
3. See Figure 1-19. Remove TORX screws with washers (1)
from clutch inspection cover (2). Remove clutch inspec-
tion cover from primary cover, but leave Quad ring (3) in b0152x6x
place.
NOTE
Quad ring removed from primary cover for illustrative pur- 6
poses only in Figure 1-19. 2
4. Remove spring (4) and adjusting screw lockplate (5).
Turn adjusting screw counterclockwise until it lightly bot-
toms.
5. Turn clutch adjusting screw (6) clockwise 1/4 turn. Install

lockplate (5) and spring (4) on adjusting screw flats. If 1
hex on lockplate does not align with recess in outer ramp, 4 5
rotate adjusting screw clockwise until it aligns. 3
6. Squeeze clutch lever to maximum limit three times to set
1. Torx screw with washer 4. Spring
ball and ramp mechanism. Pull outer cable conduit and at
2. Clutch inspection cover 5. Lockplate
the same time adjust cable adjuster to provide 1/16-1/8 in.
3. Quad ring 6. Adjusting screw
(1.6-3.2 mm) freeplay at hand lever. Adjust as follows.
Figure 1-19. Clutch Release Mechanism
a. See Figure 1-20. Pull clutch cable ferrule (end of
cable housing) away from clutch hand lever bracket.
Gap between ferrule and bracket should be 1/16-1/8 5595
in. (1.6-3.2 mm). Adjust for 1/16-1/8 in. (1.6-3.2 mm)
gap between ferrule and bracket
b. See Figure 1-18. Adjust freeplay by turning cable
adjuster (4).
c. Tighten jam nut (3) against adjuster (4).
d. Slide boot (1) over cable adjuster mechanism.
7. Change or add transmission fluid if necessary.
8. Install clutch inspection cover (2). Tighten TORX screws

with washers (1) in a crosswise pattern to 7-9 ft-lbs (9-
12 Nm).
9. Check clutch cable freeplay. See Step 6 above. Figure 1-20. Adjusting Clutch Freeplay
1-20
REAR BELT DEFLECTION
INSPECTION b0086x6x
Check rear belt deflection:

● Inspect before every ride.
● Adjust at the 500 mile (800 km) service interval.
● Adjust at every 5000 mile (8000 km) service interval
thereafter.
The secondary drive belt should be checked for unusual
Apply 10 lbs (4.5 kg)
wear, cracking or loss of teeth. Check the belt sprocket for A of upward force
unusual wear, broken teeth or damaged flange. When check-
ing deflection, have: B Belt deflection should be
7/8-1 in. (22.2-25.4 mm)
● No rider or cargo weight on motorcycle.
● Transmission in neutral.
Figure 1-21. Checking Belt Deflection
● Belt and sprockets at room temperature.
● Motorcycle upright (not on side stand).
1. See Figure 1-21. At the lower strand, position “A”, mid- 5574
way between transmission sprocket and rear wheel
sprocket, apply 10 Ibs (4.5 kg) of upward force on lower
span of rear belt using BELT TENSION GAUGE (Part No.
HD-35381).
2. Measure belt deflection “B” several times, each time with
belt moved (by rotating rear wheel) to a different position
on sprockets. With sprockets rotated to tightest belt posi-
tion, belt deflection “B” (measured at position “A”) should
be 7/8-1 in. (22.2-25.4 mm).
Axle adjuster nut
ADJUSTMENT Rear axle nut
1. Adjust shock absorber spring preload. See REAR PRE-
LOAD ADJUSTMENT on page 1-23.
2. See Figure 1-22. Loosen rear axle nut (metric), if not Figure 1-22. Rear Axle
already performed.
NOTE
After you loosen the axle nut, turn the axle and nut so the rear-
most flat on each side is parallel with the ends of the swingarm. 5585
Check to be sure rear wheel axle is parallel with swingarm

pivot shaft.
3. See Figure 1-23. Measure each side from the flat to the
end of the swingarm, to be sure rear axle is correctly
located.
4. Turn axle adjuster nuts (metric) on each side of swing-
arm to adjust belt deflection.
a. Turn clockwise to decrease deflection (increase ten- Measure each side to
sion). check wheel alignment
b. Turn counterclockwise to increase belt deflection
(decrease tension).
Turn each adjuster nut exactly the same number of turns
Figure 1-23. Checking Rear Wheel Alignment,
to maintain rear wheel alignment
Right Side Shown
5. Tighten axle nut (metric) to 66-73 ft-lbs (89.5-98.9 Nm).
CLEANING
Keep dirt, grease, oil, and debris off the belt and sprockets.
Clean the belt with a rag which is slightly damp with light
cleaning agent.
1-21
PRIMARY CHAIN
INSPECTION 5583
Primary chain
Check primary chain: inspection cover
Check primary chain for correct tension by measuring its ver-
tical freeplay through the primary chain inspection cover
opening located near the top of the primary cover.
1. See Figure 1-24. Remove two screws from primary chain
inspection cover.
2. Remove primary chain inspection cover. Screws
3. See Figure 1-25. Check primary chain tension by mea-
suring vertical freeplay (measuring midway between
sprockets) several times, each time with primary chain
moved (by rotating engine) to a different position on
sprockets.
4. Check primary chain tension against Table 1-7. If neces-
Figure 1-24. Primary Chain Inspection Cover
sary, adjust as described below.
NOTE
● Measurements are taken with sprockets rotated to tight-
est chain position. b0085x6x
● The initial primary chain vertical freeplay specification

used at the assembly plant is 1/4-1/2 in. (6.3-12.7 mm)
with a cold engine. The 1/4 in. (6.3 mm) minimum is only
allowed at the absolute tightest point in the drive, as
measured with specialized factory equipment. If a chain
has less than 1/4 in. vertical freeplay (with a cold
engine), adjust freeplay to the “field” specification of 3/8-
1/2 in. (9.5-12.7 mm).The looser specification will avoid
overtightening, which might otherwise occur during Front sprocket Rear sprocket
adjustment using “non-factory” equipment and methods.
Figure 1-25. Measuring Primary Chain Tension
Table 1-7. Primary Chain Tension
ENGINE TEMPERATURE FREEPLAY
5592
Cold 3/8-1/2 in.

(9.5-12.7 mm)
Hot (normal running temperature) 1/4-3/8 in. Locknut
(6.4-9.5 mm)
Adjusting screw
5. Install primary chain inspection cover. Tighten screws to
40-60 in-lbs (4.5-6.8 Nm).
ADJUSTMENT
NOTE Figure 1-26. Primary Chain Adjustment
If vertical freeplay cannot be set within the limits specified,
then primary chain and/or chain adjuster are worn beyond
adjustment limits. Replace parts as necessary. See Section 6.
1. See Figure 1-26. Loosen locknut and turn adjusting
screw:
a. Turn clockwise (inward) to reduce freeplay.
b. Turn counterclockwise (outward) to increase free-
play.
2. Tighten locknut to 20-25 ft-lbs (27.1-33.9 Nm).
1-22
REAR PRELOAD ADJUSTMENT
GENERAL 5540
Adjust rear preload:
● When a new rider buys the motorcycle.
● When there is a change in load (luggage, etc.) Rear turn signal
● Before changing front fork or rear shock suspension mounting bolt
settings.
Rear suspension spring preload assures that the rear sus-
pension has the proper amount of travel.
Spring preload is the most important suspension adjustment
on the S1 Lightning. Improper preload will adversely affect Rear axle nut
both the handling and motorcycle ride. Correct preload set-
ting will result in motorcycle handling that suits the rider’s size
and weight.
ADJUSTMENT Figure 1-27. Checking Rear Preload

You will need three people to carry out this adjustment.
1. Verify correct front and rear tire pressure. See TIRES
AND WHEELS on page 1-18.
bag and/or saddlebags.
3. Take the motorcycle off the side stand and bounce the
is free and not binding.
4. See Figure 1-27. Measure the distance from the center
of the rear axle nut to the rear turn signal mounting bolt
without rider/passenger/cargo/accessories on the motor- Preload adjusting
cycle. nuts (metric)
6. Bounce a few times on the seat to be sure the suspen- Figure 1-28. Adjusting Rear Preload
ment with the vehicle fully loaded (rider/passenger/lug-
gage/cargo). The assistant should help balance the
rests.
19.1 mm). If it is not, you will have to adjust the spring
preload.
1CAUTION
● Be sure to apply the same number of turns to each
mechanical preload adjusting nut to ensure that the
end plates do not become misaligned. Misaligned
end plates will cause the shock absorber spring to
bind against the adjustment rods.
● Be sure the plates are parallel within 1/64 in. (0.4 mm).
Misaligned end plates will cause the shock absorber
spring to bind against the adjustment rods.
9. See Figure 1-28. Change the spring preload by adjusting
the mechanical preload adjusting nuts (metric) on the
rods that connect the end plates.
1-23
SUSPENSION
ADJUSTMENT 5542
Adjust front forks by first turning the slotted dial clockwise with
a screwdriver until it stops. Then turn the dial counterclock-
wise the recommended 12 or 20 positions. A higher number
of clicks increases damping.
NOTE
Rear spring preload must be set before adjusting any other
suspension settings. See REAR PRELOAD ADJUSTMENT
on page 1-23. Front fork rebound Front fork compression
damping adjuster damping adjuster
Table 1-8. Suspension Settings Figure 1-29. Front Fork Adjustments
RANGE IN FACTORY SEE

ADJUSTMENT
CLICKS SETTING FIGURE 5572
Front fork 28 20 1-29

compression
Front fork 28 12 1-29
rebound
Rear shock 7 3 1-30
rebound
Rear shock rebound
Rear shock 11 5 1-31 damping adjuster
compression
Figure 1-30. Rear Shock Rebound Adjuster
REAR SHOCK
5571
Check rear shock:
Rear shock compression
● At the 500 mile (800 km) service interval. damping adjuster
Inspect the rear shock absorber for loose mounting hardware,

leaks or rod-to-spring contact. Tighten the front and rear
mounts 40-45 ft-lbs (54.2-61.0 Nm).
Figure 1-31. Rear Shock Compression Adjuster
1-24
FRONT FORK
STEERING HEAD BEARINGS 5591
Check steering head bearings:

● Lubricate every 10,000 mile (16,000 km) service interval.
1. See Figure 1-32. Lift motorcycle using FRONT WHEEL
SUPPORT STAND (Part No. B-41395) and S1 LIFT
ADAPTER (Part No. B-41686) so front wheel is off the
ground.
2. Turn front wheel to full right lock. 3.5-5.5 lbs
(1.6-2.5 kg)
3. Hook a spring scale into the axle hole and pull front
wheel to center position.
It should take 3.5-5.5 lbs (1.6-2.5 kg) to pull front wheel
Figure 1-32. Checking Steering Head Bearings
to center.
NOTE b0031a2x
Check that clutch and throttle cables do not bind when mea-
suring bearing resistance. 1
2
Lubrication
At 10,000 miles (16,000 km) and every 10,000 miles
(16,000 km) thereafter, grease the steering head bearings
with WHEEL BEARING GREASE (Part No. 99855-89).
3
See FORK STEM AND BRACKET ASSEMBLY in Section 2
4
for lubrication procedure.
5
ADJUSTMENT 5
1. Raise front wheel off floor using FRONT WHEEL SUP- 4
PORT STAND (Part No. B-41395) and S1 LIFT 3
ADAPTER (Part No. B-41686).
2. Turn front wheel to full right lock. 9
3. See Figure 1-32. Hook spring scale into front axle hole.
Pull front wheel to center position. It should take 3.5-5.5 8
lbs (1.6-2.5 kg) to pull front wheel to center.
6 7
4. Loosen pinch screws (7) on upper and lower triple
clamps.
5. See Figure 1-33. Tighten or loosen fork stem bolt (1) to
set proper tension.
6. Recheck tension using spring scale. See Step 3. 1. Fork stem bolt 6. Lower triple clamp
7. Tighten triple clamp pinch screws (7) to 18-20 ft-lbs (24.4- 2. Upper triple clamp 7. Screw (5)
27.1 Nm). 3. Dust shield (2) 8. Steering head lock
4. Roller bearing (2) 9. Steering lock key
5. Bearing cup (2)
Figure 1-33. Steering Head Assembly
1-25
FORK OIL CHANGE 5750
Replace fork oil: Outer tube
● At every 10,000 mile (16,000 km) service interval.
● If fork should be submerged in water.

9 in. (229 mm)
1. Remove and disassemble front forks. See FRONT FORK maximum
in Section 2.
NOTE
If fork oil is emulsified, aerated or light brown in color, then it
has been contaminated by water. If this happens, replace the
fork oil seals.
2. Drain forks of oil.
3. With fork in fully compressed stage, add WP FORK OIL, Figure 1-34. Maximum Outer Tube Lift
5 WEIGHT to above red retaining cap.
1CAUTION 5758
See Figure 1-34. Raise outer tube no higher than 9 in. Damper
(229 mm) or fluid loss will occur. assembly
4. See Figure 1-35. Grasp damper assembly by the

adjuster. Pull damper assembly through several full
strokes to bleed air from the fork.
5. With front fork fully compressed, clamp vertically in

FRONT FORK HOLDING TOOL (Part No. B-41177).
6. Measure distance from fork oil surface to top of tube

using PRO-LEVEL OIL GAUGE (Part No. B-59000A).
Add or drain fork oil as needed until distance from top of
fork tube to oil surface measures 4.33 in. (110 mm). See
Figure 1-36.
7. Assemble front fork and install. See FRONT FORK in

Section 2. Figure 1-35. Bleeding Fork
b0038bx2x
1
2
Correct fork oil level is
4.33 in. (110 mm) below
top of fork tube
3 Use only
WP FORK OIL, 5 WEIGHT
1. Outer tube 3. Damper assembly

2. Adjuster 4. Fork oil level
Figure 1-36. Correct Fork Oil Level
1-26
SPARK PLUGS
INSPECTION 4636
Check spark plugs:
● Inspect at every 5000 mile (8000 km) service interval.
● Replace every 10,000 mile (16,000 km) service interval.
1. Disconnect cables from both spark plugs.

2. Remove spark plugs.
3. See Figure 1-37. Compare your observations of the plug
deposits with the descriptions provided below.
a. A wet, black and shiny deposit on plug base, elec-
trodes and ceramic insulator tip indicates an oil
fouled plug. The condition may be caused by one or
more of the following: worn pistons, worn piston
rings, worn valves, worn valve guides, worn valve
seals, a weak battery or a faulty ignition system.
b. A dry, fluffy or sooty black deposit indicates a carbu-
retor air-fuel mixture that is too rich, engine idling for
excessive periods of time and/or enrichener usage
for excessive periods of time.
c. A light brown, glassy deposit indicates an over- Figure 1-37. Typical Spark Plug Deposits
heated plug. This condition may be accompanied by
cracks in the insulator or by erosion of the elec-
trodes and is caused by an air-fuel mixture that is 5581
too lean, a hot-running engine, valves not seating or
improper ignition timing. The glassy deposit on the
spark plug is a conductor when hot and may cause
high-speed misfiring. A plug with eroded electrodes,
heavy deposits or a cracked insulator must be
replaced.
d. A plug with a white, yellow, tan or rusty brown pow-
dery deposit indicates balanced combustion. Clean
off spark plug deposits at regular intervals. Tighten to 11-18
ft-lbs (15-24 Nm)
4. If the plugs require cleaning between tune-ups, proceed
as follows:
a. Degrease firing end of spark plug using ELECTRI-
CAL CONTACT CLEANER. Dry plug with com-
pressed air. Figure 1-38. Spark Plugs
b. Use a thin file to flatten spark plug electrodes. A
spark plug with sharp edges on its electrodes
requires 25%-40% less firing voltage than one with
rounded edges.
5. If the plugs cannot be cleaned, replace with No. 6R12
spark plugs.
6. Check electrode gap with a wire-type feeler gauge. Gap
should be 0.038-0.045 in. (0.96-1.14 mm).
7. See Figure 1-38. Apply LOCTITE ANTI-SEIZE to plugs.
Install and tighten spark plugs to 11-18 ft-lbs (15-24 Nm).
8. Connect spark plug cables. Verify that cables are
securely connected to coil and spark plugs.
1-27
AIR CLEANER FILTER
REMOVAL 5705
Check air cleaner filter:
1
● Inspect at the 500 mile (800 km) service interval.

● Replace at every 5000 mile (8000 km) service interval
thereafter.
NOTE
Service air cleaner more often if the motorcycle is run in a
dusty environment.
1CAUTION
Do not run engine without filter element in place. Debris
2
1. See Figure 1-39. Remove screw and nylon washer on 1. Screw and nylon washer
top of air cleaner cover. 2. Screw, nylon washer and locknut
2. Remove screw, nylon washer and locknut at rear of air Figure 1-39. Air Cleaner Cover
cleaner cover. Remove cover.
3. See Figure 1-40. Remove filter box from snorkel tube. 5749
4. Remove filter from filter box. 2
INSTALLATION 3
1. Replace filter element if damaged or if filter media cannot 1
be adequately cleaned.
1WARNING
● Low pressure air can blow debris in your face and
eyes. Not wearing eye protection or a face shield
when using pressurized air may result in personal
injury.
● Do not use gasoline or solvents to clean the filter ele-

ment. Volatile/flammable cleaning agents may cause
an intake system fire which may result in personal
injury. 1. Filter element
2. Filter box
2. Wash element in luke warm water with a mild detergent. 3. Snorkel tube
Dry the filter element using low-pressure (32 psi/221 kPa
Figure 1-40. Snorkel Tube
maximum) compressed air. Rotate element while moving
air nozzle up and down the element interior. Do not rap
the element on a hard surface.
Hold filter element up to strong light source. The element
can be considered sufficiently clean if light is uniformly
visible through the element.
3. Thoroughly clean backplate, filter box and inside of
cover.
4. See Figure 1-40. Place filter in filter box. Attach filter box
to snorkel tube.
5. See Figure 1-39. Place cover over backplate assembly.
Install top screw and nylon washer.
6. Install screw, nylon washer and locknut on rear mount.
1-28
CARBURETOR
CABLE ADJUSTMENT 5587
1WARNING
Throttle cables must not pull tight when handlebars are
turned fully to left or right fork stops. Be sure wires and
throttle cables are clear of fork stops at steering head so
they will not be pinched when fork is turned against stops.
Steering must be smooth and free with no binding or inter-
ference. Anything interfering with carburetor operation
may cause loss of vehicle control and personal injury. 4
Check throttle cable adjustment:
Check throttle cable adjustment with engine running. Turn
handlebars through full range of travel. If engine speed 3 1
2
changes during this maneuver, adjust throttle cables as fol-
lows:
5609
1. Remove air cleaner. See AIR CLEANER, REMOVAL in
Section 4.
2. See Figure 1-41. Slide rubber boot (4) off cable
1
adjusters (3).
3. Loosen jam nut on each adjuster.
NOTE 6
Cable adjusters (3) and jam nuts are metric.
4. Turn adjusters in direction which will shorten cable hous-
ings to minimum length.
5. Point front wheel straight ahead. Twist throttle control grip 5
to fully open position; hold in position.
6. Turn adjuster (3) on throttle control cable (1) until throttle
cam stop (5) touches carburetor stop plate (6). Tighten
jam nut on throttle control cable (1) adjuster (3); release
throttle control grip.
7. Turn handlebars fully to right. Turn adjuster (3) on idle
control cable (2) until end of cable housing just touches
the carburetor cable guide.
8. Twist and release throttle control grip a few times. Carbu-
retor throttle must return to idle position each time throt-
tle grip is released. If this is not the case, turn adjuster (3)
on idle control cable (2) (shortening cable housing) until
throttle control functions properly. 1. Throttle control cable 4. Rubber boot
9. Tighten jam nut on idle control cable (2) adjuster (3). 2. Idle control cable 5. Throttle cam stop
Recheck operation of throttle control (Step 7). 3. Cable adjuster 6. Carburetor stop plate
10. Slide rubber boot (4) over each cable adjuster (3). Figure 1-41. Carburetor
Recheck engine slow idle speed; adjust if required.
11. Install air cleaner. See AIR CLEANER, INSTALLATION
in Section 4.
IDLE ADJUSTMENT
Check idle adjustment:
See IGNITION TIMING on page 1-30.
1-29
IGNITION TIMING
INSPECTION x0001c2x
Check ignition timing:

● At every 5000 mile (8000 km) service interval.
Check for proper RPM and ignition timing as follows:
1. See Figure 1-42. Thread TIMING MARK VIEW PLUG Inspection hole
(Part No. HD 96295-65D) into timing inspection hole. Be
sure view plug does not touch flywheel.
2. Connect leads of INDUCTIVE TIMING LIGHT (Part No. Timing mark
HD-33813) to front spark plug cable, to battery positive
terminal and to ground.
3. Be sure vacuum hose is properly installed at carburetor
and at vacuum-operated electric switch (V.O.E.S.).
4. Start engine. Set engine speed by turning idle adjust-
ment screw clockwise to increase speed or counterclock-
Figure 1-42. Timing Inspection Hole
wise to decrease speed. Use CARBURETOR IDLE
ADJUSTMENT TOOL (Part No. HD-33413) and TIP
(SNAP-ON Part No. TMP23A) as shown in Figure 1-43. 5599
a. On world models, idle speed is 950-1050 RPM.

b. On California models, idle speed is 1150-1250 RPM.
5. Timing light will flash each time ignition spark occurs. 1 2
Aim timing light into timing inspection hole. Front cylinder
advance timing mark should be centered in timing
inspection hole. If not, see ADJUSTMENT on page 1-31.
6. Set engine slow idle speed as described in Step 4 with
engine running at normal operating temperature and with
enrichener control knob pushed in fully.
NOTE
● Buells have an enrichener circuit that will cause the
engine to idle at approximately 2000 RPM with the
engine at normal operating temperature and the
enrichener knob pulled out fully. The increase in idle
speed is intended to alert the rider that the engine is 1. Carburetor idle adjustment tool
warmed up to normal operating temperature and that the (Part No. HD-33413)
enrichener knob should be pushed in all the way. Con- 2. Tip (Snap-On Part No. TMP23A)
tinuing to use the enrichener circuit when the engine is at
normal operating temperature will cause fouled plugs. Figure 1-43. Adjusting Idle Speed
● Be sure the engine is warmed up to normal operating

temperature and the enrichener knob is pushed all the
way in before adjusting engine idle speed. Be aware that,
because there are variations in individual components, it
is possible for a properly warmed-up engine to idle at
2000 RPM with the enrichener knob pulled out partially.
1-30
1. Pop rivet (2) 14. Front spark plug cable
2. Timer cover 15. Rear spark plug cable
3. Screw (2) 16. V.O.E.S. connector [P7]
4. Inner cover 17. V.O.E.S.
5. Ignition gasket 18. Cable strap
6. Timer plate stud (2) 19. Terminal pin
7. Bolt 20. Timer connector [P16]
8. Sensor assembly 21. Secondary lock
9. Trigger rotor 22. Ignition module connector [P10]
10. Seal 23. Ignition module 17
11. Gearcase cover 24. Washer (2)
12. Spark plug (2) 25. Screw (2)
13. Ignition coil 16 22
23
15 14
18
24
19 25
21
13 20
12
10 9
8
11
3
7 6 1
5
b0223x7x
4
2
Figure 1-44. Ignition System Components
ADJUSTMENT 3. With timing light aimed into inspection hole, rotate sensor
assembly (8) until front cylinder advance timing mark is
1. See Figure 1-44. Remove outer cover pop rivets (1), centered in timing inspection hole.
outer timer cover (2), inner cover screws (3), inner cover 4. Tighten timer plate studs (6).
(4) and gasket (5).
5. Install gasket (5), inner cover (4), inner cover screws (3),
2. Loosen timer plate studs (6) just enough to allow sensor timer cover (2) and new outer cover rivets (1).
assembly (8) to be rotated using a screwdriver in the 6. Remove TIMING MARK VIEW PLUG from timing inspec-
plate’s notch. tion hole. Install hex socket timing plug.
1-31
VACUUM-OPERATED ELECTRIC SWITCH (V.O.E.S)
ADJUSTMENT/TESTING 2855
3
Timing Mark Method 5
Verify engine ignition timing. See IGNITION TIMING on 1
page 1-30. Adjust ignition timing, if necessary, and then per-
form the following V.O.E.S. check:
1. Run engine at regular idle. Disconnect V.O.E.S. vacuum

hose from carburetor fitting. See VACUUM-OPERATED
ELECTRIC SWITCH (V.O.E.S) in Section 7.
4
a. On world models, idle speed is 950-1050 RPM.
b. On California models, idle speed is 1150-1250 RPM.

2
2. Temporarily plug the open carburetor fitting. Ignition tim-
ing should retard (front cylinder advance timing mark dis-
appears from view in timing inspection hole) and engine 1. V.O.E.S. 4. Ohmmeter probes
RPM should decrease. 2. V.O.E.S. leads 5. Vacuum pump
3. Connect V.O.E.S. vacuum hose to carburetor fitting. Tim- 3. Ohmmeter
ing mark should reappear and engine speed should Figure 1-45. Checking V.O.E.S. Using Ohmmeter
increase to previous RPM. and Vacuum Pump
If speed does not first decrease and then increase as
described, check V.O.E.S. wire connection to ignition module.
Ohmmeter and Vacuum Pump Method

The V.O.E.S. can also be checked using an ohmmeter and a
VACUUM PUMP (Part No. HD-23738).
1. Remove V.O.E.S. from vehicle. See VACUUM-OPER-

ATED ELECTRIC SWITCH (V.O.E.S) in Section 7.
2. See Figure 1-45. Connect two ohmmeter leads to the two

V.O.E.S. leads.
3. Connect vacuum pump to V.O.E.S. vacuum fitting.
4. Slowly squeeze vacuum pump handle. Observe vacuum

gauge and ohmmeter readings. Ohmmeter should indi-
cate switch closed (zero ohms) with an applied vacuum
of 5.0-6.0 in. (127.0-152.4 mm) mercury (Hg). If a vac-
uum reading of more than 6.0 in. (152.4 mm) Hg or less
than 5.0 in. (127.0 mm) Hg is required to close the
switch, then the switch must be replaced.
5. Install V.O.E.S. See VACUUM-OPERATED ELECTRIC

SWITCH (V.O.E.S) in Section 7.
1-32
HANDLEBARS
INSPECTION 5589
Check handlebar adjustment:
1. See Figure 1-46. Check steering motion range to both

fork stops. Each handlebar should be spaced equally
between the windscreen and fuel tank and parts should
not make contact.
2. Handlebars should be equally spaced between outside

edge of handlebar clamp and inside edge of mirror
mounts.
If necessary, adjust handlebars as described below.
5590
ADJUSTMENT
1CAUTION
Never adjust handlebars using excessive force or dam-
age to handlebars might result.
NOTE
Windscreen and instrument support must be removed to
access front clamp screws.
1. Remove windscreen. See WINDSCREEN in Section 2.
2. Remove instrument support. See SPEEDOMETER AND Figure 1-46. Testing Handlebars
TACHOMETER in Section 2.
3. See Figure 1-47. Loosen clamp screws. 5576
4. Move handlebar to desired position.
5. Tighten clamp screws to 10-12 ft-lbs (13.6-16.2 Nm).
NOTE
Tighten front clamp screws first.
6. Install instrument support. See SPEEDOMETER AND Clamp

TACHOMETER in Section 2.
7. Install windscreen. See WINDSCREEN in Section 2.
8. Check steering motion range to both fork stops. Each

handlebar should be spaced equally between wind-
screen and fuel tank and parts should not make contact.
Figure 1-47. Adjusting Handlebars
If handlebar needs further adjustment, repeat ADJUST-
MENT beginning with Step 1.
1-33
HEADLAMP
INSPECTION b0008b7x 35 in.
(889 mm)
1WARNING
Do not modify ignition wiring to permit motorcycle opera-
tion with headlamp off. Operating with headlamp off may
reduce your visibility to other motorists and could cause
an accident resulting in personal injury.
Check headlamp alignment:
● When a new rider buys the motorcycle.
● When there is a change in load (luggage, etc.)

25 ft
Check headlamp beam for proper height and lateral align- (7.62 M)
ment as follows:
1. Verify correct front and rear tire inflation pressure. See Figure 1-48. Checking Headlamp Alignment
TIRES AND WHEELS on page 1-18.
2. Place motorcycle on level floor (or pavement) in an area 5601
with minimum light.

3. See Figure 1-48. Point front of motorcycle toward a
screen or wall which is 25 ft (7.62 M) away from front tire
contact patch on floor (i.e., directly below front axle).
4. Draw a horizontal line, on screen or wall, which is 35 in.
(889 mm) above floor.
5. Have a person whose weight is roughly the same as that
of the principal rider sit on motorcycle seat. Weight of
rider will compress vehicle suspension slightly. Headlamp adjuster
6. Stand motorcycle upright with both tires resting on floor screw (metric)
and with front wheel held in straight alignment (directly
forward).
7. Turn ignition switch to IGN. Set handlebar headlamp
switch to HIGH beam position.
Figure 1-49. Adjusting Headlamp
8. Check light beam for proper height alignment. Main
beam of light (broad, flat pattern of light) should be cen-
tered on horizontal line on screen or wall (i.e. equal area
of light above and below line).
9. Check light beam for proper lateral alignment. Main
beam of light should be directed straight ahead (i.e.
equal area of light to right and left of center).
ADJUSTMENT
If headlamp requires adjustment, perform the following:
1. See Figure 1-49. Loosen both adjuster screws (metric).

2. See Figure 1-48. Tilt headlamp up or down to aim it in
relation to the horizontal line. At the same time, turn
headlamp right or left to direct light beam straight ahead.
3. Tighten both adjuster screws (metric) to 6-8 ft-lbs (8.1-
10.8 Nm).
1-34
STORAGE
GENERAL 1WARNING
Do not apply any oil to brake rotors or brake pads. Oil on
If the motorcycle will not be operated for several months, such
brake pads degrades braking efficiency and can result in
as during the winter season, there are several things which
an accident causing personal injury.
should be done to protect parts against corrosion, to preserve
the battery and to prevent the buildup of gum and varnish in 7. Wash painted and chrome-plated surfaces. Apply a light
the carburetor. film of oil to exposed unpainted surfaces.
This work should be performed by your local Buell dealer 8. If motorcycle is to be covered, use a material that will
following Service Manual procedures. breathe, such as light canvas. Plastic materials that do
not breathe promote the formation of condensation.
1WARNING
Gasoline is flammable. Do not store motorcycle having
gasoline in tank within the home or garage where open REMOVAL FROM STORAGE
flames, pilot lights, sparks or electric motors are present.
Inadequate safety precautions may cause an accident 1WARNING
resulting in personal injury.
After extended periods of storage and prior to starting
1. Fill fuel tank and add a gasoline stabilizer. Use one of vehicle, place transmission in gear, disengage clutch and
the commercially available gasoline stabilizers following push vehicle back and forth a few times to ensure proper
the manufacturer’s instructions. Run engine until clutch disengagement. Improper clutch disengagement
gasoline has had a chance to reach carburetor float could result in personal injury.
bowl. Turn fuel supply valve OFF.
1. Remove and inspect spark plugs. Replace if necessary.
2. Fill the oil tank. Pinch off (or remove and plug) the line
leading from the oil tank bottom to the oil pump feed 2. Clean air filter element and lubricate if necessary.
fitting. This prevents oil from seeping past the check ball 3. If fuel tank was drained, fill fuel tank with fresh gasoline.
into the oil pump and filling the engine flywheel
compartment. 4. If oil feed line was pinched off or plugged, unplug it and
reconnect.
3. Remove the spark plugs, inject a few squirts of engine oil
into each cylinder and crank the engine 5-6 revolutions. 5. Start the engine and run until it reaches normal operating
Reinstall spark plugs. temperature. Check fluids and refill to proper levels if
required.
4. Adjust primary chain.
a. Check engine oil level.
5. Adjust secondary drive belt.
b. Check the transmission lubricant level.
6. Check tire inflation. If the motorcycle will be stored for an
extended period of time, securely support the motorcycle 6. Perform all of the checks in the PRE-RIDING CHECK
under the frame so that all weight is off the tires. LIST in the Owner’s Manual.
1-35
TROUBLESHOOTING
GENERAL Starts But Runs Irregularly or Misses
The following check list can be helpful in locating most 1. Spark plugs in bad condition or partially fouled.
operating troubles. Refer to the appropriate sections in this 2. Spark plug cables in bad condition and shorting.
Service Manual for detailed procedures.
3. Spark plug gap too close or too wide.
4. Ignition coil not functioning.
ENGINE 5. Ignition module not functioning.
6. Ignition sensor not functioning.
Starter Motor Does Not Operate or Does 7. Battery nearly discharged.
Not Turn Engine Over 8. Damaged wire or loose connection at battery terminals
or coil.
1. Engine stop switch in OFF position.
9. Intermittent short circuit due to damaged wire insulation.
2. Ignition key switch not ON.
10. Water or dirt in fuel system and carburetor or filter.
3. Discharged battery or loose or corroded connections.
(Solenoid chatters.) 11. Fuel tank filler cap vent plugged or carburetor float bowl
vent closed off.
4. Starter control relay or solenoid not functioning.
12. Carburetor controls improperly adjusted.
5. Electric starter shaft pinion gear not engaging or over-
running clutch slipping. 13. Air leak at intake manifold or air filter.
14. Damaged intake or exhaust valve.
Engine Turns Over But Does Not Start 15. Weak or broken valve springs.
1. Fuel tank empty. 16. Incorrect valve timing.
2. Fuel supply valve turned OFF.
Spark Plug Fouls Repeatedly
3. Fuel supply valve or filter clogged.
4. Discharged battery, loose or broken battery terminal 1. Incorrect spark plug.
connections. 2. Piston rings badly worn or broken.
5. Fouled spark plugs. 3. Fuel mixture too rich for conditions (see CARBURETOR
6. Loose or shorting spark plug cables or connections. TROUBLESHOOTING).
7. Ignition timing badly out of adjustment. 4. Valve stem seals worn or damaged.
8. Loose wire connection at coil or battery connection or 5. Valve guides badly worn.
plug between ignition sensor and module.
9. Ignition coil not functioning. Pre-Ignition or Detonation
10. Ignition module not functioning. (Knocks or Pings)
11. Ignition sensor not functioning.
12. Sticking or damaged valve or valves. 1. Excessive carbon deposit on piston head or combustion
13. Engine flooded with gasoline as a result of overchoking. chamber.
14. Engine oil too heavy (winter operation). 2. Incorrect heat range spark plug.
3. Spark plugs not firing.
Starts Hard 4. Ignition timing advanced.
5. Fuel octane rating too low.
1. Spark plugs in bad condition, have improper gap or are
partially fouled. 6. Intake manifold vacuum leak.
2. Spark plug cables in bad condition and shorting.
3. Battery nearly discharged.
Overheating
4. Loose wire connection at one of the battery terminals, at 1. Insufficient oil supply or oil not circulating.
coil or at plug between ignition sensor and module. 2. Leaking valves.
5. Carburetor controls not adjusted correctly. 3. Heavy carbon deposit.
6. Ignition coil not functioning. 4. Ignition timing retarded.
7. Engine oil too heavy (winter operation).
8. Ignition not timed properly. See dealer. Valve Train Noise
9. Vapor vent valve plugged or carburetor fuel line closed
off restricting fuel flow. 1. Hydraulic lifter not functioning properly.
10. Water or dirt in fuel system and carburetor. 2. Bent push rod.
11. Enrichener valve inoperative. 3. Cam, cam gears or cam bushings worn.
12. Air leak at intake manifold. 4. Rocker arm binding on shaft.
13. Valves sticking. 5. Valve sticking in guide.
1-36
Excessive Vibration FUEL
1. Engine tie-bars loose, broken or improperly spaced.
2. Lower mounting bolts loose.
Carburetor Floods
3. Broken frame. 1. Excessive “pumping” of throttle control grip.
4. Primary chain badly worn or links tight as a result of 2. Inlet valve sticking.
insufficient lubrication. 3. Inlet valve and/or valve seat worn or damaged.
5. Wheels not aligned and/or tires worn. 4. Dirt or other foreign matter between valve and its seat.
6. Internal engine problem. 5. Float misadjusted or filled with fuel.
ENGINE LUBRICATION SYSTEM TRANSMISSION

Shifts Hard
Oil Does Not Return To Oil Tank
1. Clutch dragging slightly.
1. Oil tank empty. 2. Shifter forks (inside transmission) damaged.
2. Return pump gears damaged. 3. Corners worn off shifter clutch dogs (inside
3. Oil feed pump not functioning. transmission).
4. Restricted oil lines or fittings.
Jumps Out of Gear
Engine Uses Too Much Oil or 1. Shifter pawl improperly adjusted.
Smokes Excessively 2. Shifter engaging parts (inside transmission) badly worn
and rounded.
1. Piston rings badly worn or broken.
3. Shifter forks bent.
2. Valve stem seals worn or damaged. 4. Damaged gears.
3. Valve guides worn.
Engine Leaks Oil From Cases, Push Rods, CLUTCH

Hoses, Etc.
Slips
1. Loose parts.
1. Clutch controls improperly adjusted.
2. Imperfect seal at gaskets, push rod cover, washers, etc.
2. Worn friction plates.
To aid locating leaks, use BLACK LIGHT LEAK
DETECTOR (Part No. HD-35457).
Drags or Does Not Release
3. Restricted oil return line to tank.
4. Restricted breather passage(s) to air cleaner. 1. Clutch controls improperly adjusted.
2. Clutch plates excessively warped.
ELECTRICAL SYSTEM Chatters

1. Friction or steel plates worn, warped or dragging.
Alternator Does Not Charge
1. Regulator-rectifier module not functioning. CHASSIS
2. Rectifier not grounded.
3. Engine ground wire loose or broken. Irregular/Inadequate Brake Action
4. Loose or broken wires in charging circuit.
1. Master cylinder low on fluid.
5. Stator not functioning. 2. Brake line contains air bubbles.
6. Rotor not functioning. 3. Master or wheel cylinder piston worn.
4. Brake pads covered with grease or oil.
Alternator Charge Rate Is Below Normal 5. Brake pads badly worn (1/16 in. (1.6 mm) minimum lining
thickness).
1. Regulator-rectifier module not functioning.
6. Brake rotor badly worn or warped.
2. Stator not functioning.
7. Brake pads dragging or excessive braking (brake fades
3. Rotor not functioning. due to heat buildup).
4. Weak battery. 8. Insufficient brake pedal or hand lever freeplay (brake
5. Loose connections. drags).
1-37
Handling Irregularities 7. Irregular or peaked front tire tread wear.
1. Tires improperly inflated. Check TIRES AND WHEELS 8. Tire and wheel unbalanced.
on page 1-18. Do not overinflate.
2. Loose wheel axle nuts. Tighten front nut to 48-53 ft-lbs 9. Steering head bearings improperly adjusted. Correct
(65.1-71.9 Nm). Tighten rear nut to 66-73 ft-lbs (90-99 adjustment and replace pitted or worn bearings and
Nm). races. See FORK STEM AND BRACKET ASSEMBLY in
3. Excessive wheel hub bearing play. Section 2.
4. Rear wheel out of alignment with frame and front wheel. 10. Shock absorber not functioning normally.
5. Rims and tires out-of-true sideways (tire runout should
not be more than 0.080 in. (2.03 mm)). 11. Heavy front end loading. Non-standard equipment on the
6. Rims and tires out-of-round or eccentric with hub (tire front end (such as heavy radio receivers, extra lighting
runout should not be more than 0.090 in. (2.29 mm)). equipment or luggage) tends to cause unstable handling.
1-38
2
SPECIFICATIONS
DIMENSIONS IN. MM CAPACITIES U.S. LITERS
Wheel Base 55 1397 Fuel Tank (including reserve) 4.0 gallons 15.14
Overall Length 79.5 2019 Reserve 0.6 gallons 2.27
Overall Width 30 762 Oil Tank 2.0 quarts 1.89
Seat Height 29.5 749 Transmission 1.0 quart 0.95
CHASSIS IN. MM PRESSURE

PRESSURE
Road Clearance 5.2 132 AT GVWR
RIDING
Front Wheel Travel 4.7 119.4
Front-Dunlop Sportmax 32 PSI 36 PSI
Rear Wheel Travel 4.9 124.5 Radial II 120/70 ZR 17 (2.2 bar) (2.5 bar)
Trail 3.9 99 Rear-Dunlop Sportmax 36 PSI 38 PSI
Rake 25 degrees
1WARNING
WEIGHT LBS. KG Do not inflate any tire beyond its maximum inflation pres-
sure as specified on tire sidewall. Overinflation may
S1 Shipping weight 446 202 cause tire to suddenly deflate leading to personal injury.
GVWR 820 372
GAWR - Front 340 154
BRAKE ROTORS IN. MM
GAWR - Rear 480 218
Front rotor minimum thickness 0.17 4.3
NOTE
Rear rotor minimum thickness 0.19 4.8
2-1
ITEM TORQUE NOTES
Clutch cable, primary

3-5 ft-lbs 4-6.87 Nm turn clockwise to install, page 2-45
cover fitting
Clutch clamp screw 30-33 in-lbs 3.4-4.0 Nm metric, page 2-45
Drive support fastener 30-35 ft-lbs 40.7-47.4 Nm page 2-53
Exhaust manifold nuts 6-8 ft-lbs 8.1-10.8 Nm page 2-50
Fender mounting screw, lower 10-15 in-lbs 1.1-1.7 Nm page 2-54
Fender mounting screw, upper 20-25 in-lbs 2.3-2.8 Nm metric, page 2-54
LOCTITE THREADLOCKER 242 (blue), metric,
Front axle nut 48-53 ft-lbs 65.1-71.9 Nm
page 2-6, page 2-10
Front axle pinch screw 13-15 ft-lbs 17.6-20.3 Nm metric, page 2-10
Front brake caliper screw 26-28 ft-lbs 35.2-38.0 Nm 2 sizes, page 2-21
Front brake carrier screw 7.5-8.5 ft-lbs 10.2-11.5 Nm LOCTITE THREADLOCKER 242 (blue), page 2-9
Front brake line clamp screw 30-35 in-lbs 3.4-4.0 Nm page 2-22
Front brake master cylinder
80-90 in-lbs 9.0-10.2 Nm metric, page 2-19
clamp screw
Front brake rotor carrier screw 20-22 ft-lbs 27.1-29.8 Nm LOCTITE THREADLOCKER 242 (blue), page 2-9
Front caliper banjo bolt 16-20 ft-lbs 21.7-27.1 Nm page 2-21, page 2-22
Front caliper bleeder valve 4-6 ft-lbs 5.4-8.1 Nm page 2-22
Front caliper center bolt 11-13 ft-lbs 14.9-17.6 Nm page 2-21
Front caliper mounting bolt 30-33 ft-lbs 40.7-44.7 Nm page 2-21
Front fork triple clamp screw 18-20 ft-lbs 24.4-27.1 Nm LOCTITE ANTI-SEIZE, page 2-31
Front master cylinder
17-20 ft-lbs 23.0-27.1 Nm metric, page 2-19, page 2-22
banjo bolt
Front master cylinder
9-13 in-lbs 1.0-1.5 Nm page 2-19, page 2-21
cover screw
Fuel tank screw 9-11 ft-lbs 12.2-14.9 Nm page 2-55
Handlebar bolt, lower clamp 30-33 ft-lbs 40.7-44.7 Nm page 2-49
Handlebar screw, upper clamp 10-12 ft-lbs 13.6-16.2 Nm page 2-49
Header tiebar screw 5-7 ft-lbs 6.8-9.5 Nm page 2-50
Headlamp adjusting screw 6-8 ft-lbs 8.1-10.8 Nm metric, page 2-56
Instrument support screw 7-9 ft-lbs 9.5-12.2 Nm page 2-46
Muffler clamp 50-55 ft-lbs 67.8-74.6 Nm discard after use, page 2-50
Muffler mounting bolt, front 22-25 ft-lbs 29.8-33.9 Nm page 2-50
Muffler mounting bolt, rear 22-25 ft-lbs 29.8-33.9 Nm page 2-50
Muffler support mounting
30-33 ft-lbs 40.7-44.7 Nm page 2-50
bolt, front
Muffler support mounting
12-15 ft-lbs 16.3-20.3 Nm page 2-50
bolt, rear
2-2
ITEM TORQUE NOTES
Rear axle nut 66-73 ft-lbs 89.5-98.9 Nm metric, page 2-6, page 2-13
Rear brake caliper banjo bolt 9.5-12.5 ft-lbs 12.9-17.0 Nm metric, page 2-26, page 2-27
Rear brake caliper
6-9 ft-lbs 8.1-12.2 Nm metric, page 2-26, page 2-27
bleeder valve
Rear brake caliper
18-22 ft-lbs 24.4-29.8 Nm metric, page 2-26
mounting screw
Rear brake lamp switch 7-8 ft-lbs 9.5-10.8 Nm LOCTITE SEALANT WITH TEFLON, page 2-27
Rear brake line clamp screw 10-12 ft-lbs 13.6-16.2 Nm page 2-27
Rear brake reservoir
12-15 in-lbs 1.4-1.7 Nm page 2-24
mounting screw
LOCTITE THREADLOCKER 242 (blue), metric,
Rear brake rotor screw 35-40 ft-lbs 47.5-54.2 Nm
page 2-12
Rear master cylinder banjo bolt 10-12 ft-lbs 13.6-16.2 Nm metric, page 2-24, page 2-27
Rear master cylinder
8-10 ft-lbs 10.8-13.6 Nm page 2-24
mounting screw
Rear master cylinder rod to
10-12 ft-lbs 13.6-16.2 Nm page 2-24
brake pedal screw
Rear shock mounting screw 40-45 ft-lbs 54.2-61.0 Nm metric, page 2-37
Sprocket bolt 55-65 ft-lbs 74.6-88.1 Nm LOCTITE THREADLOCKER 272 (red), page 2-12
Sprocket cover mounting screw 12-17 in-lbs 1.4-1.9 Nm page 2-53
Sprocket cover screw 4-6 ft-lbs 5.4-8.6 Nm page 2-53
Swingarm pinch screw 27-30 ft-lbs 36.6-40.7 Nm LOCTITE THREADLOCKER 242 (blue), page 2-34
Swingarm/drive support screw 20-25 ft-lbs 27.1-33.9 Nm page 2-53
Switchgear housing screws,
left side
right side
Tie bar bolt 30-33 ft-lbs 40.7-44.7 Nm page 2-34
Valve stem nut 42-44 in-lbs 4.7-5.0 Nm page 2-16
2-3
TIRE SPECIFICATIONS
GENERAL Tire sizes are molded on the sidewall. Rim size and contour
are marked on the rim’s exterior surface.
1WARNING Example: MT 3.5 x 17.0 DOT
Tires must be correctly matched to wheel rims. Only the
tires listed in the fitment tables below can be used for MT designates the rim contour. The 3.5 is the width of the
replacement. Mismatching tires and rims can cause dam- bead seat measured in inches. The 17.0 is the normal diame-
age to the tire bead during mounting. Using tires other ter of the rim in inches, measured at the bead seat diameter.
than those specified can adversely affect motorcycle DOT means that the rim meets Department of Transportation
handling and may result in personal injury. Federal Motor Vehicle Safety Standards.
See the tables below.
Table 2-1. Tire Fitment – Tubeless Cast Marchesini Wheels

WHEEL SIZE CONTOUR & RIM VALVE DUNLOP SPORTMAX RADIAL II
& POSITION RIM SIZE HOLE DIAMETER TIRE SIZE
17 in. – Front MT 3.5 x 17.0 DOT 0.33 in. 120/70 ZR17

17 in. – Rear MT 5.0 x 17.0 DOT 0.33 in. 170/60 ZR17
Table 2-2. Tire Fitment – Tubeless Aluminum P/M Wheels

WHEEL SIZE CONTOUR & RIM VALVE DUNLOP SPORTMAX RADIAL II
& POSITION RIM SIZE HOLE DIAMETER TIRE SIZE
17 in. – Front MT 3.5 x 17.0 DOT 0.33 in. 120/70 ZR17

17 in. – Rear MT 5.5 x 17.0 DOT 0.33 in. 170/60 ZR17
2-4
VEHICLE IDENTIFICATION NUMBER
GENERAL 5711
A 17-digit serial number, or Vehicle Identification Number
(V.I.N.), is stamped on the right side of the steering head (ex.,
4MZSS11J1T3200001). Also affixed to the steering head at
this location is an information plate bearing the V.I.N. code.
See Figure 2-1. An abbreviated V.I.N. is stamped on the front
left side of the crankcase.
NOTE
Always give the V.I.N. or abbreviated V.I.N. when ordering
parts or making inquiries about your Buell motorcycle.
Figure 2-1. Abbreviated V.I.N. Location
Motorcycle Made in U.S.A.
Manufacturer and Make: Buell Motorcycle Company
Model Designation: SS = S1 Lightning
11 = 49 state
Engine 56 = California
Horsepower Code
Factory Check Digit: Can be 0-9 or x
Year of Manufacture: T = 1996
20 = World
Market Designation 22 = California
See Note
Sequential Number
4 MZ SS 11 J * T 3 20 0001
*Varies - can be 0 through 9 or X
Sample V.I.N. as it appears on the steering head - 4MZS S 11J1T3200001

Sample abbreviated V.I.N. as it appears on the left side crankcase- S S 11T200001
NOTE
Two market destination characters have been used beginning with sequential number 38.
Figure 2-2. Vehicle Identification Number (V.I.N.)
2-5
WHEELS
GENERAL b0195x2x
Good handling and maximum tire mileage are directly related

to the care of wheels and tires. Regularly inspect wheels and
tires for damage and wear. If handling problems occur, check
the TROUBLESHOOTING guide in Section 1 or see the table
below for a list of probable causes.
See TIRES AND WHEELS in Section 1. Keep tires inflated to
the recommended air pressure. Always balance the wheel
after replacing a tire.
1WARNING
Do not inflate any tire beyond its maximum inflation pres-
sure as specified on tire sidewall. Overinflation may
cause tire to suddenly deflate leading to personal injury.
TROUBLESHOOTING
Figure 2-3. Checking Tire Inflation Pressure
See Figure 2-3. Check tire inflation pressure at least once
each week. At the same time, inspect tire tread for punctures,
cuts, breaks and other damage. Repeat the inspection before
long trips.
Table 2-3. Wheel Service

CHECK FOR REMEDY
1. Loose axle nuts. Tighten front axle nut (metric) to 48-53 ft-lbs (65.1-71.9 Nm). Tighten rear
axle nut (metric) to 66-73 ft-lbs (89.5-98.9 Nm).
2. Excessive side-play or radial (up-and- Replace wheel hub bearings.
down) play in wheel hubs.
3. Alignment of rear wheel in frame or Check WHEEL BALANCING on page 2-17 or repair swingarm as described
with front wheel. under SWINGARM on page 2-33.
4. Rims and tires out-of-true sideways; Replace rims. See TIRES, INSTALLATION on page 2-16.
should not be more than 0.080 in.
(2.03 mm).
5. Rims and tires out-of-round or eccen- See Item 4 above.
tric with hub; should not be more than
0.090 in. (2.29 mm).
6. Irregular or peaked front tire wear. Replace as described under FRONT WHEEL (page 2-8), REAR WHEEL
(page 2-11) and TIRES (page 2-15).
7. Correct tire inflation. Inflate tires to correct pressure. See SPECIFICATIONS on page 2-1.
8. Correct tire and wheel balance. Static balance may be satisfactory if dynamic balancing facilities are not
available. However, dynamic balancing is strongly recommended.
9. Steering head bearings. Correct adjustment and replace pitted or worn bearings. See FORK STEM
AND BRACKET ASSEMBLY on page 2-32.
10. Damper tubes. Check for leaks. See FRONT FORK on page 2-28.
11. Shock absorbers. Check damping action and mounts. See SWINGARM on page 2-33.
12. Swingarm bearings. Check for looseness. See SWINGARM on page 2-33.
2-6
1WARNING 1WARNING
To prevent personal injury, use the following guidelines
when installing a new tire or repairing a flat:
Excessively worn tires adversely affect motorcycle trac-
1. Always locate and eliminate the cause of the original tion, steering and handling and could result in personal
tire failure. injury.
2. Do not patch or vulcanize a tire casing. These proce-
dures weaken the casing and increase the risk of a
blowout. At regular intervals of 5000 miles (8000 km) or whenever han-
dling irregularities are noted, perform the recommended ser-
3. The use of tires other than those specified can vice checks. See Table 2-3.
adversely affect handling resulting in personal injury.
4. Tires and wheels are critical safety items. Since the
servicing of these components requires special If tires must be replaced, same as original equipment tires
tools and skills, Buell recommends that you see your must be used. Other tires may not fit correctly and may be
dealer for these services. hazardous to use.
2-7
FRONT WHEEL
REMOVAL 5680
1. See Figure 2-4. Raise front wheel off floor using FRONT
WHEEL SUPPORT STAND (Part No. B-41395) and S1
LIFT ADAPTER (Part No. B-41686).
2. Remove front brake caliper. See FRONT BRAKE CALI-
PER, REMOVAL/DISASSEMBLY on page 2-20.
NOTE
Do not operate front brake lever with front wheel removed or
caliper pistons may be forced out. Reseating pistons requires
caliper disassembly.
3. See Figure 2-5. Insert screwdriver/rod through hole in
axle (1) and loosen front axle nut (4) (metric).
4. Loosen pinch screws (2) (metric).
5. Remove front axle nut (4) and washer (3). Pull front axle
out of hub while supporting front wheel.
6. See Figure 2-6. Detach speedometer drive spacer (3) Figure 2-4. Front Wheel Support Stand (Part No. B-41395)
and speedometer drive (4) from left side of wheel. with S1 Lift Adapter (Part No. B-41686)
Remove front wheel.
5710
DISASSEMBLY
1. See Figure 2-6. Move wheel to bench area. On the side 2 3
1
of the wheel opposite the brake rotor, remove left axle 4
spacer (5).
2. On brake rotor side of wheel, remove right axle
spacer (12).
3. Remove wheel bearings (6, 11) using BUSHING AND
BEARING PULLER (Part No. HD-95760-69A) and 3/4 in.
COLLET (Part No. HD-95767-69A).
4. Remove six locknuts (14), washers (21), spring washers
(20), screws (19) and brake drive pins (18). Remove
brake rotor (17).
5. Remove five screws (16) and front brake carrier (15).
6. Remove tire. See TIRES, REMOVAL on page 2-15.
1. Hole in front axle 3. Washer

CLEANING, INSPECTION 2. Pinch screws (4) 4. Front axle nut (metric)
AND REPAIR (metric)
1. Thoroughly clean all parts in solvent. Figure 2-5. Front Wheel Mounting
1WARNING
Never use compressed air to “spin-dry” bearings. Very
high bearing speeds can damage unlubricated bearings.
Spinning bearings with compressed air can also cause a
bearing to fly apart, which may result in personal injury.
2. Inspect all parts for damage or excessive wear.
3. Inspect brake rotor. Replace rotor if warped or badly
scored. Measure rotor thickness for excessive wear. Min-
imum rotor thickness is 0.17 in. (4.4 mm).
2-8
b0196x2x
1
2
3
4
5
6
10 7
11 9
12
1. Nut (metric)
14 2. Washer
3. Speedometer drive
spacer
4. Speedometer drive
21 5. Left axle spacer
20 6. Wheel bearing
13 7. Wheel
8. Valve stem
18 9. Wheel weight
10. Spacer
11. Wheel bearing
12. Right axle spacer
16 15 13. Front axle
14. Locknut (6)
19 15. Front brake carrier
16. Screw (5)
17. Front brake rotor
18. Brake drive pin (6)
19. Screw (6)
20. Spring washer (6)
17 21. Washer (6)
Figure 2-6. Front Wheel
ASSEMBLY 3. Install spacer (10).

4. Install new wheel bearings (6, 10) into hub using suitable
1WARNING driver. Press on outer race only.
Do not allow brake fluid, bearing grease, lubricants, etc.
to contact brake rotor or reduced braking ability will 5. On the side of the wheel opposite the brake rotor insert
occur, possibly resulting in personal injury. left axle spacer (5) into hub until it seats in bore. Spacer
sleeve must not be cocked or tilted in bore.
1. See Figure 2-6. Verify that the front brake carrier is thor-
oughly clean. Apply LOCTITE THREADLOCKER 242 6. On the right side of the wheel insert right axle spacer
(blue) to each screw (16). Install carrier (15) on hub with (12) into hub until it seats in bore. Spacer sleeve must
five screws. Tighten to 20-22 ft-lbs (27.1-29.8 Nm). not be cocked or tilted in bore.
2. Verify that the brake rotor is thoroughly clean. Apply LOC-
7. Install tire, if removed. See TIRES, INSTALLATION on
TITE THREADLOCKER 242 (blue) to each screw (19).
page 2-16.
Install rotor on front brake carrier with six screws, brake
drive pins (18), spring washers (20), washers (21) and 8. Verify that wheel and tire are true. See CHECKING
locknuts (14). Tighten to 7.5-8.5 ft-lbs (10.2-11.5 Nm). CAST RIM RUNOUT on page 2-14.
2-9
INSTALLATION b0197x2x
Speedometer
1. Apply LOCTITE ANTI-SEIZE LUBRICANT to axle. drive tab
2. Position wheel between forks with brake rotor on right

side of vehicle. With pinch screws (metric) loose, insert
threaded end of axle through right side fork. Push axle
through fork and wheel hub until axle begins to emerge
from left side of hub. Speedometer drive
1CAUTION
Speedometer drive tab must be properly inserted or dam-
age to the unit will occur. If drive tab is damaged, it must
be replaced.
3. See Figure 2-7. Align speedometer drive tab and wheel

hub. Push axle through speedometer drive, speedometer
drive spacer and left fork leg.
4. Compress the front suspension to make sure it is free Figure 2-7. Speedometer Drive
and not binding.
5. See Figure 2-6. Apply LOCTITE THREADLOCKER 242

(blue) to axle nut. Install washer (2) and axle nut (1) (met-
ric) over threaded end of axle. Insert screwdriver or steel
rod through hole in axle on right side of vehicle. While
holding axle stationary, tighten axle nut to 48-63 ft-lbs
(65.1-71.9 Nm).
6. See Figure 2-5. Tighten the four front axle pinch screws
(2) (metric) to 13-15 ft-lbs (17.6-20.3 Nm).
7. Install front brake caliper. See FRONT BRAKE CALI-

PER, INSTALLATION on page 2-21.
2-10
REAR WHEEL
REMOVAL 5574
1. Raise rear wheel off floor using REAR WHEEL SUP-
PORT STAND (Part No. B-41174). Rear axle
2. Remove rear fender. See FENDERS, REMOVAL/ nut (metric)
INSTALLATION on page 2-54.
3. Remove rear brake caliper. See REAR BRAKE CALI-
NOTE
Do not operate rear brake pedal with rear wheel removed or
caliper piston may be forced out. Reseating piston requires
caliper disassembly.
4. See Figure 2-8. Loosen rear axle nut (metric). Axle adjuster nut
5. Loosen rear axle adjuster nuts. Push wheel as far for-
ward as possible.
6. Slip secondary drive belt from bottom of rear wheel
sprocket and remove.
7. See Figure 2-9. Remove rear axle nut (14) (metric), lock- Figure 2-8. Rear Wheel Mounting
washer (13), and washer (12). Pull axle (3) and washer
(4) out from left side and remove wheel.
b0013a2x
16 15 3
17
4
5
6 1. Screw (4) (metric)
2. Rear brake rotor
3. Rear axle
4. Washer
10 5. Wheel bearing
6. Spacer sleeve
8 7 7. Wheel
8. Valve stem
9. Wheel weight
9 10. Bearings (2)
11. Right axle spacer
11 12. Washer
12 13. Lockwasher
13 14. Axle nut (metric)
14 15. Belt sprocket
16. Washer (5)
17. Bolt (5)
Figure 2-9. Rear Wheel
2-11
DISASSEMBLY 4878
1. See Figure 2-10. Move wheel to bench area. On the
brake rotor side of the wheel, remove bearing using
BUSHING AND BEARING PULLER (Part No. HD-
95760-69A) and 1 1/8 in. COLLET (Part No. HD-95769-
69).
2. Remove two bearings from sprocket side of wheel.
3. See Figure 2-9. Remove four screws (1) (metric) to
remove rear brake rotor (2) from hub.
4. Remove five bolts (17) and washers (16) on belt sprocket
(15). Remove belt sprocket from wheel.
CLEANING, INSPECTION
AND REPAIR
1. Thoroughly clean all parts in solvent.
1WARNING
Never use compressed air to “spin-dry” bearings. Very
high bearing speeds can damage unlubricated bearings.
Spinning bearings with compressed air can also cause a
bearing to fly apart, which may result in personal injury.
2. Inspect all parts for damage or excessive wear.
3. Inspect brake rotor. Replace rotor if warped or badly
scored. Measure rotor thickness for excessive wear. Min-
imum acceptable thickness (0.19 in. (4.8 mm)) is
stamped on side of rotor.
ASSEMBLY Figure 2-10. Removing Wheel Bearing Using Bushing/

Bearing Puller (Part No. HD-95760-69A) and
1WARNING 1 1/8 in. Collet (Part No. HD-95769-69)
Do not allow brake fluid, bearing grease, lubricants, etc.
to contact brake rotor or reduced braking ability will 3. On the sprocket side of the wheel, insert two bearings
occur, possibly resulting in personal injury. (10) into hub until they contact shoulder for spacer
1. See Figure 2-9. Verify that brake rotor (2) is thoroughly sleeve. Press bearings in separately, pressing on outer
clean. Apply LOCTITE THREADLOCKER 242 (blue) to race only.
each screw (1) (metric). Fasten rotor to hub with four 4. Insert spacer sleeve (6) into hub.
5. On the brake rotor side of the wheel, insert bearing (5)
NOTE into hub until it contacts end of spacer sleeve. Press on
P/M wheels use a nut (not shown) with each screw (1). outer race only.
2. Apply two drops of LOCTITE THREADLOCKER 272 6. Install tire, if removed. See TIRES, INSTALLATION on
(red) to threads of each sprocket bolt (17). Install belt page 2-16.
sprocket (15) using five bolts (17) and washers (16). 7. Verify that wheel and tire are true. See CHECKING
Tighten bolts to 55-65 ft-lbs (74.6-88.1 Nm). CAST RIM RUNOUT on page 2-14.
2-12
INSTALLATION 5. Install rear brake caliper. See REAR BRAKE CALIPER,
1. Place wheel centrally in the swingarm with the brake
rotor in the caliper. Slide wheel far enough forward to slip
belt over sprocket and then slide wheel back. 6. Check for proper belt tension and wheel alignment. See
2. See Figure 2-9. Apply LOCTITE ANTI-SEIZE LUBRI- REAR BELT DEFLECTION in Section 1.
CANT to axle (3).
3. Insert axle (3) through washer (4), left side of swingarm,
7. Tighten rear axle nut (14) (metric) to 66-73 ft-lbs (89.5-
rear brake caliper mount, wheel assembly, spacer (11)
98.9 Nm).
and right side of swingarm.
4. Install washer (12), lockwasher (13), and axle nut (14)
(metric) on right side of axle. Do not fully tighten rear axle 8. Install rear fender. See FENDERS, REMOVAL/INSTAL-
nut at this time. LATION on page 2-54.
2-13
CHECKING CAST RIM RUNOUT
GENERAL f1378x2x
Check wheels for lateral and radial runout before installing a Wheel Truing and Balancing
new tire. Stand (Part No. HD-99500-80)
Rim Lateral Runout
1. See Figure 2-11. Install truing arbor in wheel hub and

place wheel in WHEEL TRUING AND BALANCING
STAND (Part No. HD-99500-80).
2. Tighten arbor nuts so hub will turn on its bearings.
3. Check rim lateral runout by placing a gauge rod or dial

indicator near the rim bead. Replace wheel if lateral
runout exceeds specification shown in Table 2-4.
Gauge rod
Rim Radial Runout

Figure 2-11. Checking Cast Rim Lateral Runout
1. See Figure 2-12. Install truing arbor in wheel hub and
place wheel in WHEEL TRUING AND BALANCING f1379x2x
STAND (Part No. HD-99500-80).
2. Tighten arbor nuts so hub will turn on its bearings. Wheel Truing and Balancing
Stand (Part No. HD-99500-80)
3. Check radial runout as shown. Replace wheel if runout

exceeds specification shown in Table 2-4.
Table 2-4. Wheel Runout

MAXIMUM MAXIMUM
WHEEL TYPE LATERAL RADIAL
RUNOUT RUNOUT
Cast Marchesini 0.040 in. 0.030 in.

(1.02 mm) (0.76 mm)
Gauge rod
Aluminum P/M 0.020 in. 0.020 in.
(0.51 mm) (0.51 mm)
Figure 2-12. Checking Cast Rim Radial Runout
2-14
TIRES
GENERAL b0198x2x
Tires should be inspected for punctures, cuts, breaks and

wear at least weekly.
1WARNING
Always check both tire sidewalls for arrows indicating
forward rotation. Some tires require different tire rotation
depending on whether tire is used on front or rear wheel.
Installing a tire with the wrong rotation could result in
personal injury.
Some tires have arrows molded into the tire sidewall. These
tires should be mounted on the rim with the arrow pointing in
the direction of forward rotation. The red circle on the sidewall
is a balance mark and should be located next to the valve A bead breaker machine
stem hole. simplifies tire removal
Figure 2-13. Loosening Beads from Rim Flange

REMOVAL
1. Remove wheel from motorcycle. See FRONT WHEEL, b0199x2x
REMOVAL on page 2-8 or REAR WHEEL, REMOVAL

on page 2-11. Pry bead over rim edge and
2. Deflate tire. remove tire from rim
3. See Figure 2-13. Loosen both tire beads from rim flange.
1WARNING
Do not use excessive force when starting bead over rim.
Excessive force may damage tire or rim and adversely
affect handling resulting in personal injury.
4. If a bead breaker machine is not available, attach RIM

PROTECTORS (Part No. HD-01289) to the rim. Using
tire tools (not sharp instruments), start upper bead over
edge of rim at valve. Repeat all around rim until first bead Figure 2-14. Starting Tire Off RIm
is over rim.
b0200x2x
5. See Figure 2-14. Push lower bead into rim well on one
side and insert tire tool underneath bead from opposite
side. Pry bead over rim edge. Remove tire from rim. Lubricate rim flange and both
beads before installation
6. Remove valve stem if it is damaged or leaks.
7. Mount tire on TIRE SPREADER (Part No. HD-21000) for

inspection and repair procedures.
AND REPAIR
1. Clean inside of tire.
2. If rim is dirty or corroded, clean with a stiff wire brush.
3. Inspect tire for wear and damage. Replace worn tires. Figure 2-15. Starting Bead on Rim
Use TIRE REPAIR KIT (Part No. HD-20000) for tire
repair. Follow the kit manufacturer’s instructions.
2-15
1WARNING
● Only install original equipment (stock) tire valves
and valve caps. A valve or valve and cap combina-
tion that is too long may interfere with (strike) adja- Tire lateral
cent components, damage the valve and cause rapid runout 0.080 in.
tire deflation. Rapid tire deflation could cause loss of (2.03 mm)
control and personal injury. maximum
● Also, aftermarket valve caps that are heavier than the
stock cap may have clearance at slow speeds; but, at
high speed the valve/cap will be moved outward by
centrifugal force. This outward movement could Gauge
cause the valve/cap to strike the adjacent compo-
nents, damage the valve and cause rapid tire defla-
tion. Rapid tire deflation could cause loss of control
and personal injury.
1. Damaged or leaking valve stems must be replaced.
Place rubber grommet on valve stem with shoulder in
recess of the valve stem head.
Figure 2-16. Checking Tire Lateral Runout
2. Install and tighten nut to 42-44 in-lbs (4.7-5.0 Nm).
3. Thoroughly lubricate rim flanges and both beads of tire b0088x2x
with tire lubricant.
4. See Figure 2-15. Starting at the valve stem, start first
bead into the rim well using a bead breaker machine. If
no machine is available, work bead on as far as possible
by hand. Use a tire tool to pry the remaining bead over
rim flange.
5. Start 180° from valve stem hole and place second bead
on rim. Work bead onto rim with tire tools, working
toward valve in both directions.
Tire radial
1WARNING runout 0.060
Do not inflate over 40 psi (2.8 bars) to seat the beads. (1.52 mm)
Inflating the tire beyond 40 psi (2.8 bars) to seat the maximum
beads can cause the tire rim assembly to burst with force
sufficient to cause personal injury. If the beads fail to
seat to 40 psi (2.8 bars), deflate and relubricate the bead
and rim and reinflate to seat the beads, but do not exceed Gauge
40 psi (2.8 bars).
6. Apply air to stem to seat beads on rim. It may be neces-
sary to use a TIRE BEAD EXPANDER (Part No. HD-
28700) on the tire until beads seal on rim.
Figure 2-17. Checking Tire Radial Runout
Checking Tire Lateral Runout
Checking Tire Radial Runout
1. See Figure 2-16. Turn wheel on axle and measure
amount of displacement from a fixed point to tire side- 1. See Figure 2-17. Turn wheel on axle and measure tread
wall. radial runout.
2. Tire tread lateral runout should be no more than 0.080 in. 2. Tire tread radial runout should not be greater than 0.060
(2.03 mm). If runout is more than 0.080 in. (2.03 mm), in. (1.52 mm). If runout exceeds specification, remove
remove tire from rim. tire from rim.
3. Check rim bead side runout. See CHECKING CAST RIM 3. Check rim bead runout. See CHECKING CAST RIM
RUNOUT on page 2-14. Replace rims not meeting spec- RUNOUT on page 2-14. Replace rims not meeting spec-
ifications. ifications.
4. Install tire and check again for tire tread lateral runout. 4. Install tire and check tire tread radial runout again.
2-16
ADJUSTMENT The maximum weight permissible to accomplish balance is
1 oz. (28 g) (total weight applied to the rim). Wheels should
be balanced to within 1/4 oz. (7 g) at 60 MPH (97 KM/H).
Wheel Balancing
These weights are applied to the flat surface of the wheel rim
Wheel balancing is recommended to improve handling and according to the following procedures.
reduce vibration, especially at high road speeds.
In most cases, static balancing using WHEEL TRUING AND 1. Make sure that area of application is completely clean,
BALANCING STAND (Part No. HD-99500-80) will produce dry, and free of oil and grease.
satisfactory results. However, dynamic balancing, utilizing a
2. Remove paper backing from weight. For additional adhe-
wheel spinner, can be used to produce finer tolerances for
sive strength, apply three drops of LOCTITE SUPER-
best high-speed handling characteristics. Follow the instruc-
BONDER 420 to adhesive side of weight. Place weight
tions supplied with the balance machine you are using.
on flat surface of wheel rim. Press weight firmly in place
WEIGHTS FOR CAST WHEELS and hold for ten seconds.
Buell specifies WHEEL WEIGHTS (Part No. 43692-94Y) 3. Allow eight hours for adhesive to cure completely before
which have special self-adhesive backings. using wheel.
2-17
BRAKES
GENERAL 1WARNING
● Clean brake system components using denatured
alcohol. Do not use mineral-base cleaning solvents,
The front and rear brakes are fully hydraulic disc brake sys- such as gasoline or paint thinner. Use of mineral-
tems that require little maintenance. The front brake master base solvents causes deterioration of rubber parts
cylinder is an integral part of the brake hand lever assembly. that continues after assembly. This could result in
The rear brake master cylinder is located on the right side of improper and unsafe brake operation which may
the motorcycle near the brake pedal. cause personal injury.
● Always test motorcycle brakes at low speed after
Check the master cylinder reservoirs for proper fluid levels servicing or bleeding system. To prevent personal
every 5000 miles (8000 km). See BRAKES in Section 1. injury, Buell recommends that all brake repairs be
performed by a Buell dealer or other qualified
mechanic.
Check brake pads and rotors for wear every 2500 miles (4000 ● Exercise caution when handling brake fluid. Brake
km). Replace brake pads if friction material is worn to 1/16 in. fluid can cause irritation of eyes and skin and may be
(1.6 mm) or less. Replace brake rotors not meeting minimum harmful or fatal if swallowed. If swallowed, adminis-
rotor thickness. See BRAKES in Section 1. ter two tablespoons of salt in a glass of warm water
to induce vomiting. Call a doctor immediately. In
case of contact with skin or eyes, flush with plenty of
If determining probable causes of poor brake operation, see water. Get medical attention for eyes. KEEP BRAKE
Table 2-5. FLUID OUT OF THE REACH OF CHILDREN.
Table 2-5. Brake Troubleshooting

CONDITION CHECK FOR REMEDY
Excessive lever/pedal travel or Air in system. Bleed brake(s).

spongy feel. Master cylinder low on fluid. Fill master cylinder with approved
brake fluid.
Chattering sound when brake is Worn pads. Replace brake pads.
applied. Loose mounting bolts. Tighten bolts.
Warped rotor. Replace rotor.
Ineffective brake – Low fluid level. Fill master cylinder with approved
lever/pedal travels to limit. brake fluid, and bleed system.
Piston cup not functioning. Rebuild cylinder.
Ineffective brake – Distorted or glazed rotor. Replace rotor.
lever/pedal travel normal. Distorted, glazed or contaminated
brake pads. Replace pads.
Brake pads drag on rotor – Cup in master cylinder not uncovering Inspect master cylinder.
will not retract. relief port.
Rear brake pedal linkage out of Adjust linkage.
adjustment.
2-18
FRONT BRAKE MASTER CYLINDER
REMOVAL b0203a2x 3
NOTE 1 2
The front master cylinder contains no user serviceable parts.
Do not remove the master cylinder unless problems are being 4 5
experienced. Replace the entire assembly when necessary.
1. Remove mirror mounting hardware (metric, left hand

threads).
2. Open bleeder nipple cap on front caliper. Install end of a
length of plastic tubing over caliper bleeder valve, while
placing free end in a suitable container. Open bleeder
6
valve about 1/2-turn. Pump brake hand lever to drain
brake fluid. 7
3. See Figure 2-18. Remove banjo bolt (6) (metric) and two 8 9
gaskets (4) to disconnect brake line from master cylinder.
Discard gaskets. 10
4. Remove screw (10), lockwasher (9) and washer (8) to
detach brake lamp switch (7).
NOTE
The individual parts of the brake lamp switch are not service- 1. Clamp screws (2) 6. Banjo bolt (metric)
able. Replace switch upon failure. (metric) 7. Front brake lamp
2. Clamp switch
5. Remove two screws (1) (metric) and clamp to free mas- 3. Master cylinder 8. Washer
ter cylinder assembly from handlebar. cover screws (2) 9. Lockwasher
4. Gaskets (2) 10. Screw
5. Brake line
INSTALLATION
1. See Figure 2-18. Fasten master cylinder to handlebar by Figure 2-18. Front Master Cylinder Banjo Bolt
installing clamp (2) and screws (1) (metric). Tighten
screws to 80-90 in-lbs (9.0-10.2 Nm).
1WARNING
A plugged or covered relief port can cause brake drag or
1CAUTION lockup, which may result in loss of vehicle control and
To avoid leakage, verify that gaskets, banjo bolt, hydrau- possible personal injury.
lic brake line and master cylinder bore are completely
clean. 6. Verify proper operation of the master cylinder relief port.
Actuate the brake lever with the reservoir cover removed.
2. Place new gaskets on each side of the hydraulic brake A slight spurt of fluid will break the surface if all internal
line. Install banjo bolt through gaskets and brake line fit- components are working properly.
ting into master cylinder. Tighten banjo bolt (6) (metric) to
17-20 ft-lbs (23.0-27.1 Nm). 7. Install master cylinder cover screws (3) and cover.
3. Attach brake lamp switch (7) with screw (10), lockwasher Tighten cover screws to 9-13 in-lbs (1.0-1.5 Nm).
(9) and washer (8).
8. Bleed brake system. See BRAKES in Section 1.
4. Remove both master cylinder cover screws (3) and cover.
9. Install mirror parallel to handlebars. Mirror mount has
5. With the master cylinder in a level position, add D.O.T. 5 metric, left hand threads.
SILICONE HYDRAULIC BRAKE FLUID. Bring fluid level
to within 1/8 in. (3.2 mm) of molded boss inside front mas- 10. Test brake lamp operation with the brake hand lever
ter cylinder reservoir. applied and the ignition/headlamp switch turned to IGN.
2-19
FRONT BRAKE CALIPER
REMOVAL/DISASSEMBLY 5712
NOTE 3
Step 1 (draining fluid) is not required for caliper removal. 5
Drain brake fluid only when disassembling caliper.
1. See Figure 2-19. Remove banjo bolt (4) and gaskets to

4
disconnect brake line from caliper. Drain brake fluid into a
clean, suitable container. Discard gaskets.
2. Remove cotter and support pins (1).
3. Remove center caliper bolt (2) and spacer.
4. Remove brake pads from front brake caliper. Pads must 2
be removed in order to remove caliper from rotor. 1
5. Remove both caliper mounting bolts (3).
6. Free caliper from front brake rotor.
7. Move caliper assembly to bench area. 1. Cotter and 3. Caliper mounting bolts
8. See Figure 2-20. Remove screws (13, 14) to separate support pins 4. Banjo bolt
caliper halves (7, 12). Remove O-rings (11) and discard. 2. Center caliper bolt 5. Wire guide
Figure 2-19. Front Brake Caliper Mounts
b0016a2x Front caliper rebuild kit,

Part No. 44148-94Y
14
15
16
13
5
6 12
11
2 8 10
3 9
7
1. Support pins (2) 9. O-ring (3 sizes, 2 each)
2. Cotter pins (2) 10. Pistons (3 sizes, 2 each)
1 3. Center caliper bolt 11. O-ring (2)
4. Caliper mounting bolts (2) 12. Left caliper half
4 5. Banjo bolt 13. Screw
6. Gaskets (2) 14. Screw (3)
7. Right caliper half 15. Brake pads (2)
8. Bleeder valve 16. Spacer
Figure 2-20. Front Brake Caliper
2-20
1WARNING
When using air pressure to remove pistons from caliper, 5737
pistons may be ejected with considerable force. Wear

safety glasses, heavy gloves and hold caliper with heavy
towel to prevent personal injury.
1CAUTION
Exercise care to avoid dropping piston on hard surface.
9. See Figure 2-21. Use BRAKE CALIPER PISTON
REMOVER (Part No. B-42079) to remove caliper pistons.
10. See Figure 2-20. Pry O-rings (9) out of their respective
grooves on each side of caliper. Discard O-rings.
CLEANING, INSPECTION AND

REPAIR
1WARNING Figure 2-21. Removing Brake Caliper Pistons Using
Clean brake system components using denatured alco- Brake Caliper Piston Remover (Part No. B-42079)
hol. Do not use mineral-base cleaning solvents, such as
gasoline or paint thinner. Use of mineral-base solvents 4. Install center caliper bolt (3) and spacer (16). Tighten
causes deterioration of rubber parts that continues after center caliper bolt to 11-13 ft-lbs (14.9-17.6 Nm).
assembly. This could result in improper and unsafe brake
operation which may cause personal injury. 5. Install two support pins (1) and new cotter pins (2).
1. Thoroughly clean brake system components using dena-

6. Connect brake line to caliper using new gaskets. Tighten
tured alcohol. Blow dry using compressed air. Carefully
banjo bolt (5) to 16-20 ft-lbs (21.7-27.1 Nm).
inspect all components. Replace any parts that appear
damaged or worn. Do not hone caliper piston bore.
7. With the master cylinder in a level position, verify that the
2. Inspect brake rotor. Replace if warped or badly scored. brake fluid level is 1/8 in. (3.2 mm) from molded boss
Measure rotor thickness for excessive wear. Replace inside reservoir. Add D.O.T. 5 SILICONE HYDRAULIC
rotors less than 0.17 in. (4.3 mm) thick. BRAKE FLUID if necessary.
1WARNING
Always replace brake pads in complete sets for correct 1WARNING
and safe brake operation. Never replace just one brake
pad. Failure to install brake pads as a set may cause per- A plugged or covered relief port can cause brake drag or
sonal injury. lockup, which may result in loss of vehicle control and
possible personal injury.
3. Inspect brake pads for damage or wear. Replace both
pads as a set if the friction material of either pad is worn
to 1/16 in. (1.6 mm) or less. 8. Verify proper operation of the master cylinder relief port.
Actuate the brake lever with the reservoir cover removed.
A slight spurt of fluid will break the surface if all internal
ASSEMBLY components are working properly.
1. See Figure 2-20. Install new O-rings (11) in groove of
each caliper half (7, 12). Install new O-rings (9) in groove 9. Install cover gasket, cover and screws. Tighten screws to
of piston bores. 9-13 in-lbs (1.0-1.5 Nm).
2. Install pistons (10) in each caliper piston bore.
10. Depress front brake lever several times to set brake pads
3. Tighten caliper halves together with four screws (13, 14). to proper operating position within caliper. Bleed brake
Smallest screw (13) is placed on top next to bleeder system. See BRAKES in Section 1.
valve (8). Tighten screws to 26-28 ft-lbs (35.2-38.0 Nm).
11. Test brake lamp operation with the brake hand lever
INSTALLATION applied and the ignition/headlamp switch turned to IGN.
1. Fit caliper on front brake rotor without brake pads.
NOTE
2. See Figure 2-20. Tighten both caliper mounting bolts (4)
to 30-33 ft-lbs (40.7-44.7 Nm). To allow new brake pads to “wear in” properly with the brake
3. Insert brake pads (15) from top. rotor, avoid making hard stops for the first 100 miles (160 km).
2-21
FRONT BRAKE LINE
REMOVAL b0203x2x
1. Open bleeder nipple cap on front brake caliper. Install Top right side-
end of a length of plastic tubing over caliper bleeder master cylinder
valve, while placing free end in a suitable container.
Open bleeder valve about 1/2-turn. Pump brake hand 3
lever to drain brake fluid.
2. See Figure 2-22. Remove screw (4) to detach brake line
clamp (5) from lower triple clamp (right side).
3. Slide brake line out of wire guide (6) on front fender.
4. Remove master cylinder banjo bolt (1) (metric) and two
gaskets (2) to detach brake line from master cylinder 2
body. Discard gaskets.
1
5. Remove caliper banjo bolt (7) and two gaskets (8) to
detach brake line from front brake caliper. Discard gas-
kets.
6. Carefully inspect the brake line for dents, cuts or other
defects. Replace the brake line if any damage is noted.
INSTALLATION 4
1. See Figure 2-22. Position new master cylinder gaskets
(2) on each side of the banjo fitting. Insert banjo bolt (1) 5
(metric) through gaskets and banjo fitting. Loosely install
bolt into master cylinder.
2. From the master cylinder, the brake line runs downward
in front of the right handlebar, where it turns inboard at
the upper triple clamp. Loosely install clamp (5), and
screw (4) to attach front brake line to right side of lower 7
6
triple clamp.
3. Place brake line inside wire guide (6) on front fender.
4. Position new gaskets (8) on each side of banjo fitting at
free end of brake line. Insert caliper banjo bolt (7)
through gaskets. Loosely install bolt into caliper.
5. Tighten clamp screw (4) on lower triple clamp to 30-35
in-lbs (3.4-4.0 Nm). Lower right side-
brake caliper 8
6. Tighten master cylinder banjo bolt (1) (metric) to 17-20 ft-
lbs (23.0-27.1 Nm).
7. Tighten brake caliper banjo bolt (7) to 16-20 ft-lbs (21.7- 1. Master cylinder 4. Screw
27.1 Nm). banjo bolt (metric) 5. Clamp
2. Master cylinder 6. Wire guide
8. Install bleeder valve if removed. Refill master cylinder gasket (2) 7. Caliper banjo bolt
and bleed brakes. See BRAKES in Section 1. 3. Brake line 8. Caliper gasket (2)
9. Test operation of brake lever.
Figure 2-22. Front Brake Line
10. Tighten front bleeder valve to 4-6 ft-lbs (5.4-8.1 Nm).
Install bleeder cap.
11. Test brake lamp operation with the brake hand lever
applied and ignition/headlamp switch turned to IGN.
2-22
REAR BRAKE MASTER CYLINDER
ADJUSTMENT 5569
Brake Pedal
1. See Figure 2-23. Brake pedal must have 1/8 in. (3.2 mm)
pushrod freeplay. If adjustment is necessary, hold push- 1
rod (1) and loosen locknut (2) (metric).
2. Rotate pushrod to increase or decrease freeplay. 2
3. Tighten locknut.
NOTE
If you alter pedal height, always check pushrod freeplay. 6
5
NOTE 4
Do not disassemble the master cylinder unless problems are
experienced. Discard all seals during the disassembly proce- 1. Pushrod 5. Pedal height
dure. Install a complete rebuild kit upon assembly. 2. Locknut (metric) adjustment screw
3. Screw and locknut 6. Brake pedal
1. Open bleeder nipple cap on rear caliper. Install end of a 4. Male end of pushrod
placing free end in a suitable container. Open bleeder Figure 2-23. Brake Pedal
valve (metric) about 1/2-turn. Pump brake pedal to drain
brake fluid.
5721
2. See Figure 2-23. Remove screw and locknut (3) to
detach male end of push rod (4) from brake pedal. 1
Remove push rod. 2
1CAUTION
Damaged banjo seating surfaces will leak when reassem-
bled. Prevent damage to seating surfaces by carefully
removing brake line components.
3. See Figure 2-24. Remove banjo bolt (metric) (3) and two
gaskets (4) from rear master cylinder. Discard gaskets.
4. Remove two screws and locknuts (5) holding the rear 3
brake master cylinder to frame.
5. Remove reservoir hose clamp from rear master cylinder.
4
6. Remove screw on reservoir assembly.
5
REPAIR 6
1WARNING
Clean brake system components using denatured alco-
gasoline or paint thinner. Use of mineral-base solvents
causes deterioration of rubber parts that continues after
assembly. This could result in improper and unsafe brake
operation which may cause personal injury.
1. Thoroughly clean master cylinder and all brake system 1. Master cylinder 4. Gaskets (2)
components. Examine walls of master cylinder reservoir reservoir 5. Screws and locknuts
for scratches and grooves. Replace if damaged. Verify 2. Screw 6. Hose clamp
that vent holes on master cylinder are completely open 3. Banjo bolt (metric)
and free of dirt or debris. Stand master cylinder on Figure 2-24. Rear Master Cylinder
wooden block or towel to protect seating surfaces.
2. Inspect cover gasket on front of master cylinder for cuts,
tears or general deterioration. Replace as necessary.
2-23
ASSEMBLY/INSTALLATION 5559
Upper mark
1. See Figure 2-24. Mount reservoir assembly on frame
with screw. Tighten screw to 12-15 in-lbs (1.4-1.7 Nm).
Clamp reservoir hose to rear master cylinder with a new
clamp and HOSE CLAMP PLIERS (Part No. HD-41137). Lower mark
2. Attach rear master cylinder to frame with two screws and

locknuts. Tighten to 8-10 ft-lbs (10.8-13.6 Nm).
1CAUTION
To avoid leakage after assembly, verify that gaskets,

banjo bolt, rear brake line and bore of master cylinder are
completely clean.
3. Position new gaskets on each side of rear brake line at

master cylinder. Insert banjo bolt (metric) through gas- Figure 2-25. Proper Rear Brake Fluid Level
kets and brake line. Thread banjo bolt (metric) into rear
brake master cylinder and tighten to 10-12 ft-lbs (13.6-
16.2 Nm).
4. See Figure 2-23. Place push rod into rear master cylinder.
Install male rod end behind brake pedal with screw and
locknut. Tighten screw to 10-12 ft-lbs (13.6-16.2 Nm).
5. Adjust brake pedal freeplay.
6. See Figure 2-25. With the master cylinder in a level posi-

tion, check that the brake fluid level is between the upper
and lower marks on reservoir. Add D.O.T. 5 SILICONE
HYDRAULIC BRAKE FLUID if necessary. Be sure cap is
securely screwed on.
1WARNING

lockup, which may result in loss of vehicle control and
7. Bleed brake system. See BRAKES in Section 1.
8. Test brake lamp operation with the rear brake pedal

applied and the ignition/headlamp switch turned to IGN.
2-24
REAR BRAKE CALIPER
REMOVAL/DISASSEMBLY NOTE
Do not remove piston from caliper unless there are signs of
NOTE hydraulic fluid leakage or piston is not operating properly. If
Step 1 (draining fluid) is not required for caliper removal. piston must be removed, proceed to Step 7.
Drain brake fluid only when disassembling caliper.
1WARNING
1. See Figure 2-26. Open bleeder nipple cap on rear cali- When using air pressure to remove piston from caliper,
per. Install end of a length of plastic tubing over caliper piston may be ejected with considerable force. Wear
bleeder valve (2), while placing free end in a suitable safety glasses, heavy gloves and hold caliper with heavy
container. Open bleeder valve (metric) about 1/2-turn. towel to prevent personal injury.
Pump brake pedal to drain brake fluid.
1CAUTION
2. Remove both caliper mounting screws (11) (metric) and
washers (10) to free caliper from caliper mount. Exercise care to avoid dropping piston on hard surface.
3. Pump brake pedal until piston reaches its full travel.
Remove banjo bolt (1) (metric) and two gaskets (3) to 7. Hold caliper with piston facing downward. Place a clean
disconnect brake line from caliper. Discard gaskets. shop towel under piston. Apply low air pressure to
hydraulic brake line inlet hole until piston is forced out
4. Remove slave pad from rear pad bracket (9).
caliper bore. If piston is tight in bore, tap lightly around
5. Remove rear pad bracket and dust boots (12, 13) from caliper while applying air pressure.
rear caliper assembly (4).
8. Remove and discard O-ring (5) from groove within piston
6. Remove master brake pad (7) from piston (6). bore.
b0017a2x Rear caliper rebuild kit,

Part No. 44149-94Y
12
13
11
10
1 9
2 8
6
5
3 1. Banjo bolt (metric) 8. Slave brake pad
2. Bleeder valve (metric) 9. Rear pad bracket
3. Gaskets (2) 10. Washer (2)
4. Rear caliper assembly 11. Screw (2) (metric)
5. O-ring 12. Large dust boot
4
6. Piston 13. Small dust boot
7. Master brake pad
Figure 2-26. Rear Brake Pads and Caliper
2-25
CLEANING, INSPECTION AND INSTALLATION
REPAIR
1. With friction material facing brake rotor, align rear caliper
1WARNING assembly on mounting bracket.
Clean brake system components using denatured alco-
gasoline or paint thinner. Use of mineral-base solvents 2. See Figure 2-26. Install washers and screws (metric) to
causes deterioration of rubber parts that continues after fasten rear caliper assembly to mounting bracket.
assembly. This could result in improper and unsafe brake Tighten screws to 18-22 ft-lbs (24.4-29.8 Nm).
operation which may cause personal injury.
1. Clean brake system components using denatured alco- 3. Install bleeder valve (metric) if removed. Tighten valve to
hol. Blow dry using compressed air. Carefully inspect all 6-9 ft-lbs (8.1-12.2 Nm). Install bleeder cap.
components. Replace any parts that appear damaged or
worn. Replace rubber dust boots (12, 13) if damaged or
worn. Do not hone caliper piston bore. 4. Position new gaskets on each side of banjo fitting. Insert
banjo bolt (metric) through gaskets and banjo fitting into
2. Inspect brake rotor. Replace rotor if warped or badly caliper. Tighten banjo bolt (metric) to 9.5-12.5 ft-lbs
scored. Measure rotor thickness for excessive wear. (12.9-17.0 Nm).
Replace rotors less than 0.19 in. (4.8 mm) thick.
1WARNING 5. With the master cylinder in a level position, check that the
Always replace brake pads in complete sets for correct brake fluid level is between the upper and lower marks
and safe brake operation. Never replace just one brake on reservoir. See Figure 2-25. Add D.O.T. 5 SILICONE
pad. Failure to install brake pads as a set may cause per- HYDRAULIC BRAKE FLUID if necessary. Be sure cap is
sonal injury. securely screwed on.
3. Inspect brake pads for damage or excessive wear.

Replace both pads as a set if friction material of either 1WARNING
pad is worn to 1/16 in. (1.6 mm) or less.

ASSEMBLY lockup, which may result in loss of vehicle control and
1. See Figure 2-26. Install new O-ring (5) within groove in
piston bore of rear caliper assembly (4).
2. Apply light coat of D.O.T. 5 SILICONE HYDRAULIC 6. Depress rear brake pedal several times to set brake pads
BRAKE FLUID to piston OD, including chamfer. Apply a to proper operating position within caliper. Bleed brake
light coat to caliper piston bore (6) and ID of installed pis- system. See BRAKES in Section 1.
ton O-ring (5). Install piston into caliper piston bore. Use
a “C” clamp to press in piston, if necessary.
7. Verify proper reservoir fluid level as described in Step 5.
NOTE
To ensure proper brake pad-to-brake rotor clearance when 8. Test brake lamp operation with the rear brake pedal
the caliper is installed, piston must be pressed all the way into applied and the ignition/headlamp switch turned to IGN.
the bore whenever new brake pads are used.
3. Install master brake pad (7) on piston (6).

NOTE
4. Install dust boots (12, 13) and rear pad bracket (9) into
rear caliper assembly.
To allow new brake pads to “wear in” properly with the brake
5. Install slave brake pad (8). rotor, avoid making hard stops for the first 100 miles (160 km).
2-26
REAR BRAKE LINE AND SWITCH
REMOVAL 5560
Bleeder valve
1. Open bleeder nipple cap on rear caliper. Install end of a (metric)
placing free end in a suitable container. Open bleeder
valve (metric) about 1/2-turn. Pump rear brake pedal to
drain brake fluid.
2. See Figure 2-27. Remove banjo bolt (metric) and two

gaskets to detach brake line from rear brake caliper. Dis- Banjo bolt
card gaskets. (metric)
3. See Figure 2-28. Remove banjo bolt (metric) and two

gaskets to detach brake line from rear master cylinder.
Discard gaskets.
4. See Figure 2-29. Remove screw and clamp to detach

Figure 2-27. Rear Brake Caliper Banjo Bolt
brake line clamp from frame.
5. Remove brake line from clamp under oil tank. 5521
6. Pull terminal sockets from spade connections at top of Banjo bolt

brake lamp switch. Unthread switch from tee nut. (metric)
INSTALLATION
1. See Figure 2-29. Coat brake lamp switch threads with
LOCTITE PIPE SEALANT WITH TEFLON. Thread brake
lamp switch to tee nut of brake line. Tighten switch
assembly to 7-8 ft-lbs (9.5-10.8 Nm). Install terminal
sockets on switch spade connections.
2. From left side of vehicle, feed new brake line from rear
brake caliper mount forward to frame mount. Thread
brake line right to rear master cylinder. Figure 2-28. Rear Master Cylinder Banjo Bolt
3. Install screw and clamp to secure rear brake line to frame.

5559
Tighten clamp screw to 10-12 ft-lbs (13.6-16.2 Nm).
4. Attach brake line to clamp under oil tank.

Brake lamp
5. See Figure 2-28. Position new gaskets on each side of switch
master cylinder banjo fitting. Insert banjo bolt (metric)
through gaskets and banjo fitting. Thread bolt into master
cylinder and tighten to 10-12 ft-lbs (13.6-16.2 Nm).
6. See Figure 2-27. Position new gaskets on each side of

caliper banjo fitting. Insert banjo bolt (metric) through
gaskets and banjo fitting into caliper. Tighten banjo bolt
to 9.5-12.5 ft-lbs (12.9-17.0 Nm). Install bleeder valve if
removed. Refill master cylinder and bleed brakes. See
BRAKES in Section 1.
Clamp
7. Tighten bleeder valve (metric) to 6-9 ft-lbs (8.1-12.2 Nm).
Install bleeder cap.
8. Test brake lamp operation with the rear brake pedal Figure 2-29. Brake Line and Switch
applied and the ignition/headlamp switch turned to IGN.
2-27
2
FRONT FORK
GENERAL 5761
The front fork consists of two telescoping outer tube/inner
slider assemblies. Each tube/slider assembly has an internal
compression spring which supports the forward weight of the
vehicle/rider. The compression spring extends and retracts to
cushion the ride over rough or irregular road surfaces. An oil-
filled damping mechanism controls the telescoping action of
each tube/slider assembly.
See FRONT FORK in Section 1 for fork oil change procedure.
Front Fork Holding Tool,

REMOVAL (Part No. B-41177)
1. Raise front wheel off floor using FRONT WHEEL SUP-
PORT STAND (Part No. B-41395) and S1 LIFT
ADAPTER (Part No. B-41686).
3. Remove front wheel. See FRONT WHEEL, REMOVAL
on page 2-8.
4. Remove front fender. See FENDERS, REMOVAL/ Figure 2-30. Front Fork Holding Tool
5. Loosen left and right headlamp brackets. See HEAD- b0206x2x
LAMP, REMOVAL in Section 7.
6. Loosen all five pinch screws on both the upper and lower
triple clamps.
EB OM
7. Remove front forks. R C
DISASSEMBLY
1. See Figure 2-30. Clamp the fork vertically in a vise using
FRONT FORK HOLDING TOOL (Part No. B-41177). Left fork leg adjuster- Right fork leg adjuster-
2. See Figure 2-31. Turn adjuster to full slow position (com- Rebound damping Compression damping
pletely clockwise).
FORK ADJUSTMENTS
3. See Figure 2-32. Remove fork cap (2) (metric), O-ring (3)
and washer (4). Increase rebound/compression (slower):
4. Reduce spring pressure and remove both retaining Turn appropriate adjuster clockwise.
clips (5).
5. Remove preload shim(s) (6) and steel washer (7). Decrease rebound/compression (faster):
Turn appropriate adjuster counterclockwise.
6. Remove fork spring (8).
7. Invert fork and drain fork oil. Figure 2-31. Fork Adjusters
8. Clamp fork outer tube (9) horizontally using FRONT
FORK HOLDING TOOL (Part No. B-41177). Loosen fork 12. Remove lower DU bushing (10), support ring (11) and
seal retaining ring (14) and spacer ring (13). fork oil seal (12). Discard fork oil seal and support ring.
9. Using ROBINAIR HEAT GUN (Part No. HD-25070) heat 13. Invert fork. Hold damper assembly and remove bolt (20)
bottom of outer tube. When the tube has sufficiently (metric) and copper washer (19). Discard copper washer.
expanded, drive inner tube (18) from outer tube with a
slide hammer action. Inner tube will retain fork oil seal 14. Remove damper assembly (22).
(12) and support ring (11) in place.
10. Spread red retaining cap (15) and remove. Remove NOTE
upper DU bushing (16) and washer (17). The damper assembly (22) contains no user serviceable
11. Remove retaining ring (14) and spacer ring (13). parts.
2-28
b0033a2x
2 NOTE
● Quantities are listed per individual fork leg.
3 ● Left leg controls rebound damping. Right leg
4 controls compression damping.
5 ● Number of preload shims (6) may vary
between fork assemblies.
6
7
8
1
15
16
17
9 22
18
10
11
12 19
13 20 21
14
1. Front fork assembly 7. Steel washer 13. Spacer ring 19. Copper washer
2. Fork cap 8. Spring 14. Retaining ring 20. Bolt (metric)
3. O-ring 9. Outer tube 15. Retaining cap (red) 21. Bolt (2) (metric)
4. Washer 10. DU bushing (lower) 16. DU bushing (upper) 22. Damper assembly
5. Retaining clip (2) 11. Support ring 17. Washer
6. Preload shim 12. Fork oil seal 18. Inner tube
Figure 2-32. Front Forks
2-29
CLEANING, INSPECTION AND 5760
REPAIR
Slide fork seal
1. Thoroughly clean and inspect all parts. Replace any
over installer
parts that are bent, broken or damaged.
2. Inspect the O-rings for damage, wear or general deterio-
ration; replace as necessary. Replace all other removed
seals.
3. See Figure 2-32. Check inner tube (18). Tube surface
should be shiny, smooth and free of scoring or abrasions.
ASSEMBLY
1. Install new fork seal retaining ring (14) and spacer ring
(13) on inner tube.
2. See Figure 2-33. Using FRONT FORK BUSHING/SEAL
INSTALLER (Part No. B-41176), install new fork oil seal
on inner tube. External spring on fork oil seal faces bot-
tom of fork leg. Figure 2-33. Installing New Fork Seal Using Front Fork
3. See Figure 2-32. Install new support ring (11). Bushing/Seal Installer (Part No. B-41176)
4. Install upper DU bushing (16) with large end towards the

bottom of the fork leg. Install washer (17) and lower DU 5759
bushing (10). Install red retaining cap (15).
NOTE
Inspect both DU bushings upon assembly. Bushings are
bronze with a Teflon layer. A DU bushing should be replaced Use tool to fully
when 20-30% of the Teflon layer has been worn through. In seat DU bushings
this circumstance, a visual inspection will show 20-30% of the
bronze base. Also replace bushings if bushing interiors show
any small grooves. Such grooves will damage the outside sur-
face of the inner tubes.
5. Clamp outer tube (9) upside down using FRONT FORK
HOLDING TOOL (Part No. B-41177).
6. See Figure 2-34. Place inner tube assembly inside outer
tube. Using bushing side of FRONT FORK BUSHING/
SEAL INSTALLER (Part No. B-41176), drive in DU bush-
ings until fully seated.
7. Reverse FRONT FORK BUSHING/SEAL INSTALLER.
(Part No. B-41176). Seat fork oil seal with seal side of
tool. Drop seal retaining ring in place. Fully seat retaining
ring. Figure 2-34. Installing Bushings and Seals Using Front
8. See Figure 2-32. Clamp fork in a horizontal position. Fork Bushing/Seal Installer (Part No. B-41176)
Install damper assembly (22) using bolt (20) (metric) and
a new copper washer (19). Tighten bolt to 18-23 ft-lbs
(24.4-31.2 Nm).
9. Clamp fork upright in the fully compressed stage.
10. Fill fork with oil. See FRONT FORK in Section 1.
11. Install fork spring (8).
12. Pull damper assembly above fork spring. Place steel
washer (7) and preload shim(s) (6) on top of spring.
13. Installing the retaining clips (5) requires two people.
Have one person compress the spring, steel washer and
preload shim(s). At the same time, have the second per-
son install both retaining clips.
14. Install washer (4), new O-ring (3) and fork cap (2) (metric).
2-30
INSTALLATION 5517
1. Insert fork assembly through front fork triple clamps and

headlamp brackets. Flush
NOTE
When installing the front forks, use a screwdriver to pry apart

the triple clamps.
2. See Figure 2-35. Position fork tubes so that top of each

fork cap fits flush with the top surface of upper triple
clamp.
3. Spread LOCTITE ANTI-SEIZE on the last three threads

of all five front fork triple clamp pinch screws. Tighten 2.375 in. (60.3 mm)
screws to 18-20 ft-lbs (24.4-27.1 Nm).
4. Position headlamp bracket 2.375 in. (60.3 mm) above

lower triple clamp. Tighten headlamp bracket screws.
5. Install front fender. See FENDERS, REMOVAL/INSTAL- Figure 2-35. Aligning Front Forks
LATION on page 2-54.
6. Install front wheel. See FRONT WHEEL, INSTALLATION

on page 2-10.
7. Install front brake caliper. See FRONT BRAKE CALI-

PER, INSTALLATION on page 2-21.
8. Set rebound and compression adjusters to the desired

settings.
2-31
FORK STEM AND BRACKET ASSEMBLY
REMOVAL/DISASSEMBLY b0031a2x
1. Remove fork assemblies. See FRONT FORK, REMOVAL

on page 2-28.
1
2. See Figure 2-36. Remove fork stem bolt (1) and upper 2
triple clamp (2).
3. Remove upper dust shield (3) and upper roller
bearing (4).
4. Lower the lower triple clamp (6). The lower bearing cone
3
is a press fit on fork stem. Chisel through outer bearing
cage to allow rollers to fall free. Apply heat to remove the 4
remaining portion of bearing cone. Continuously move
flame around its entire circumference until bearing falls
5
free. Remove lower dust shield (3).
5
5. If replacement of bearing cups (5) is necessary, drive
cups from steering head using STEERING HEAD BEAR- 4
ING RACE REMOVER (Part No. HD-39301A) and UNI- 3
VERSAL DRIVER HANDLE (Part No HD-33416).
9
8
REPAIR
See FRONT FORK in Section 1 for adjustment procedures.
6 7
1. See Figure 2-36. Clean the dust shields (3), bearing
cups (5), fork stem and lower triple clamp (6) and frame
with solvent.
2. Carefully inspect bearing races and assemblies for pit-
ting, scoring, wear and other damage. Replace damaged 1. Fork stem bolt 6. Lower triple clamp
bearing as a set. 2. Upper triple clamp 7. Screw (5)
3. Dust shield (2) 8. Steering head lock
3. Check the fork stem and lower triple clamp (6) for dam-
4. Roller bearing (2) 9. Steering lock key
age. Replace damaged fork stem.
5. Bearing cup (2)
Figure 2-36. Bearing Cup Removal

ASSEMBLY/INSTALLATION
1. See Figure 2-36. If removed, install new bearing cups (5) 5. Install the upper triple clamp (2) and loosely install fork
into frame steering head using STEERING HEAD BEAR- stem bolt (11).
ING RACE INSTALLER (Part No. HD-39302).
2. Liberally coat the bearing cones (4) with grease using 6. Install fork assemblies. See FRONT FORK, INSTALLA-
WHEEL BEARING PACKER TOOL (Part No. HD-33067). TION on page 2-31.
Work the grease into the rollers.
3. Place lower bearing dust shield (3) over fork stem. Find a
section of pipe having an inside diameter slightly larger 7. Tighten the fork stem bolt (1) until the bearings have no
than the outside diameter of the fork stem. Press bearing freeplay. Make sure the fork stem turns freely, then
cone (4) onto fork stem and bracket (1) using the pipe as tighten the fork stem clamp screw (rearmost pinch screw
a press on tool. on upper triple clamp).
4. Insert lower triple clamp (6) through the steering head.

Install the upper bracket bearing (4) and dust shield (3) 8. Check bearing adjustment. See FRONT FORK,
onto fork stem. ADJUSTMENT in Section 1.
2-32
SWINGARM
REMOVAL 16. Detach tie bars from frame mounts in the following
sequence. Do not remove tie bars from engine.
NOTE a. Rear tie bar. Use a swivel socket.
Mark all hardware as it is removed so that it may be returned b. Top tie bar.
to its original location.
c. Front tie bar and clutch cable clamp.
1. Swingarm removal requires motorcycle to be supported 17. See Figure 2-37. Remove isolator screws (9) and wash-
in several areas. First, secure front wheel and then raise ers on each side.
rear wheel off ground with REAR WHEEL SUPPORT
STAND (Part No. B-41174). 18. Slowly raise floor hoist until rubber isolators (10) can be
removed. Frame will rise while engine and swingarm
1WARNING remain secured to lift by crating strap.
To avoid accidental start-up of vehicle and possible per- 19. Loosen one pinch screw (8) on the swingarm mount
sonal injury, disconnect the battery cables before pro- block (7).
ceeding. Always disconnect the negative cable first. If
20. Remove bearing adjusting bolt (1) on that side with
the positive cable should contact ground with the nega-
PIVOT SHAFT BEARING ADJUSTER (Part No. B-
tive cable installed, the resulting sparks may cause a bat-
41175).
21. Loosen the remaining pinch screw. Extract pivot shaft (5)
1CAUTION and second adjuster as an assembly.
Hold battery cable when loosening battery terminal hard- 22. Remove swingarm.
ware. Failure to hold cable may cause battery damage.
2. Disconnect both battery cables, negative cable first. DISASSEMBLY

3. Remove seat, fuel tank and tail section. See TAIL SEC-
TION, REMOVAL on page 2-55. 1CAUTION
Carefully mark all bearing components as they are
4. Drain oil tank and remove filter. Detach feed, vent and removed, so that they may be returned to their original
return hoses from oil tank. See ENGINE LUBRICATION locations. Do not intermix bearing components.
SYSTEM in Section 1.
1. See Figure 2-37. Remove and discard swingarm seal (2).
5. Support motorcycle frame with a floor hoist such as the
CENTRAL HYDRAULICS FOLDING CRANE (Model T- 2. Remove roller bearings (3).
5466).
NOTE
6. Remove rear fender. See FENDERS, REMOVAL/ Remove roller bearing cups (4) only if replacement is
INSTALLATION on page 2-54. required. The complete bearing assembly must be replaced
7. Remove rear brake caliper assembly from swingarm.
as a unit when replacement is necessary. Do not intermix
See REAR BRAKE CALIPER, REMOVAL/DISASSEM-
bearing components.
BLY on page 2-25. 3. See Figure 2-38. Carefully press roller bearing cups (4)
8. Remove rear wheel. See REAR WHEEL, REMOVAL on from swingarm using STEERING HEAD BEARING
page 2-11. RACE REMOVER (Part No. HD-39301A) and UNIVER-
SAL DRIVER HANDLE (Part No. HD-33416).
9. Remove rear shock. See REAR SHOCK ABSORBER,
10. Remove rider footrests. See FOOTRESTS, REMOVAL
CLEANING/INSPECTION
on page 2-52. 1. Clean all components in solvent and blow dry. Carefully
inspect all bearing components for wear and/or corro-
11. Remove air cleaner assembly. See AIR CLEANER,
sion. Replace complete bearing assembly if any compo-
REMOVAL in Section 4.
nent is damaged.
12. Remove carburetor. See CARBURETOR, REMOVAL in 2. Check that swingarm is not bent or twisted. Replace if
Section 4. damaged.
13. Remove muffler and exhaust header. See EXHAUST
SYSTEM, REMOVAL/DISASSEMBLY on page 2-50.
ASSEMBLY
14. Support engine under crankcase. Avoid pushing tie bar
1. See Figure 2-39. If necessary, draw new roller bearing
assembly upward.
cups (4) into swingarm using BEARING INSTALLATION
15. Place a crating strap between the engine cylinders and BOLT (Part No. B-35316-5) and STEERING HEAD
around the lift. Tighten crating strap until snug. BEARING RACE INSTALLER (Part No. HD-39302).
2-33
b0210x2x
5
4
3
2
1
1. Bearing adjusting bolt (2)

2. Swingarm seal (2)
3. Roller bearing (2)
9 8
4. Roller bearing cup (2)
5. Pivot shaft
6. Swingarm
7. Swingarm mount block
8. Pinch screw (2)
9. Isolator screw (2)
10. Rubber isolator (2)
Figure 2-37. Swingarm Assembly and Swingarm Mount Block
NOTE INSTALLATION
Timkin roller bearing assemblies should be replaced as a 1. Adjust swingarm preload. Using a scale as shown in Fig-
unit. Do not intermix components. Mark all components so ure 2-40. Preload should measure 3.5-5.5 lbs (1.6-
they may be correctly installed. 2.5 kg).
2. Coat bearing components with WHEEL BEARING 2. Remove both pinch screws (8). Apply LOCTITE
GREASE (Part No. HD-99855-89) and assemble. THREADLOCKER 242 (blue) to pinch screw threads.
3. Check that swingarm is centered between mounts.
1CAUTION Torque pinch screws (8) to 27-30 ft-lbs (36.6-40.7 Nm).
Pivot shaft (5) must be installed between inner races (3) 4. Install rubber isolators and bolts. See SECONDARY
or bearing failure can result. DRIVE BELT in Section 6.
3. Install a new swingarm seal (2) flush to the swingarm. 5. Attach tie bars to the frame in the following order. Torque
to 30-33 ft-lbs (40.7-44.7 Nm)
4. Apply LOCTITE ANTI-SEIZE LUBRICANT to pivot shaft
threads. a. Front tie bar. Clutch cable clamp holds cable on air
cleaner side of motor.
5. Install one bearing adjustment bolt (1) into pivot shaft (5). b. Top tie bar.
Bottom out the adjustment bolt.
c. Rear tie bar. Tie bar must be horizontal and below
6. Slide swingarm assembly into position. frame tab.
7. Slide pivot shaft assembly through mount block and 6. Install carburetor. See CARBURETOR, INSTALLATION
swingarm. Install the opposing bearing adjustment bolt in Section 4.
(1) using PIVOT SHAFT BEARING ADJUSTER (Part No. 7. Install muffler and exhaust header. See EXHAUST SYS-
B-41175). TEM, ASSEMBLY/INSTALLATION on page 2-50.
8. Tighten one pinch screw (8) into swingarm mount block. 8. Install air cleaner. See AIR CLEANER, INSTALLATION in
Do not tighten the other pinch screw (8) at this time. Section 4.
2-34
5702 5701
Figure 2-38. Removing Roller Bearing Cups Figure 2-39. Installing Bearings into Swingarm
9. Install rear shock. See REAR SHOCK ABSORBER,

b0250x2x
10. Install rear brake caliper assembly. See REAR BRAKE
CALIPER, INSTALLATION on page 2-26.
11. Install rear wheel. See REAR WHEEL, INSTALLATION Acceptable preload is
on page 2-13. 3.5-5.5 lbs (1.6-2.5 kg)
12. Install rider footrests. See FOOTRESTS, INSTALLATION
on page 2-52.
13. Install rear fender. See FENDERS, REMOVAL/INSTAL-
LATION on page 2-54.
14. Connect and fill lubrication system. See ENGINE LUBRI- Pivot Shaft Bearing
CATION SYSTEM in Section 1. Adjuster (Part No. B-41175)
1WARNING
Always connect positive battery cable first. If the positive
sion resulting in personal injury and/or property damage.
1CAUTION
Hold battery cable when tightening battery terminal hard-
15. Connect battery cables, positive cable first.
1WARNING
during vehicle operation and startle the rider, causing Figure 2-40. Adjusting Swingarm Preload
16. Install tail section, fuel tank and seat. See TAIL SEC-
TION, INSTALLATION on page 2-55.
2-35
REAR SHOCK ABSORBER
GENERAL 5541a
See Figure 2-41. The rear suspension features a WP Suspen- 2 3
sion shock absorber. The shock adjusts for compression and
rebound damping as well as spring preload.
1
The most important rear shock adjustment is the preload set-
ting. Before making any suspension adjustments, set the
proper preload. This procedure can be found under SUSPEN-
SION ADJUSTMENTSon page 2-39. 4
NOTE
Rear shock absorber contains no user serviceable parts. 1. Rear allen screw and locknut (metric)
2. Rear reservoir clamp
3. Front reservoir clamp
REMOVAL 4. Front allen screw and locknut (metric)
1. Lift rear wheel off ground using REAR WHEEL SUP- Figure 2-41. Rear Shock Mounting Hardware
PORT STAND (Part No. B-41174).
2. Remove seat, fuel tank and tail section. See TAIL SEC- 5129a
TION, REMOVAL on page 2-55.
3. Support motorcycle frame with a floor hoist such as the
CENTRAL HYDRAULICS FOLDING CRANE.
4. See Figure 2-41. Use a flex socket and extension to Hydraulic press
remove allen screw on front reservoir clamp (3).
5. Remove allen screw and locknut (4) (metric) on front Rear Shock Compressing
mounting point. Tool (Part No. B-41178-A)
6. Remove allen screw and locknut (1) (metric) on rear
mount while supporting shock absorber.
7. Loosen rear reservoir clamp (2).
8. Remove shock absorber assembly.
DISASSEMBLY Rear drawing

ring
1WARNING Preload adjusting
The following steps require using a press. Wear eye pro- nuts (metric)
tection and make certain set-up is stable. The force
involved could cause parts to “flyout” at great speeds
causing personal injury. Front drawing ring
1. See Figure 2-42. Place rear shock absorber in a hydrau-
lic press with REAR SHOCK COMPRESSING TOOL
(Part No. B-41178-A) on rear drawing ring.
2. Apply pressure to compress shock spring. Loosen and
remove preload adjusting nuts (metric).
3. Release pressure. Remove REAR SHOCK COM-
PRESSING TOOL (Part No. B-41178-A) and shock from
press.
Figure 2-42. Compressing Rear Shock
4. See Figure 2-43. Remove rear drawing ring (2).
5. Remove support ring (3) and bump rubber (4).
6. Remove circlip (5) on end of shock cartridge.
7. Remove steel spring retainer (6).
8. Remove spring (7).
2-36
ASSEMBLY INSTALLATION
1. See Figure 2-43. Install spring (7). 1. See Figure 2-41. Loosely install reservoir clamps (2, 3).
2. Install steel spring retainer (6). 2. With banjo bolt facing upward, place shock in mounts and
3. Install circlip (5) on end of shock cartridge. loosely install front allen screw and locknut (4) (metric).
4. Install bump rubber (4) and support ring (3). 3. Loosely install rear allen screw and locknut (1) (metric).
Tighten reservoir clamp hardware (2, 3).
1WARNING
The following steps require using a press. Wear eye pro- 4. Tighten front and rear allen screws (1, 4) (metric) to 40-
tection and make certain set-up is stable. The force 45 ft-lbs (54.2-61.0 Nm).
involved could cause parts to “flyout” at great speeds
causing personal injury. 1WARNING
5. See Figure 2-42. Place rear shock absorber in a hydrau- After installing seat, pull upward on front of seat to be
lic press with REAR SHOCK COMPRESSING TOOL sure it is locked in position. If seat is loose, it could shift
(Part No. B-41178-A) on rear drawing ring. during vehicle operation and startle the rider, causing
6. Apply pressure to compress shock spring. Install rear
preload adjusting nuts (metric). 5. Install tail section, fuel tank and seat. See TAIL SEC-
7. Release pressure. Remove REAR SHOCK COM- TION, INSTALLATION on page 2-55.
PRESSING TOOL (Part No. B-41178-A) and shock from 6. Check rear shock preload. See SUSPENSION ADJUST-
press. MENTS on page 2-39.
2
8
3
4
5 1. Preload adjusting nut
6 (2) (metric)
2. Drawing ring, rear
14 13 3. Support ring
15 7 4. Bump rubber
12 5. Circlip
3
6. Spring retainer (steel)

9 7. Spring
10 8. Rod (2)
9. Spring retainer (nylon)
12 10. Drawing ring, front
11. Shock mount and
hardware
12. Seal (4)
16
11 13. Bushing (2)
17 14. Heim joint (2)
15. Adaptor bushing (2)
16. Clamp
17. Clamp w/nut and
b0213x2x washer
Figure 2-43. Rear Shock
2-37
SUSPENSION THEORY
DEFINITIONS 5572
● Compression: Suspension is compressed when the

wheel moves upward.
● Damping: Resistance to movement. Damping affects

how easily the suspension can move and limits oscilla-
tion of the system once movement has begun.
● Preload: The spring is compressed somewhat during

assembly. This initial compression provides a “loaded”
condition in the spring. This compression is referred to as 7 adjustments
preload.
● Rebound: The suspension is rebounding when it is mov- Figure 2-44. Rear Shock Rebound Adjuster
ing back from being compressed.
5571
GENERAL 12 adjustments
1WARNING
Before evaluating and adjusting suspension settings,
check the motorcycle’s tires. Tires must be in good con-
dition and properly inflated. Failure to check the tires
may cause personal injury.
See Figure 2-44 and Figure 2-45. The rear suspension fea- Figure 2-45. Rear Shock Compression Adjuster
tures a WP Suspension shock absorber that adjusts for com-
pression and rebound damping as well as spring preload. 5542
See Figure 2-46. The front suspension uses WP Suspension

inverted forks that adjust for compression and rebound damp-
ing. These forks offer strength and stiffness for improved slid-
ing action, better shock absorption and compliance with the
road.
If the preload adjustment is correct, and you have the

rebound and compression damping set at the factory recom-
mended points the motorcycle should handle and ride prop-
erly. If you are unhappy with these settings they can be Front fork rebound Front fork compression
changed according to the following procedures. damping adjuster damping adjuster
Figure 2-46. Front Fork Adjusters

NOTE
Evaluating and changing the rebound and compression

damping is a very subjective process. Many variables affect
motorcycle handling under different circumstances. Changes
should be approached carefully.
2-38
SUSPENSION ADJUSTMENTS
REAR SHOCK PRELOAD 5540

Rear shock spring preload must be adjusted before any other
adjustments can be attempted. This adjustment assures the
rear suspension has the proper amount of travel for the rider’s
weight. This setting should be made before the motorcycle is Rear turn signal
ridden any distance. Your Buell dealer can assist you with rear mounting bolt
shock spring preload settings.
Improper preload will adversely affect both the handling and
the ride of the motorcycle. Correct setting of preload will
result in a motorcycle that suits the rider’s size and weight.
You will need three people to carry out this adjustment. Rear axle nut
1. Verify correct front and rear tire pressure. See SPECIFI-
CATIONS on page 2-1.
bag and/or saddlebags.
3. Take the motorcycle off the side stand and bounce the Figure 2-47. Checking Rear Preload
is free and not binding.
4. See Figure 2-47. Measure the distance from the center
of the rear axle nut to the rear turn signal mounting bolt
without rider/passenger/cargo/accessories on the motor-
cycle.
6. Bounce a few times on the seat to be sure the suspen-
ment with the vehicle fully loaded (rider/passenger/lug- Preload adjusting
gage/cargo). The assistant should help balance the nuts (metric)
rests. Figure 2-48. Adjusting Rear Preload
19.1 mm). If it is not, you will have to adjust the spring
preload.
1CAUTION
● Be sure to apply the same number of turns to each
mechanical preload adjusting nut to ensure that the
end plates do not become misaligned. Misaligned
end plates will cause the shock absorber spring to
bind against the adjustment rods.
● Be sure the plates are parallel within 1/64 in. (0.4 mm).
Misaligned end plates will cause the shock absorber
spring to bind against the adjustment rods.
9. See Figure 2-48. Change the spring preload by adjusting
the mechanical preload adjusting nuts (metric) on the
rods that connect the end plates.
2-39
ADJUSTMENTS b0206x2x
Evaluating and changing the rebound and compression

damping is a very subjective process. A good performing sus-
pension finds a proper balance between spring, spring pre- R
EB
C
OM
load, damping, track conditions and riding speed. However,
all settings are at best a compromise. If a rider fails to find a
good set-up, go back to the factory recommended settings
and start over again.
Make all suspension adjustments in one or two click incre- Left fork leg adjuster- Right fork leg adjuster-
Rebound damping Compression damping
ments. Adjusting more than one or two clicks at a time may
cause you to skip the best adjustment. Test ride after each
FRONT FORK ADJUSTMENTS
adjustment. When an adjustment makes no difference, return
to the previous adjustment and try a different approach. Increase rebound/compression (slower):
Turn appropriate adjuster clockwise.
To find the optimum settings you will need the preload prop-
erly adjusted, the tires properly inflated and a familiar bumpy
Decrease rebound/compression (faster):
road. It is useful if the road contains a variety of different
Turn appropriate adjuster counterclockwise.
bumps from small sharp bumps such as potholes or frost
heaves to large undulations. Begin the process by putting all Figure 2-49. Fork Adjustments
the damping adjustments at the factory recommended set-
tings. Ride the bike over a variety of different surfaces and
bumps at different speeds. When the suspension is set prop- TROUBLESHOOTING
erly the motorcycle will be stable and comfortable. The following tables list possible suspension and operating
troubles and their probable causes. Use the tables to keep
Rear Suspension Adjustments your motorcycle in good operating condition.
Beyond the rear preload adjustment, the rear shock can also When making adjustments, remember there are two medi-
be adjusted for rebound and compression damping. However, ums in setting up a bike, geometry and suspension. Both
it is important to note the rear preload must be set correctly components work together because suspension is a part of
before performing any other adjustments. geometry. In order to solve handling problems, it is important
to diagnose the problem’s true nature. Chattering, sliding or
See Table 2-6. The compression damping adjuster has 11 an uncomfortable feeling are suspension problems. Handling
possible settings. Adjust compression damping by using the and a swinging fork are geometric problems, but often these
black dial at the rear of the shock. Position #1 sets the mini- problems can be solved by suspension adjustments.
mum amount of compression damping. This is the softest set-
ting. Position #11 maximizes compression damping. The
1WARNING
factory recommended setting is Position #5. This section is intended solely as a guide to diagnosing
problems. Carefully read the appropriate sections of this
The rebound damping adjuster has 7 possible settings. manual before performing any work. Improper suspen-
Changes are made using the dial on the remote nitrogen res- sion adjustments may cause loss of control and personal
ervoir. When set to Position #1, the rear shock exhibits mini- injury.
mum rebound damping. At this setting, the shock will have a
very fast rebound. Position #7 sets the rear shock to maxi- Table 2-6. Factory Recommended
mum rebound damping. The factory recommended setting is Suspension Settings
Position #3.
RANGE IN FACTORY SEE
Front Suspension Adjustments PART
CLICKS SETTING FIGURE
See Table 2-6. The fork compression damping adjuster on Rear shock
right fork leg has 28 positions. Position #20 is the factory rec- 7 3 Figure 2-44.
rebound
ommended setting.
Rear shock
The fork rebound adjuster on the left fork leg has 28 positions. 11 5 Figure 2-45.
compression
Position #12 is the factory recommended setting.
Front fork
28 12 Figure 2-46.
See Figure 2-49. To set the forks to their factory recom- rebound
mended setting, turn the adjusters clockwise until they lock.
Then turn the knobs counterclockwise the recommended 12 Front fork
28 20 Figure 2-46.
or 20 positions. A higher number of clicks increases damping. compression
2-40
Table 2-7. General Suspension Problems
TROUBLESHOOTING CONDITION ADJUSTMENT SOLUTION
Bike wallows through turns. Increase rebound damping.
Feels loose or vague after bumps.
Wheel tends to “pogo” after passing over a bump. This is noticeable
by watching the bike continue to bounce as it travels over multiple
bumps.
Wheel responds to bump, but doesn’t return to ground quickly after Reduce rebound damping.
bumps. This is more pronounced over a series of bumps and is
often referred to as “packing down.”
The bike bottoms out or dips while cornering. Increase compression damping.
Bike has excessive brake dive.
Harsh ride particularly over washboard surfaces. Reduce compression damping.
Bumps kick through handlebars or seat.
Suspension seems not to respond to bumps. This is evidenced by
tire chattering (a movement with short stroke and high frequency)
through corners or by jolting the rider over rough roads.
Table 2-8. Rear Suspension Problems

“Pumping on the Rear” occurs when you are accelerating out of a 1. The shock is too soft. Increase compression
corner. This problems occurs in two varieties. damping. If the adjuster is already set to the maxi-
1. The first type has a movement with a long stroke and a high mum, add more preload to the spring (one turn
frequency. maximum).
2. The second version has a movement with a short stroke and 2. In this case the shock is too hard. Decrease com-
high frequency. pression damping.
Chattering during braking. Decrease the compression damping. If the problem

persists, decrease rebound damping for a faster
rebound rate. Less spring preload may also help.
Lack of tire feedback. The suspension is too soft. Increase compression
damping.
Sliding during cornering. Sliding may occur going into the corner or The suspension is too hard. Decrease compression
accelerating out of the corner. damping.
Table 2-9. Front Suspension Problems

Not absorbing bumps. A good suspension is a balance between damping and
track condition. Finding this balance requires exploring
all possible compression settings.
Lack of tire feedback. Increase compression damping.
Tire slides. Decrease compression damping.
2-41
Table 2-10. Rider Suspension Preferences
NOTE
All adjustments require rear shock preload to be properly adjusted for the rider’s size and weight. For information on setting rear
shock preload, see SUSPENSION ADJUSTMENTS, REAR SHOCK PRELOAD in this section.
FRONT FORK FRONT FORK REAR SHOCK REAR SHOCK

DATE RESULTS
REBOUND COMPRESSION COMPRESSION REBOUND
Position #12 Position #20 Position #5 Position #3 Factory recommended

settings.
2-42
THROTTLE CONTROL
1. See Figure 2-50. Slide rubber boot (5) off the cable
adjusters (2). Loosen jam nut (metric) on each adjuster.
2. Remove two screws (1) (metric). Separate housings from 1
handlebar.
3. See Figure 2-51. Unhook ferrules (7) from cable wheel (8).
4. Remove cables from under cable guide (6).
5. Remove cables from housings (5, 9) by loosening cable
5
adjusters (2) (metric).
7. Disconnect cables from carburetor.
8. Remove cables from motorcycle. 2 4
3
CLEANING, INSPECTION 1. Screws (2) (metric) 4. Throttle control cable

2. Cable adjusters (2) 5. Rubber boot
AND REPAIR 3. Idle control cable
Clean all parts in a non-flammable cleaning solvent. Blow dry Figure 2-50. Throttle Control Cables
with compressed air. Replace cables if frayed, kinked or bent.
5719
ASSEMBLY/INSTALLATION 3 10
4
1. See Figure 2-51. Screw cable assemblies (3, 4) into
housings (5, 9). Throttle control cable (4) has a larger fit- 2
ting end and is positioned inside the front housing (5).
Idle control cable (3) has a smaller fitting end and is posi-
tioned inside the rear housing (9).
2. Run cables in grooves on cable guide (6). 9 5
6 1
3. Attach ferrules (7) to cable wheel (8). When properly
assembled, notches for ferrules will be at 12 o’clock.
4. Position housings on right handlebar by engaging locat-
ing pin (10) on front housing with hole in handlebar.
Attach housings with screws (1) (metric). Tighten to 12- 8 7
17 in-lbs (1.4-1.9 Nm).
5. Route idle and throttle control cables.
a. Cables must be routed forward from throttle control 1. Screws (2) (metric) 6. Cable guide
grip, forward of upper triple clamp and down and to 2. Cable adjusters (2) 7. Ferrules
the left. 3. Idle control cable 8. Cable wheel
4. Throttle control cable 9. Rear housing
b. Continue between side of frame steering head and 5. Front housing 10. Locating pin
left frame tube. Cables should be above and to the
left of the D-shaped washer behind the steering Figure 2-51. Cable Connections
head.
c. Route cables below the fuel tank and above the horn
mount. Continue downward to carburetor.
6. Install idle control cable into longer, inboard cable guide
on carburetor.
7. Install throttle control cable into shorter, outboard cable
guide on carburetor.
8. Adjust throttle cables. See CARBURETOR, CABLE
ADJUSTMENT in Section 1.
9. Install air cleaner. See AIR CLEANER, INSTALLATION
in Section 4.
2-43
CLUTCH CONTROL
ADJUSTMENT Clutch Hand Control

See CLUTCH in Section 1. 1. See Figure 2-53. Detach clutch switch (7) as follows.
a. Remove screw (8).
REMOVAL/DISASSEMBLY b. Depress clutch lever and hold.
c. Detach switch by depressing switch trigger button
Clutch Cable – Lower and pulling switch towards the end of the handlebar.
NOTE
The individual parts of the clutch switch are not serviceable.
Replace switch upon failure.
2. See Figure 2-52. Remove four TORX screws (1) with
washers and clutch inspection cover (2). Do not damage 2. Remove bolt (2) (metric) and nut (6) (metric).
or dislodge quad ring (14) in primary cover (11). 3. Remove handlever from clutch clamp (5). Detach clutch
3. Slide spring (3) with attached hex lockplate (4) from flats cable from handlever.
of adjusting screw (12). 4. Slide clutch cable out of wire guide (10) on right fork leg.
4. Turn adjusting screw clockwise to release ramp and cou- 5. Remove clutch cable clamp (11) from frame.
pling mechanism. As the adjusting screw is turned, ramp 6. Remove clutch clamp as follows.
assembly moves forward. Unscrew nut (5) from end of
adjusting screw. a. Cut off left handgrip.
5. Remove hook of ramp (6) from button at the rear of cable b. Remove left handlebar switch housing. See HAN-
end coupling (16). Remove cable end (10) from slot in DLEBAR SWITCHES in Section 7.
coupling. c. Detach mirror mounting hardware (metric, left hand
6. Turn cable end fitting (9) counterclockwise to remove threads).
clutch cable lower section from primary cover (11). d. Remove clamp screw (4) (metric). Slide clamp off
Remove O-ring (8) from cable end fitting. the end of the handlebar.
1. TORX screw with washer (4) b0131x6x
2. Clutch inspection cover 11

3. Spring
4. Adjusting screw lockplate
5. Nut 12
6. Outer ramp
10
7. Ball (3)
8. O-ring
9. Cable end fitting
10. Clutch cable end 9
11. Primary cover
12. Clutch adjusting screw
assembly
8
13. Retaining ring
14. Quad ring
7
6
15. Inner ramp 5
16. Coupling 4
2 3
13
1
14
15
NOTE
16 Outer ramp (6) and coupling (16) configura-
tion may vary. See CLUTCH in Section 1.
2-44
ASSEMBLY/INSTALLATION b0221x2x
Clutch Cable – Lower

1. See Figure 2-52. Install O-ring (8) over cable end fitting
(9) of clutch cable lower section. Turn fitting clockwise to
install into primary cover (11). Tighten fitting to 3-5 ft-lbs
(4.0-6.8 Nm).
2. Fit coupling (16) over cable end. Place hook of ramp
around coupling button and rotate assembly counter-
3
clockwise until tang on inner ramp (15) fits in slot of pri-
mary cover (11).
3. Thread nut (5) on adjusting screw (12) until slot of screw
is accessible with a screwdriver. Fit nut hex into recess of
outer ramp (6) and turn adjusting screw counter-clock- 1
2
wise.
4
4. If not yet performed, route clutch cable from hand grip
across front of upper triple clamp to right side, down
between right fork leg and steering neck above lower tri-
ple clamp. Continue down to left side of bike through 7)
clamp along primary chaincase to clutch. 5 tch(
6 i
sw
5. With clutch cable upper section connected to clutch 9 ve
lever, adjust primary chain tension. See PRIMARY emo
R
CHAIN in Section 1. 7
6. Adjust clutch. See CLUTCH in Section 1. 8
Clutch Hand Control

1. See Figure 2-53. Attach clutch clamp (5) as follows.
a. Slide clamp over handlebar.
11
b. Install left switchgear housing. See HANDLEBAR
SWITCHES in Section 7.
c. Place clamp next to switchgear housing. Fasten to
handlebar with screw (4) (metric). Tighten screw to
30-35 in-lbs (3.4-4.0 Nm). 10
1. Clutch handlever 7. Clutch switch
d. Install mirror parallel to handlebars. Mirror mount
2. Bolt (metric) 8. Screw
has metric, left hand threads.
3. Mirror assembly 9. Clutch cable
e. Install a new left handgrip. See HANDLEBAR, 4. Screw (metric) 10. Wire guide
INSTALLATION on page 2-49. 5. Clutch clamp 11. Cable clamp
6. Nut (metric)
2. Connect end of clutch cable upper section to clutch han-
dlever. Position lever within clutch clamp. Figure 2-53. Clutch Hand Control
3. Apply small amount of LOCTITE ANTI-SEIZE LUBRI-
CANT to bolt (2). Secure handlever with bolt (2) (metric)
and nut (6) (metric).
4. Attach clutch switch (7) with screw (8).
5. If not yet performed, route clutch cable from hand grip
across front of upper triple clamp to right side, down
between right fork leg and steering neck above lower tri-
ple clamp. Continue down to left side of bike through
clamp along primary chaincase to clutch.
6. With clutch cable lower section connected to primary
cover, adjust clutch. See CLUTCH in Section 1.
2-45
SPEEDOMETER AND TACHOMETER
GENERAL 5716
Replace the speedometer or tachometer if the unit is not 2
working properly. These instruments are not repairable. How-
1
ever, before replacing the instrument check that the problem
is not caused by a faulty cable or loose wire connection.
4
REMOVAL
3
Speedometer
1. Detach windscreen from mounts. See WINDSCREEN,
5
2. See Figure 2-54. Loosen and remove the speedometer
cable (5) from the speedometer. 6
3. Remove nuts and lockwashers (4) from speedometer
cover (1).
1. Speedometer cover 4. Nut and lockwasher (3)
4. Straighten reset cable cotter pin and remove. Discard 2. Tachometer cover 5. Speedometer cable
pin. Detach reset cable assembly from speedometer. 3. Windscreen mount 6. Odometer reset cable
5. Remove cover. Remove wires from clamp inside cover.
Figure 2-54. Instruments
6. Detach ground wire.
7. See Figure 2-55. Disconnect wire terminals from back of 2. Attach ground wire with screw and lockwasher.
speedometer. Pull bulbs (3) from bores. 3. Connect wire terminals on back of speedometer. Insert
8. Remove speedometer (1) through front of instrument bulbs into bores at back of speedometer.
support (8).
4. See Figure 2-54. Using a new cotter pin, connect reset
Tachometer cable assembly (6) to speedometer.
1. Detach windscreen from mounts. See WINDSCREEN, 5. Place speedometer cover over speedometer. Tighten
REMOVAL on page 2-56. nuts and lockwashers (4).
2. See Figure 2-54. Remove nut and lockwasher (4) from 6. Connect speedometer cable (5) to speedometer.
tachometer cover (2).
7. Attach windscreen. See WINDSCREEN, INSTALLATION
3. Remove nut on windscreen mount (3). Remove wind- on page 2-56.
screen mount from tachometer cover.
4. Remove tachometer cover. Tachometer
5. Remove ground wires from bottom stud. 1. See Figure 2-55. If removed, install instrument support
6. See Figure 2-55. Disconnect wire terminals from back of (8). Slide tachometer into instrument support (8).
tachometer. Pull bulbs (3) from bores. 2. Connect wire terminals on back of tachometer. Insert
7. Remove tachometer (2) through front of instrument sup- bulbs into bores.
port (8). 3. Attach ground wire.
Instrument Support 4. See Figure 2-54. Slide tachometer cover (2) over
1. Remove speedometer and tachometer. tachometer. Install nut and lockwasher (4).
2. See Figure 2-55. Remove knurled nut (5), washer (6) and 5. Install windscreen mount (3) with nut.
odometer reset cable. 6. Attach windscreen. See WINDSCREEN, INSTALLATION
3. Pull indicator lights assembly (4) out towards the head- on page 2-56.
lamp. Pull bezel (19) out towards the tail lamp.
4. Remove two screws (7).
Instrument Support
5. Remove instrument support. 1. See Figure 2-55. Attach instrument support to mounts
using two screws (7). Tighten screws to 7-9 ft-lbs (9.5-
12.2 Nm).
INSTALLATION
2. Install odometer reset cable using washer (6) and
Speedometer knurled nut (5).
1. See Figure 2-55. If removed, install instrument support 3. Insert bezel (19) through instrument support. Attach indi-
(8). Slide speedometer into instrument support. cator lights assembly (4) to bezel.
2-46
b0214x2x
1 3
5 8
6
11
19
9
12
11 14
7 10
17 13
15
18
16
14
15
1. Speedometer 8. Instrument support 15. Nut (2)

2. Tachometer 9. Odometer reset cable 16. Wire guide
3. Bulb 10. Cotter pin 17. Speedometer drive
4. Indicator light assembly 11. Rubber cushion (2) 18. Speedometer cable
5. Knurled nut 12. Speedometer cover 19. Indicator lamp bezel
6. Washer 13. Tachometer cover
7. Screw (2) 14. Lockwasher (3)
Figure 2-55. Speedometer and Tachometer
2-47
SPEEDOMETER CABLE 5575
Cable Cleaning, Inspection

and Lubrication
Clip on headlamp
Clean, inspect and lubricate speedometer cable every 5000
miles (8000 km). Proceed as follows:
1. See Figure 2-56. Examine speedometer cable housing
(outer sheathing) for kinks or other damage. Replace
entire cable assembly if any damage is noted.
2. Detach windscreen from mounts. See WINDSCREEN,
3. Loosen and remove the speedometer cable assembly
from the speedometer. Wire guide
4. Carefully withdraw inner speedometer cable from its
housing. Exercise caution to avoid stretching coils of
inner cable. Outer cable housing remains attached to
speedometer drive unit.
5. Carefully wipe off old lubricant from inner cable. Inspect
cable coils for bends, bulges, discoloration or other
defects. Replace entire cable assembly if any damage or
defect is noted.
Speedometer
6. Apply a good quality graphite grease to entire length of
cable housing
inner cable. Wipe off excess grease.
7. Insert inner cable fully into its housing, rotating inner
Figure 2-56. Speedometer Cable
cable somewhat to allow its lower end to engage with
speedometer drive unit. Inner cable will no longer rotate
once engaged with drive unit.
8. Insert pin of speedometer cable into receptacle at back
of speedometer. Tighten to secure cable.
9. Attach windscreen. See WINDSCREEN, INSTALLATION
on page 2-56.
Speedometer Drive Unit

See the procedures listed under FRONT WHEEL starting on
page 2-8.
2-48
HANDLEBAR
REMOVAL b0220x2x
1. Remove front brake master cylinder. See FRONT

BRAKE MASTER CYLINDER, REMOVAL on page 2-19. 1
2. Remove left and right handlebar switch housings. See
HANDLEBAR SWITCHES in Section 7.
3. Cut left handlebar grip and remove. 2
4. Remove instrument support. See SPEEDOMETER AND
TACHOMETER on page 2-46.
3
5. Loosen four screws (1) on upper handlebar clamp (2).
6. Move handlebar towards the air cleaner to increase clutch 5
cable freeplay. Remove clutch control. See CLUTCH 4
CONTROL, REMOVAL/DISASSEMBLY on page 2-44.
7. Remove four screws (1), upper handlebar clamp (2) and
handlebars (3). 6
8. Remove four bolts (8), lockwashers (7) and washers (6)
7
to detach lower handlebar clamps (4, 5) from upper triple 8
clamp.
1. Screw (4) 5. Lower left handlebar
2. Upper handlebar clamp
INSTALLATION clamp 6. Washer (4)
3. Handlebar 7. Lockwasher (4)
1. Install lower handlebar clamps (4, 5) with four bolts (8), 4. Lower right handlebar 8. Bolt (4)
lockwashers (7) and washers (6). Tighten to 30-33 ft-lbs clamp
(40.7-44.7 Nm).
2. Install clutch control. See CLUTCH CONTROL, ASSEM- Figure 2-57. Handlebars
BLY/INSTALLATION on page 2-45.
3. Install handlebar (3) using upper handlebar clamp (2)
and four screws (1). Tighten screws to 10-12 ft-lbs (13.6-
16.2 Nm).
4. Install instrument support. See SPEEDOMETER AND
TACHOMETER on page 2-46.
5. Install left and right handlebar switch housings. See
HANDLEBAR SWITCHES in Section 7.
6. Install a new left handgrip.
a. Clean end of handlebar with M600.
b. Place LOCTITE 411 ADHESIVE around inside of
grip.
c. Push grip onto handlebar end. Twist grip on bar until
end touches left switchgear housing.
d. Wipe off excess adhesive with a rag.
7. Install front brake master cylinder. See FRONT BRAKE
MASTER CYLINDER, INSTALLATION on page 2-19.
2-49
EXHAUST SYSTEM
REMOVAL/DISASSEMBLY 3. Coat inside of muffler inlet with PERMATEX ULTRA-

COPPER HIGH TEMP RTV SILICON GASKET material.
Muffler
4. Place a new muffler clamp (14) over slotted end of muf-
1. See Figure 2-58. Remove bolts (2), locknuts (9) and fler. Place muffler and clamp on end of exhaust header.
washers (6) from rear muffler supports (19). Loosely tighten clamp.
2. Remove bolt (3) and locknut (9) from muffler support (15).
3. Loosen muffler clamp (14). NOTE
4. Loosen screw (1) on header tiebar (26).
If necessary, use a fiber hammer to fit muffler on header.
5. Remove muffler (13) and muffler clamp. Discard clamp.
6. Remove muffler/header supports (15, 19) as follows: 5. Install bolt (3) and locknut (9). Tighten to 22-25 ft-lbs
a. Remove bolts (4), locknuts (9) and washers (21). (29.8-33.9 Nm).
b. Remove rear muffler mounts (24) and mount spac-
ers (20). 1WARNING
c. Remove bolts (5), locknuts (10) and washers (7).
Before tightening muffler hardware, position muffler to
d. Remove muffler support (15). Remove front muffler
provide adequate clearance from rear shock absorber
mounts (25) and mount spacer.
and side stand spring post. Failure to provide adequate
clearance may cause personal injury during motorcycle
Exhaust Header operation.
1. See Figure 2-58. Remove muffler as described above.
2. Remove screw (1), locknut (11) and washers (27) from 6. Install rear mounting bolts (2), washers (6), and locknuts
header tiebar (26). (9). Tighten to 22-25 ft-lbs (29.8-33.9 Nm).
3. Using a SNAP-ON SWIVEL SOCKET (Part No.
PFSX916), remove nuts (8) from front and rear cylinder 7. Tighten muffler clamp (13) to 50-55 ft-lbs (67.8-74.6 Nm).
head exhaust studs.
4. Remove exhaust header clamps (18), exhaust clamp
retaining rings (17) and exhaust port gaskets (16). Exhaust Header
5. Remove exhaust header (12).
1. See Figure 2-58. Install new exhaust port gaskets (16),
6. Remove heat shield clamps (23) and heat shield (22)
exhaust clamp retaining rings (17), exhaust header
from exhaust header.
clamps (18), and nuts (8). Loosely tighten nuts with
SNAP-ON SWIVEL SOCKET (Part No. PFSX916).
2. Install screw (1) with washers (27) and locknut (11).
Muffler Tighten to 5-7 ft-lbs (6.8-9.5 Nm).
1. See Figure 2-58. If removed, install exhaust header (12). 3. Place a new muffler clamp (14) over slotted end of muf-
2. If removed, install muffler/header supports (15, 19). fler. Place muffler and clamp on end of exhaust header
(20). Loosely tighten clamp.
a. Hold rear muffler mounts (24), mount spacers (20)
and muffler supports (19) in place. Fasten with bolts
(4), locknuts (9), washers (21). Tighten to 12-15 ft- 4. Tighten manifold nuts (8) to 6-8 ft-lbs (8.1-10.8 Nm).
lbs (16.3-20.3 Nm).
b. Fasten muffler support (15) to crankcase with bolts 5. Tighten muffler clamp (13) to 50-55 ft-lbs (67.8-74.6 Nm).
(5), washers (7) and locknuts (10). Tighten to 30-33
ft-lbs (40.7-44.7 Nm).
6. If removed, install heat shield (22) with heat shield
c. Install front muffler mounts (25) and mount spacer. clamps (23).
2-50
b0212x2x
24
9
19
21 5
21 20 7
4 15
7
9 6 2
6 25
10
20
25
16 13
17
18
8
14
22
11
26 27
23
12
27
1
1. Screw 11. Locknut 20. Mount spacer (3)
2. Bolt (2) 12. Exhaust header 21. Washer (4)
3. Bolt 13. Muffler 22. Heat shield
4. Bolt (2) 14. Muffler clamp 23. Heat shield clamp (2)
5. Bolt (2) 15. Muffler support 24. Rear muffler mount (2)
6. Washer (4) 16. Exhaust port gasket (2) 25. Front muffler mount (2)
7. Washer (5) 17. Exhaust clamp retaining 26. Header tiebar
8. Nut (4) ring (2) 27. Washer (2)
9. Locknut (5) 18. Exhaust header clamp (2)
10. Locknut (2) 19. Muffler support (2)
Figure 2-58. Exhaust System
2-51
FOOTRESTS
REMOVAL b0215x2x
1. See Figure 2-59. Remove locknut (1) and bolt (2).
2. Remove footrest.
a. Detach passenger footrests (3) from frame.

1
b. Detach rider footrests (4) from footrest mounts (5).
3. If necessary, remove bolts (10) and washers (9) to

remove footrest mounts from frame.
NOTE
Brake pedal and shift lever must be removed with footrest

mounts. See REAR BRAKE MASTER CYLINDER in this sec- 3 2
8
tion and PRIMARY COVER in Section 6 or more information. 1 5
10
9
INSTALLATION
1. See Figure 2-59. Install passenger footrests with bolts (2)
2 6 7
and locknuts (1). Tighten securely. 4
NOTE
1. Locknut (4) 6. Thrust washer (2)
Tighten bolts (2) so footrests are tight, but not binding. 2. Bolt (4) 7. Rear brake pedal
3. Passenger footrest (2) 8. Bushing (2)
2. If removed, install footrest mounts (5). 4. Rider footrest (2) 9. Washer (2)
5. Footrest mount (2) 10. Bolt (2)
a. Assemble brake pedal with bushing (8) on the inside
Figure 2-59. Footrests, Right Side
and thrust washer (6) on the outside. Fasten brake
pedal to frame with bolt (10), washer (9) and footrest
mount.
b. Assemble shift lever with bushing on the inside and

thrust washer on the outside. Fasten shift lever to
frame with bolt, washer and footrest mount.
3. Install rider footrests with bolts (2) and locknuts (1).

Tighten securely.
4. Adjust shift lever and brake pedal for smooth operation.
2-52
SPROCKET COVER
REMOVAL/DISASSEMBLY b0204x2x
1. See Figure 2-60. Remove nut (1) and washer (2).

9
2. Remove two screws (3).
3. Remove sprocket cover screw (5), washer (6) and

spacer (8). 8
4. Remove swingarm drive/support (4) and sprocket cover
(7) as an assembly.
5. Remove two screws (9) to separate sprocket cover from

6 7
5
swingarm/drive support.
3
1. See Figure 2-60. If removed, attach sprocket cover to 2

swingarm/drive support with two screws (9). Tighten 1
1. Nut 5. Sprocket cover crew
2. Install sprocket cover assembly with screw (5), washer (6) 2. Washer 6. Washer
and spacer (8). Tighten screw to 4-6 ft-lbs (5.4-8.6 Nm). 3. Screw (2) 7. Sprocket cover
4. Swingarm/drive 8. Spacer
3. Install screws (3). Tighten to 20-25 ft-lbs (27.1-33.9 Nm).
support 9. Screw (2)
4. Install nut (1) and washer (2). Tighten nut to 30-35 ft-lbs Figure 2-60. Sprocket Cover
(40.7-47.4 Nm).
2-53
FENDERS
REMOVAL/INSTALLATION b0216x2x
Front Fender
1
1. Raise front wheel off ground with FRONT WHEEL SUP-
PORT STAND (Part No. B-41395) and S1 LIFT
ADAPTER (Part No. B-41686). 2 5 6
PER, REMOVAL/DISASSEMBLY on page 2-20. 7
3. See Figure 2-61. Remove lower fender mounting screws
(8) (metric), washers (9) and plastic spacers (6).
4
4. Remove upper fender mounting screws (3), washers (4), 3
wire guides (5), plastic spacers (6) and locknuts (7). 9
5. Carefully remove fender (1) from between front forks.
6
6. Install in reverse order.
8
a. Tighten upper fender mounting screws (3) to 20-25
in-lbs (2.3-2.8 Nm). 1. Front fender 6. Plastic spacer (4)
2. Reflector (2) 7. Locknut (2)
b. Tighten lower fender mounting screws (8) (metric) to 3. Screw (2) 8. Screw (2) (metric)
10-15 in-lbs (1.1-1.7 Nm). 4. Washer (2) 9. Nylon washer (2)
5. Wire guide (2)
Rear Fender/Lower Belt Guard Figure 2-61. Front Fender
1. See Figure 2-62. Unplug connector (10)
b0218x2x
2. Remove screws (13) and nylon washers (2) on right side 3
to detach lower belt guard (11). 2 4
3. Remove shoulder bolts (7), washers (8) and grommets
(9) on left side.
4. Remove rear fender (6) from swingarm. 1 5

5. Install in reverse order. 6
Frame Heat Shield 7
8
1. Remove seat and tail section. See TAIL SECTION,
REMOVAL on page 2-55. 1. Torx screw (3)
2. Nylon washer (5)
2. See Figure 2-62. Remove screws (1), nylon washers (2) 3. Clamp 9
and locknut (4). 4. Locknut
3. Remove frame heat shield (5).
5. Frame heat shield 13
6. Rear fender
4. If necessary, remove clamp (3). 7. Shoulder bolt (2) 11
8. Washer (2) 2 10
5. Install in reverse order. 9. Grommet (2)
10. Connector 12
11. Lower belt guard
12. Well nut (3)
13. Torx screw (3)
Figure 2-62. Rear Fender, Lower Belt Guard

and Heat Shield
2-54
TAIL SECTION
REMOVAL b0217x2x
1. See Figure 2-63. Loosen seat wing screw (1). Remove 4

seat by pulling up and back. 5
2
3
2. Remove two screws (4) and nylon washers (3).
3. Loosen fuel tank screw (6).
4. Lift fuel tank (8) and withdraw tail section.

6
7
NOTE
See FUEL TANK, REMOVAL in Section 4 for information on

removing fuel tank from frame. 1
8
INSTALLATION
1. Seat wing screw 5. Seat
1. Place tail section on frame so mounting holes align with 2. Tail section 6. Screw
holes on frame. 3. Nylon washer (2) 7. Washer
4. Torx screw (2) 8. Fuel tank
2. See Figure 2-63. Install two screws (4) and nylon wash- Figure 2-63. Tail Section
ers (3).
NOTE
If fuel tank was removed, see FUEL TANK, INSTALLATION in

Section 4.
3. Tighten screw (6) to 9-11 ft-lbs (12.2-14.9 Nm).
1WARNING
4. Place seat on tail section. Tighten wing screw.
2-55
WINDSCREEN
REMOVAL 5724
1. See Figure 2-64. Remove two screws and nylon washers

on each side.
2. Detach windscreen from center bracket on tachometer Screws and

cover. Remove windscreen. nylon washers
3. If necessary, remove the three windscreen brackets.
a. See Figure 2-65. Remove center windscreen

bracket by removing nut on tachometer cover.
b. While holding headlamp, remove left and right head-

lamp adjusting screws (metric). Slide windscreen
brackets from between headlamp housing and
headlamp brackets.
Figure 2-64. Windscreen, Right Side

INSTALLATION
1. If removed, install the three windscreen brackets. 5723
a. See Figure 2-65. Install center bracket using nut. 1

b. Install left and right brackets between headlamp
housing and headlamp brackets. Tighten headlamp
adjusting screws (metric) 6-8 ft-lbs (8.1-10.8 Nm).
2. Align windscreen on right, left and center brackets.

Attach windscreen to center bracket velcro strip.
3. See Figure 2-64. Install two screws and nylon washers

on each side.
2 3
1. Center bracket with 2. Right bracket

nut and velcro strip 3. Left bracket
Figure 2-65. Windscreen Brackets
2-56
SEAT
REMOVAL 5725
1. See Figure 2-66. Detach seat from frame by loosening

the wing screw underneath the tail section.
2. Remove seat by pulling up and back.
INSTALLATION
1. See Figure 2-67. Install seat by sliding the metal locating
tab on the underside of the seat into the opening on the
motorcycle.
Figure 2-66. Seat Wing Screw

1WARNING
After installing seat, pull upward on front of seat to be 5722

2. See Figure 2-66. Fasten seat to frame with wing screw.

Tighten securely.
Tab
Opening
Figure 2-67. Seat Mount
2-57
SIDE STAND
GENERAL b0219x2x
The side stand is located on the left side of the motorcycle.

The side stand swings outward to support the motorcycle for
parking.
3
2
Test the side stand in the following manner. Without vehicle 1
weight resting on it, side stand should move freely into
extended (down) and retracted (up) positions.
REMOVAL/DISASSEMBLY
1. See Figure 2-68. Remove spring (6) from side stand and
8
4
spring pin (5).
2. Remove retaining clip (7) and pivot pin (8). Detach side
stand from frame.
3. Remove screw (2) and side stand dragger (1).
4. Remove bumper (3) from frame.
7
6
5
ASSEMBLY/INSTALLATION 1. Side stand dragger 5. Spring pin
1. See Figure 2-68. Attach bumper (3) to frame. 2. Screw 6. Spring
3. Bumper 7. Retaining clip
2. Attach side stand dragger (1) to side stand with screw (2).
4. Side stand 8. Pivot pin
3. Install side stand using pivot pin (8) and retaining clip (7).
Figure 2-68. Side Stand
4. Connect spring (6) to side stand and spring pin (5).
1WARNING
● If the side stand is not in the full forward position
when vehicle weight is rested on it, the vehicle could
fall over, possibly causing personal injury.
● Always park motorcycle on a level, firm surface.
Vehicle weight could cause motorcycle to fall over,
possibly causing personal injury.
● Be sure side stand is fully retracted before riding the
motorcycle. If side stand is not fully retracted during
vehicle operation, it could contact the road surface
causing a momentary disturbance before retracting.
This momentary disturbance could distract the rider,
possibly causing loss of vehicle control and per-
sonal injury.
2-58
3
SPECIFICATIONS
GENERAL ENGINE IGNITION SPECIFICATIONS
Number of cylinders 2 Timing during engine

5° BTDC
cranking
Type 4-cycle, 45°V Twin
Timing with engine at
Horsepower 91 @ 5800 RPM
RPM listed below and 20° BTDC
Torque (foot-pounds) 87 @ 5200 RPM V.O.E.S. connected
Compression ratio 10.0 to 1 Regular idle 950-1050 1150-1250
RPM RPM
Bore 3.500 in. 88.9 mm
(49 State) (Calif.)
Stroke 3.812 in. 96.82 mm
Fast idle (all models) 2000 RPM
Piston displacement 73.4 in.3 1203 cc
Spark plug gap 0.038-0.045 in. 0.96-1.14 mm
Oil tank capacity with filter 2.1 quarts 1.90 liters
NOTE
Service wear limits are given as a guideline for measuring components that are not new. For measurements not given under
SERVICE WEAR LIMITS, see NEW COMPONENTS.
ITEM NEW COMPONENTS SERVICE WEAR LIMITS
VALVE
Fit in Exhaust 0.0015-0.0033 in. 0.038-0.084 mm 0.0040 in. 0.102 mm
guide Intake 0.008-0.0026 in. 0.020-0.066 mm 0.0035 in. 0.089 mm
Seat width 0.040-0.062 in. 1.02-1.57 mm 0.090 in. 2.29 mm
Stem protrusion from
1.975-2.011 in. 50.17-51.08 mm 2.031 in. 51.59 mm
cylinder valve pocket
OUTER VALVE SPRING
Free length 2.105-2.177 in. 53.47-55.30 mm 2.105 in. (min) 53.47 mm (min)
Intake 1.751-1.848 in.
72-92 lbs 32.6-41.7 kg
(closed)
1.286-1.383 in.
183-207 lbs 82.9-93.8 kg
(open)
Exhaust 1.751-1.848 in.
72-92 lbs 32.6-41.7 kg
(closed)
1.332-1.429 in.
171-195 lbs 77.5-88.3 kg
(open)
INNER VALVE SPRING
Free length 1.926-1.996 in. 48.92-50.70 mm 1.926 in. (min) 48.92 mm (min)
Intake 1.577-1.683 in.
38-49 lbs 17.2-22.2 kg
(closed)
1.112-1.218 in.
98-112 lbs 44.4-50.7 kg
(open)
Exhaust 1.577-1.683 in.
38-49 lbs 17.2-22.2 kg
(closed)
1.158-1.264 in.
91-106 lbs 41.2-48.0 kg
(open)
3-1
ROCKER ARM
Shaft fit in bushing (loose) 0.0005-0.0020 in. 0.013-0.051 mm 0.0035 in. 0.089 mm
End clearance 0.003-0.013 in. 0.08-0.33 mm 0.025 in 0.64 mm
Bushing fit in rocker arm (tight) 0.004-0.002 in. 0.10-0.05 mm
ROCKER ARM SHAFT
Shaft fit in rocker cover (loose) 0.0007-0.0022 in. 0.018-0.056 mm 0.0035 in. 0.089 mm
PISTON
Compression ring gap
0.007-0.020 in. 0.18-0.51 mm 0.032 in. 0.81 mm
(top and 2nd)
Oil control ring rail gap 0.009-0.052 in. 0.23-1.32 mm 0.065 in 1.65 mm
Compression Top 0.0020-0.0045 in. 0.051-0.114 mm 0.0065 in. 0.165 mm
ring side
2nd 0.0016-0.0041 in. 0.041-0.104 mm 0.0065 in. 0.165 mm
clearance
Oil control ring side clearance 0.0016-0.0076 in. 0.041-0.193 mm 0.0094 in. 0.239 mm
Pin fit
0.00005-0.00045 in. 0.0013-0.0114 mm 0.00100 in. 0.0254 mm
(loose, at room temperature)
CYLINDER HEAD
Valve guide in head (tight) 0.0033-0.0020 in. 0.084-0.051 mm
Valve seat in head (tight) 0.0035-0.0010 in. 0.089-0.025 mm
Head gasket surface (flatness) 0.006 in. total 0.15 mm total 0.006 in. total 0.15 mm total
CYLINDER
Taper 0.002 in. 0.05 mm
Out of round 0.003 in. 0.08 mm
Warpage Top 0.006 in. 0.15 mm
(gasket surfaces) Base 0.008 in. 0.20 mm
Bore diameter Standard 3.4978 in. 88.844 mm 3.5008 in. 88.920 mm
± 0.0002 in. 0.005 OS 3.502 in. 88.95 mm 3.505 in. 89.03 mm
0.010 OS 3.507 in. 89.08 mm 3.510 in. 89.15 mm
OS=over size 0.020 OS 3.517 in. 89.33 mm 3.520 in. 89.41 mm
0.030 OS 3.527 in. 89.59 mm 3.530 in. 89.66 mm
CONNECTING ROD
Piston pin fit (loose) 0.00125-0.00175 in. 0.0318-0.0445 mm 0.00200 in. 0.0508 mm
Side play between flywheels 0.005-0.025 in. 0.13-0.64 mm 0.030 in. 0.76 mm
Fit on crankpin (loose) 0.0004-0.0017 in. 0.010-0.043 mm 0.0027 in. 0.069 mm
TAPPET
Fit in guide 0.0008-0.0023 in. 0.020-0.058 mm 0.003 in. 0.08 mm
Roller fit 0.0006-0.0013 in. 0.015-0.033 mm
Roller end clearance 0.008-0.022 in. 0.203-0.599 mm 0.026 in. 0.660 mm
OIL PUMP
Oil pressure at 1000 RPM 7-12 PSI 0.5-0.8 kN/cm2
normal operating
temperature 2500 RPM 10-17 PSI 0.7-1.2 kN/cm2
Shaft to pump clearance 0.0025 in. 0.064 mm

Feed/scavenge inner/outer
0.003 in. 0.08 mm 0.004 in. 0.10 mm
gerotor clearance
3-2
GEARCASE
Cam gear shaft in
0.0007-0.0022 in. 0.018-0.056 mm 0.003 in. 0.08 mm
bushing (loose)
Cam gear shaft end play
0.005-0.024 in. 0.13-0.61 mm 0.025 in. 0.64 mm
(min) (except rear intake)
Rear intake cam gear shaft
0.006-0.024 in. 0.15-0.61 mm 0.040 in. 1.02 mm
end play (min)
FLYWHEEL
Runout Flywheels at rim 0.000-0.010 in. 0.00-0.25 mm 0.010 in. 0.25 mm
Shaft at
0.000-0.002 in. 0.00-0.05 mm 0.002 in. 0.05 mm
flywheel end
End play 0.001-0.005 in. 0.025-0.13 mm 0.005 in. 0.13 mm
SPROCKET SHAFT BEARING
Outer race fit in
0.0004-0.0024 in. 0.010-0.061 mm
crankcase (tight)
Bearing inner race fit
0.0002-0.0015 in. 0.005-0.038 mm
on shaft (tight)
PINION SHAFT BEARINGS
Pinion shaft jounal diameter 1.2496-1.2500 in. 31.740-31.750 mm 1.2496 in. (min) 31.375 mm (min)
Outer race diameter in
1.5646-1.5652 in. 39.741-39.756 mm 1.5672 in. (max) 39.807 mm (max)
right crankcase
Bearing running clearance 0.00012-0.00088 in. 0.0030-0.0224 mm
Fit in cover bushing
0.0023-0.0043 in. 0.058-0.109 mm 0.0050 in. 0.127 mm
(loose)
3-3
ITEM TORQUE NOTES
Crank pin nut 150-185 ft-lbs 203-251 Nm LOCTITE 620 RETAINING COMPOUND, page 3-59
Crankcase 1/4 in. screws 70-110 in-lbs 7.9-12.4 Nm page 3-63
Crankcase 5/16 in. screws 15-18 ft-lbs 20-24 Nm page 3-63
Crankcase cover screws 80-110 in-lbs 9.0-12.4 Nm special pattern to tighten, page 3-46
Cylinder head screws See note special pattern to tighten, page 3-20
Cylinder studs 10 ft-lbs 13.6 Nm install shoulder end down, page 3-63
Front isolator to 98.9-105.7
73-78 ft-lbs LOCTITE THREADLOCKER 262 (red), page 3-19
cylinder head bolt Nm
Front sprocket nut 150-165 ft-lbs 203-224 Nm LOCTITE THREADLOCKER 262 (red), page 3-63
135.6-149.1
Isolator bolt, front 100-110 ft-lbs page 3-10
Nm
135.6-149.1
Isolator bolts, side 100-110 ft-lbs LOCTITE THREADLOCKER 262 (red), page 3-10
Nm
Oil filter adapter 8-12 ft-lbs 11-16 Nm LOCTITE THREADLOCKER 242 (blue), page 3-37
Oil pressure signal light switch 5-7 ft-lbs 7-9 Nm page 3-37
Oil pressure switch wire nut 4-10 in-lbs 0.4-1.1 Nm page 3-37
125-150
Oil pump cover screws 14.1-16.9 Nm page 3-36
in-lbs
125-150
Oil pump mounting screws 14.1-16.9 Nm page 3-36
in-lbs
Pinion shaft nut 35-45 ft-lbs 47-61 Nm LOCTITE THREAD-LOCKER 262 (red), page 3-46
Rocker box bolts 10-13 ft-lbs 13.6-18 Nm page 3-21
Rocker box cover screws 10-13 ft-lbs 13.6-18 Nm page 3-21
Rocker box screws 90-120 in-lbs 10.2-13.6 Nm page 3-21
Rocker box to head bolts 15-18 ft-lbs 20-24 Nm 2 sizes, page 3-21
Swingarm mount 92.2-101.7
68-75 ft-lbs page 3-10
block bolts, lower Nm
Swingarm mount
41-45 ft-lbs 55.6-61.0 Nm page 3-10
block bolts, upper
Tappet plate screw 80-110 in-lbs 9.0-12.4 Nm page 3-20, page 3-39
Tappet retainer screw 11-15 ft-lbs 20-24 Nm page 3-20, page 3-39
Tie bar bolts 30-33 ft-lbs 40.7-44.7 Nm front tie bar uses LOCITITE PST SEALANT, page 3-10
3-4
ENGINE
GENERAL FUEL
The V2 EvolutionTM engine is a two-cylinder, four-cycle, air- Gasoline/alcohol Blends
cooled, overhead-valve V-twin. It has three major component
assemblies. Buell motorcycles were designed to obtain the best perfor-
mance and efficiency using unleaded gasoline (91 pump
octane or higher). Some fuel suppliers sell gasoline/alcohol
Cylinder blends as a fuel. The type and amount of alcohol added to the
fuel is important.
The cylinder assembly includes cylinder head, valves, rocker
arm cover, rocker arms and piston. Cylinders mount on the ● DO NOT USE GASOLINES CONTAINING METHANOL.
crankcase in a 45 degree “V” with both connecting rods con- Using gasoline/methanol blends will result in starting and
nected to a single crank pin. driveability deterioration and damage to critical fuel sys-
tem components.
Crankcase ● ETHANOL is a mixture of 10% ethanol (Grain alcohol)

and 90% unleaded gasoline. Gasoline/ethanol blends
can be used in your motorcycle if the ethanol content
The up-and-down motion of the piston in the cylinder is con-
does not exceed 10%.
verted to circular motion in the crankcase. The multi-piece
crankshaft consists of a crank pin mounted between two ● Gasolines containing ETHER: Gasoline/ether blends are
counterweighted flywheels, which rotate on two end shaft a mixture of gasoline and as much as 15% ether. Gaso-
bearings. The lower end of the rear cylinder connecting rod is line/ether blends can be used in your motorcycle if the
forked to fit around the single-end front cylinder connecting ether content does not exceed 17%.
rod, allowing a single connecting rod crank pin connection to
● REFORMULATED OR OXYGENATED GASOLINES
the flywheel.
(RFG): “Reformulated gasoline” is a term used to
describe gasoline blends that are specifically designed to
Gearcase burn cleaner than other types of gasoline, leaving fewer
“tailpipe” emissions. They are also formulated to evapo-
The gearcase is located on the right side of the crankcase. rate less when you are filling your tank. Reformulated
The gearcase houses the gear train, which operates and gasolines use additives to “oxygenate” the gas. Your
times the valves and ignition. The cam gear train, consisting motorcycle will run normally using this type of gas. Buell
of four cam shafts with one cam lobe on each shaft, is gear recommends you use it when possible, as an aid to
driven. The engine valves are opened and closed through the cleaner air in our environment.
mechanical linkage of tappets, push rods and rocker arms. Because of their generally higher volatility, these blends may
Hydraulic lifters, located in the tappets, automatically com- adversely affect the starting, driveability and fuel efficiency of
pensate for heat expansion to maintain the no-lash fit of valve your motorcycle. If you experience these problems, Buell rec-
train components. Tappets serve to transmit the cam action to ommends you operate your motorcycle on straight, unleaded
the valve linkage. Valve timing is obtained by aligning timing gasoline.
marks when installing cam gears.
Ignition spark is produced by the operation of a microproces- LUBRICATION

sor-controlled electronic ignition module, ignition coil, and The engine has a force-feed (pressure) type oiling system,
spark plugs. Spark timing is determined by a trigger rotor, incorporating oil feed and return pumps in one pump body,
magnetic sensing unit and vacuum-operated electric switch. with one check valve on the oil feed side. The feed pump
forces oil to the engine, lubricating lower connecting rod bear-
The trigger rotor has two openings which time the cylinders. ings, rocker arm bushings, valve stems, valve springs, push
rods and tappets. Cylinder walls, pistons, piston pins, timing
Both spark plugs fire simultaneously each crankshaft revolu- gears and bushings and main bearings are lubricated by oil
tion. The spark plug in the front cylinder will fire at the end of spray thrown off connecting rods and crankshaft, and by oil
that cylinder’s compression stroke, igniting the air/fuel mixture draining from each rocker box through an internal drain pas-
in the front cylinder. At the same instant, however, the spark sage in each cylinder and each tappet guide. A small amount
in the rear cylinder will fire ineffectually during the end of that of oil is sprayed through an oil galley jet onto the rear intake
cylinder’s exhaust stroke. During the next engine revolution, cam gear in the gearcase; oil is transferred to the teeth of all
the simultaneous firing of the spark plugs will occur during the the cam gears by way of the gear meshing action. The oil-
middle of the front cylinder’s exhaust stroke and at the end of scavenging section of the pump returns oil to the tank from
the rear cylinder’s compression stroke (igniting the air/fuel the engine. See LUBRICATION SYSTEM on page 3-28 for
mixture in the rear cylinder). further information.
3-5
ADJUSTMENT/TESTING Compression Test Procedure
Combustion chamber leakage can result in unsatisfactory
engine performance. A compression test can help determine
General the source of cylinder leakage. Use CYLINDER COMPRES-
SION GAUGE (Part No. HD-33223-1).
When an engine needs repair, it is not always possible to A proper compression test should be performed with the
determine definitely beforehand whether repair is possible engine at normal operating temperature when possible. Pro-
with only cylinder heads, cylinders and pistons disassembled ceed as follows:
or whether complete engine disassembly is required for
crankcase repair.
1CAUTION
After completing the compression test(s), make sure that
the throttle plate is in the closed position before starting
Most commonly, only cylinder head and cylinder repair is engine. Engine will start at an extremely high RPM if
needed (valves, rings, piston, etc.) and it is recommended throttle plate is left open.
procedure to service these units first, allowing engine crank-
case to remain in frame. 1. Disconnect spark plug wires. Clean around plug base
and remove plugs.
2. Connect compression tester to front cylinder.
See DISASSEMBLING ENGINE FOR CYLINDER HEAD
REPAIR on page 3-8 to strip motorcycle for removal of cylin- 3. With carburetor throttle plates in wide open position,
der heads, cylinders, and pistons. crank engine continuously through 5-7 full compression
strokes.
4. Note gauge readings at the end of the first and last com-
After disassembling “upper end” only, it may be found that pression strokes. Record test results.
crankcase repair is necessary. In this situation, remove the
engine crankcase from the chassis. See REMOVING ENGINE 5. Connect compression tester to rear cylinder.
CRANKCASE OR COMPLETE ENGINE on page 3-8.
6. Repeat Steps 3 and 4 on rear cylinder.
7. Compression is normal if final readings are 120 psi
1CAUTION (8.4 kgN/cm2) or more and do not indicate more than a
10 psi (0.7 kgN/cm2) variance between cylinders. See
Table 3-1.
If engine is removed from chassis, do not lay engine on
primary side. Placing engine on primary side will damage 8. Inject approximately 1/2 oz. (15 ml) of SAE 30 oil into
clutch cable end fitting. If fitting is damaged, clutch cable each cylinder and repeat the compression tests on both
must be replaced. cylinders. Readings that are considerably higher during
the second test indicate worn piston rings.
Symptoms indicating a need for engine repair are often mis-

leading, but generally, if more than one symptom is present, Table 3-1. Compression Test Results
possible causes can be narrowed down to make at least a
partial diagnosis. An above-normal consumption of oil, for DIAGNOSIS TEST RESULTS
example, could be caused by several mechanical faults. See
TROUBLESHOOTING in Section 1. However, when accom- Ring trouble. Compression low on first stroke;
panied by blue-gray exhaust smoke and low engine compres- tends to build up on the following
sion, it indicates the piston rings need replacing. Low strokes but does not reach normal;
compression by itself, however, may indicate improperly improves considerably when oil is
seated valves, in addition to or in lieu of worn piston rings. added to cylinder.
Valve trouble. Compression low on first stroke;
Most frequently, valves, rings, pins, bushings, and bearings does not build up much on follow-
need attention at about the same time. If the possible causes ing strokes; does not improve con-
can be narrowed down through the process of elimination to siderably with the addition of oil.
indicate any one of the above components is worn, it is best
to give attention to all of the cylinder head and cylinder parts. Head gasket leak. Same reaction as valve trouble.
3-6
Cylinder Leakage Test Table 3-2. Air Leakage Test
The cylinder leakage test pinpoints engine problems including
leaking valves, worn, broken or stuck piston rings and blown AIR LEAK LOCATION POSSIBLE CAUSES
head gaskets. The cylinder leakage tester applies com-
Carburetor intake. Intake valve leaking.
pressed air to the cylinder at a controlled pressure and vol-
ume, and measures the percent of leakage from the cylinder. Exhaust pipe. Exhaust valve leaking.
Use a CYLINDER LEAKDOWN TESTER (Part No. HD- Timing inspection hole. Piston rings leaking.
35667) and follow the specific instructions supplied with the Worn or broken piston.
tester. Worn cylinder.
The following are some general instructions that apply to Head gasket. Leaking gasket.
Buell motorcycle engines:
1. Run engine until it reaches normal operating tempera- Diagnosing Smoking Engine or High Oil
ture. Consumption
2. Stop engine. Clean dirt from around spark plugs and
Perform Compression or Cylinder Leakdown Test as
remove spark plugs.
described previously. If further testing is needed, remove sus-
3. Remove air cleaner and set carburetor throttle in wide pect head(s) and inspect the following:
open position.
● Valve guide seals.
4. Remove timing inspection plug from crankcase. ● Valve guide-to-valve stem clearance.
5. The piston, in cylinder being tested, must be at top dead ● Gasket surface of both head and cylinder.
center of compression stroke during test. ● Oil return passages for clogging.
6. To keep engine from turning over when air pressure is
applied to cylinder, engage transmission in fifth gear and
lock the rear brake.
7. Following the manufacturer’s instructions, perform a cyl-
inder leakage test on the front cylinder. Make a note of
the percent leakdown. Any cylinder with 12% leakdown,
or more, requires further attention.
8. Listen for air leaks at carburetor intake, exhaust, head
gasket and timing inspection hole. See Table 3-2.
NOTE
If air is escaping through valves, check push rod length.
9. Repeat procedure on rear cylinder.
1CAUTION
After completing the compression test(s), make sure that
the throttle plate is in the closed position before starting
engine. Engine will start at an extremely high RPM if
throttle plate is left open.
3-7
STRIPPING MOTORCYCLE FOR ENGINE REPAIR
DISASSEMBLING ENGINE FOR 5673
CYLINDER HEAD REPAIR

1. Lift and secure the motorcycle.
a. Place vehicle on a lift and anchor front wheel in Attach straps
place. Raise lift so the top of the cylinder head is to frame
easy to access.
Floor hoist
b. Raise rear wheel off lift using REAR WHEEL SUP-
1WARNING
1CAUTION Figure 3-1. Floor Hoist
Hold battery cable when loosening battery terminal hard-
ware. Failure to hold cable may cause battery damage. 8. Drain oil tank and remove oil filter. See ENGINE LUBRI-
CATION SYSTEM in Section 1.
2. Disconnect both battery cables, negative cable first.
9. Disconnect wire to oil pressure signal light switch. See
3. Remove seat and fuel tank. See FUEL TANK in Section 4. OIL PRESSURE SIGNAL LIGHT SWITCH on page 3-31.
4. Remove air cleaner assembly. See AIR CLEANER, 10. Detach feed, vent and return hoses from oil tank. See
REMOVAL in Section 4. OIL TANK on page 3-30.
5. Remove exhaust header. See EXHAUST SYSTEM in 11. Remove both rider footrests from frame. See FOOT-
Section 2. RESTS in Section 2.
6. Remove carburetor and manifold. See CARBURETOR, 12. Remove rear shock mounting bolt (metric) from swing-
REMOVAL in Section 4. arm. Allow rear shock to hang from front mount.
7. If removing front cylinder, remove ignition coil and horn. 13. Disconnect wiring. See Section 7.
See IGNITION COIL in Section 7.
a. Disconnect neutral switch wire from crankcase.
8. Disconnect spark plug cables.
b. Unplug ignition timer plate wires from wiring har-
NOTE ness.
At this stage, the lower rocker boxes, the cylinder heads and c. Disconnect 18-gauge green wire from starter motor.
the cylinders may be removed. See CYLINDER HEAD on
page 3-11. d. Disconnect regulator/rectifier from the alternator sta-
tor at the plug near the regulator. See VOLTAGE
REGULATOR in Section 7.
REMOVING ENGINE CRANKCASE e. Disconnect V.O.E.S. wire from ignition module.
OR COMPLETE ENGINE 14. Remove muffler. See EXHAUST SYSTEM in Section 2.
1. Perform the steps listed above. 15. See Figure 3-2. Place a wooden cradle underneath the
2. Remove tail section. See TAIL SECTION, REMOVAL in crankcase.
Section 2. 16. Place a crating strap between the engine cylinders and
3. See Figure 3-1. Place a floor hoist behind the lift. Attach around the lift. Tighten crating strap until snug.
straps to frame and hoist. Raise hoist until straps tighten. 17. See Figure 3-3. Remove engine ground strap (1) from
4. Detach clutch cable from handgrip. swingarm mount block.
5. Remove REAR FENDER/LOWER BELT GUARD and 18. Detach tie bars from frame mounts.
SPROCKET COVER. See Section 2. a. Remove rear tie bar using a swivel socket.
6. Remove rear caliper. See REAR BRAKE CALIPER in b. See Figure 3-4. Remove front tie bar (1) and clutch
Section 2. cable clamp.
7. Detach belt from rear sprocket and remove rear wheel. 19. Remove front isolator bolt (6), nut (9), D-washer (8) and
See REAR WHEEL in Section 2. washers (7).
3-8
b0202x3x
b0251x3x 2
1
1. Ground strap
2. Rear isolator
3. Swingarm mount
Crating 3 block bolts
strap (2, upper)
4. Swingarm mount
block bolts
(2, lower)
4 5. Rubber isolator (2)
6 5 6. Lockwashers (2)
7 7. Isolator bolts (2)
Figure 3-3. Rear Tie Bar Assembly

Figure 3-2. Supporting the Engine
20. See Figure 3-3. Remove isolator bolt (7) and lockwasher 1. Front tie bar
9 2. Spacer
(6) on each side.
3. Washer
8
4. Lockwasher
21. Slowly raise floor hoist until rubber isolators (5) can be 5. Tie bar bolt
removed. Frame will rise while engine remains secured 6. Front isolator bol
to lift by crating strap. 7 7. Washer (2)
8. D-washer
9. Nut
NOTE
Rubber isolators align with a frame mounted metal pin.
22. Raise frame and walk forward over and away from the
engine.
23. If necessary, remove rear swingarm. See SWINGARM in

Section 2.
24. If necessary, detach swingarm mount block from power- 2 1

train by removing bolts (3, 4), washers and locknuts.
3
4
5 7
b0201x3x 6
Figure 3-4. Front Tie Bar Assembly
3-9
INSTALLING THE ENGINE
ENGINE CRANKCASE INSTALLATION 18. Install rear brake caliper. See REAR BRAKE CALIPER in
Section 2.
1. See Figure 3-2. Place engine crankcase on supports so
frame may be installed over the top of the engine. 19. Attach disconnected wires. See Section 7.
2. See Figure 3-3. If removed, attach swingarm mount block a. Connect 18-gauge green wire to starter motor.
to engine. Install upper bolts (3), washers and locknuts b. Plug ignition switch assembly into main harness
finger tight. Install lower bolts (4), washers and locknuts plug.
finger tight. Tighten upper bolts to 41-45 ft-lbs (55.6-61.0 c. Plug regulator/rectifier into stator connection.
Nm) and lower bolts to 68-75 ft-lbs (92.2-101.7 Nm).
d. Attach ignition sensor to wire harness.
3. If removed, install swingarm. Adjust swingarm bearing
e. Connect V.O.E.S. to ignition module.
preload. See SWINGARM in Section 2.
f. Connect neutral switch.
4. Remove oil filter (if installed). Walk frame over powertrain.
g. Connect oil pressure switch wire.
5. See Figure 3-4. Install front isolator bolt. Attach front iso-
lator mount with bolt (6), washers (7), D-washer (8) and 20. Install REAR FENDER/LOWER BELT GUARD and
locknut (9). Tighten bolt finger tight. SPROCKET COVER. See Section 2.
21. Install footrests. See FOOTRESTS in Section 2.
1CAUTION
Isolator bolts must be tightened within 30 minutes of 22. Continue with the steps listed below.
applying LOCTITE THREADLOCKER. Failure to tighten
bolts within 30 minutes may cause LOCTITE to set.
ENGINE INSTALLATION AFTER
6. See Figure 3-3. Apply LOCTITE THREADLOCKER 262
(red) to side isolator bolts (7). Align pins on frame into CYLINDER HEAD REPAIR
holes in rubber isolators. Install bolts (7) and lockwash- 1. Install new oil filter, engine oil, and primary chaincase
ers (6) finger tight. lubricant as necessary. See Section 1.
1CAUTION 2. Install carburetor with intake manifold. See CARBURE-
Do not adjust tie bar assemblies. Tie bar tension is set at TOR, INSTALLATION in Section 4.
the factory. Any attempt at adjusting tension will cause 3. Install exhaust system as described under EXHAUST
damage to tie bars. Damaged tie bars must be replaced. SYSTEM in Section 2.
7. See Figure 3-3. Attach rear tie bar assembly (2). Install 4. Install air cleaner assembly. See AIR CLEANER,
bolt, lockwasher, and washer on swingarm mount block. INSTALLATION in Section 4.
Install bolt and locknut on frame. Tighten bolts to 30-33 5. If removed, install horn and ignition coil. See Section 7.
ft-lbs (40.7-44.7 Nm).
6. Connect spark plug cables. See SPARK PLUG CABLES
8. Attach top center tie bar assembly. Install bolt, washer, in Section 7.
front tie bar spacer and locknut on ignition mount. Install
bolt and locknut on frame. Tighten bolts to 30-33 ft-lbs 1WARNING
(40.7-44.7 Nm). Always connect positive battery cable first. If the positive
9. See Figure 3-4. Attach front tie bar assembly to engine. installed, the resulting sparks may cause a battery explo-
Install bolt (5), lockwasher (4), washer (3) and front tie sion producing personal injury.
bar spacer (2).
10. See Figure 3-3. Tighten the two side isolator bolts (7) to
1CAUTION
100-110 ft-lbs (135.6-149.1 Nm). Hold battery cable when tightening battery terminal hard-
11. See Figure 3-4. Tighten front isolator bolt (6) to 100-110
ft-lbs (135.6-149.1 Nm). 7. Install battery. Connect battery cables, positive first.
12. Connect feed, return and vent lines to oil tank. See OIL 8. Install tail section, fuel tank and seat. See TAIL SEC-
HOSE ROUTING on page 3-29. Use new hose clamps. TION in Section 2.
13. Attach battery ground strap to swingarm mount block. 9. If engine crankcase installation was performed:
14. Attach clutch cable to handlebar lever. a. Adjust belt according to REAR BELT DEFLECTION
in Section 1.
15. Remove strap from between engine cylinders. Using a
floor hoist, lift motorcycle by the frame and remove the b. Adjust rear shock spring preload. See REAR PRE-
wooden cradle from underneath the crankcase. LOAD ADJUSTMENT in Section 1.
16. Install rear shock. See REAR SHOCK ABSORBER, c. Adjust clutch lever. See CLUTCH in Section 1.
INSTALLATION in Section 2. Remove floor hoist straps. d. Check rear brake pedal freeplay. See BRAKES in
17. Install rear wheel and attach secondary drive belt. See Section 1.
REAR WHEEL, INSTALLATION in Section 2. 10. Check all electrical components for proper operation.
3-10
CYLINDER HEAD
REMOVAL 1CAUTION
All washers and fasteners used in the V2TM engine are
Before removing the cylinder head assembly, see DISAS- hardened. Do not mix or replace hardened washers and
SEMBLING ENGINE FOR CYLINDER HEAD REPAIR on fasteners with unhardened parts. Do not reuse fiber
page 3-8. The rocker arm covers and internal components cover seals. These actions may result in accelerated wear
must be removed before removing cylinder heads. and increased noise.
1. See Figure 3-5. Remove screws (1) and fiber seals (2). 2. Remove top (4) and middle (5) sections of rocker box.
Discard fiber seals. Remove and discard gaskets (6, 7 and 8).
xlhrock
1
2
3
6
12
8 10 1. Screws (4)
14 13 2. Fiber seal (4)
3. Umbrella Valve (2)
4. Upper rocker cover
5. Middle rocker cover
11 6. Gasket
19
7. Gasket
8. Gasket
9. Rocker arm shafts
10. Rocker arm
11. Rocker arm
18 12. Bolt and washer (2)
9 13. Bolt and washer (2)
15 14. Screw and washer (2)
15. Bolt and washer (3)
16. Gasket
17 17. Gasket
18. Lower rocker arm cover
16 19. Rocker arm bushing (8)
Figure 3-5. Rocker Arm Cover
3-11
3. Rotate crankshaft until both valves are closed on head
being repaired. 5698
Position of rocker
arm retaining bolts
4. Remove two 5/16 in. rocker arm retaining bolts (12) at
push rod end.
5. Remove remaining fasteners and washers (13, 14 and
15) holding lower rocker arm cover to cylinder head.
6. Remove lower rocker cover (18).
NOTE
Retaining notch
Remove lower rocker boxes as an assembly; then disassem-
ble as required.
1CAUTION
Mark rocker arm shafts for reassembly in their original
positions. Valve train components must be reinstalled in
their original positions to prevent accelerated wear and
increased valve train noise. Figure 3-6. Removing Rocker Arm Shafts
7. See Figure 3-6. Remove rocker arm shafts by tapping
them out using a hammer and a soft metal punch. 5740
8. See Figure 3-5. Remove rocker arms (10, 11); mark

them for reassembly in their original locations.
1CAUTION
Distortion to the head, cylinder and crankcase studs may
result if head screws are not loosened (or tightened)
gradually in the sequence shown in Figure 3-8.
9. See Figure 3-8. Loosen each head screw 1/8-turn follow-

ing the sequence shown.
1CAUTION
See Figure 3-7. Do not attempt to remove the front isola-
tor mount from front cylinder head. Isolator mount is an
integral component and is not meant to be removed Figure 3-7. Front Isolator Mount Warning
unless absolutely necessary. Repeated removals and
installations will damage cylinder head threads.
5112 2857a
3
1
1 3
2
4
2 4
Front cylinder Rear cylinder
Figure 3-8. Head Screw Loosening/Tightening Sequence
3-12
.
xlhcylhead
7
8
5
6
1 11
9
7
8 16
5
6 5
11
9
16
2
17
18
10
1. Head screw, long (2)
2. Head screw, short (2) 17
3. Arrow, piston direction
4. Head gasket 4
5. Inner valve spring (2) 10
6. Outer valve spring (2)
7. Valve keeper (4)
8. Upper collar (2)
9. Lower collar (2) 14
10. Valve (1 intake, 1 exhaust)
11. Valve stem seal (2) 12
15
12. Stud (4)
13. Base gasket 3
14. O-ring (2) 19
15. Insert/Dowel (2)
16. Valve guide (2)
17. Valve seat (2)
18. Cylinder head 20
19. Cylinder 13
20. Piston
Figure 3-9. Cylinder Head, Cylinder and Piston
10. Support motorcycle under front header mount. Do not DISASSEMBLY

allow engine to drop when performing Step 11.
11. Continue loosening in 1/8-turn increments until screws NOTE
are loose. Remove screws and thick washers. Disassembly of front cylinder exhaust valve components
12. See Figure 3-9. Remove cylinder head (18), head gasket requires front isolator mount removal.
(4), and O-rings (14). 1. See Figure 3-9. Compress valve springs (5, 6) with
NOTE VALVE SPRING COMPRESSOR (Part No. HD-34736B)
Front cylinder must be removed through upper triangular (as shown in Figure 3-11.)
frame members with front isolator mount attached. 2. Remove keepers (7), upper collar (8) and springs (5, 6).
13. See Figure 3-10. Remove socket screws (11), washers Mark keepers for reassembly in original position.
(13), and retainers (9). Remove push rod covers (7), 3. Use a fine tooth file to remove any burrs on the valve
seals (8), O-rings (10) and push rods (12). Mark the loca- stem at the keeper groove.
tion and orientation (top and bottom) of each push rod.
4. Mark valve to ensure that it will be reassembled in the
14. Remove socket screw (5), washer (14) and plate (4).
same head. Remove valve (10), valve stem seal (11) and
Remove O-rings (3) from ends of pins (2). Grasp pins (2)
lower collar (9).
and pull from crankcase. Use a pliers if necessary.
Remove lifter from crankcase bore. 5. Repeat Steps 1-5 for the other valve.
15. Repeat Steps 1-13 for the other head. 6. Disassemble the other head following Steps 1-6.
3-13
b0134x3x 5694
7
12
10
6
1 11
Valve Spring Compressor
13 (Part No. HD-34736B)
9 Figure 3-11. Compressing Valve Springs
4 2767a
15
14
5
2
3
1. Right 8. Seal (2)

crankcase half 9. Retainer (2)
2. Pin (2) 10. O-ring (2)
3. O-ring (2) 11. Screw (2)
4. Plate 12. Push rod (2)
5. Screw 13. Washer (2)
6. Tappet lifter (2) 14. Washer
7. Push rod cover (2) 15. Locating pin (2)
Figure 3-10. Middle Valve Train Components

(Quantities per Engine Cylinder)
AND REPAIR Figure 3-12. Measuring Rocker Arm Shaft Diameter
1. Bead blast or scrape carbon from head, top of cylinder (Rocker Cover Position)
and valve ports. Be careful to avoid scratching or nicking
cylinder head and cylinder joint faces. Blow off loosened 5. See Figure 3-12 and Figure 3-13. Measure rocker arm
carbon or dirt with compressed air. shaft diameter at the positions where shaft fits in lower
2. Soak cylinder head in an aluminum-compatible cleaner/ rocker arm cover and where rocker arm bushings ride.
solvent to loosen carbon deposits. Record the measurements.
3. Wash all parts in non-flammable solvent, followed by a 6. See Figure 3-14 and Figure 3-15. Measure rocker arm
thorough washing with hot, soapy water. Blow out oil pas- shaft bore diameter in lower rocker cover and rocker arm
sages in head. Be sure they are free of sludge and car- bushing inner diameter. Record the measurements.
bon particles. Remove loosened carbon from valve head
and stem using a wire wheel. Never use a file or other 7. Check the clearances and measurements obtained in
hardened tool which could scratch or nick valve. Polish Steps 5 and 6 against the SERVICE WEAR LIMITS.
valve stem with very fine emery cloth or steel wool. Repair or replace parts exceeding the SERVICE WEAR
LIMITS.
4. Check each rocker arm, at pad end and push rod end, for
uneven wear or pitting. Replace rocker arm if either con- 8. Assemble rocker arms and rocker arm shafts into lower
dition exists. rocker cover.
3-14
2768a 2770a
Figure 3-13. Measuring Rocker Arm Shaft Diameter

(Rocker Arm Bushing Position)
Figure 3-15. Measuring Rocker Arm Bushing
5699 Inner Diameter
diameter and valve guide inner diameter. Check mea-

surements against SERVICE WEAR LIMITS.
15. Inspect spark plug threads for damage. If threads in head
are damaged, a special plug type insert can be installed
using a 12 mm spark plug repair kit.
16. Inspect valve springs for broken or discolored coils.
17. See Figure 3-16. Check free length and compression
force of each spring. Compare with SPECIFICATIONS. If
spring length is shorter than specification, or if spring
compression force is below specification, replace spring.
Figure 3-14. Measuring Rocker Arm Shaft Bore 18. Examine push rods, particularly the ball ends. Replace
Diameter in Lower Rocker Cover any rods that are bent, worn, discolored, or broken.
19. See Figure 3-17. Check head gasket surface on head for
9. Check end play of rocker arm with feeler gauge.
flatness. Machine or replace any head which exceeds
10. Replace rocker arm or lower cover or both if end play SERVICE WEAR LIMIT of 0.006 in. (0.15 mm).
exceeds 0.025 in. (0.63 mm).
11. Valve heads should have a seating surface width of Rocker Arms and Bushings
0.040-0.062 in. (1.02-1.57 mm), and should be free of pit
marks and burn spots. The color of carbon on exhaust 1. See Figure 3-18. To replace worn bushings, press or
valves should be black or dark brown. White or light buff drive them from the rocker arm. If bushing is difficult to
carbon indicates excessive heat and burning. remove, turn a 9/16-18 tap into bushing. From opposite
side of rocker arm, press out bushing and tap.
12. Valve seats are also subject to wear, pitting, and burning.
They should be resurfaced whenever valves are refin- 2. Press replacement bushing into rocker arm, flush with
ished. arm end, and split portion of bushing towards top of arm.
13. Clean valve guides by lightly honing with VALVE GUIDE 3. Using remaining old bushing as a pilot, line ream new
HONE (Part No. HD-34723). bushing with ROCKER ARM BUSHING REAMER (Part
No. HD-94804-57).
14. Scrub guides with VALVE GUIDE BRUSH (Part No. HD-
34751) and hot soapy water. Measure valve stem outer 4. Repeat for other end of rocker arm.
3-15
2771a 2411a
9/16 in. -18 tap
Figure 3-16. Checking Spring Free Length
5700
Gasket surface flat
within 0.006 in. (0.15 mm)
Figure 3-18. Removing Rocker Arm Bushing
3. Measure outer diameter of a new standard valve guide.

The guide diameter should be 0.0020-0.0033 in. (0.051-
0.084 mm). larger than bore in head. If it is not, select
one of the following oversizes: +0.001 in., +0.002 in., or
Figure 3-17. Checking Gasket Surface +0.003 in. (+0.025, +0.05 +0.08 mm) (intake and
exhaust).
Replacing Valve Guides 4. See Figure 3-19. Install shoulderless guides using
VALVE GUIDE INSTALLATION TOOL (Part No. HD-
Valve guide replacement, if necessary, must be done before 34731) and DRIVER HANDLE (Part No. HD-34740).
valve seat is ground. It is the valve stem hole in valve guide Press or drive guide until the tool touches the machined
that determines seat grinding location. Valve stem-to-valve surface surrounding the guide. At this point, the correct
guide clearances are listed in Table 3-3. If valve stems and/or guide height has been reached.
guides are worn beyond service wear limits, install new parts.
5. Ream guides to final size or within 0.0010 in. (0.025 mm)
of final size using VALVE GUIDE REAMER (Steel, Part
Table 3-3. Valve Stem Clearances No. HD-39932 or Carbide, Part No. HD-39932-CAR).
and Service Wear Limits Use REAMER LUBRICANT (Part No. HD-39964) or lib-
eral amounts of suitable cutting oil to prevent reamer
SERVICE WEAR chatter.
VALVE CLEARANCE
LIMIT 6. See Figure 3-20. Apply the proper surface finish to the
Exhaust 0.0015-0.0033 in. 0.0040 in. valve guide bores using the VALVE GUIDE HONE (Part
No. HD-34723). Lubricate hone with honing oil. Driving
Intake 0.008-0.0026 in. 0.0035 in. hone with an electric drill, work for a crosshatch pattern
with an angle of approximately 60°.
1. To remove shoulderless guides, press or tap guides NOTE
toward combustion chamber using DRIVER HANDLE The hone is not intended to remove material.
AND REMOVER (Part No. HD-34740).
7. Thoroughly clean valve guide bores using VALVE GUIDE
2. Clean and measure valve guide bore in head. BRUSH (Part No. HD-34751) and hot soapy water.
3-16
5692 5695
Driver Handle Valve Guide Brush

(Part No. HD-34740) (Part No. HD-34751)
Valve Guide Installation

Tool (Part No. HD-34741)
Cylinder Head Holding

Fixture (Part No. HD-39786)
Figure 3-20. Honing Valve Guides
b0169x3x
Cylinder Head Stand Head

(Part No. HD-39782)
Seat 60°
Figure 3-19. Installing Shoulderless Valve Guide
0.040-0.062 in.
Grinding Valve Faces and Seats (1.02-1.57 mm)
Valve
After installing valve guides, valve seats must be refaced to
make them concentric with guides.
31° 46° Cutting
Valve face angle is 45° for both intake and exhaust valves. If a 45° Grinding Margin
valve refacing grinder is used, it must be adjusted exactly to
this angle. It is important to remove no more metal than is
necessary to clean up and true valve face. Install a new valve Figure 3-21. Valve Seat Angles
if grinding leaves the valve edge (the margin) with a width of
less than 1/32 in. (0.8 mm). A valve with too thin a margin 2. Apply a small amount of lapping compound to the valve
does not seat normally, burns easily, may cause pre-ignition face. Rotate valve against seat using VALVE LAPPING
and can also lead to valve cracking. Valves that do not clean TOOL (Part No. HD-96550-36A).
up quickly are probably warped or too deeply pitted to be
reused. Replace the valve if end of valve stem shows uneven 3. See Figure 3-21. Check the contact pattern on valve
wear. After valves have been ground, handle with care to preface. It should be 0.040-0.062 in. (1.02-1.57 mm) wide,
vent damage to the ground faces. and its center should be positioned 2/3 of the way toward
the outside edge of face.
The valve seats may be refinished with cutters or grinders.
Cut seats to a 46° angle or grind seats to a 45° angle. Valve 4. If valve seat pattern is too close to the stem side of valve
seat tools and fixtures are available commercially. Seat each face, cut 60° angle in order to raise seat. If pattern is too
valve in the same position from which it was removed. close to the edge of valve face, cut 31° angle in order to
lower seat.
The correct 3-angle valve seat angles are shown in Figure 3-
5. After cutting either or both 31° or 60° angles to position
21. Use a NEWAY VALVE SEAT CUTTER (Part No. 444-HDF;
seat, final cut 46° (or grind 45°) seat angle to obtain
part of NEWAY VALVE SEAT CUTTER SET, Part No. HD-
proper 0.040-0.062 in. (1.02-1.57 mm) width.
35758) to cut the seats. Always grind valves before cutting
seats. 6. Recheck valve seat width and location with lapping com-
pound as described in Step 2.
1. Cut 46° (or grind 45°) valve seat angle first. Use cutting
oil to avoid chatter marks. Cut or grind only enough to 7. To achieve a smooth even finish, place a piece of 280 grit
clean up the seat. emery paper under the cutter head and rotate cutter.
3-17
1CAUTION
5696
Do not grind valve to shorten. Grinding will remove the
case hardening and expose the stem’s mild steel core
resulting in rapid end wear.
8. See Figure 3-22. Wipe valve seats and valve faces clean.
Measure valve stem protrusion. If valve stem protrudes
more than 2.034 in. (51.66 mm), replace valve seat or
cylinder head. If valve stem protrusion is within the Valve stem must not protrude
acceptable range, valves and seats are ready for lapping. more than 2.034 in. (51.66 mm)
Replacing Valve Seats

Replacing a valve seat is a complex operation requiring spe-
cial equipment. If the seat is loose or is not fully seated in the
head, then seat movement will prevent the proper transfer of
heat from the valve. The seat surface must be flush with (or
below) the head surface. See SPECIFICATIONS for valve
seat-to-cylinder head fit.
To remove the old seat, lay a bead of weld material around

the inside diameter of the seat. This will shrink the seat out-
side diameter and provide a surface for driving the seat out
the port side.
Lapping Valve Faces and Seats Figure 3-22. Measuring Valve Stem Protrusion
NOTE
5118
If valve faces and seats have been smoothly and accurately Valve Lapping Tool
refaced, very little lapping will be required to complete the (Part No. HD-96550-36A)
seating operation.
1. See Figure 3-23. Apply a light coat of fine lapping com-

pound to valve face. Insert valve in guide. Position one
rubber cup end of VALVE LAPPING TOOL (Part No. HD-
96550-36A) onto head of valve. Holding lapping tool as
shown, apply only very light pressure against valve head,
and rotate lapping tool and valve alternately clockwise
and counterclockwise a few times.
2. Lift valve and rotate it about 1/3 of a turn clockwise.

Repeat lapping procedure in Step 1.
3. Repeat Step 2. Then, remove valve.

Cylinder Head Holding
4. Wash valve face and seat; dry with a new, clean cloth or
Fixture (Part No. HD-39786)
towel.
5. If inspection shows an unbroken lapped finish of uniform

width around both valve and seat, valve is well seated. If
lapped finish is not complete, further lapping (or grinding Figure 3-23. Lapping Valves
and lapping) is necessary.
3-18
ASSEMBLY b0172x3x
1CAUTION
2
Make sure all lapping compound is removed from cylin-
der head and valves after lapping is completed. If lapping
compound contaminates any internal engine compo- 1
nents or engine oil, excessive engine wear and damage
may result.
1. Wash cylinder head and valves in warm, soapy water to

remove all lapping compound.
2. Scrub valve guide bores with VALVE GUIDE BRUSH

(Part No. HD-34751) and hot, soapy water.
3. Blow dry with compressed air. 3

4. Apply a liberal amount of engine oil to the valve stem.
4
5. See Figure 3-24. Insert valve into guide and install lower
collar (4). 5
6. See Figure 3-25. Place a protective sleeve over the valve
stem keeper groove. Coat the sleeve with oil and place a
new seal over the valve stem.
1CAUTION
● Always use a protective sleeve on the valve stem
keeper groove when installing valve stem seal. If the
seal is installed without using the protective sleeve,
the seal will be damaged.
● Do not remove valve after seal is installed. Other-

wise, sharp edges on keeper groove will damage
seal.
7. See Figure 3-24. Tap the seal onto the guide using the 1. Valve seal 3. Valve stem seal
VALVE SEAL INSTALLATION TOOL (Part No. HD- installation tool 4. Lower collar
34643A) and DRIVER HANDLE (Part No. HD-34740). 2. Driver handle 5. Valve guide
The seal is completely installed when the tool touches
Figure 3-24. Valve Seal Installation
the lower collar (4).
8. See Figure 3-9. Install valve springs (5, 6) and upper col- 5686
lar (8). Protective sleeve
9. Compress springs with VALVE SPRING COMPRESSOR
(Part No. HD-34736B).
10. Insert keepers (7) into upper collar (8), making sure they
engage groove in valve stem. The keeper gaps should be
equal.
11. Release and remove VALVE SPRING COMPRESSOR.
12. Repeat Steps 4-11 for the remaining valve(s).
NOTE
If front isolator mount was removed from front cylinder, rein-
stall in the following manner.
Figure 3-25. Valve Guide Seal Protector Sleeve
13. Coat new bolts with LOCTITE THREADLOCKER 262
(red). Tighten bolts to 73-78 ft-lbs (98.9-105.7 Nm).
3-19
If only cylinder head work was needed, reinstall cylinder head View View
following these instructions. If further repair is required, see A B
CYLINDER AND PISTON on page 3-22.
1. See Figure 3-9. Coat mating surfaces of cylinder studs
(12) and head screws (1, 2) with parts cleaning solution.
2. Scrape old oil and any carbon deposits from threads by
using a back-and-forth motion, threading each head
screw onto its mating cylinder stud.
3. Remove head screws from studs. Wipe or blow dry
Tighten head screws 1/4-turn in
thread surfaces.
the third stage of installation
4. Apply oil to stud threads and to the underside of the head
screw shoulder. Figure 3-26. Tightening Head Screws
1CAUTION 13. Apply a liberal amount of engine oil to tappet assembly
Only oil film must remain on the head screw surfaces.
(especially roller needles) for smooth initial operation.
Too much oil will pool in the head screw sleeve. Pooled
oil may prevent proper torque application and full thread 14. Insert tappet (6) into bore in crankcase (1). Rotate tappet
so that flats at upper end of tappet face the front and rear
engagement.
of the engine. If the tappet is installed incorrectly, pins (2)
cannot be inserted.
5. Blow or wipe off excess oil from head screws.
15. Insert pins (2) in the holes in crankcase. Place new O-
6. Thoroughly clean and dry the gasket surfaces of cylinder rings (3) over ends of pins. Install plate (4) using screw
(19) and cylinder head (18). (5) with washer (14). Tighten screw (5) to 80-110 in-lbs.
7. Install a new O-ring (14) on each dowel (15). (9.0-12.4 Nm).
16. Slide new seal (8), and place retainer (9), over top of
1CAUTION push rod cover (7). Position new O-ring (10) at top of
O-rings (14) help to properly position the head gasket (4). push rod cover. Hold cover at an angle and insert top
O-rings must be installed before the head gasket. through hole in cylinder head. Push up on cover while
aligning bottom of cover with tappet bore in crankcase.
8. Install a new head gasket (4) to cylinder. Lower retainer (9) with seal (8) onto crankcase, aligning
9. Carefully lower cylinder head over studs and position on locating pin (15) with hole in retainer.
dowels. Use great care so as not to disturb head gasket. 17. Insert screw (11) with washer (13) through hole in
retainer (9), and thread into tapped hole in crankcase.
10. Install head screws (1, 2) finger tight.
Tighten screw (11) to 15-18 ft-lbs (20-24 Nm).
1CAUTION 18. Identify push rod color coding, length and respective push
The procedure for tightening the head screws is critical rod positions in engine. See Table 3-4. Place intake and
to proper distribution of pressure over gasket area. It pre- exhaust push rods (1, 2) onto seat at top of tappet (6).
vents gasket leaks, stud failure, and head and cylinder
distortion.
Table 3-4. Push Rod Selection Table
11. See Figure 3-8. For each cylinder head, start with screw
numbered one, as shown. In increasing numerical COLOR CODE,
sequence (i.e. – 1, 2, 3 and 4), tighten head screws in POSITION PART NUMBER,
three stages: LENGTH
FIRST STAGE: Tighten each screw to 7-9 ft-lbs Exhaust (Front & Rear) 3 Band - Pink,
(9-12 Nm). 17904-89,
10.800 in.
SECOND STAGE: Tighten each screw to 12-14 ft-lbs
(16-19 Nm). Intake (Front & Rear) 1 Band - Brown,
THIRD STAGE: See Figure 3-26. Mark cylinder head 17897-89,
and head screw shoulder with a line as 10.746 in.
shown (View A). Tighten each screw a
1/4-turn (90°) (View B).
19. See Figure 3-5. Install new gaskets (16, 17) with the
12. See Figure 3-10. Rotate engine so that both tappets (6), bead facing up. Place lower rocker box assembly (with
from the cylinder being serviced, will be installed on the rocker arms and shafts) into position. Place push rods in
base circle (lowest position) of the cam. rocker arm sockets.
3-20
1CAUTION NOTES
Tubular frame prohibits direct access to bolt (12) on right rear
Do not turn engine over until both push rods can be cylinder. Use TORQUE ADAPTOR (SNAP-ON Part No.
turned with fingers. Otherwise, damage to push rods or FRDH 181) and TORQUE COMPUTER (Part No. SS-306G)
rocker arms may result. to correctly assemble.
21. Place new gasket (7), middle rocker cover (5), (with
20. See Figure 3-5. Install fasteners (12, 13, 14 and 15). breather valve on intake side) new gasket (6) and upper
Slowly snug all fasteners in small increments (one turn at rocker cover (4) on lower rocker box. Install screws (1)
a time). Use a cross pattern on the four large bolts (12, with new fiber seals (2). Tighten screws (1) to 10-13 ft-
13) that fasten the lower rocker box to head. This will lbs (14-18 Nm).
bleed the lifters. Tighten screws (14) to 90-120 in-lbs
(10.2-13.6 Nm). Tighten bolts (15) to 10-13 ft-lbs (13.6- Repeat above procedures for other cylinder.
18 Nm). Tighten bolts (12, 13) to 15-18 ft-lbs (20-24 Nm).
See Table 3-5.
Table 3-5. Rocker Arm Cover Hardware

ITEM
QTY SIZE TORQUE
(NUMBER)
Bolt (12) 2 5/16-18 X 2-3/4 15-18 ft-lbs

Bolt (13) 2 5/16-18 X 2-1/2 (20-24 Nm)
Screw (14) 90-120 in-lbs

2 1/4-20 X 1-1/2
(10.2-13.6 Nm)
Bolt (15) 10-13 ft-lbs

3 1/4-20 X 1-1/4
(14-18 Nm)
3-21
3
CYLINDER AND PISTON
1. Strip motorcycle as described under DISASSEMBLING

ENGINE FOR CYLINDER HEAD REPAIR on page 3-8.
2. Remove cylinder head as described under CYLINDER
HEAD, REMOVAL on page 3-11.
3. Clean crankcase around base of cylinder to prevent dirt and 6
debris from entering crankcase while removing cylinder.
4. See Figure 3-27. Turn engine over until one piston (3) is
at bottom of its stroke.
5. Carefully raise cylinder just enough to permit placing 7
clean towel under piston to prevent any foreign matter
from falling into crankcase. 8
7
NOTE 10
If cylinder does not come loose, tap lightly with plastic ham- 9
mer. Never try to pry cylinder up.
3 1
6. Carefully lift cylinder over piston and studs. Do not allow
piston to fall against cylinder studs. Discard cylinder base
gasket (5).
1CAUTION
With cylinder removed, be careful not to bend the studs.
The slightest bend could cause a stress riser and lead to
stud failure.
2
7. Install a 6 in. (150 mm) length of 1/2 in. (12.7 mm) ID
plastic or rubber hose over each stud. This will protect
the studs and the pistons.
1WARNING 4
The next step covers removing the piston pin retaining
rings. These rings are highly compressed in the ring 5
groove and may “fly out” with considerable force when
pried out of the groove. Safety glasses or goggles must
be worn while removing or installing retaining rings or 1. Cylinder 6. Ring set
personal injury may occur. 2. Dowel (2) 7. Retaining ring (2)
and O-ring (2) 8. Piston pin
1CAUTION 3. Piston 9. Piston pin bushing
The piston pin retaining rings must not be reused. 4. Stud (4) 10. Connecting rod
Removal may weaken retaining rings and they may break 5. Gasket
or dislodge. Either occurrence may damage engine.
Figure 3-27. Cylinder and Piston
8. Insert an awl in the recessed area below the piston pin
bore, and pry out the piston pin retaining rings. To pre-
vent the ring from flying out, place your thumb over the
retaining ring.
3-22
NOTE CLEANING, INSPECTION
Since the piston pin is a loose fit in the piston, the pin will eas- AND REPAIR
ily slide out. The pins have tapered ends to help seat the 1. Soak cylinder and piston in an aluminum-compatible
round retaining rings. See Figure 3-28. 1200cc piston pins cleaner/solvent until deposits are soft, then clean with a
are stamped with a V-groove at one end. brush. Blow off loosened carbon and dirt particles and
wash in solvent.
2. Clean oil passage in cylinder with compressed air.
b0057a3x
3. Clean piston ring grooves with a piece of compression
ring ground to a chisel shape.
4. Examine piston pin to see that it is not pitted or scored.
5. Check piston pin bushing to see that it is not loose in
connecting rod, grooved, pitted or scored. A piston pin
properly fitted to upper connecting rod bushing has a
0.00125 to 0.00175 in. (0.0317-0.0444 mm) clearance in
bushing. If piston pin-to-bushing clearance exceeds
V-groove 0.00200 in. (0.0508 mm), replace worn parts. See CON-
NECTING ROD BUSHING on page 3-26.
6. Clean piston pin retaining ring grooves.
7. Examine piston and cylinder for cracks, burnt spots,
grooves and gouges.
8. Check connecting rod for up and down play in lower
bearings. When up and down play is detected, lower
bearing should be refitted. This requires removing and
Figure 3-28. Piston Pin and Piston Identification
disassembling engine crankcase.
9. Mark each pin boss with either an “F” or an “R” to indi- Checking Gasket Surface
cate front or rear cylinder, respectively. See Figure 3-28.
The arrow at the top of 1200cc pistons must always point 1CAUTION
toward the front of the engine. If either cylinder gasket surface does not meet flatness
specifications, replace cylinder and piston. Proper toler-
ances will extend component life and prevent leaks.
1CAUTION
1. See Figure 3-29. Check that cylinder top (head) gasket
Handle the piston with extreme care. The alloy used in surface is flat within 0.006 in. (0.15 mm). Lay a straight
these pistons is very hard. Any scratches, gouges or edge across the surface, then try to insert a feeler gauge
other marks in the piston could score the cylinder during between the straightedge and the gasket surface.
engine operation and cause engine damage.
2. Check that the cylinder base gasket surface is flat within
0.008 in. (0.20 mm). Lay a straightedge across the sur-
10. Spread piston rings (6) outward until they clear grooves face, then try to insert a feeler gauge between the
in piston (3) and lift off. straightedge and the gasket surface.
3-23
2781a 2782a
Gasket surface flat within
0.006 in. (0.15 mm)
Figure 3-29. Checking Gasket Surfaces
Measuring Cylinder Bore
1. Remove any burrs from the cylinder gasket surfaces.
2. See Figure 3-30. Install a head and base gasket, and

CYLINDER TORQUE PLATES (Part No. HD-33446A)
and TORQUE PLATE BOLTS (Part No. HD-33446-86). Figure 3-30. Measuring Cylinder Bore Using Torque
Tighten the bolts using the same method used when Plates (Part No. HD-33446A)
installing the cylinder head screws. See CYLINDER
HEAD, INSTALLATION on page 3-20.
Table 3-6. 1200cc Cylinder Bore

NOTE
Service Wear Limits
Torque plates, properly tightened and installed with gaskets,
simulate engine operating conditions. Measurements will vary BORE SIZES IN. MM
as much as 0.001 in. (0.025 mm) without torque plates.
Standard Bore 3.5008 88.920
3. Take cylinder bore measurement in ring path, starting
about 1/2 in. (13 mm) from top of cylinder, measuring 0.005 in. OS bore 3.5050 89.027
from front to rear and then side to side. Record readings. (0.13 mm)
4. Repeat measurement at center and then at bottom of 0.010 in. OS bore 3.5100 89.154
ring path. Record readings. This process will determine if (0.25 mm)
cylinder is out-of-round (or “egged”) and will also show
any cylinder taper or bulge. 0.020 in. OS bore 3.5200 89.408
(0.51 mm)
5. See Table 3-6. If cylinder is not scuffed or scored and is
0.030 in. OS bore 3.5300 89.662
within service limit, see FITTING CYLINDER TO PIS-
(0.76 mm)
TON on page 3-25.
NOTE
If piston clearance exceeds service limit, cylinders should be

rebored and/or honed to next standard oversize, and refitted
with the corresponding piston and rings. Do not fit piston
tighter than 0.0007 in. (0.018 mm) See SPECIFICATIONS.
3-24
Measuring Piston 2747a
Because of their complex shape, the pistons cannot be accu-

rately measured with standard measuring instruments.
2
The pistons have the typical elliptical shape when viewed 3
from the top. However, they also are barrel-shaped when
viewed from the side. This barrel shape is not symmetrical.
1
Any damage to the piston will change its shape, which will
lead to problems.
Fitting Cylinder to Piston

Since pistons cannot be accurately measured with standard
measuring instruments, the bore sizes must be observed.
Bore sizes are listed in Table 3-7. Example: A 0.005 in.
(0.13 mm) oversize piston will have the proper clearance with
a bore size of 3.502 in. ± 0.0002 in. (88.95 mm ± 0.005 mm)
for the 1200cc engine.
1. Top compression ring – Install either side up
2. Second compression ring – Install dot toward top
Boring and Honing Cylinder 3. Oil control rings
1. The cylinder must be bored with gaskets and torque Figure 3-31. Piston Rings
plates attached. Bore the cylinder to 0.003 in. (0.08 mm)
under the desired finished size. Fitting Piston Rings
2. Hone the cylinder to its finished size using a 280 grit rigid NOTE
hone followed by a 240 grit flexible ball hone. Honing Ring sets and pistons, 0.040 in. (1.02 mm) oversize, are not
must be done with the torque plates attached. All honing available on 1200cc engines.
must be done from the bottom (crankcase) end of the cyl-
inder. Work for a 60° crosshatch pattern. See Figure 3-31. Piston rings are of two types: compression
and oil control. The two compression rings are positioned in
the two upper piston ring grooves. The dot on the second
compression ring must face upward. Ring sets are available
Table 3-7. Final Cylinder Bore Sizes to fit standard and oversize pistons.
Piston ring sets must be properly fitted to piston and cylinder:
BORE SIZES IN. MM
1. See Figure 3-32. Place piston in cylinder about 1/2 in.
(12.7 mm) from top. Set ring to be checked squarely
Standard bore* 3.4978 in. 88.844 mm
against piston as shown. Check end gap with thickness
0.005 in. OS bore 3.502 in. 88.95 mm gauge. See SPECIFICATIONS for tolerance.
(0.13 mm) NOTE
See SERVICE WEAR LIMITS for end gap dimensions. Do not
0.010 in. OS bore 3.507 in. 89.08 mm file rings to obtain proper gap.
(0.25 mm)
2. See Figure 3-33. Apply engine oil to piston grooves. Use
0.020 in. OS bore 3.517 in. 89.33 mm TRANSMISSION SHAFT RETAINING RING PLIERS
(0.51 mm) (Part No. J-5586) to slip compression rings over piston
into their respective grooves. Be extremely careful not to
0.030 in. OS bore 3.527 in. 89.59 mm over expand, twist rings, or damage piston surface when
(0.76 mm) installing rings.
*All bore sizes + 0.0002 in. (0.005 mm) NOTE

Install second compression ring with dot towards top.
When cylinder requires oversize reboring to beyond 0.30 in. 3. See Figure 3-34. Install rings so end gaps of adjacent
(0.76 mm), the oversize limit has been exceeded and cylinder rings are a minimum of 90° apart. Ring gaps are not to
must be replaced. be within 10° of the thrust face centerline.
4. See Figure 3-35. Check for proper side clearance with
NOTE thickness gauge, as shown. See SPECIFICATIONS for
tolerance.
The same piston may be used if cylinder bore was not
changed, unless it is scuffed or grooved. However, replace NOTE
rings and hone the cylinder walls with a No. 240 grit flexible If the ring grooves are clean and the side play is still not cor-
hone to facilitate ring seating. rect, replace the rings, the piston or both.
3-25
2783a b0095x3x Position ring end gaps at arrows–
minimum of 90° apart
FRONT
Piston
pin
REAR
Figure 3-34. Ring End Gap Position
2785a
Figure 3-32. Measuring Ring End Gap
2784a
Apply engine oil to piston
grooves to aid ring installation
Transmission Shaft Retaining Figure 3-35. Measuring Ring Clearance in Groove

Ring Pliers (Part No. J-5586)
4. Use two box wrenches and push worn bushing from con-
Figure 3-33. Installing Piston Rings necting rod.
5. Remove piston pin bushing tool from connecting rod.
Connecting Rod Bushing 6. Remove bushing from receiver cup.
REMOVAL/INSTALLATION 7. See Figure 3-37. Attach PISTON PIN BUSHING TOOL
(Part No. HD-95970-32C) to connecting rod; place new
When connecting rod bushing is worn to excessive pin clear- bushing between connecting rod and driver.
ance (0.002 in. or more) (0.05 mm) it must be replaced.
NOTE
1. See Figure 3-37. Install plastic hoses over studs. The driver must be attached facing the opposite direction as it
was for removal of the bushing.
2. Secure connecting rod with CONNECTING ROD
CLAMPING TOOL (Part No. HD-95952-33A). 8. Clean up and size bushing to 0.0010-0.0005 in.
(0.025-0.013 mm) undersize using REAMER (Part No.
NOTE HD-94800-26A). Sizing bushing with less than 0.00125
in. (0.0317 mm) clearance can result in a bushing loos-
If CONNECTING ROD CLAMPING TOOL holes are too
ening and/or seized pin in rod.
small, enlarge the holes in the tool.
9. Hone bushing to final size using WRIST PIN BUSHING
3. See Figure 3-36. Attach PISTON PIN BUSHING TOOL HONE (Part No. HD-35102). Use a liberal amount of
(Part No. HD-95970-32C) to the connecting rod (receiver honing oil to prevent damage to hone or bushing. Use
cup on one side of the rod and the driver on the opposite care to prevent foreign material from falling into the
side) as shown. crankcase.
3-26
b0173x3x
1 3
1. Receiver cup
2. Driver
3. Washer
4. Nut
5. Bolt
Figure 3-36. Piston Pin Bushing Tool Assembly for Bushing Removal
REPAIR
2786a
Piston Pin Bushing Tool
1CAUTION (Part No. HD-95970-32C)
Replace bent connecting rods. Do not attempt to
straighten. Straightening rods by bending will damage
the bearing on the crank pin and the piston pin bushing.
Installing bent connecting rods will damage cylinder and
piston beyond repair.
1. Install piston assembly over connecting rod.
NOTE
New 1200cc pistons must be installed with the arrow, at the
top of the piston, pointing towards the front of the engine.
2. Install piston pin.
1CAUTION Rod Clamping Fixture

Always use new retaining ring. Make sure retaining ring
(Part No. HD-95952-33A)
groove is clean and that ring seats firmly in groove. If it
does not, discard the ring. Never install a used retaining
ring or a new one if it has been installed and then Figure 3-37. Installing New Piston Pin Bushing
removed for any reason. A loosely installed ring will
come out of the piston groove and damage cylinder and 7. Compress the piston rings using PISTON RING COM-
piston beyond repair. PRESSOR (Part No. HD-96333-51B).
3. Install new piston pin retaining rings with the PISTON 8. Remove cylinder stud sleeves. Install a new cylinder
PIN RETAINING RING INSTALLER (Part No. HD- base gasket. Make sure the piston does not bump the
34623A). Make sure the ring groove is clean and that the studs or crankcase.
ring is fully seated in the groove with the gap away from 9. Install cylinder over piston.
the slot at the bottom.
10. Remove piston ring compressor.
4. See Figure 3-34. Make sure the piston ring end gaps are
properly positioned as shown. 11. Assemble and install cylinder head. See CYLINDER
5. Lubricate cylinder wall, piston, pin and rod bushing with HEAD, ASSEMBLY starting on page 3-19.
engine oil. 12. Install assembled engine. See INSTALLING THE
6. Turn engine until piston is at top dead center. ENGINE on page 3-10.
3-27
LUBRICATION SYSTEM
CHECKING AND ADDING OIL WINTER LUBRICATION

Normal fuel combustion in a gasoline engine produces water
Check engine oil level in oil tank at least once every 500 miles
vapor and carbon dioxide along with other gases and particu-
(800 km). Check level more frequently if engine uses more oil
lates. When first starting and warming an engine, some of the
than normal or if vehicle is operated under harsh conditions.
water vapor that gets into the engine crankcase condenses to
Oil tank capacity is 2.0 quarts (1.9 liters).
form liquid water. If the engine is driven long enough to thor-
oughly warm the crankcase, most of this liquid water is again
See ENGINE LUBRICATION SYSTEM in Section 1 for more vaporized and exhausted through the crankcase breather
information. system.
A moderately driven vehicle making short runs may not be

able to vacate water vapors allowing liquid water to accumu-
CHANGING OIL AND FILTER lates in the oil tank. This is especially true if the vehicle is
operated in cold weather. In freezing weather, an accumula-
tion of water in the engine oil may become slush or ice, which
After a new engine has run its first 500 miles (800 km) and at
can block oil lines and lead to severe engine damage. Water
5000 mile (8000 km) intervals or annually thereafter, com-
remaining in the engine oil for long periods of time can form
pletely drain oil tank of used oil. Refill with fresh oil. If vehicle is
an acidic sludge that is corrosive to metal engine parts and
driven extremely hard, used in competition or driven on dusty
causes accelerated wear of moving components.
roads, change engine oil at shorter intervals. Always change
oil filter when changing engine oil.
In winter the oil change interval should be shorter than nor-
mal. The colder the weather, the shorter the recommended oil
See ENGINE LUBRICATION SYSTEM in Section 1 for more change interval. A vehicle used only for short runs in cold
information. weather must have the engine oil drained frequently.
3-28
OIL HOSE ROUTING
GENERAL b0248x3x
4
See Figure 3-38. The oil tank has four hoses. The drain hose
(2) attaches to a fitting on the left side of the frame. From the
top of the tank, the vent hose (3) and the return hose (4) join 3
the bottom feed hose (1) near the battery tray. Cable straps
secure the hoses in place.
2
See Figure 3-39. The feed (1) and return hoses (3) run
together between the swingarm mount block and crankcase,
beneath the engine and forward to the oil pump. The feed
hose attaches to the rear most oil pump fitting; the return
hose connects forward and above.
After diverging from the feed and return hoses, the vent hose
is routed beneath the starter. The vent hose continues on to 1
the right side of the motorcycle and goes behind the gearcase
1. Feed hose (3/8 in. ID by 5/8 in. OD)
cover assembly where it connects to an elbow fitting.
2. Drain hose (3/8 in. ID by 5/8 in. OD)
3. Vent hose (1/4 in. ID by 1/2 in. OD)
4. Return hose (3/8 in. ID by 5/8 in. OD)
Figure 3-38. Oil Tank Hoses
5709
3
2
1 4
1. Feed hose 3. Return hose

2. Oil pump 4. Oil filter connection
Figure 3-39. Oil Pump Connections
3-29
OIL TANK
1. Remove seat, fuel tank and tail section. See TAIL SEC-
TION, REMOVAL in Section 2. 10
2. Remove rear fender. See FENDERS in Section 2. 9
3. Drain oil tank. See ENGINE LUBRICATION SYSTEM,
CHANGING ENGINE OIL AND FILTER in Section 1. 8
The oil filter need not be removed unless it is due to be 7
replaced.
4. See Figure 3-40. Disconnect hoses from oil tank. Label
each hose upon removal.
a. Remove worm clamp (3) from feed hose (4). 6
b. Remove clamp (5) from drain hose (6).
c. Remove clamp (8) from vent hose (7). 1
d. Remove clamp (10) from return hose (9)
2
5. Remove bolts and lockwashers from well nuts.
3
6. Detach oil tank from frame. 5
1. See Figure 3-40. Place oil tank on frame and align 1. Bolt, lockwasher 6. Drain hose
mounts. Loosely install bolts and lockwashers (1) at all and well nut (4) 7. Vent hose
four mounting points. 2. Oil tank 8. Hose clamp, 1/4 in.
3. Worm clamp, 3/8 in. 9. Return hose
NOTE
4. Feed hose 10. Hose clamp, 3/8 in.
Starting at the top mounting points will simplify installation.
5. Hose clamp, 3/8 in.
2. Connect the four oil tank hoses. Tighten new clamps (5,
Figure 3-40. Oil Tank
8 and 10) using HOSE CLAMP PLIERS (Part No. HD-
41137).
NOTE
Worm clamp (3) may be reused on feed hose (4).
3. Fill oil tank. See ENGINE LUBRICATION SYSTEM,
CHANGING ENGINE OIL AND FILTER in Section 1.
4. Install rear fender. See FENDERS in Section 2.
1WARNING
5. Install tail section, fuel tank and seat. See TAIL SEC-
TION in Section 2.
3-30
OIL PRESSURE SIGNAL LIGHT SWITCH
GENERAL 5681
The oil pressure signal light switch is a pressure-actuated dia-

phragm-type switch. When oil is not circulating through the Oil Pressure Gauge Adapter
system or when oil pressure is abnormally low, spring tension (Part No. HD-96940-52A)
holds the switch contacts closed, thereby completing the sig-
nal light circuit and causing the indicator lamp to illuminate.
OIL PRESSURE SIGNAL LIGHT

The oil pressure signal light turns ON when:
● Ignition switch is turned on prior to starting engine. Oil Pressure Gauge

(Part No. HD-96921-52A)
● Oil is not circulating through the running engine.
● Oil pressure is abnormally low on the running engine. Figure 3-41. Checking Oil Pressure
● Engine is idling far below 1000 RPM.
5516
The oil pressure signal light turns OFF when:
● Oil is circulating with adequate pressure through the

engine running at 1000 RPM or greater.
Troubleshooting information is listed in Table 3-8.

Oil pressure Oil filter
switch
NOTE
If the ignition is turned back on immediately after the engine is
stopped, the oil light may not turn on right away because of oil
pressure retained in the filter housing.
Figure 3-42. Oil Pressure Signal Light Switch

OIL PRESSURE
See Figure 3-41. The oil pump is nonregulatory and delivers
Table 3-8. Troubleshooting Oil
its entire volume of oil under pressure to the oil filter mount. Pressure Signal Light
When an engine is cold, the engine oil will be more viscous
(i.e., thicker). During start-up of a cold engine, oil pressure will OIL
be higher than normal and oil circulation will be somewhat PRESSURE PROBABLE CAUSES
restricted within the oiling system. As the engine warms to SIGNAL LIGHT
normal operating temperature, the engine oil will warm up Stays on at ● Empty oil tank.
and become less viscous — oil pressure decreases. speeds above ● Clogged feed line (ice and sludge,
idle. freezing temperatures).
When an engine is operated at high speeds, the volume of oil ● Air-bound oil line.
circulated through the oiling system increases, resulting in ● Grounded oil switch wire.
higher oil pressure. As engine speed is reduced, the volume ● Malfunctioning signal switch.
of oil pumped is also reduced, resulting in lower oil pressure. ● Diluted oil.
● Malfunctioning check valve (see OIL
To check oil pressure, use OIL PRESSURE GAUGE (Part No. FILTER MOUNT on page 3-37).
HD-96921-52A) and OIL PRESSURE GAUGE ADAPTER
Flickers at idle. ● Incorrect idle speed. Malfunctioning
(Part No. HD-96940-52A). Remove oil pressure switch and
or improperly installed check valve
insert pressure gauge fitting. See Figure 3-42.
(see OIL FILTER MOUNT).
Run engine until oil reaches normal operating temperature Does not glow ● Malfunctioning signal switch.
(motorcycle should be driven at least 20 miles (32 km) at or when ignition ● Malfunction in wiring.
above 50 MPH (80 KM/H)). At 2500 RPM, oil pressure will is turned on ● Burned-out signal bulb.
vary from 10-17 psi (69-117 kN/m2). At idle speed (950-1050 (prior to oper- ● Dead battery (see NOTE above).
RPM), oil pressure will vary from 7-12 psi (48-83 kN/m2). ating engine).
3-31
CRANKCASE BREATHING SYSTEM
GENERAL
See Figure 3-43. On piston downstroke, a mixture of crankcase
air and oil mist is vented up the push rod covers (1) through an
umbrella valve (3) in each middle rocker box section. The oil
mist separates from the crankcase air, collects and passes
through a small drain hole (2) where it eventually returns to the
crankcase. The crankcase air is routed through a passage in
each cylinder head. The crankcase air then travels through
each air cleaner breather bolt (4) into a hose leading into the
air cleaner.
b0143a3x
1. Push rod cover (2)

2. Oil drain hole
3. Umbrella valve
4. Breather bolt
Figure 3-43. Crankcase Breathing System – Typical Cylinder
3-32
OILING SYSTEM (COLOR FOLDOUT)
NOTE flywheel to the crankpin. Oil is forced through the crank-

The following paragraph numbers correspond with the num- pin to properly lubricate the rod bearing assembly.
bered callouts in the INTERNAL ENGINE PASSAGES illus-
tration.
11. Oil flows up passages in the push rods to the rocker arm
1. Oil is gravity-fed from the oil tank to the gerotor-style oil shafts and bushings.
pump through a feed hose. Oil enters the feed section
and fills a cavity located under the feed pump.
12. The valve stems are lubricated by oil supplied through
NOTE drilled oil holes in the rocker arms.
A complete explanation of the gerotor pump is given under
OIL PUMP. 13. Oil collected in the push rod areas of the cylinder heads
2. The feed pump transfers oil from the inlet cavity through flows down the push rod covers, through drain holes in
the feed hose to the oil filter mount. the tappet blocks and into the gearcase.
3. Oil flows through the filter mount cavity to the oil filter.
4. Oil enters the peripheral cavity of the oil filter, passes 14. Feed oil to the rocker area is returned to the crankcase
through the filtering medium into the central cavity of the through a passage in the head and cylinder.
oil filter, and flows into the filter adapter (fitting which con-
nects filter to filter mount). 15. Oil collected in the sump is splash-fed to the pistons, cyl-
5. Adequate oil pressure in the filter mount cavity activates inder walls and flywheel components.
the oil pressure signal light switch and shuts off the oil
pressure signal light.
16. Oil collected in the sump area returns to the scavenge
6. Oil flowing from the filter adapter opens the check ball. section of the oil pump through a passage located in the
The check ball opens at 4-6 psi (28-41 kN/m2) oil pres- rear section of the sump. Oil flow to the pump is accom-
sure. plished by the scavenging effect of the pump and by the
7. With the check ball open, oil flows into the crankcase pressure created by the downward stroke of the pistons.
feed galley.
8. Oil flows through the feed galley in the crankcase to the 17. Return oil fills a cavity above the pump's return gears.
tappet blocks and hydraulic lifters. Cross-drilled pas- The return gears pump oil back to the oil tank.
sages intersect the main feed galley and carry oil to each
hydraulic lifter.
18. A small amount of oil flows from the feed galley in the
9. Oil also enters an intersecting passage in the gearcase right crankcase half through a restricted orifice, which
cover. Oil flow is then routed to the crankshaft area. sprays the oil onto the rear intake cam gear in the gear-
10. Oil enters a hole in the end of the pinion gear shaft and case. Oil is transferred to the teeth of all the cam gears
travels to the right flywheel where it is routed through the through the gear meshing action.
3-33
OIL PUMP
GENERAL Gravity-fed oil from the oil tank enters the pump through
fitting (5). It is forced by gerotor set (7) through a hose to
See Figure 3-44. The oil pump consists of two gerotor gear the oil filter. Return oil from the flywheel compartment is
sets, feed and scavenge (return), housed in one pump body. drawn back into the pump and is forced by gerotor set (9)
The feed pump distributes oil to the engine, the scavenge back to the oil tank.
pump returns oil to the tank.
See INTERNAL ENGINE PASSAGES for oil passages within
A gerotor-type gear set has two parts — an inner and an the engine.
outer gerotor. The inner gerotor has one less tooth than the
outer gerotor. Both gerotors have fixed centers which are off- The oil pump seldom needs servicing. Before you disassem-
set to each other. ble an oil pump suspected of not producing adequate oil pres-
sure, be absolutely certain that all possible related
In a gerotor gear set, oil is transferred from inlet to outlet as it malfunctions have been eliminated:
is trapped between the rotating inner and outer gerotors. The
illustration below shows the principle of gerotor operation: 1. Make sure all oil hose clamps are tight and that hoses
are not pinched or damaged.
1. During the first 180° of rotation, the cavity between inner
and outer gerotors gradually increases in size until it 2. Check oil level and condition of oil in tank. Pressure will
reaches its maximum size, equivalent to the full volume be affected if oil is diluted. In freezing weather, proper cir-
of the “missing tooth.” The gradually enlarging cavity cre- culation of oil can be affected if the oil feed hose
ates a vacuum into which oil flows from the inlet. becomes clogged with ice and sludge.
2. During the next 180° of rotation, the size of the cavity 3. Check for a grounded oil pressure switch wire or faulty
decreases forcing oil into the outlet. See Figure 3-46. switch if oil indicator light fails to go out with engine running.
b0098x3x
Oil drawn into cavity
Inner gerotor Outer gerotor between gerotor teeth
Oil inlet
Oil outlet
Oil trapped between

gerotor teeth
Oil inlet 1 Oil outlet 2 Oil forced out
Oil trapped between inner

and outer gerotor teeth
Oil
3 4 outlet
Figure 3-44. Principle of Gerotor Operation
3-34
NOTE
Oil pump can be removed with engine in frame and without
removing gearcase cover.
1. Drain oil from oil tank.
2. See Figure 3-45. Detach clamp (6) from oil hose. Move 10
rear shock rebound canister aside. 9
3. Disconnect feed hose (3) and oil filter mount
connection (5). 8
11
NOTE
Loosen nut on oil filter mount connection (5) and then remove
pressurized hose. 12
4. Carefully remove screws (1) and washers that secure
pump to crankcase. Pump will drop with screws
removed. Discard mounting gasket. 7
5. Remove clamp and return hose connection (4).
6
5709 14 5
4
6 13 3
3 2 1 5 4
15 2
16
1
1 2
1. Mounting screw, long (2) 9. Gerotor assembly,
1. Mounting screw and 4. Return hose 2. Cover screw, short (2) scavenge pump
washer (2) connection 3. Washer (4) 10. Mounting gasket
2. Cover screw and 5. Oil filter mount 4. Connector 11. Gear shaft
washer (2) connection 5. Hose fitting 12. Body, oil pump
3. Feed hose connection 6. Clamp 6. Cover, oil pump 13. Elbow
7. Gerotor assembly, 14. O-ring
Figure 3-45. Oil Pump Hardware feed pump 15. Washer, thrust
8. Gerotor separator plate 16. Retaining ring
6. See Figure 3-46. Remove cover screws (2) and washers
(3). Lift cover (6) off body (12). Remove and discard O- Figure 3-46. Oil Pump
ring (14).
7. Slide both pieces of feed gerotor set (7), separator plate
(8) and both pieces of scavenge gerotor set (9) off gear
shaft (11).
8. Remove and discard retaining ring (16). Remove thrust
washer (15) and gear shaft (11).
3-35
CLEANING, INSPECTION b0097x3x
AND REPAIR Inner gerotor

1. Clean all parts in cleaning solvent. Blow out holes and oil
passages with compressed air.
2. See Figure 3-47. Inspect both gerotor sets for wear.
Mesh pieces of each set together as shown. Use a feeler
gauge to determine clearance. Wear limit
NOTE Outer gerotor
The maximum allowable clearance between gerotors is
0.004 in. (0.10 mm). Replace gerotors as a set if clearance
exceeds this dimension. Figure 3-47. Gerotor Wear Limits
3. Measure thickness of feed gerotors with a micrometer. If 7. Place new mounting gasket (10) in position.
they are not the same thickness, replace as a set.
4. Check gear shaft (11) teeth for damage or wear. Replace 8. See Figure 3-45. Attach return hose (4) to oil pump.
if necessary.
9. Secure pump to crankcase with screws (1) and washers.
Tighten mounting screws to 125-150 in-lbs (14.1-
ASSEMBLY/INSTALLATION 16.9 Nm).
1. See Figure 3-46. Install gear shaft (11) through body
(12). Position thrust washer (15) over end of shaft. Install 10. Connect feed hose (3) and oil filter mount connection (5)
new retaining ring (16) into groove in shaft. to oil pump.
NOTE
Liberally coat all moving parts with clean engine oil to ensure NOTE
easy assembly and smooth operation at start-up. Use new hose clamps. If fittings were removed, use
2. Insert inner gerotor of the scavenge gerotor set (9) over TEFLON® PIPE SEALANT or HYLOMAR® on fitting threads.
gear shaft.
3. Place outer gerotor over inner to complete scavenge 11. Attach clamp (6) and canister to oil hose.
set (9).
12. Prime oil pump. Loosen feed hose connection and start
4. Position separator plate (8) into case and line up slots on
engine. Operate at idle and allow about 2.0 ounces
perimeter with tabs inside oil pump body (12).
(0.06 liter) of engine oil to be forced through hose con-
5. Place feed gerotor set (7) over gear shaft (11). nection. Stop engine and tighten hose connection.
6. Install a new O-ring (14) into groove in cover (6). Place
cover onto pump body. Install cover screws (2) with 13. Check engine oil level in tank. Add oil to correct level if
washers (3). Tighten cover screws (2) to 125-150 in-lbs needed. See ENGINE LUBRICATION SYSTEM in Sec-
(14.1-16.9 Nm). tion 1.
3-36
OIL FILTER MOUNT
GENERAL b0170x3x
See Figure 3-48. Oil is pressure-fed from the oil pump to the
oil filter mount (4) via a hose connection (5). Oil travels
through the filter mount into the filter via outer filter holes. 4
Adequate oil pressure activates the oil pressure signal light
switch (6) in the filter mount, which turns off the oil pressure 3
indicator lamp.
The check ball (2) in the filter adapter (1) “opens” at 4-6 psi 2
(28-41 kN/m2) oil pressure. Filtered oil leaves the filter, flow-
1
ing past the check ball.
DISASSEMBLY
1. Remove oil filter adapter (1) from oil filter mount (4).
Remove check ball (2) and spring (3).
2. Remove oil pressure signal light switch (6).
CLEANING/INSPECTION
Thoroughly clean all parts in cleaning solvent. Blow out holes 5 6
and passages using compressed air.
1. Oil filter adapter 5. Feed hose
ASSEMBLY 2. Check ball 6. Oil pressure signal
3. Spring light switch
NOTE 4. Oil filter mount (part of
right crankcase half)
Use TEFLON PIPE SEALANT or HYLOMAR on all fittings
installed to oil filter mount. Figure 3-48. Oil Filter Mount
1. Install oil pressure signal light switch (6). Tighten to 5-
4. Connect pressure switch wire. Tighten nut which secures
7 ft-lbs (7-9 Nm).
wire to 4-10 in-lbs (0.4-1.1 Nm).
2. Apply LOCTITE THREADLOCKER 242 (blue) to the 5. Pour about 4.0 ounces (0.12 liter) of clean engine oil into
threads on that end of the oil filter adapter (1) which is filter. Apply a light coat of oil to oil filter gasket. Install oil
installed into oil filter mount (4). Do not apply LOCTITE to filter onto oil filter mount/adapter assembly; tighten filter
adapter threads on oil filter element side. an additional 1/2-3/4 turn after gasket contacts filter
NOTE mount surface.
The oil filter adapter (1) has identical ends; either end may be 6. Fill oil tank with proper oil. See ENGINE LUBRICATION
installed into the oil filter mount. SYSTEM, CHANGING ENGINE OIL AND FILTER in
Section 1.
3. Place spring (3) and check ball (2) into threaded hole at
center of mount (4). Push adapter (1) against ball to
compress spring. Install threaded end (with LOCTITE)
into threaded hole at center of mount (4). Tighten adapter
to 8-12 ft-lbs (11-16 Nm).
3-37
VALVE TAPPETS
GENERAL REMOVAL
See Figure 3-49. The tappet assembly consists of tappet and 1. Clean all dirt from around crankcase. Blow loose parti-
roller. The tappet and roller, under compression force from cles from area with compressed air.
valve spring, follow the surface of the revolving cam. The up-
and-down motion produced is transmitted to the valve by the 2. Remove the upper, middle, and lower rocker covers. See
push rod and rocker arm. The tappet contains a piston (or CYLINDER HEAD, REMOVAL on page 3-11. Pull the
plunger) and cylinder; it also contains a check valve, which push rod upward through top of cylinder head.
allows the unit to fill with engine oil, thereby reducing clear-
ance in the valve train. 3. See Figure 3-50. Remove screw (11) and washer (13). Lift
retainer (9) and seal (8) upward a few inches on push rod
When a tappet is functioning properly, the assembly operates cover (7). Push upward on push rod cover while pulling
with minimal tappet clearance. The unit automatically com- bottom of cover (7) clear of crankcase. Remove cover (7).
pensates for heat expansion to maintain a no-clearance
condition. 4. Remove screw (5), washer (14), and plate (4). Pull O-
rings (3) off ends of pins (2) and discard. Grasp ends of
pins (2) and pull outward free of crankcase. A pliers is a
It is normal for tappets to click when engine is started after
handy tool to free pins (2). With a thin-bladed screwdriver
standing for some time. Tappets have a definite leakdown rate
in the retainer groove at the top of the tappet, pry upward
which permits the oil in the tappets to escape. This is neces-
on the tappet until it extends above the gearcase and can
sary to allow units to compensate for various expansion con-
be pulled out by hand.
ditions of parts and still maintain correct clearance operation.
Tappets are functioning properly if they become quiet after a
few minutes of engine operation.
CLEANING/INSPECTION
1. Clean all parts, except roller/tappet assembly, thoroughly
b0174x3x in solvent. Blow dry with compressed air.
Piston 2. Inspect valve tappets for excessive clearance in guide.

Clearance should be 0.0008-0.0020 in. (0.020-0.051 mm).
Accurately measure tappet bore inner diameter with a
gauge. Service wear limit is 0.0030 in. (0.076 mm).
Excessive tappet guide clearance is corrected by fitting a
new tappet and/or replacing crankcases.
Oil
Oil NOTE
Inside and outside micrometers used for measuring tappets

and tappet guides must be calibrated to ensure accurate
readings.
3. Check tappet roller freeplay. Roller clearance on pin

Check valve should be within 0.0006-0.0010 in. (0.015-0.025 mm).
Recommended service practice is tappet replacement.
Service wear limit is 0.0015 in. (0.038 mm).
4. Check tappet roller end clearance. Clearance should be

0.008-0.022 in. (0.203-0.559 mm). Service wear limit is
Roller 0.026 in. (0.660 mm).
5. Tappets should be soaked in clean engine oil and kept

Figure 3-49. Tappet Assembly covered until assembly.
3-38
3
1. See Figure 3-50. Rotate engine so that both tappets (6),

from the cylinder being serviced, will be installed on the
base circle (lowest position) of the cam.
8
2. Apply a liberal amount of engine oil to tappet assembly,
especially the roller needles, to ensure smooth initial
operation.
3. Insert tappet (6) into bore in crankcase (1). Rotate tappet
so that flats at upper end of tappet face the front and rear
7
of the engine. If the tappet is installed incorrectly, pins (2) 12
cannot be inserted.
4. Insert pins (2) in the holes in crankcase. Place new O-
rings (3) over ends of pins. Install plate (4) using screw 10
(5) with washer (14). Tighten screw (5) to 80-110 in-lbs
(9.0-12.4 Nm). 6
5. Slide new seal (8) and place retainer (9), over top of 1 11
push rod cover (7). Position new O-ring (10) at top of
push rod cover. Hold cover at an angle and insert top
13
through hole in cylinder head. Push up on cover while
aligning bottom of cover with tappet bore in crankcase.
Lower retainer (9) with seal (8) onto crankcase, aligning 9
locating pin (15) with hole in retainer.
6. Insert screw (11) with washer (13) through hole in 4
retainer (9), and thread into tapped hole in crankcase. 15
Tighten screw (11) to 15-18 ft-lbs (20-24 Nm). 14
7. Install rocker covers. See CYLINDER HEAD, INSTALLA- 5
TION starting on page 3-20. 2
3
1. Right 8. Seal (2)

crankcase half 9. Retainer (2)
2. Pin (2) 10. O-ring (2)
3. O-ring (2) 11. Screw (2)
4. Plate 12. Push rod (2)
5. Screw 13. Washer (2)
6. Tappet lifter (2) 14. Washer
7. Push rod cover (2) 15. Locating pin (2)
Figure 3-50. Valve Tappet Service
3-39
GEARCASE COVER AND CAM GEARS
GENERAL REMOVAL/DISASSEMBLY
1. See Figure 3-51. Thoroughly clean area around gear-
Read the complete gearcase section carefully before you case cover (17) and tappets. Blow loose dirt from crank-
begin any service work. case with compressed air.
2. Remove any parts that will interfere with gearcase disas-
sembly (i.e., exhaust header, footrest, air cleaner, etc.).
For the gearcase components to operate at their optimum, all
components must be properly fitted and matched. Changing 3. Remove push rods as described under CYLINDER
one component can affect many others. It is important to HEAD, REMOVAL on page 3-11.
know and understand all inspection procedures and how 4. Remove tappets. See VALVE TAPPETS, REMOVAL on
components interact. page 3-38.
b0058a3x
13
10 4
13 8
3
7
12
5
9 13 16
17
2
11
15
13
1
14
6
1. Rear exhaust cam gear 7. Front intake cam gear bushing 13. Cam gear bushing (4)
2. Rear intake cam gear 8. Front exhaust cam gear bushing 14. Rear exhaust cam gear bushing
3. Front intake cam gear 9. Gearcase cover gasket 15. Rear intake cam gear bushing
4. Front exhaust cam gear 10. Right crankcase half 16. Pinion shaft bushing
5. Pinion gear 11. Nut 17. Gearcase cover
6. Seal 12. Oil pump drive gear
Figure 3-51. Gearcase and Valve Train Components
3-40
5. Check for minimum cam gear end play. See page 3-46.
Record readings. 2223a
6. Remove ignition system. See Section 7.

7. Place a pan under gearcase to collect oil. Remove cover
screws. Carefully remove gearcase cover. Discard old
gasket (9).
NOTE
If cover does not come loose on removal of screws, tap lightly
with a plastic hammer. Never pry cover off.
8. Remove cam gears (1, 2, 3 and 4). Carefully mark each
component to ensure correct installation.
NOTE
Nut (11) is secured by LOCTITE THREADLOCKER 262 (red)
on the nut threads.
Gauge Pin Set
9. Remove nut (11). Slide pinion gear (5) and oil pump drive
(Part No. HD-38361)
gear (12) off pinion shaft.
Figure 3-52. Measuring Gear Size

AND REPAIR b0096a3x
1. Thoroughly clean gearcase compartment, gearcase

cover, and gears in solvent to remove oil and carbon Identify cams by
deposits. stamped number
2. Blow out all cover oil passages and bushings with com-
pressed air.
3. Clean old gasket material from gearcase and cover faces
with cleaning solvent.
Cam and Pinion Gear Identification,

Inspection, and Selection
See Figure 3-52. Cam lobes are stamped with the number “15”
followed by a number (1, 2, 3 or 4). The number “15” indicates
model year application; the number identifies the cam location/
function:
Figure 3-53. Cam Identification
15-1 = rear exhaust
15-2 = rear intake NOTE
15-3 = front intake On flywheel pinion shaft, a paint dot is located on the shaft
15-4 = front exhaust perimeter near the centerline of the keyway. This dot identifies
Use only “15” cams on 1996 models. the pinion shaft inner race size. Do not use this dot to select
pinion gear size.
See Figure 3-53. Measure the gear diameter with a microme-
ter over 0.108 in. (2.74 mm) diameter gauge pins on opposite See Table 3-9. Compare the previously measured diameter of
sides of the gear. The pins are of the proper size to fit each gear with the specifications (listed in inches) shown in
between the contacting surfaces of the gear teeth. Gear the table to determine amount of wear on gear teeth.
diameter should be measured in at least two places 90°
apart. Use GAUGE PIN SET (Part No. HD-38361) when mea-
suring pinion and cam gear sizes.
Cam and pinion gears are individually selected for each spe-
cific gear cover through sophisticated computer-aided mea-
suring techniques in a controlled environment. Each gear is
assigned an individual color code based on its diameter
(measured with gauge pins). When cam and/or pinion gears
are replaced, always use the same color code as found on
gears being replaced to ensure that the gear operation
remains as quiet as possible. For location of cam and pinion
gear color codes, see Figure 3-54.
3-41
b0209x3x
2 3 4
5 = Color code location on gear face
1. Rear exhaust cam gear (15-1) 4. Front exhaust cam gear (15-4)
2. Rear intake cam gear (15-2) 5. Pinion gear
3. Front intake cam gear (15-3)
Figure 3-54. Cam and Pinion Gear Color Code Location and Timing Mark Indexing
NOTE
Prior to changing any cam gears, check gear shaft fit within corresponding bushings. Worn bushings can cause excessive back-
lash.
Table 3-9. Cam and Pinion Gear Color Code and Diameter
2 2
GEAR NO. & POSITION 1 3 4 5
INBOARD OUTBOARD
COLOR CODE Rear Rear Rear Front Front
Pinion
(1 paint dot) Exhaust Intake Intake Intake Exhaust
BROWN 1.9005-1.9009 1.9035-1.9039 2.4021-2.4025 1.9005-1.9009 1.9035-1.9039 1.2753-1.2756

(48.272-48.283) (48.349-48.359) (61.013-61.023) (48.272-48.283) (48.349-48.359) (32.393-32.400)
BLUE 1.9010-1.9014 1.9030-1.9034 2.4026-2.4030 1.9010-1.9014 1.9030-1.9034 1.2749-1.2752

(48.285-48.295) (48.336-48.346) (61.026-61.036) (48.285-48.295) (48.336-48.346) (32.382-32.390)
RED 1.9015-1.9019 1.9025-1.9029 2.4031-2.4035 1.9015-1.9019 1.9025-1.9029 1.2745-1.2748

(48.298-48.308) (48.323-48.333) (61.038-61.049) (48.298-48.308) (48.323-48.333) (32.372-32.380)
WHITE 1.9020-1.9024 1.9020-1.9024 2.4036-2.4040 1.9020-1.9024 1.9020-1.9024 1.2741-1.2744

(48.310-48.321) (48.310-48.321) (61.051-61.061) (48.310-48.321) (48.310-48.321) (32.362-32.369)
GREEN 1.9025-1.9029 1.9015-1.9019 2.4041-2.4045 1.9025-1.9029 1.9015-1.9019 1.2737-1.2740

(48.323-48.333) (48.298-48.308) (61.064-61.074) (48.323-48.333) (48.298-48.308) (32.352-32.359)
YELLOW 1.9030-1.9034 1.9010-1.9014 2.4046-2.4050 1.9030-1.9034 1.9010-1.9014 1.2733-1.2736

(48.336-48.346) (48.285-48.295) (61.076-61.087) (48.336-48.346) (48.285-48.295) (32.341-32.349)
BLACK 1.9035-1.9039 1.9005-1.9009 2.4051-2.4055 1.9035-1.9039 1.9005-1.9009 1.2729-1.2732

(48.349-48.359) (48.272-48.283) (61.089-61.099) (48.349-48.359) (48.272-48.283) (32.331-32.339)
3-42
Bushing Inspection and Removal 2806a
1. See Figure 3-51. Bushings (7, 8, 13, 14, 15 and 16) are
press fit in gearcase cover (17) and crankcase. Inspect
each bushing against its corresponding cam gear shaft
or pinion gear shaft. See Table 3-10.
Table 3-10. Gear Shaft Specifications

CORRECT SERVICE WEAR
GEAR SHAFT
CLEARANCE LIMIT
Cam 0.0007-0.0022 in. 0.003 in.
(0.018-0.056 mm) (0.08 mm)
Pinion 0.0023-0.0043 in. 0.005
(0.058-0.109 mm) (0.13 mm)
2. See Figure 3-55. Use a BUSHING AND BEARING

PULLER (Part No. HD-95760-69A) to remove bushings
from gearcase cover and crankcase.
Bushing and Bearing Puller
Bushing Installation (Part No. HD-95760-69A)
NOTE
Installing and reaming crankcase and gearcase cover bush-
ings may alter the center distances between mating gears
and may result in an increase in gear noise. For quiet-running
gears, the gears should be matched to the center distances. Figure 3-55. Removing Bushing
CAM GEAR BUSHINGS IN RIGHT

xlh0355
CRANKCASE HALF Drill 5/32 in.
(3.97 mm)
1. See Figure 3-57. Each cam gear bushing (1), to be
installed in right crankcase half (2), must be positioned in Slot
crankcase bore with its oiling slot at exact top of bore (12
o’clock position).
2. Using an arbor press, install each bushing in its crank-
case bore so that bushing shoulder contacts crankcase
boss.
3. After you install a new bushing in right crankcase half,
ream the bushing to correct size. See BUSHING REAM-
ING on page 3-44.
CAM GEAR BUSHINGS (EXCEPT REAR INTAKE
BUSHING) IN GEARCASE COVER
1. See Figure 3-51. Using an arbor press, install each bush-
ing (7, 8 and 14) in its gearcase cover (17) bore so that 1. Rear intake cam gear bushing
bushing shoulder contacts cover boss. There is no need 2. Gearcase cover
to orient these particular bushings in any specific position
of rotation within gearcase cover bores. Figure 3-56. Rear Intake Cam Gear Bushing
Installed in Gearcase Cover
2. After you install a new bushing in gearcase cover, line-
ream the bushing to correct size. See BUSHING REAM-
2. See Figure 3-56. Position bushing (1) over bore of gear-
ING on page 3-44.
case cover (2) with chamfered edge downward and slot
REAR INTAKE CAM GEAR BUSHING IN upward. Align slot in bushing with slot in gearcase cover
boss. Press bushing into cover bore until bushing is flush
GEARCASE COVER.
with cover boss.
1. See Figure 3-51. Rear intake cam gear bushing (15)
3. Drill a 5/32 in. (3.97 mm) diameter hole through bushing
must be installed in its gearcase cover (17) bore using an
using existing hole in gearcase cover as a guide.
arbor press. You will need to orient the bushing in a spe-
cific position of rotation within the cover bore, and will 4. After you install a new bushing in gearcase cover, line-
need to drill a lubrication hole in the bushing, according ream the bushing to the correct size. See BUSHING
to the following procedures REAMING on page 3-44.
3-43
b0089x3x
Oiling slot must be 3319a
at 12 o’clock position
1
Replacement bushing
requires dowel pin hole
1. Cam gear bushing 2. Right crankcase half

Figure 3-58. Drilling Dowel Pin Hole
Figure 3-57. Cam Gear Bushing Installed in Crankcase
CAM GEAR BUSHINGS IN
PINION SHAFT BUSHING IN GEARCASE COVER RIGHT CRANKCASE HALF
1. Separate two halves of crankcase, if not already accom-
1. See Figure 3-51. Using an arbor press, install pinion
plished. Place right crankcase half on flat surface with
shaft bushing (16) in its gearcase cover (17) so that
gearcase side upward. Bushing to be reamed must be
bushing is flush with cover boss. There is no need to ori-
oriented as shown in Figure 3-57.
ent this particular bushing in any specific position of rota-
tion within the gearcase cover bore. 2. See Figure 3-59. Position CAMSHAFT BUSHING
REAMER PILOT (Part No. HD-38871) onto gearcase
2. Although the original pinion shaft bushing is not “pinned,” side of crankcase half; upper right and lower left indexing
the replacement bushing must be secured, from possible holes in pilot must be placed over dowels in crankcase
rotation within the cover bore, by installation of a dowel half. Insert two bolts (supplied with pilot) through two
pin. See Figure 3-58. Drill a No. 31 hole, 0.281 in. remaining holes in pilot, and into threaded holes of
(7.14 mm) deep, at top side of boss (side toward top of crankcase half. Tighten bolts securely.
gearcase cover), centering the drill bit on the cover bore
circle (hole is drilled half in bushing OD and half in cover 3. Insert the 11/16 in. diameter reamer through pilot hole
bore ID). and into bushing while turning reamer clockwise. Con-
tinue turning reamer clockwise through bushing until
3. Drive a new dowel pin no more than 0.20 in. (5.1 mm) smooth shank of reamer passes through hole in pilot.
below the bushing face. Carefully peen edges of hole to 4. Detach reamer from handle. Pull reamer out opposite
lock the pin in place. side of crankcase half.
4. After you install a new bushing in gearcase cover, line- 5. Thoroughly clean right crankcase half, removing all metal
ream the bushing to the correct size. See BUSHING chips/shavings. Blow out all oil passages using com-
REAMING. pressed air.
CAM GEAR BUSHINGS (EXCEPT REAR INTAKE
Bushing Reaming
BUSHING) IN GEARCASE COVER
NOTE
NOTE
● Installing and reaming crankcase and gearcase cover Newly installed cam gear bushings in the gearcase cover
bushings may alter the center distances between mating must be line reamed, using the right crankcase half as a pilot
gears and may result in an increase in gear noise. For for the reamer, to establish correct clearance and to ensure
quiet-running gears, the gears should be matched to the perfect alignment. If crankcase halves are not separated on
center distances. your motorcycle, use a spare right crankcase half to perform
the following line reaming procedures.
● Bushings in right crankcase half serve as pilots for ream-
ing gearcase cover bushings and must, therefore, be 1. See Figure 3-51. Bushings (7, 8 and 14) to be reamed
reamed to size first. must be installed in gearcase cover (17) as described in
BUSHING INSTALLATION on page 3-43. Attach gear-
● After reaming any bushing, check shaft fit in the bushing. case cover to right crankcase half (10), which has been
It may be necessary to make a second pass with reamer disassembled from left crankcase half, securing with a
to attain proper fit. minimum of three mounting screws.
3-44
1. See Figure 3-51. Rear intake cam gear bushing (15)
3534a must be installed in gearcase cover (17) as described in
BUSHING INSTALLATION on page 3-43.
2. Identify the previously reamed rear intake cam gear
bushing (13) in right crankcase half (10), which has been
disassembled from left crankcase half. Insert the shank
Camshaft Bushing Reamer end of REAR INTAKE CAMSHAFT BUSHING REAMER
Pilot (Part No. HD-38871) (Part No. HD-94803-67) through gearcase side of this
bushing.
3. With reamer inserted into bushing in right crankcase half,
attach gearcase cover to right crankcase half, securing
with a minimum of three mounting screws.
4. Turn reamer clockwise through bushing in gearcase
cover until reamer bottoms. Then give reamer one com-
plete clockwise turn to size the bushing. Continue turning
reamer clockwise while extracting reamer from bushing.
5. Separate gearcase cover from right crankcase half.
Inspect bushing for proper cam gear shaft fit. Repeat line
reaming operation if necessary.
6. Thoroughly clean gearcase cover, removing all metal
chips/shavings. Blow out all oil passages using com-
pressed air.
PINION SHAFT BUSHING IN GEARCASE COVER
Figure 3-59. Reaming Cam Gear Bushing in Right NOTE

Crankcase Half
A newly installed pinion shaft bushing in the gearcase cover
2. Insert a standard 11/16 in. diameter reamer through the
must be line reamed, using both the right crankcase half and
previously reamed cam gear bushing (13) in right crank-
Part No. HD-94812-87 as pilots for the reamer, to establish
case half, which is in line with one of the bushings to be
correct clearance and to ensure proper alignment. If crank-
reamed in gearcase cover.
case halves are not separated on your motorcycle, use a
spare right crankcase half to perform the following line ream-
3. Turn reamer clockwise through bushing in cover until ing procedures.
reamer bottoms. Then give reamer one complete clock-
wise turn to size the bushing. Continue turning reamer 1. See Figure 3-51. Pinion shaft bushing (16) must be
clockwise while extracting reamer from bushing. installed in gearcase cover (17) as described in BUSH-
ING INSTALLATION on page 3-43. Attach gearcase
4. Repeat Steps 2 and 3 for remaining two cam gear bush-
cover to right crankcase half (10), which has been disas-
ings (except rear intake bushing) in gearcase cover, if
sembled from left crankcase half, securing with a mini-
required.
mum of three mounting screws.
Inspect bushings for proper cam gear shaft fit. Repeat 2. See Figure 3-60. Install PINION SHAFT BUSHING
line reaming operation if necessary. REAMER PILOT (Part No. HD-94812-87) into right
crankcase roller race. Insert PINION SHAFT BUSHING
6. Thoroughly clean gearcase cover, removing all metal REAMER (Part No. HD-94812-1) through the pilot.
chips/shavings. Blow out all oil passages using com-
pressed air. 3. Turn reamer clockwise through bushing in gearcase
cover until reamer bottoms. Then give reamer one com-
REAR INTAKE CAM GEAR BUSHING IN plete clockwise turn to size the bushing. Continue turning
GEARCASE COVER reamer clockwise while extracting reamer from bushing.
NOTE
Inspect bushing for proper pinion shaft fit. Repeat line
A newly installed rear intake cam gear bushing in the gear- reaming operation if necessary.
case cover must be line reamed, using the right crankcase
half as a pilot for the reamer, to establish correct clearance 5. Remove pilot from right crankcase roller race. Thor-
and to ensure perfect alignment. If crankcase halves are not oughly clean gearcase cover, removing all metal chips/
separated on your motorcycle, use a spare right crankcase shavings. Blow out all oil passages using compressed
half to perform the following line reaming procedures. air.
3-45
3545a b0178x3x
Pinion Shaft Bushing Reamer
Pilot (Part No. HD-94812-87)
Pinion Shaft Bushing Reamer

(Part No. HD-94812-1)
Timing mark at
centerline of
Pinion gear keyway
Figure 3-61. Pinion Gear Timing Mark and Keyway

Figure 3-60. Line Reaming Pinion Shaft Bushing
b0166x3x
4
1. See Figure 3-51. Install oil pump drive gear (12) and pin-
ion gear (5) to pinion shaft. Note that timing mark on pin-
2
ion gear tooth is aligned with keyway in ID of pinion gear,
as shown in Figure 3-61. See Figure 3-62. The timing
mark will allow you to easily position pinion gear (1) over
shaft key (2) and against oil pump drive gear (3) on pin-
ion shaft (4).
2. See Figure 3-51. Clean pinion shaft threads and nut (11) 3
threads. Apply several drops of LOCTITE THREAD-
LOCKER 262 (red) to threads of nut. Install nut to pinion
shaft, tightening to 35-45 ft-lbs (47-61 Nm). 1
3. See Table 3-9 and Figures 3-53 and 3-54. Liberally apply 1. Pinion gear 3. Oil pump drive gear
engine oil to bushings, shafts, and gears. Install all cam 2. Shaft key 4. Pinion shaft
gears into bushings of right crankcase half, properly
Figure 3-62. Oil Pump Drive Gear and Pinion Gear
aligning timing marks of cam gears and pinion gear as
Installed on Pinion Shaft
shown in Figure 3-54.
6. Check cam gear end play for each cam gear as follows:
NOTE
a. Turn engine over until lobe of cam gear being
Because of the larger diameter additional gear (which
checked is pointing toward its respective tappet
meshes with the pinion gear) on the outboard end of the rear
guide hole.
intake (15-2) cam gear, the rear exhaust (15-1) and front
intake (15-3) cam gears must both be installed before the rear b. Using a flat blade screwdriver, gently pry the cam
intake (15-2) cam gear is installed. gear toward gearcase cover.
c. Using a feeler gauge, measure gap between bush-
4. See Figure 3-51. Install a new seal (6) and new dry gas- ing (in crankcase half) and cam gear shaft thrust
ket (9) on gearcase cover (17). face (shoulder). This is cam gear end play.
5. Install gearcase cover over all gears and onto right d. Compare your cam gear end play measurements
crankcase half (10). Secure cover to crankcase half with with the SPECIFICATIONS on page 3-3. Make
11 socket head screws. Tighten screws evenly to 80- repairs as required if end gap is less than the mini-
110 in-lbs (9.0-12.4 Nm) according to the torque mum specified, or greater than the maximum speci-
sequence shown in Figure 3-63. fied (Service Wear Limits).
3-46
7. Install valve tappets and push rods. See VALVE TAP-
b0064a3x
PETS, INSTALLATION on page 3-39. 8
8. Install ignition system. See Section 7. 1
3
9. Install any components removed to gain access to gear- 9
case (i.e. exhaust system components, air cleaner, etc.). 7
10
11
6
4
2
5
Figure 3-63. Gearcase Cover Mounting Screw

Torque Sequence
3-47
CRANKCASE
GENERAL 4. Rotate and push on sprocket shaft while reading dial

indicator. Then rotate and pull on sprocket shaft while
When rod bearings, pinion shaft bearing or sprocket shaft reading dial indicator. If difference (end play) in indicator
bearing are in need of repair, the engine must be removed readings is not 0.001-0.005 in. (0.025-0.13 mm), bearing
from the chassis. See REMOVING ENGINE CRANKCASE inner spacer (shim) (item 6, Figure 3-68.) must be
OR COMPLETE ENGINE on page 3-8. It is recommended replaced. Choose spacer from Table 3-11. Use a thinner
procedure to check and make repairs to cylinder heads, cylin- spacer for less end play; use a thicker spacer for more
ders, gearcase and transmission at the same time (perform end play.
entire engine overhaul).
1CAUTION
If engine is removed from chassis, do not lay engine on
Table 3-11. Flywheel End Play
primary side. Placing engine on primary side will damage Spacers (Shims)
clutch cable end fitting. If fitting is damaged, clutch cable
must be replaced. PART THICKNESS
NUMBER IN. MM
ADJUSTMENT/TESTING 9155 0.0975-0.0985 2.476-2.502
9142 0.0995 - 0.1005 2.527-2.553
Flywheel End Play
9143 0.1015-0.1025 2.578-2.603
See Figure 3-64. Before completely disassembling crank-
9144 0.1035 - 0.1045 2.629-2.654
cases, check flywheel end play.
9145 0.1055 - 0.1065 2.680-2.705
9146 0.1075 - 0.1085 2.730-2.756
3536a
9147 0.1095 - 0.1105 2.781-2.807
9148 0.1115 - 0.1125 2.832-2.857
9149 0.1135 - 0.1145 2.883-2.908
DISASSEMBLY
Crankcase Halves
1. Remove cylinder heads as described under CYLINDER
HEAD, REMOVAL on page 3-11.
1CAUTION
After removing cylinders, install plastic or rubber hose
over cylinder studs. Lifting or moving crankcase by
Figure 3-64. Checking Flywheel End Play grasping studs will cause cylinder stud damage.
2. Remove cylinders and pistons. See CYLINDER AND

1. After engine has been removed from chassis, securely PISTON, REMOVAL/DISASSEMBLY on page 3-22.
fasten it to a stand or workbench.
3. Remove oil pump as described under OIL PUMP,
2. Remove gearcase cover. Attach a dial indicator to gear
REMOVAL/DISASSEMBLY on page 3-35.
side crankcase with indicator stem on end of gearshaft.
4. Remove gearcase components. See GEARCASE
3. Sprocket shaft bearings must be preloaded to obtain an
COVER AND CAM GEARS, REMOVAL/DISASSEMBLY
accurate flywheel end play reading. A suitable tool can
on page 3-40.
be made by welding two handles to an old sprocket shaft
nut. Install the nut and sprocket. Tighten nut to 150- 5. Remove clutch and primary drive components. See PRI-
165 ft-lbs (203-224 Nm). MARY DRIVE/CLUTCH in Section 6.
3-48
b0069a3x
2
2
2
4
1. Crankcase
2. Upper case hex socket head screw – 5/16-18 X 2-1/2 in. long (4)
3. Bottom case hex head bolt – 1/4-20 X 3/4 in. long (3)
4. Muffler mount bolt – 3/8-16 X 5-1/2 in. long (2, with washers and locknuts)
Figure 3-65. Crankcase Hardware
6. Remove starter motor as described under STARTER, 1WARNING

REMOVAL in Section 5. The following step requires using a press. Wear eye pro-
tection and make certain set-up is stable. The force
7. Remove transmission. See TRANSMISSION CASE in involved could cause parts to “fly out” and cause per-
Section 6. sonal injury.
8. See Figure 3-65. Remove screws (2) and rear engine 10. See Figure 3-66. Mount the left case half and flywheel
mount bolt securing crankcase halves together. assembly on a press table, supporting crankcase on par-
allel bars. Press on end of sprocket shaft with arbor
9. Position crankcase on work bench, gearcase side up. press until flywheel assembly is free from case half. Do
Tap crankcase with plastic mallet to loosen top half and not drive flywheel assembly from case half as flywheels
separate the halves. may be knocked out of alignment.
3-49
NOTE
3528a
See Figure 3-68. If it is necessary to remove either the pinion
shaft bearing (11) or sprocket shaft bearing (4 and 9), pro-
ceed as follows:
11. Pinion bearing (11) will remain on pinion shaft. Remove
retaining ring (10), and bearing (11) may be slipped off
pinion shaft.
12. See Figure 3-69. Pull sprocket shaft bearing with
WEDGE ATTACHMENT FOR CLAW PULLER (Part No.
HD-95637-46A) and ALL PURPOSE CLAW PULLER
(Part No. HD-95635-46) using bolts in place of jaws.
13. See Figure 3-67. Use CRANKSHAFT BEARING TOOL Press on end of sprocket
(Part No. HD-94547-101) to remove sprocket shaft outer shaft with an arbor press
races.
NOTE
See Figure 3-68. Do not remove retaining ring (7); the crank-
case can easily be damaged during the removal process.
Removal of the retaining ring is not necessary for the removal
or installation of the outer bearing races.
Flywheels
1. See Figure 3-70. Place flywheel assembly in holding fix-
ture. Remove crank pin nut (1). Strike left flywheel with
soft metal mallet at about 90° from crank pin hole on
wheel periphery to loosen. Lift left flywheel (2) off crank
pin. Figure 3-66. Pressing Flywheel from Crankcase
2. Hold down crank pin bearing assembly (4) with a short

length of pipe or tubing so connecting rods (3) may be 2809
slipped off bearings, then remove bearing assembly.
Secure bearings (4) together in set until they are washed
and refitted to crank pin.
3. Remove crank pin nut (9), then tap crank pin (6) out of
flywheel and remove key (7).
CLEANING/INSPECTION
1. Wash all parts in solvent and blow dry with compressed
air. Examine crank pin for wear, grooving and pitting. If
the surface is at all worn, replace with new pin. Examine Crankshaft Bearing Tool
flywheel washers. If either washer is worn or grooved, it (Part No. HD-9457-101)
should be replaced. See REPLACING FLYWHEEL
WASHERS on page 3-51.
2. Examine connecting rod lower races. If they appear
slightly grooved or shouldered where edge of bearing
rollers ride, they may be lapped out, and an oversize
crank pin and new bearing installed. If they appear badly
worn, grooved or pitted, new rods should be installed,
preferably as an assembly with new bearings and crank
pin.
3. Inspect bearing for wear, pitting and heat discoloration.
Replace as required.
4. Inspect crank pin, crank pin roller and connecting rods for
correct freeplay. Figure 3-67. Sprocket Shaft Outer Race Removal
3-50
b0130x3x
4
6 5
13 10 11
12 2 7
8 9
1. Right crankcase half
2. Left crankcase half
3. Connecting rod and flywheel 8. Sprocket left outer race
assembly 9. Sprocket left bearing
4. Sprocket right bearing 10. Retaining ring
5. Sprocket right outer race 11. Pinion shaft bearing
6. Spacer 12. Pinion shaft bearing inner race
7. Retaining ring 13. Pinion shaft bearing outer race
Figure 3-68. Crankcase and Flywheel Assembly
Replacing Flywheel Washers 2810a
Replace worn flywheel washers as follows:

1
1. See Figure 3-70. The washer (10) is a close fit in flywheel
recess and is secured originally by punching flywheel
metal tight against the washer at several points. It is usu-
ally necessary to drill a small hole (1/8 in. (3.2 mm) or
smaller) at the outer edge of the washer to permit prying
with a pointed tool.
2
NOTE
Drill hole only slightly deeper than thickness of washer. Avoid
removing more material than necessary.
2. Before installing a new washer, scrape outer edge of

recess, where metal was punched against original
washer, so new washer will seat fully against recess bot-
tom. If washer does not seat fully, forked rod will not have
necessary clearance (side play).
1CAUTION
Be sure stepped thrust washers are installed with step
facing crank pin bearing. Improper installation will dam- 1. All purpose claw puller (Part No. H-D 95637-46)
age washer and bearing set and cause accelerated wear 2. Wedge attachment (Part No. H-D 95637-46A)
and increased noise.
Figure 3-69. Removing Sprocket Shaft Roller
3. Carefully tap new washers into place and using a punch, Bearing
peen metal over edge to retain washer.
3-51
b0059x3x 1
3
2
10
6
10 Counterbore for Under cut
stepped washer (10) (shaded area)
9
NOTE
Same configuration on both flywheels.
1. Crank pin nut (sprocket side) 6. Crank pin

2. Flywheel (sprocket side) 7. Crank pin key
3. Connecting rods 8. Crank pin nut (gear side)
4. Crank pin roller and retaining set 9. Pinion bearing inner race
5. Flywheel (gear side) 10. Flywheel washer (2)
Figure 3-70. Flywheel and Connecting Rod Assembly
Lapping Connecting Rod Races NOTE

A loose lap will BELL MOUTH bearing races, so lap must be
Connecting rod lower races that are likely to clean up within kept adjusted at all times.
range of oversize bearing rollers and are otherwise in service-
able condition, should be trued and sized with CONNECTING 4. Start lathe and work rod back and forth, over full length of
ROD LAPPING ARBOR (Part No. HD-96740-36). lap. Hold rod as near race end as possible.
1. Clean lap before using. 5. Check rod frequently. When rod is lapped true and all
traces of pit marks or grooves are cleaned up, wash and
2. See Figure 3-71. Clamp lap into lathe chuck, carefully blow rod dry.
load lap with #220 grit grinding compound, mixed with oil.
Adjust lathe to turn at approximately 150-200 RPM. 6. Repeat lapping procedure for other rod race.
3. Carefully slide connecting rod over lap. Adjust lap to a 7. Bearing races should have a soft velvety appearance
dragging, but free, fit in rod race. and be free of shiny spots.
3-52
2182 3032a
Coat arbor with #220 grit

grinding compound and oil
Front rod bearing

Connecting Rod Lapping
Arbor (Part No. HD-96740-36)
Rear rod bearings
Figure 3-72. Crank Pin Bearing Set
3033a
Figure 3-71. Lapping Connecting Rod Races
Fitting Rod Bearings

See Figure 3-72. The new crank pin bearing set packages
are color coded with either a red or blue identification. This
color coding is used by the bearing manufacturer only. The
color coding DOES NOT indicate size selection for crank pin
bearing replacement.
1CAUTION
Either a red or a blue coded bearing set may be used. DO
NOT intermix bearings from a red and a blue bearing set
because this may cause excessive loading on one bear-
ing, resulting in premature bearing failure.
The bearings consist of rollers retained in steel cages.

The wide bearing (male/front rod) retains rollers both
internally and externally. The two narrow bearings
(female/rear rod) only retain the rollers externally, so care
must be taken to slide the bearing set directly from the
inner sleeve onto the crank pin; this will prevent the roll-
ers from dropping out of the cage.
Only one size replacement bearing set (standard, either

red or blue coding) is sold. Oversize bearings are not
available. Bearing clearance or fit is controlled by the b0179x3x
connecting rod race inside diameters and the crank pin Measure ID of each race
diameter. Two oversize crank pins are available. at four locations
1. See Figure 3-73. Measure inside diameter (ID) of lapped

connecting rod races with a dial bore gauge that has
0.0001 in. (0.0025 mm) graduations. Measure the ID at
four places as shown. Record the four measurements. If
any race ID exceeds Service Wear Limit of 1.6270 in.
(41.326 mm), replace races or connecting rod set. If race Figure 3-73. Measuring Connecting Rod Race
ID measurements are less than 1.6270 in. (41.326 mm), Inside Diameter
continue procedure as follows:
3-53
2. Compare the measurements recorded in Step 1 with the
b0061x3x
ranges given in Table 3-12. If the four measurements
taken in each race differ, use the smallest measure-
ments.
NOTE
Paint dot
Front and rear rod race ID must be within the same tolerance
range given in the above table. The following example will
illustrate the procedure necessary if the lapped connecting
rod races on both rods do not fall in the same range.
Blue = 0.0010 in OS (0.025 mm)

Table 3-12. Race Diameter and Red = 0.0020 in OS (0.051 mm)
Crank Pin Size Figure 3-74. Oversize Crank Pin Identification
CONNECTING ROD CRANK PIN 1CAUTION

RACE ID REQUIRED REQUIRED After the appropriate connecting rod race ID range speci-
1.6245-1.6250 in. Standard fied in RACE DIAMETER AND CRANK PIN SIZE table has
(41.262-41.275 mm) been achieved, verify that the following CONNECTING
ROD SPECIFICATIONS are also met:
1.6255-1.6260 in. 0.0010 in. oversize (0.025 mm)
(41.288-41.300 mm) CONNECTING ROD SPECIFICATION
1.6265-1.6270 in. 0.0020 in. oversize (0.051 mm) Rear . . . . . . . . . . . . . . Difference in ID of two races must not
(41.313-41.326 mm) exceed 0.0001 in. (0.0025 mm).
Greater than 1.6270 in. Service Wear Limit exceeded. Front and rear . . . . . . Difference in ID of races in front and
(41.326 mm) Replace races or connecting rod rear connecting rods must not exceed
set. 0.0002 in. (0.005 mm).
Front and rear . . . . . . Races must be round within
0.00025 in. (0.0064 mm). (Difference
3. As an example, assign the following values to the mea- between largest and smallest ID mea-
surements taken in Step 1. surement in any race must not exceed
0.00025 in. (0.0064 mm)).
Front connecting rod race diameter: 1.6255 in. NOTE
(41.288 mm) Always use new bearings and crank pin after resizing (lap-
ping) connecting rods to insure proper running clearance.
Rear connecting rod race diameter: 1.6250 in.
(41.275 mm) 1CAUTION
Fitting components tighter than recommended may result
See Table 3-12. For the above example measurements, the in seizing and bearing damage when heat expands the
front connecting rod would require a 0.0010 in. (0.025 mm) parts. Such damage requires component replacement.
oversize crank pin, while the rear connecting rod could use
the standard sized crank pin. The rear connecting rod races Fitting Sprocket Bearings
must be lapped so they have the same ID (within 0.0002 in.
(0.005 mm)) as the front rod. If flywheel end play is within tolerance, and if tapered roller
bearings and races pass visual check and have no apparent
4. See Figure 3-74. Oversize (OS) crank pins are available wear, the same set may be reinstalled. Make certain all parts
in two oversizes: 0.0010 and 0.0020 in. (0.025 and 0.051 of bearing are installed in exactly the same order in which
mm) OS crank pins will have a blue or red paint dot they were removed. If any part of bearing assembly is worn,
applied to the ends of the pins. A blue dot indicates entire assembly should be replaced.
0.0010 in. (0.025 mm) OS, a red dot indicates 0.0020 in.
(0.051 mm) OS. Standard size crank pins will not be Fitting Pinion Bearings
marked.
See Figure 3-68. A pressed-in bushing in the right crankcase
5. Before assembling the flywheel assembly, recheck con- half is the outer race (13). The inner race (12) is pressed on
necting rods as follows: the pinion shaft.
3-54
See Figure 3-75. To remove pinion shaft inner race, use TWO
b0060x3x
CLAW PULLER (Part No. HD-97292-61), CENTER CAP (Part
HD-95652-43A), and BEARING SEPARATOR (SNAP-ON Inner
TOOLS Stock No. CJ950). Apply heat to race to aid removal. race
Four sizes of pinion bearings are available. Pinion bearing
selection at the factory, during engine rebuild, or replacement
of crankcase set or flywheel assembly is based on the largest
measured outside diameter (OD) of the inner race and the
smallest measured inside diameter (ID) of the outer race Paint dot
(crankcase bushing). A running clearance of 0.0002-
0.0008 in. (0.005-0.020 mm) is established during crankcase
set or flywheel assembly replacement and engine rebuild.
See Figure 3-76. Installed inner races are identified at the fac-
tory as shown.
See Figure 3-77. Outer races are identified at the factory as

shown. RACE OD CLASS IDENTIFICATION*
1.2498-1.2500 in.
A White
(31.745-31.750 mm)
3106a
1.2496-1.2498 in.
B Green
(31.740-31.745 mm)
* Paint dot on end of spline
Service Wear Limit: 1.2492 in.
1 Figure 3-76. Factory Inner Race Sizes
b0176x3x
Outer race
2 ID
Right crank-
case half
3
Stamped
class no.
CLASS STAMPED
RACE ID
NO. IDENTIFICATION*
1.5646-1.5648 in.
1 1
(39.741-39.746 mm)
1.5648-1.5650 in.
2 2
(39.746-39751 mm)
1.5650-1.5652 in.
3 3
1. Puller (Part No. HD-97292-61) (39.751-39756 mm)
2. Center cap (Part No. HD-95652-43A)
* Stamped number inside crankcase near race
3. Bearing separator (Snap-On Part No. CJ950)
Service Wear Limit: 1.5672 in.
Figure 3-75. Pulling Pinion Shaft Inner Race
Figure 3-77. Factory Outer Race Sizes
3-55
NOTE b0065x3x
The different sizes of crankcase sets and flywheel assemblies
will not have separate part numbers. That is, a replacement
A – Roller OD cannot
crankcase set may have a class 1, 2 or 3 pinion outer race.
be measured
Replacement flywheel assemblies will have either a class A
to required accu-
or B inner race.
racy with
See Figure 3-78. Pinion bearings are identified as shown. micrometer
BEARING SELECTION
Select bearings using the identification information given for
inner and outer races and bearings. See Table 3-13.
NOTE
IDENTIFICATION
If either inner or outer race show wear, measure both races to ROLLER OD (A)
(Package color)
confirm correct bearing fit.
1. Measure ID of outer race at four places with a dial bore Largest Red
gauge. Take measurement on ID where bearing rollers Blue
ride. Record the four measurements. White (Grey)
Smallest Green
2. If the largest measurement is larger than 1.5672 in.
(39.807 mm) or the required lapping to remove wear
marks would enlarge bore beyond 1.5672 in., continue at Figure 3-78. Bearing Identification
Step 8.
3. If the largest measurement is 1.5672 in. (39.807 mm) or b0165x3x
less, cover the cam bearings with masking tape to pre-

vent debris from entering bearings. Assemble crankcase 1.145 in.
halves. (29.08 mm)
1.135 in.
NOTE (28.83 mm)
The next step requires lapping the outer race. To keep
sprocket shaft and pinion shaft bearings aligned the lap must
be supported by an adaptor or pilot in the left crankcase half.
4. See LAPPING ENGINE MAIN BEARING RACES on
page 3-58. Race must be lapped until all wear marks are
removed.
5. Measure ID of race at four places and record the mea-
2
surements.
6. Check measurements against these specifications: 1
Largest ID measured: 1.5672 in. (39.807 mm) or less
Roundness of ID: within 0.0002 in. (0.005 mm) 1. Pinion shaft inner race
Taper: within 0.0002 in. (0.005) 2. Flywheel (gear side)
7. If lapping increased bore ID to larger than 1.5672 in. Figure 3-79. Inner Race Location
(39.807 mm), go to Step 8. If roundness or taper do not
meet specifications, continue lapping until specifications
are met. If all specifications are met, continue at Step 10
to remove and size inner race.
8. Press the outer race from the right crankcase. Press new
outer race into crankcase flush with inside edge of cast-
in insert.
See Figure 3-80. Dimensions are shown for fabrication of
tools used in pressing the outer race into or out of crank-
case.
9. The new outer race must be lapped slightly to true and
align with left case bearing and to meet the following
specifications. See LAPPING ENGINE MAIN BEARING
RACES on page 3-58.
ID: 1.5646 - 1.5652 in. (39.741 - 39.756 mm)
Roundness: within 0.0002 in. (0.005 mm)
Taper: within 0.0002 in. (0.005 mm)
Surface finish: 16 RMS
3-56
Table 3-13. Pinion Shaft Bearing Selection
FACTORY
STAMPED OUTER RACE ID BEARING SIZE AS IDENTIFIED BY COLOR CODING
NUMBER
over 1.5672 in.

Service Wear Limit Exceeded – Replace Outer Race and Resize
39.807 mm
1.5670-1.5672 in. Red

39.802-39.807 mm
1.5668-1.5670 in. Red Blue

39.797-39.802 mm
1.5666-1.5668 in. Red Blue White-Gray

39.792-39.797 mm
1.5664-1.5666 in. Red Blue White-Gray Green

39.787-39.792 mm

39.781-39-787 mm

39.776-39.781 mm

39.771-39.776 mm

39.766-39.771 mm

39.761-39.766 mm

39.756-39.761 mm
3 1.5650-1.5652 in. Red Blue White-Gray Green

39.751-39.756 mm
2 1.5648-1.5650 in. Blue White- Green

39.746-39.751 mm Gray
1 1.5646-1.5648 in. White- Green

39.741-39.746 mm Gray
INNER 1.2496- 1.2498- 1.2500- 1.2502- 1.2504- 1.2506- 1.2508- 1.2510- 1.2512- 1.2514- 1.2516-
RACE OD (In) 1.2498 in. 1.2500 in. 1.2502 in. 1.2504 in. 1.2506 in. 1.2508 in. 1.2510 in. 1.2512 in. 1.2514 in. 1.2516 in. 1.2518 in.
31.740 31.745 31.750- 31.755- 31.760- 31.765- 31.770- 31.775- 31.780- 31.786- 3.791-
31.745 mm 31.750 mm 31.755 mm 31.760 mm 31.765 mm 31.770 mm 31.755 mm 31.780 mm 31.786 mm 31.791 mm 31.796 mm
FACTORY COLOR CODE Green White
10. See Figure 3-75. Pull inner race from pinion shaft using EXAMPLE:
TWO CLAW PULLER (Part No. HD-97292-61), CENTER
a. If smallest measured ID of outer race is 1.5651 in.
CAP (Part No. HD-95652-43A), and BEARING SEPARA-
(39.754 mm) Table 13 indicates an inner race OD
TOR (SNAP-ON TOOLS Stock No. CJ950). Apply heat to
range of 1.2496-1.2504 in. (31.740 - 31.760 mm) is
race to aid removal.
required.
11. See Figure 3-79. Press new inner race on pinion shaft as NOTE
shown. The new inner race must be ground by a compe- Have machinist grind outer race to center or middle of
tent machinist to OD dimension range given in the PIN- required OD range. This will prevent grinding outer race
ION SHAFT BEARING SELECTION TABLE, for the undersize and gives a more easily achieved tolerance range.
finished lapped ID of the outer race. The finished inner b. Grind inner race. Measure OD at four places and
race must meet these specifications. For necessary check that specifications in Step 11 are met.
dimensions for constructing a press-on tool see Figure 3-
80. When the tool bottoms against the flywheel, correct c. For example purposes, the largest measured OD of
inner race location is automatically established. inner race after grinding is 1.2499 in. (31.747 mm)
OD.
Roundness: within 0.0002 in. d. See Table 3-13. With a 1.5651 in. ID outer race and
Taper: within 0.0002 in. (0.005 mm) a 1.2499 in. (31.747 mm) OD inner race, a blue
Surface finish: 16 RMS bearing is required.
NOTE
12. The following example illustrates how to determine the Always use the smallest outer race ID measurement and the
required inner race OD. largest OD inner race measurement when selecting bearings.
3-57
b0177x3x Pinion outer race 3546a
installation
2.00"
Crankcase Main
(50.8 mm)
.187" (4.75 mm)
Bearing Lapping Tool
(Part No. HD-96710-40B)
5/16" 1.00
(7.94 mm) (25.4 mm)
DRILL
1.560"
(39.62 mm) Pinion outer race
removal
.187" (4.75 mm)
5/16" 1.00"
(7.94 mm) (25.4 mm)
DRILL
1.560"
(39.62 mm)
1.50" (38.1 mm)

Pinion inner race
1.00"
(25.4 mm) installation
Figure 3-81. Lapping Pinion Shaft Main Bearing
bushing surface has a dull, satin finish rather than a

5.50" (139.7 mm) glossy, smooth appearance. If necessary, flush off lap in
cleaning solvent, air dry and apply fresh, light coat of fine
lapping compound.
ASSEMBLY
1.145" (29.08 mm)
1.135" (28.83 mm)
Flywheels
After correct connecting rod bearing fit has been attained,
1.272" (32.31 mm) clean and assemble parts as follows:
1.262" (32.05 mm)
1. Carefully clean all flywheel components using a non-

Figure 3-80. Pinion Shaft Bearing Tools petroleum-based solvent, such as LOCTITE CLEANING
SOLVENT or electrical contact cleaner. Thoroughly dry
Lapping Engine Main Bearing Races all components.
1. Secure right and left crankcase halves with three crank- 2. See Figure 3-70. Apply two drops of LOCTITE 620
case stud bolts (top center and bottom left and right). The RETAINING COMPOUND to the crank pin threads, and
sprocket shaft bearing outer races and large spacer must apply no more than two drops to the nut bearing faces.
be installed in left crankcase.
1CAUTION
2. See Figure 3-81. Obtain CRANKCASE MAIN BEARING Do not apply any LOCTITE THREADLOCKER COM-
LAPPING TOOL (Part No. HD-96710-40B). Assemble POUND or RETAINING COMPOUND to shaft tapers. Any
CRANKCASE MAIN BEARING LAP (Part No. HD- material on shaft tapers will cause component damage.
96718-87) to lapping handle. Assemble guide sleeve to
sprocket shaft bearing bushing. Sleeves, for use with 3. Assemble crank pin (6) to gear-side flywheel (5) making
tapered bearing, are assembled to case with bearings sure that key (7) is in proper position. Tighten crank pin
and small spacer collar. Finger-tighten the sleeve parts. nut. See SPECIFICATIONS for proper torque.
3. Insert lap shaft with arbor assembled through pinion 4. Position gear-side flywheel assembly in a flywheel fixture
bearing bushing and into guide sleeve. Tighten arbor with crank pin pointing up. Wipe crank pin taper clean.
expansion collars using a length of 0.156 in. (3.96 mm) 5. See Figure 3-82. Slip bearings, and connecting rods over
rod as spanner until arbor begins to drag. Do not adjust crank pin. Assemble angular boss of the female rod adja-
arbor snug in bushing or bushing will “bell,” a condition cent to large radius side of the male rod as shown. The
where hole is larger at ends than it is in the center. side of the male rod with the larger radius is narrower in
the area where it fits between the forks of the female rod.
4. Withdraw arbor far enough to coat lightly with 220 grit
lapping compound. Do not apply a heavy coat. Reposi- 6. Verify that oil passages through pinion shaft, gear-side
tion lap in bushing and turn handle at moderate hand flywheel and crank pin are clear by blowing compressed
speed. Work lap back and forth in bushing, as it is air into oil galley at end of pinion shaft.
revolved, to avoid grooving and tapering. 7. Install sprocket-side flywheel. Lightly tighten nut.
5. At frequent intervals, remove lap from crankcase wash 8. See Figure 3-83. Hold steel straightedge along outer face
and inspect bushing. Lapping is completed when entire of wheel rims at 90° from crank pin as shown. Tap outer
3-58
b0167x3x
Note position of boss
Male rod – assemble to front cylinder

Forked or female rod –
assemble to rear cylinder
Large radius
Note position
of radius
MALE ROD
Figure 3-82. Installing Connecting Rods
rim of top wheel until wheels are concentric. Tighten nut,

xlh0381
recheck with straightedge at frequent intervals.
NOTE
Use soft metal hammer to realign wheels.
9. Tighten crank pin nut to 150-185 ft-lbs (203-251 Nm).
See Figure 3-85. Install flywheel assembly in FLYWHEEL
TRUING STAND (Part No. HD-96650-80) as shown.
Adjust so centers are snug. Wheels must turn freely;
however, shafts must not be loose in centers. If flywheel
assembly is either loose or squeezed, indicators will not
indicate accurately. Adjust indicators to take reading as
near to flywheels as possible, so pointers read at about
the middle of the scales. Figure 3-83. Squaring Flywheel Faces
10. Turn flywheels slowly and observe the movement of indi-
15. When wheels are out of true in a combination of any of
cator pointers. Movement toward flywheels indicate high
the conditions shown, correct C first, tapping rim of
points of shafts. Find highest point of each shaft and
offending wheel only, and then correct condition A or B.
chalk-mark flywheel rims at those points. Remove fly-
wheel from stand and make corrections as follows:
11. See Figure 3-84. Flywheel may be out of true three ways, NOTE
A, B and C or a combination of two of the three ways.
The number of blows required and how hard they should be
12. When wheels are both out of true as indicated in A, struck depends on how far shafts are out of true and how tight
tighten C-clamp on rims or wheels opposite crank pin nuts are drawn. Always remove the flywheels from the stand,
and lightly tap the rim at the crank pin with lead or copper and strike the flywheel rim only at 90° to the crank pin. Use
mallet. only a soft metal mallet. Never strike wheels a hard blow near
13. When wheels are both out of true as indicated in B, drive crank pin. This could result in a broken crank pin.
a hardwood wedge between the wheels opposite the
crank pin and lightly tap the rims near the crank pin with 16. See Figure 3-85. Readjust centers, revolve wheels and
a lead or copper mallet. take reading from indicator. Repeat truing operation until
14. When wheels are out of true as indicated in C, strike the indicated shaft runout does not exceed 0.001 in.
rim of the wheel a firm blow at about 90° from crank pin (0.025 mm) (each graduation on indicator is 0.002 in.
on high side. (0.05 mm)).
3-59
17. If it is impossible to true wheels, check for a cracked fly-
xlh0383
wheel, damaged or enlarged tapered hole or a sprocket
or pinion shaft worn out-of-round at surface where indi-
cator reading is being taken.
18. See Figure 3-86. When wheels are true, check connect-
ing rod side play with thickness gauge as shown. If it is Crank pin
greater than tolerance shown in SPECIFICATIONS,
CONNECTING ROD draw up crank pin nuts until within
tolerance. Insufficient play between rods and flywheel
face is caused by one of the following conditions:
a. Flywheels and crank pin assembled with oil on
tapers and nut over-tightened. Disassemble, clean
and reassemble. Hardwood wedge
b. New flywheel washers installed and not fully seated.
Disassemble, inspect, replace deepest seating fly- Figure 3-84. Correcting Flywheel Alignment
wheel or crank pin. As last resort, grind down width
of forked rod. 19. After rod side play is checked and adjusted, check that
crank pin nut is tightened to specified torque, again
c. Taper holes enlarged as a result of having been check wheel trueness on truing device. Correct any
taken apart several times. Replace deepest seating runout as above.
wheel.
d. Cracked flywheel at tapered hole. Replace flywheel.
4179
Flywheel Truing Stand

(Part No. HD-96650-80)
Figure 3-85. Truing Flywheel
3-60
2812a b0168x3x
2
1
Sprocket Shaft Bearing Outer Race
Installation Tool (Part No. HD-39458)
3
Figure 3-86. Checking Connecting Rod Sideplay 4
Crankcase Halves
Lubricate all parts with Harley-Davidson 20W50 engine oil,
and proceed as follows: 1. Installer base 4. Left outer race
1. See Figure 3-87. The original retaining ring (3) is left in 2. Installer plug 5. Right outer race
place to avoid damaging the bearing bore of the left 3. Retaining ring 6. Left crankcase half
crankcase half (6). Verify that gap in retaining ring is
Figure 3-87. Installing Sprocket Shaft Bearing
aligned with oil supply hole in bearing bore of left crank-
Outer Races
case half.
NOTE NOTE
See Figure 3-87. USE SPROCKET SHAFT BEARING See Figure 3-88. Use SPROCKET SHAFT BEARING/SEAL
OUTER RACE INSTALLATION TOOL (1-2 Part No. HD- INSTALLATION TOOL (1 - 8, Part No. HD-37047A) to install
39458) to install left and right outer races (4, 5) of sprocket sprocket shaft tapered roller bearings and seal.
shaft tapered roller bearings into left crankcase half (6).
Always install left outer race (4) prior to installing right outer 8. See Figure 3-89. Place bearing cone (3), small end
race (5); the installer base (1) is usable only when you follow upward, over end of sprocket shaft. Position spacer (2)
this sequence of race installation. over sprocket shaft with (radius) rounded end downward.
Thread nut driver (1) on sprocket shaft. Turn nut driver
2. Insert “SPORTSTER” end of installer base (1) into onto shaft until nut bottoms at end of threads. Remove
inboard side of left crankcase half (6) bearing bore until nut driver and spacer (2).
base contacts installed retaining ring (3).
9. See Figure 3-88. Repeat procedure using spacers (3, 4,
3. Position left outer race (4) over bearing bore on outboard 5 and 6) until bearing cone bottoms against the shaft
side of left crankcase half (6). shoulder.
4. Insert shaft of installer plug (2) through left outer race (4)
10. See Figure 3-90. Position left crankcase over sprocket
and into installer base (1). Press race into bore until
shaft so that the shaft is through the bearing cups in the
firmly seated against retaining ring (3).
bearing bore. Place the spacer that determines end play
5. Insert “SPORTSTER” end of installer base (1) into out- (item 6 in Figure 3-68.) over sprocket shaft. Position left
board side of left crankcase half (6) bearing bore until bearing cone over end of shaft with small end downward.
base contacts outboard surface of installed left outer Place spacer (2) over sprocket shaft with flat end down-
race (4). ward. Thread nut driver (1) on sprocket shaft. Turn nut
6. Position right outer race (5) over bearing bore on inboard driver onto shaft until threads bottom. Remove nut driver
side of left crankcase half (6). and spacer. See Figure 3-88. Install spacers (3, 4 and 5)
and nut driver (1) in same manner, and tighten until bear-
7. Insert shaft of installer plug (2) through right outer race
ing cones and spacer are drawn together.
(5) and into installer base (1). Press race into bore until
firmly seated against retaining ring (3). 11. Remove nut driver and spacer.
3-61
xlhsprtl 3533a
2
5
7
4
8
2 1. Nut driver 2. Spacer

1
Figure 3-90. Installing Left Crankcase
1. Nut driver 5. Spacer (2.06 in.)
2. Spacer (0.75 in.) 6. Spacer (2.5 in.) 4600
3. Spacer (1.2 in.) 7. Seal/spacer driver
4. Spacer (1.6 in.) 8. Driver handle
Figure 3-88. Sprocket Shaft Bearing/Seal

Installation Tool
3320a
1
2
3 Spacer
Seal (open side)
Figure 3-91. Install Spacer in Seal
13. See Figure 3-92. Center seal/spacer driver over seal, so

that the sleeve (smaller OD) seats between seal wall and
garter spring. Fit the sleeve of the driver handle into the
recess at the top of the seal/spacer driver. Using a rub-
ber or plastic mallet, drive the seal and spacer simulta-
neously into the bore until the spacer makes solid
contact with the Timken bearing cage. Remove the driver
handle and seal/spacer driver.
1. Nut driver 3. Bearing cone 1CAUTION

2. Spacer
Do not remove the spacer after installation or the new
Figure 3-89. Installing Bearing Cone seal will have to be discarded and the procedure
repeated.
12. See Figure 3-91. Install spacer in seal ID. With the open
(lipped) side facing outward, center seal/spacer assem- 14. Apply a thin coat of DOW CORNING SILASTIC or 3-M
bly over bearing bore. 800 sealant to crankcase joint faces.
3-62
4598a b0066x3x
Install this
end up
Shoulder
Figure 3-93. Cylinder Studs

1. Crankcase 3. Driver handle
2. Rubber mallet 4. Seal/spacer driver
3531a
Figure 3-92. Install Bearing Seal/Spacer
15. Assemble crankcase halves together. See Figure 3-65.

Install hardware to secure crankcase halves. Tighten 1/4-
in. fasteners to 70-110 in-lbs (7.9-12.4 Nm), and 5/16-in.
fasteners to 15-18 ft-lbs (20-24 Nm).
16. See Figure 3-68. Lubricate pinion shaft bearing (11) with
engine oil. Slip bearing (11) on pinion shaft and into outer
race in right crankcase. Install new retaining ring (10) in
groove of pinion shaft bearing inner race (12).
17. See Figure 3-93. The cylinder studs have a shoulder at Install cylinder studs
the lower end. shoulder end down
18. Pack clean towels into crankcase opening.

19. Place a steel ball into a head bolt, then place the
unpainted end of the stud into the head bolt.
20. See Figure 3-94. Install the stud in the crankcase with
the shoulder end down. Tighten to 10 ft-lbs (13.6 Nm).
21. See Figure 3-65. Install crankcase in chassis using hard-
ware shown.
22. Install transmission mainshaft sprocket. See TRANSMIS-
SION INSTALLATION AND SHIFTER PAWL ADJUST-
MENT in Section 6.
Figure 3-94. Install Cylinder Stud
23. Install starter. See STARTER, INSTALLATION in Section 5.
24. Install primary drive components, clutch and clutch NOTE
release mechanism. See PRIMARY DRIVE/CLUTCH in
Be sure to refill transmission with lubricant. See CLUTCH,
Section 6.
TRANSMISSION FLUID in Section 1.
25. Apply two or three drops of LOCTITE THREADLOCKER
262 (red) on threads of sprocket shaft. Tighten front 26. Install transmission. See TRANSMISSION INSTALLA-
sprocket nut to 150-165 ft-lbs (203-224 Nm). TION AND SHIFTER PAWL ADJUSTMENT in Section 6.
3-63
27. Install oil pump. See OIL PUMP, ASSEMBLY/INSTALLA- 30. Install cam gears, gearcase cover, tappet guides and
TION on page 3-36. tappets. See GEARCASE COVER AND CAM GEARS,
28. Install cylinders and pistons. See CYLINDER AND PIS- ASSEMBLY/INSTALLATION on page 3-46.
TON, ASSEMBLY/INSTALLATION on page 3-27. 31. Refer to INSTALLING THE ENGINE on page 3-10 and
29. Install cylinder heads. See CYLINDER HEAD, INSTAL- perform the applicable steps.
LATION on page 3-20. 32. Install ignition system and check/adjust engine ignition
timing. See IGNITION SYSTEM in Section 7.
3-64
INTERNAL ENGINE PASSAGES
RETURN OIL
FEED OIL
RETURN OIL
FEED OIL
4
SPECIFICATIONS
CARBURETOR JET SIZES CARBURETOR ADJUSTMENTS
Main jet 195 Engine fast idle speed

2000 RPM
(using enrichener circuit)
Slow jet 42
Engine speed for setting ignition
950-1050 RPM
timing-world models
FUEL TANK CAPACITY GALLONS LITERS
Engine speed for setting ignition
Total (including reserve) 4.0 15.14 1150-1250 RPM
timing-California models
Reserve 0.6 2.27
ITEM TORQUE NOTES
Air cleaner backplate screw 7-9 ft-lbs 9.5-12.2 Nm LOCTITE THREADLOCKER 242 (blue), page 4-19
Air cleaner cover rear screw 6-8 ft-lbs 8.1-10.8 Nm page 4-19
Air cleaner front support screw 3-5 ft-lbs 4.1-6.8 Nm LOCTITE THREADLOCKER 242 (blue), page 4-19
Canister clamp screws 6-8 ft-lbs 8.1-10.8 Nm page 4-25
Cylinder head breather bolts 10-15 ft-lbs 13.6-20.3 Nm HYLOMAR, page 4-19
Fuel cap flange screws 22-25 in-lbs 2.5-2.8 Nm special pattern to tighten, page 4-21
Fuel supply valve screws 34-37 in-lbs 3.8-4.2 Nm page 4-22
Fuel tank screw 9-11 ft-lbs 12.2-14.9 Nm page 4-21
Intake manifold screws 6-10 ft-lbs 8.1-13.6 Nm page 4-17
Snorkel tube screw 6-8 ft-lbs 8.1-10.8 Nm LOCTITE THREADLOCKER 242 (blue), page 4-19
Tie bar bolts 30-33 ft-lbs 40.7-44.7 Nm page 4-17
Torx ignition bracket screw 25-30 ft-lbs 33.9-40.7 Nm page 4-17
4-1
CARBURETOR
GENERAL 5609
See Figure 4-1. Buell motorcycles use a constant-velocity,
gravity-fed carburetor. This carburetor features a float-oper-
ated inlet valve, a variable venturi, a throttle stop screw (for
idle speed adjustment) and a fuel enrichment system (for
starting).
1
Idle and transfer ports provide a balanced fuel mixture during
the transition period from stop to mid-range. A vacuum piston
controls venturi opening.
The carburetor is specifically designed to control exhaust
emissions. All jets are fixed. The idle mixture has been pre-
set at the factory. The idle mixture screw is recessed in the
carburetor casting. The opening is sealed with a plug
because it is intended that the idle mixture be non-adjustable.
NOTE
Adjusting mixture setting by procedures other than specified
3
in this section may be in violation of Federal or State regula-
tions.
2
This system partially compensates for changes in the mixture
that are normally caused by changes in altitude. Because
atmospheric pressures drop as altitude increases, the pres-
sure difference in the upper and lower chambers is reduced;
this results in less fuel being delivered to the engine, thereby
maintaining the correct air/fuel ratio for better engine perfor- 1. Vacuum piston chamber 3. Accelerator pump
mance and reduced exhaust emissions. 2. Float chamber
The carburetor has a drain for emptying the float chamber Figure 4-1. Carburetor
during seasonal or extended periods of storage.
The carburetor is equipped with an accelerator pump. The
accelerator pump system uses sudden throttle openings
(rapid accelerations) to quickly inject raw fuel into the carbu-
retor venturi; this provides extra fuel for smooth acceleration.
4-2
Table 4-1. Fuel System Troubleshooting
OVERFLOW
Check for: Remedy:

1. Restricted fuel tank vent system. 1. Correct restricted hose. Replace vapor vent valve.
2. Loose float bowl screws. 2. Tighten screws.
3. Damaged float bowl O-ring. 3. Replace O-ring.
4. Damaged or leaking float assembly. 4. Replace float assembly.
5. Particle contamination in fuel inlet fitting cavity. 5. Clean and clear cavity and fuel supply tract.
6. Worn or dirty inlet valve or seat. 6. Clean or replace valve and clean seat.
7. Improper fuel level in float bowl. 7. Adjust float tab for correct fuel level.
POOR IDLING
Check for: Remedy:

1. Idle speed improperly adjusted. 1. Adjust operating idle speed.
2. Inlet system air leak (faster idling). 2. Correct as required.
3. Loose low speed jet. 3. Tighten jet.
4. Contaminated or plugged low speed system. 4. Clean, clear and correct as required.
5. Enrichener valve not seated or leaking. 5. Adjust, clean or replace.
6. Leaking accelerator pump. 6. Repair.
POOR FUEL ECONOMY
Check for: Remedy:

1. Excessive use of enrichener system. 1. Limit system use.
3. Dirty air cleaner filter element. 3. Clean or replace as required.
5. High speed riding style. 5. Modify riding habits.
7. Loose jets. 7. Tighten jets.
8. Fuel level too high. 8. Adjust float tab for correct fuel level.
9. Plugged or restricted bowl vent. 9. Clean and clear passages.
10. Worn or damaged needle or needle jet. 10. Replace needle or needle jet.
11. Vacuum piston assembly malfunction. 11. See Vacuum Piston Troubleshooting on page 4-4.
12. Plugged air jets or passages. 12. Clean, clear and correct as required.
13. Excessive accelerator pump output. 13. Check and clean accelerator pump bypass orifice.
POOR ACCELERATION
Check for: Remedy:

1. Throttle cables misaligned. 1. Adjust throttle cables.
2. Inlet system air leak. 2. Correct as required.
4. Restricted fuel supply passages. 4. Correct and clear restriction.
5. Plugged bowl vent or overflow. 5. Clean and clear passages.
7. Worn or damaged needle or needle jet. 7. Replace assembly.
8. Vacuum piston malfunction. 8. See Vacuum Piston Troubleshooting on page 4-4.
9. Plugged jets or passages. 9. Clean and clear as required.
10. Fuel level too low. 10. Adjust float tab for correct fuel level.
11. Accelerator pump leaking or no output. 11. Repair as necessary.
HARD STARTING
Check for: Remedy:

1. Enrichener system plugged, not properly functioning or 1. Clean, adjust or replace; or read Owner’s Manual.
improperly operated.
3. Restricted fuel supply. 3. Correct fuel supply or passages.
4. Fuel overflow. 4. See Overflow Troubleshooting on page 4-3.
5. Plugged slow jet or passages. 5. Clean, clear and correct as required.
4-3
Table 4-1. Fuel System Troubleshooting (cont.)
POOR PERFORMANCE ON ROAD
Check for: Remedy:

4. Dirty or damaged air cleaner element. 4. Clean or replace.
6. Restricted fuel supply tract. 6. Correct and clear restriction.
7. Plugged bowl vent or overflow. 7. Clean and clear passages.
8. Loose or plugged fuel and air jets or passages. 8. Clean, clear and correct as required.
10. Vacuum piston assembly malfunction. 10. See Vacuum Piston Troubleshooting below.
11. Accelerator pump inoperative. 11. Repair as required.
POOR HIGH-SPEED PERFORMANCE
Check for: Remedy:

1. Inlet system air leak. 1. Clean or replace.
4. Restricted fuel supply tract. 4. Correct and clean restriction.
5. Dirty or damaged air cleaner element. 5. Clean or replace.
6. Plugged bowl, vent or overflow. 6. Clean and clear passages.
8. Vacuum piston assembly malfunction. 8. See Vacuum Piston Troubleshooting below.
9. Loose or plugged main jets or passages. 9. Clean, clear and correct as required.
10. Improper fuel level. 10. Adjust float level.
11. Accelerator pump inoperative. 11. Repair as required.
Table 4-2. Vacuum Piston Assembly Troubleshooting
PISTON DOES NOT RISE PROPERLY
Check for: Remedy:

1. Piston atmosphere vent blocked. 1. Clear vent.
2. Diaphragm cap loose, damaged or leaking. 2. Tighten or replace cap.
3. Spring binding. 3. Correct or replace spring.
4. Diaphragm pinched at lip groove. 4. Reposition diaphragm lip.
5. Torn diaphragm. 5. Replace piston diaphragm assembly.
6. Piston binding. 6. Clean piston slides and body or replace piston.
7. Piston vacuum passage plugged. 7. Clean and clear passage.
PISTON DOES NOT CLOSE PROPERLY
Check for: Remedy:

1. Spring damaged. 1. Replace spring.
2. Piston binding. 2. Clean piston slides and body or replace piston.
3. Piston diaphragm ring dirty or damaged. 3. Clean or replace piston.
4-4
OPERATION OMF3
Normal running position

Enrichener
The enrichener knob, next to the ignition switch, controls the
opening and closing of the enrichener valve at the carburetor.
Full out position
1CAUTION 1/2 way position
Avoid idling with the enrichener knob in the full out posi-
tion for periods longer than 30 seconds. Such operation
may cause poor performance, erratic idle, poor fuel econ-
omy and spark plug fouling.
Figure 4-2. Enrichener Knob Positions
NOTE
The 1996 C.V. carburetor has an enrichener circuit that will COOL ENGINE
cause the engine to idle at approximately 2000 RPM with the
OUTSIDE TEMPERATURE WARMER THAN 50° F
engine at normal operating temperature and the enrichener
knob pulled fully out. 1. Set engine stop switch to RUN.
The increase in idle speed is intended to alert the rider that
the engine is warmed up to normal operating temperature 2. Raise side stand.
and the enrichener knob should be pushed all the way in.
3. Turn fuel supply valve ON.
Continuing to use the enrichener when the engine is at full
operating temperature WILL CAUSE FOULED PLUGS. 4. Turn ignition key switch to IGN.
IMPORTANT NOTE 5. BE SURE THROTTLE IS CLOSED. Pull enrichener knob

This motorcycle features a starter interlock. All the fol- to full out position.
lowing conditions must be met to operate the engine
starter. 6. Press electric starter switch to operate starter.
● Engine stop switch on right handlebar control group After starting the motorcycle, proceed as follows:
must be in the RUN (ignition ON) position.
1. After initial 15-30 second warm-up, ride for 3 minutes or
● Clutch must be disengaged before starting motorcy- 2 miles with enrichener knob in full out position.
cle in gear. Note that it is not necessary to disengage
clutch before starting the vehicle in neutral. 2. After 3 minutes or 2 miles, push enrichener knob in to the
● Side stand must be retracted before the clutch is 1/2 way position. Ride 2 minutes or 2 miles.
engaged if the motorcycle is in gear. 3. After 2 minutes or 2 miles, push enrichener knob fully in.
See STARTER INTERLOCK in Section 7 for troubleshoot-
ing information. WARM OR HOT ENGINE
COOL ENGINE 1. Set engine stop switch to RUN.
OUTSIDE TEMPERATURE COOLER THAN 50° F
2. Raise side stand.
1. Set engine stop switch to RUN.
2. Raise side stand. 3. Turn fuel supply valve ON.
3. Turn fuel supply valve ON. 4. Turn ignition key switch to IGN.
4. Turn ignition key switch to IGN.
5. DO NOT USE ENRICHENER. Open throttle 1/8-1/4.
5. BE SURE THROTTLE IS CLOSED. Pull enrichener knob
to full out position. 6. Press electric starter switch to operate starter.
6. Press electric starter switch to operate starter.
NOTE
After starting the motorcycle, proceed as follows:
If the engine does not start after a few turns or if one cylinder
1. After initial 15-30 second warm-up, ride for 5 minutes or
fires weakly but engine does not start, it is usually because of
3 miles with enrichener knob in full out position.
an over-rich (flooded) condition. This is especially true of a
2. After 5 minutes or 3 miles, push enrichener knob in to the hot engine. If the engine is flooded, push the enrichener knob
1/2 way position. Ride 2 minutes or 2 miles. fully in, turn ignition key switch to IGN and operate starter with
3. After 2 minutes or 2 miles, push enrichener knob fully in. throttle wide open. Do not “pump” the throttle while starting.
4-5
Fuel Supply System When fuel is used by the running engine, the fuel level in the
float chamber drops; this lowers the float and inlet valve,
thereby causing the valve to open and the fuel flow to resume.
See Figure 4-3. Fuel from the fuel tank passes through the
carburetor inlet valve into the carburetor float chamber. The
rising fuel level in the float chamber lifts the float, which in turn The float chamber is vented to atmosphere through an air
lifts the attached inlet valve closer to the valve seat. When the passage in the carburetor body. The opening for the float
fuel reaches the level predetermined by the float level setting, chamber vent passage is next to the carburetor main venturi
the float will lift the inlet valve into its seated position, thereby inlet, on the carburetor body surface to which the air cleaner
closing the valve and stopping fuel flow to the float chamber. backplate is mounted.
Float bowl
vent
Fuel inlet
(from side)
Inlet valve
Float
AIR
FUEL
Drain line
AIR/FUEL
Figure 4-3. Fuel Supply System
4-6
Starting Circuit When the enrichener knob is pulled outward, the enrichener
valve opens the air/fuel passage to the low pressure carbure-
See Figure 4-4. The starting circuit consists of a cable-actu- tor venturi. Fuel in the float bowl, at atmospheric pressure,
ated enrichener valve and converging fuel and air passages flows upward through a metering enrichener jet and then
in the carburetor body. through a passage to the lower pressure enrichener valve
chamber. Air in the enrichener air inlet, at atmospheric pres-
The enrichener air/fuel passage opens to the carburetor ven- sure, also flows into the lower pressure enrichener valve
turi, where low pressure exists when the engine is running. chamber and mixes with the incoming fuel. The resulting air/
Fuel in the carburetor float bowl and air in the enrichener air fuel mixture flows through the air/fuel passage into the carbu-
inlet are vented to atmosphere and are at atmospheric pres- retor venturi, effectively increasing the amount of fuel deliv-
sure (greater pressure than in the carburetor venturi). ered to the combustion chambers.
Enrichener
Enrichener valve
air inlet
Air/fuel
passage
Enrichener
valve cable
Enrichener
jet
AIR
FUEL
AIR/FUEL
Figure 4-4. Starting Circuit
4-7
Idle- and Low-Speed Circuit
See Figure 4-5. At idle (with the throttle plate closed and the During the transition period from idle speed to mid-range, the
main air stream obstructed), engine idle speed is maintained idle and transfer ports also supply some fuel to the carburetor
by fuel metered through the slow jet. Air from the slow air jet barrel; this allows for a smoother transition.
mixes with the fuel and is delivered to the idle port at the low
pressure side of the throttle plate. The venturi opening is reduced by the low position of the vac-
uum piston. This enables initial air stream velocities to be
At low-speed (with the throttle plate slightly open), the transfer higher than normally attainable with fixed-venturi carburetors.
ports are exposed to the low pressure side of the throttle plate, The higher air stream velocities provide improved atomization
and additional fuel is directed to the barrel of the carburetor. of fuel necessary for good acceleration and driveability.
Spring
Diaphragm
Throttle plate
Vacuum
Vacuum piston
piston
Transfer ports
Vacuum port
Idle port
Slow air jet
Idle mixture
screw Slow jet AIR
FUEL
AIR/FUEL
Figure 4-5. Idle- and Low-Speed Circuit
4-8
Mid-Range Slide Position
See Figure 4-6. As the throttle plate is opened, air flow The tapered needle moves upward with the vacuum piston,
increases through the carburetor; this causes air pressure to thereby opening the needle jet. With the needle jet open, the
decrease in the carburetor venturi (near the needle jet) and in main bleed tube is exposed to the lower pressure of the car-
the chamber above the diaphragm (which is vented to the buretor venturi. This causes fuel in the float bowl (at atmo-
venturi through a vacuum port and passage in the vacuum spheric pressure) to flow through the main jet and into the
piston). main bleed tube. Air from the main air jet (at atmospheric
pressure) flows through the main bleed tube openings and
The chamber beneath the diaphragm is vented to higher atmo- mixes with the incoming fuel. The air/fuel mixture is then
spheric pressure by a passage to the carburetor inlet. The delivered through the needle jet into the main air stream of
higher air pressure at the underside of the diaphragm over- the venturi.
comes spring pressure and moves the vacuum piston upward
in proportion to the pressure difference between the chambers.
Diaphragm
Spring
Vacuum piston
Vacuum port
Throttle
plate Needle
Needle jet
Main air jet
Main bleed AIR

tube Main jet FUEL
AIR/FUEL
Figure 4-6. Mid-Range Slide Position
4-9
High-Speed Circuit Slide Position The venturi opening increases and the needle is lifted further
out of the needle jet. The quantity of fuel and the volume of air
are simultaneously increased and metered to the proportions
of engine demand by the variable venturi and needle lift. With
the vacuum piston fully upward, the venturi opening is fully
See Figure 4-7. As the throttle plate is opened, the pressure enlarged and the needle jet opening exposure to the air
difference between the chambers above and below the dia- stream is at its maximum. Air and fuel supplies are now
phragm increases and the vacuum piston moves further available in quantities sufficient to meet maximum engine
upward. demand.
Diaphragm
Spring
Vacuum piston
Vacuum
port
Needle
Throttle
plate
Needle jet
Main air jet
Main bleed tube

AIR
Main jet FUEL
AIR/FUEL
Figure 4-7. High-Speed Circuit
4-10
Accelerator Pump System pump diaphragm. This forces fuel in the pump to flow through
a fuel passage (which has a “one-way” check valve), through
See Figure 4-8. The accelerator pump system uses sudden the pump nozzle, and then into the venturi. When the throttle
throttle openings (rapid acceleration) to quickly inject fuel into closes, the pump rod lifts up and away from the pump
the carburetor venturi; the extra fuel provides for smooth diaphragm; a spring below the diaphragm pushes the
acceleration. This fuel also assists engine operation during diaphragm upward, thereby causing the lower pump cavity to
cold engine warm-up when the enrichener is turned off pre- refill with fuel from the float bowl. The check valve prevents
maturely.
backflow of fuel from the pump nozzle/fuel passage during
Rapid throttle action, during the first third of throttle travel, this refilling phase.
causes the accelerator pump rod to depress the accelerator
Throttle
shaft
Venturi
Pump lever Throttle
rod
Pump
nozzle
Spring
Check Pump
valve rod
FUEL
Diaphragm
Spring
Figure 4-8. Accelerator Pump System
4-11
ADJUSTMENT 3. Install float and recheck setting.
4. Install float bowl. Install carburetor as described in CAR-
Idle BURETOR, INSTALLATION on page 4-17.
See IGNITION TIMING in Section 1.

OPERATION CHECK –
Enrichener Control
VACUUM PISTON
See Figure 4-9. Check enrichener operation. Enrichener knob
(1) should open (and remain open) and close without binding.
Plastic nut (2), next to the enrichener knob, controls the sliding Opening Malfunction
resistance of the enrichener control cable within the cable con-
duit. If adjustment is needed, perform the following:
1WARNING
While observing piston slide movement, be sure to main-
1. Loosen hex nut (5) at backside of mounting bracket. tain a safe distance from the carburetor and to wear suit-
2. Move cable assembly free of slot in mounting bracket. able eye protection. An unexpected engine backfire could
cause personal injury.
3. Hold cable assembly at flats (4) with a wrench. Adjust
resistance until knob slides outward and remains fully 1. See Figure 4-10. Test vacuum piston as follows.
open without assistance. Knob must also slide inward
unaided. a. Remove air cleaner cover and snorkel.
a. Turn plastic nut (2) by hand counterclockwise b. Start engine running.
(reducing sliding resistance). c. Twist throttle control partially open and closed sev-
b. Turn plastic nut clockwise (increasing sliding resis- eral times.
tance).
Observe whether or not vacuum piston has upward
4. Position cable assembly into slot in mounting bracket. movement. If piston does not rise, see VACUUM PIS-
Tighten hex nut at backside of bracket. TON ASSEMBLY TROUBLESHOOTING on page 4-4.
NOTE 2. With engine not running, lift vacuum piston with finger.
Do not lubricate the cable or inside of conduit. The cable must Feel whether piston lifts fully and smoothly or whether
have friction to work properly. there is a binding condition.
b0090c4x
5679
1 2 4 5
Vacuum piston
3
1. Enrichener knob 4. Flat
2. Plastic nut 5. Hex nut
3. Lockwasher
Figure 4-9. Fuel Enrichener Control
Float Level
1. Remove carburetor and place on a flat, clean surface on
engine manifold side. This is the “base.” Tilt carburetor
Figure 4-10. Vacuum Piston
counterclockwise 15˚ to 20˚ from base until float comes
to rest. See Figure 4-11.
Closing Malfunction
NOTE
If carburetor is tilted less than 15˚ or more than 20˚, your 1. See Figure 4-10. With engine not running, lift vacuum
measurements will be inaccurate. piston to full open position, then release. Observe
whether piston slides downward smoothly and fully to
2. Use a vernier or dial caliper depth gauge to measure
stop.
from the carburetor flange face to the perimeter of the
float. Be careful not to push on float while measuring. 2. Observe position of piston slide at its lowest downward
The measurement must be 0.413-0.453 in. point. Lower edge of slide should rest at horizontal
(10.49-11.51 mm). If measurement is not within given groove at lower end of slide track. See VACUUM PIS-
dimension, remove float and carefully bend tab in order TON ASSEMBLY TROUBLESHOOTING on page 4-4 if
to reposition float at proper level. problems are noted.
4-12
XLH0404
Start float position
Pin
Fuel inlet valve
Float
“Base”
Correct float position
Float
0.413-0.453 in.
(10.49-11.51 mm)
15 to 20˚
Incorrect float position
Pin return
spring collapsed
Float
Greater than 20˚
Figure 4-11. Carburetor Float Adjustment
4-13
REMOVAL 5751
3
Carburetor
1WARNING
Gasoline can be extremely flammable and highly explo-
sive. Do not smoke or allow open flame or sparks when
refueling or servicing the fuel system. Inadequate safety
precautions may result in personal injury.
1. Turn fuel supply valve OFF.
2. Remove air cleaner cover and backplate. See AIR 2
CLEANER, REMOVAL on page 4-18.
3. Loosen rear breather bolt. Remove front breather bolt
and washer. Remove air cleaner support ring.
1WARNING 1
A small amount of gasoline may drain from the fuel hose
when disconnected from the carburetor. Thoroughly wipe
up any spilt fuel immediately and dispose of rags in a
suitable manner. Gasoline can be extremely flammable
and highly explosive. Inadequate safety precautions may 1. Fuel hose
result in personal injury. 2. Canister vent hose (California models only)
3. V.O.E.S. connection (on back of carburetor)
4. See Figure 4-12. Disconnect fuel hose from carburetor.
Discard fuel hose clamp. Figure 4-12. Carburetor Hoses
5. Detach enrichener cable from bracket near ignition key
switch.
6. Disconnect vacuum hose from carburetor V.O.E.S. fitting.
7. Add freeplay to throttle cable adjusters (metric). Remove
b0101x4x
throttle cables at carburetor. 1 4
8. Pull carburetor free of intake manifold.
9. Disconnect fuel drain hose from drain fitting. On Califor-
nia models, disconnect canister vent hose.
Carburetor Manifold
6
1. Remove carburetor as described above.
2. Remove fuel tank. See FUEL TANK, REMOVAL on
page 4-20.
3. Remove ignition key switch bracket. 5
a. Remove bolt and locknut to detach top tie bar from 2
ignition key switch bracket. 6 3
b. Cut cable strap holding ignition wires to main wiring
harness.
c. Remove two TORX screws and washers from cylin-
der heads.
1. Rear mounting flange
d. Place bracket to the side.
2. Front mounting flange
4. See Figure 4-13. Loosen two intake manifold screws (4) 3. Intake manifold seal (2)
on primary side of engine. Do not remove. 4. Screw (4)
5. Remove two manifold mounting screws (4) on gearcase 5 5. Intake manifold
side of engine. 6. Seal ring
6. Remove intake manifold (5) and seal ring (6). Slide both Figure 4-13. Intake Manifold
mounting flanges (1, 2) over primary side screws (4).
Remove intake manifold seals (3).
4-14
DISASSEMBLY 12. Clean all internal fuel/air passages and jets. Check that
all passages and jets are open and free of obstruction.
Vacuum Piston Chamber 13. Check needle jet holder (10). Clean bleed tube orifices.
Replace holder if damaged.
1. See Figure 4-14. Remove screws (26, 25) and throttle
cable bracket (24). 14. Check float (16) for cracks or other leaks. Replace if
2. Remove three shouldered screws (2). Remove top cover damaged.
(1) and spring (3). 15. Clean main jet (11) with carburetor cleaner and inspect
3. Lift out vacuum piston (4) with jet needle (6) and spring for damage. Replace if damaged.
seat (5). Remove loose parts from vacuum piston.
Accelerator Pump
Carburetor Body
1. See Figure 4-14. Inspect the accelerator pump dia-
1. See Figure 4-14. Remove four screws and lockwashers phragm (44) for holes, cracks or deformation. Replace as
(18). Remove float bowl assembly (38). necessary.
2. Remove pin (14), float (16) and fuel inlet valve (13).
2. Replace the accelerator pump rod (51) if it is bent;
3. Back out main jet (11) and needle jet holder (10). Needle replace the boot (50) if cracked.
jet (9) is free to be removed from bottom end of passage.
4. Insert thin-bladed screwdriver into slow jet passage to
remove slow jet (12). ASSEMBLY
Accelerator Pump Vacuum Piston Chamber
1. Remove three screws (49), lockwashers (48), accelerator
1. See Figure 4-14. Place jet needle (6) through center hole
pump housing (42), spring (43) and diaphragm (44).
in vacuum piston (4). Place spring seat (5) over top of
Remove O-ring (45) from housing.
needle.
2. Insert vacuum piston (4) into carburetor body. The slides
CLEANING, INSPECTION AND on the piston are off-center and the piston will fit into the
REPAIR slide track grooves one way only. If piston does not fit,
rotate 180°.
Vacuum Piston Components 3. Check to be sure diaphragm is seated evenly into groove
at top of carburetor body. Place spring (3) over spring
1. See Figure 4-14. Hold vacuum piston up to strong light.
seat (5), and carefully lower top cover (1). Keep spring
Examine diaphragm at top of vacuum piston (4) for evi-
straight while lowering top cover.
dence of pinching, holes or tears. Replace if damaged.
2. Examine vacuum passage through bottom of piston (4). 4. After top cover (1) is seated, hold top cover while lifting
Clean passage if restricted. vacuum piston (4) upward. Piston should raise to top
smoothly. If piston movement is restricted, spring (3) is
3. Examine spring (3) for stretching, crimping, distortion or cocked; lift up top cover, then lower carefully, keeping
damage. Replace if necessary. spring coils straight.
4. Examine slide on sides of piston (4) to be sure surface is
5. Once top cover is installed correctly, install three shoul-
smooth and clean. Clean or buff out any rough surfaces.
dered screws (2). Place throttle cable bracket (24) in
5. Examine jet needle (6) for evidence of bending or dam- position with idle screw (27), resting on top of throttle
age. Needle should be straight; surface of taper should cam stop. Install body screw and washer (26) first, then
be smooth and even. top screw (25) to prevent bending bracket or throttle cam.
6. Check float bowl O-ring (53) for any distortion or dam-
age. Replace if seating surfaces are damaged. Carburetor Body
7. Examine fuel inlet valve (13) and inlet valve seat. Clean
with carburetor cleaner. Replace if seating surfaces are 1CAUTION
damaged. Slow jets from fixed-venturi carburetors look the same as
8. Clean slow jet (12) with carburetor cleaner. Check to be the slow jet of the C.V. carburetor. However, the air bleed
sure all orifices are open. hole sizes are different on fixed-venturi carburetors and
they must not be installed on C.V. carburetors.
9. Check enrichener valve (22). Be sure needle guide is
clean, straight and undamaged. Check composition seat- 1. See Figure 4-14. Thread slow jet (12) into slow jet pas-
ing surface for wear or damage. Replace if damaged. sage with narrow-bladed screwdriver.
10. Check enrichener valve chamber. Clean with carburetor 2. Turn carburetor upside down. Place needle jet (9) in main
cleaner. Check that all passages are open and free of jet passage with needle passing through center hole. Be
obstruction. sure end of jet with larger opening and chamfered sur-
11. Clean needle jet (9). Replace if damaged. face enters passage first.
4-15
b0005b4x 1. Top cover 15. Pump linkage
2. Shouldered screw (3) 16. Float
2 3. Spring 17. Carburetor body
4. Vacuum piston 18. Screw w/ lockwasher (4)
5. Spring seat 19. Cable guide
3 6. Jet needle 20. Starter cap
7. Fitting (V.O.E.S.) 21. Cable sealing cap
8. Fuel inlet fitting 22. Enrichener valve
9. Needle jet 23. Spring
10. Needle jet holder 24. Throttle cable bracket
11. Main jet 25. Screw
1
12. Slow jet 26. Screw and lockwasher
13. Fuel inlet valve 27. Idle speed adj. screw
5 14. Pin 28. Spring
29. Washer (2)
30. Drain hole
21 31. Drain hose
6 32. Clip
33. Washer
19 34. Cotter pin (2)
4 35. Washer (3)
36. Washer
37. Lever
20 38. Float bowl
57 39. E-clip
40. Accelerator pump nozzle
54 23 41. Spring
22 7
55
54 27 25
29 24
15
8
52 28
17 26
34 35
37
12 39 36
56
33 41
14 34
9
16 51
10 50 42. Pump housing
53
13 40 43. Spring
11 30 44. Diaphragm
45. O-ring
47 46. O-ring
46 47. Drain screw
18 31 48. Lockwasher (3)
49. Screw (3)
38 32 50. Boot
44 43 51. Accelerator pump rod
52. Collar
53. Float bowl O-ring
45 42 54. Clamp (2)
55. Hose
56. Washer
49 48 57. Vacuum hose
Figure 4-14. Constant-Velocity (C.V.) Carburetor
4-16
3. Insert needle jet holder (10) into main jet passage with Carburetor
needle inserted into center of holder. Thread holder into
passage and tighten. Thread and tighten main jet (11) in
1. Attach throttle cables to carburetor.
tapped hole in needle jet holder (10).
4. Place float assembly (16) into position with fuel inlet a. Install idle control cable into longer, inboard cable
valve (13) inserted into valve seat and with pivot arm guide on carburetor.
aligned with holes in mounting posts (at bottom of carbu-
retor body). Insert pin (14) through float pivot arm and b. Install throttle control cable into shorter, outboard
float mounting posts. cable guide on carburetor.
5. Check float level setting and adjust if necessary. See
FLOAT LEVEL on page 4-12. NOTE
6. Place float bowl (38) over float and onto carburetor body
flange. Bowl will only fit in one position. Install and tighten The fit between the carburetor and the seal ring is tight. For
screws and lockwashers (18). ease of installation, lubricate the mating surfaces, carburetor
body and seal ring with liquid dish soap or tire mounting lube
prior to assembly.
Accelerator Pump
Install diaphragm (44), spring (43), O-ring (45) and pump 2. See Figure 4-12. Connect fuel drain hose to drain fitting.
housing (42). Secure with screws (49) and lockwashers (48). Connect vacuum hose to V.O.E.S. fitting. On California
models, connect canister hose to carburetor.
INSTALLATION 3. Lubricate only the inside surface of seal ring that will be
in contact with the carburetor. Also apply a light coat of
Carburetor Manifold lubricant to the spigot of the carburetor body. Push car-
buretor body into seal ring.
1. See Figure 4-13. Place mounting flanges (1, rear and 2,
front) on aluminum manifold (5).
4. Attach fuel hose to carburetor with a new clamp.
2. Place intake manifold seals (3) on each spigot of manifold
with chamfered edge against mounting flanges (1, 2). 5. Install enrichener cable on bracket and adjust. See
3. Place channel of seal ring (6) over inlet end of manifold. ENRICHENER CONTROL on page 4-12.
4. Position manifold against intake ports of cylinder head, 6. Adjust throttle cables. See CARBURETOR in Section 1.
with slotted and round holes in flanges (1, 2) aligned with
holes in cylinder head. Manifold should slide over screws
7. Install air cleaner components. See AIR CLEANER,
on primary side of engine. Insert two screws (4) through
manifold flanges on gearcase side and loosely thread
into tapped holes in cylinder head. Tighten intake mani-
8. Install fuel tank. See FUEL TANK, INSTALLATION on
fold screws (4) to 6-10 ft-lbs (8.1-13.6 Nm).
page 4-21.
5. Install ignition key switch bracket.
a. Fasten bracket to cylinder heads with two TORX
screws and washers. Tighten to 25-30 ft-lbs (33.9-
Carburetor Drain Hose Routing
40.7 Nm).
Route fuel drain hose from the carburetor drain fitting down-
b. Attach top tie bar to bracket. Tighten locknut to 30-
ward and forward through the space between the engine rear
33 ft-lbs (40.7-44.7 Nm).
cylinder and the rear cylinder push rod covers (intake and
c. Secure ignition wires to main wiring harness using a exhaust), and then downward through the space between the
new cable strap. engine crankcase and the oil pump.
4-17
4
AIR CLEANER
GENERAL 5705
The air cleaner prevents foreign material from entering the 1
carburetor and engine by trapping airborne dust and dirt in
the filter element.
Service air cleaner filter element every 5000 miles (8000 km)
or more often if the motorcycle is run in a dusty environment.
See AIR CLEANER FILTER in Section 1 for more information.
REMOVAL
1CAUTION
Do not run engine without filter element in place. Debris 2
1. Screw and nylon washer
1. See Figure 4-15. Remove screw and nylon washer on
2. Screw, nylon washer and locknut
top of air cleaner cover.
2. Remove screw, nylon washer and locknut at rear of air Figure 4-15. Air Cleaner Cover
cleaner cover. Remove cover.
3. See Figure 4-16. Detach backplate hoses. 5707
a. Detach cylinder head breather hoses from tee fitting. 2

b. Detach snorkel breather hose at snorkel. 1 3 4
c. On California models, slide fresh air hose from can-
4. See Figure 4-17. Remove two screws and snorkel plate.
5. Remove snorkel and filter box.
5
6. See Figure 4-18. Remove screw with spacer and gasket.
7. See Figure 4-19. Remove screw under air cleaner sup-
port.
1. Snorkel 4. Front head breather
NOTE 2. Snorkel breather 5. Tee fitting
Step 7 may require a cut down allen wrench. 3. Rear head breather
8. Draw breather hoses through backplate. Remove back- Figure 4-16. Breather Hoses
plate.
9. If necessary, remove air cleaner support ring. 5678
a. Detach breather hoses from cylinder head breather
bolts.
b. Remove front breather bolt. 1
c. Loosen rear bolt.
d. Slide air cleaner support ring upward and remove.
4
NOTE
See Figure 4-20. Air cleaner support ring fits around breather 2 3
bolts. Fitting on rear breather bolt may not clear the frame if
bolt removal is attempted. Do not remove rear breather bolt
unless absolutely necessary. 1. Screw (2) 3. Screw
2. Snorkel plate 4. Snorkel tube
Figure 4-17. Snorkel Ring
4-18
INSTALLATION 5679
1. See Figure 4-20. If removed, apply HYLOMAR to threads 2

of breather bolts. Install air cleaner support ring using
breather bolts and washer. Tighten breather bolts to 10-
1
15 ft-lbs (13.6-20.3 Nm).
2. See Figure 4-16. Attach breather hoses.
a. If removed, attach hoses to breather bolts in cylinder

heads.
b. Slide hoses through backplate.
c. Connect hoses to tee fitting. 1. Air cleaner spacer with gasket

2. Screw
d. On California models, insert fresh air hose from can-
ister through backplate. Figure 4-18. Air Cleaner Spacer
3. See Figure 4-19. Apply LOCTITE THREADLOCKER 242 b0249x4x

(blue) to air cleaner front support screw. Install support/
backplate and tighten screw to 3-5 ft-lbs (4.1-6.8 Nm).
NOTE Front isolator mount
Step 3 may require a cut down allen wrench.

Air cleaner front
4. See Figure 4-18. Apply LOCTITE THREADLOCKER 242 support
(blue) to screw. Install ring with screw through backplate.
NOTE
Air cleaner backplate
5. See Figure 4-17. Apply LOCTITE THREADLOCKER 242 Screw
not shown.
(blue) to screws. Fasten snorkel tube with ring and two
Figure 4-19. Air Cleaner Front Support
6. Check air cleaner filter. See AIR CLEANER FILTER in
Section 1. Attach filter box with filter to snorkel tube.
5752
7. Connect breather hose to snorkel tube.
8. See Figure 4-15. Place cover over backplate assembly.

Install screw and washer into top well nut.
9. Install screw, nylon washer and locknut at rear mount.

Figure 4-20. Breather Bolts
4-19
FUEL TANK
GENERAL b0254x4x
1WARNING 3
Verify that the fuel tank vent hose does not contact hot 11
exhaust or engine parts. The hose contains flammable 4 12
vapors that can be ignited if damaged, thereby resulting 1
in personal injury. 5
2 10
See Figure 4-21. The fuel tank is vented through a vent valve
assembly within the tank. A vent hose connects to the vent
6 9
valve fitting at the top of the fuel tank. The vent hose is then
cable strapped to the left side of the vehicle frame.
8
REMOVAL
1WARNING
Gasoline can be extremely flammable and highly explo-
sive. Do not smoke or allow open flame or sparks when
7
1. Turn fuel supply valve OFF.
1. Screw 7. Fuel tank
1WARNING 2. Washer 8. Vent valve
A small amount of gasoline may drain from the fuel hose 3. Fuel cap 9. Fuel cap flange
when disconnected from the carburetor. Thoroughly wipe 4. O-ring 10. Vent valve fitting
up any spilt fuel immediately and dispose of rags in a 5. Screw (8) 11. Vent hose
suitable manner. Gasoline can be extremely flammable 6. Fuel cap boot 12. Cable strap
and highly explosive. Inadequate safety precautions may
result in personal injury. Figure 4-21. Fuel Tank
2. Remove fuel hose and hose clamp from fuel supply

valve.
NOTE
Fuel tank can be removed from motorcycle without being
drained. Drain tank only when necessary.
3. Drain fuel from tank.
a. Attach an additional length of hose to fuel supply
valve. Place free end of drain hose into a proper,
clean container of adequate size.
b. Turn supply valve to reserve (RES). Drain gasoline
from tank into container. Remove temporary drain
hose.
4. See Figure 4-21. Remove cable strap (12) holding vent
hose (11) to vent valve fitting (10). Disconnect vent hose
from vent valve fitting.
5. Remove seat.
6. Remove fuel tank screw (1) and washer (2).
1CAUTION
Use caution when removing fuel tank. If tank should con-
tact other chassis parts, tank finish may be damaged.
7. Lift rear of tank from frame and remove.
4-20
DISASSEMBLY/ASSEMBLY 5742
1WARNING
Even with the fuel tank completely drained, a small
amount of gasoline may leak from the bore when the fuel
3
supply valve is loosened or removed. Thoroughly wipe 6 7
suitable manner. Gasoline can be extremely flammable
result in personal injury.
2
1
1. If the fuel supply valve requires cleaning or repair, see
FUEL SUPPLY VALVE, REMOVAL on page 4-22.
2. See Figure 4-21. Remove fuel filler cap (3) and O-ring (4). 8
3. Remove vent valve fitting (10) and vent valve (8). 5
4
4. Remove self-tapping screws (5) from fuel cap flange (9).
5. Remove fuel cap flange and fuel cap boot (6). Figure 4-22. Tightening Flange
6. Assemble in reverse order.
a. Apply HYLOMAR to fuel cap boot, fuel cap flange
1CAUTION
and top of fuel tank.
Avoid pinching wiring harness and vent hose between
b. See Figure 4-22. Tighten screws to 22-25 in-lbs fuel tank and frame during tank installation. Pinched
(2.5-2.8 Nm) in the order shown. hoses will negatively affect vehicle operation.
CLEANING, INSPECTION 2. Connect vent hose (11) to vent valve fitting (10). Clamp
hose to fitting with a new cable strap (12).
AND REPAIR
1WARNING 3. Connect fuel hose to fuel supply valve with a new clamp
and HOSE CLAMP PLIERS (Part No. HD-41137)
An open flame or spark may cause a fuel tank explosion
if all traces of fuel are not purged from the tank. Use
extreme caution when servicing fuel tanks. Inadequate 1WARNING
safety precautions may result in personal injury.
Clean tank interior with commercial cleaning solvent or a soap sure it is locked in position. If seat is loose, it could shift
and water solution. Plug fuel tank openings. Shake tank to agi- during vehicle operation and startle the rider, causing
tate the cleaning agent. Thoroughly flush fuel tank after clean- loss of control and personal injury.
ing. Allow tank to air dry. Carefully inspect fuel hose for
damage, wear or general deterioration. Replace as necessary.
4. Install seat. See SEAT, INSTALLATION in Section 2.
INSTALLATION 5. Fill fuel tank with fuel supply valve turned OFF.
1. See Figure 4-21. Place fuel tank on frame. Install fuel
tank screw (1) and washer (2). Tighten to 9-11 ft-lbs 6. Open fuel supply valve and carefully inspect for leaks.
(12.2-14.9 Nm). Turn valve OFF after the inspection is performed.
4-21
FUEL SUPPLY VALVE
GENERAL b0029b2x
The fuel supply valve is located on the left side, below the fuel
tank. The gasoline supply to the carburetor is shut OFF when
the handle is in the vertical position. For gasoline main sup-
ply, turn the handle to the 3 o’clock position (horizontal rear-
ward). For gasoline reserve supply, turn the handle to the 9
o’clock position (horizontal forward). Turn valve to OFF posi-
tion (vertical) when engine is not running.
REMOVAL
1WARNING
Gasoline can be extremely flammable and highly explo-
sive. Do not smoke or allow open flame or sparks when
Filter strainer
1. See Figure 4-23. Turn fuel supply valve OFF. (shown unscrewed
from valve body)
1WARNING
A small amount of gasoline may drain from the fuel hose
when disconnected from the carburetor. Thoroughly wipe
suitable manner. Gasoline can be extremely flammable
and highly explosive. Inadequate safety precautions may Screw Screw
result in personal injury.
2. Remove fuel hose and clamp from fuel supply valve. Handle in
RES(ERVE)
3. Attach an additional length of hose to fuel supply valve.
position
Place free end of drain hose into a proper, clean con-
tainer of adequate size. Turn supply valve to reserve
(RES). Drain gasoline from tank into container. Remove
temporary drain hose.
Handle in ON
1WARNING position
Even with the fuel tank completely drained, a small
Handle in
amount of gasoline may leak from the bore when the fuel
OFF position
supply valve is loosened or removed. Thoroughly wipe
suitable manner. Gasoline can be extremely flammable Figure 4-23. Fuel Supply Valve
result in personal injury. INSTALLATION
4. Remove two screws and fuel supply valve assembly. 1. See Figure 4-23. Attach fuel supply valve to tank with two
screws. Tighten to 34-37 in-lbs (3.8-4.2 Nm).
CLEANING, INSPECTION AND 1CAUTION

Screws thread directly into plastic fuel tank. Overtighten-
REPAIR ing screws will strip the tank threads and require a
1. Clean or replace filter strainer (located inside fuel tank replacement fuel tank to be installed upon subsequent
above fuel supply valve). Filter strainer threads into valve removal of the fuel supply valve.
body.
2. Connect fuel hose with a new clamp and HOSE CLAMP
2. Flush fuel tank to remove all dirt. PLIERS (Part No. HD-41137).
4-22
EVAPORATIVE EMISSIONS CONTROL
CALIFORNIA MODELS
GENERAL Vapors to canister Captured
Buell motorcycles sold in the state of California are equipped check ball
with an evaporative (EVAP) emissions control system. The
EVAP system prevents fuel hydrocarbon vapors from escap-
ing into the atmosphere and is designed to meet the Califor-
nia Air Resource Board (CARB) regulations in effect at the
time of manufacture.
Gasoline
The EVAP functions in the following manner:
● See Figure 4-24. Hydrocarbon vapors in the fuel tank are
directed through the vent valve and stored in the carbon
canister. If the vehicle is tipped at an abnormal angle, the
VEHICLE UPRIGHT VEHICLE TIPPED
vent valve closes to prevent liquid gasoline from leaking
out of the fuel tank through the vapor vent hose. Hydrocarbon vapors Check balls stop liquid
● See Figure 4-25. When the engine is running, carburetor released to canister gasoline from escaping
venturi negative pressure (vacuum) slowly draws off the through vent valve fuel tank
hydrocarbon vapors from the carbon canister through the
vent hose. These vapors pass through the carburetor and
Vent valve and
are burned as part of normal combustion in the engine.
check balls
The large diameter canister-to-air cleaner hose (canister
clean air inlet hose) supplies the canister with fresh air
from the air cleaner.
TROUBLESHOOTING
b0258a4x
1WARNING
Verify that the evaporative emissions vent hoses do not Figure 4-24. Vent Valve Operation
contact hot exhaust or engine parts. The hoses contain
flammable vapors that can be ignited if damaged, thereby 5753
resulting in personal injury. 4
The system has been designed to operate with a minimum of
maintenance. Check that all hoses are properly routed and 2
connected and are not pinched or kinked.
1 3
1. Overflow vent hose from fuel tank

2. Vent hose to carburetor
3. Fresh air inlet from air cleaner backplate
4. Cable strap around all three hoses
Figure 4-25. Carbon Canister
4-23
REMOVAL b0255x4x
7
Vent Valve
6
1. See Figure 4-26. The vent valve fitting (5) is screwed into
the top of the fuel tank. 5
2. Remove vent hose cable strap. Disconnect hose (6) from 4
fitting. Remove fitting.
3
3. Remove check balls (4, 3) from vent valve. 2
4. Remove fuel filler cap and O-ring. Remove vent valve.
1
5. If necessary, label overflow vent hose connected to can-
ister and remove from canister fitting.
Canister
1. Fuel tank 5. Vent valve fitting
1. See Figure 4-25. The canister assembly mounts on a 2. Vent valve 6. Vent hose
frame tube along the left side of the motorcycle. 3. Steel check ball 7. Cable strap
4. Plastic check ball
2. Label the three hoses connected to canister. Disconnect
hoses from canister. Figure 4-26. Vapor Vent Valve
3. Depress locking tab at the front end of the canister

mounting bracket. Slide canister towards the front wheel 5754
until it disengages from the bracket and remove.
4
4. See Figure 4-27. Remove screws, washers and locknuts
3
(5) to detach mounting plate (2) from clamps (1).
5
2
5. Remove countersunk screws and locknuts (4) to sepa-
rate bracket (3) from mounting plate (2).
1
INSTALLATION
Vent Valve
1WARNING
1. Clamp (2)
Verify that the fuel tank vapor vent hose does not contact
2. Mounting plate
hot exhaust or engine parts. The hose contains flamma-
3. Canister mounting bracket
ble vapors that can be ignited if damaged, thereby result-
4. Countersunk screw and locknut (2)
ing in personal injury.
5. Screw, washer and locknut (2)
1. See Figure 4-26. Screw vent valve (2) into fuel tank.
Figure 4-27. Carbon Canister Mounting
2. Drop check balls (3, 4) into vent valve.
3. Attach vent valve fitting (5).
4. Install fuel cap and new O-ring.
5. Attach overflow vent hose to fitting with a new cable
strap.
6. Attach overflow vent hose to bottom fitting on canister if
disconnected.
4-24
Canister 5757
1. See Figure 4-27. Install canister bracket (3) on mounting

plate (2) with countersunk screws and locknuts (4).
1
2. Install mounting plate assembly on frame by attaching
mounting clamps (1) using screws, washers and locknuts
(2). Tighten to 6-8 ft-lbs (8.1-10.8 Nm). 3
3. See Figure 4-25. Depress locking tab and slide canister 4

into locked position on canister bracket. Clip on canister
bracket must engage canister; bend clip outward some- 2
what if canister is not held securely.
4. Connect the three marked hoses to the canister.
1. V.O.E.S. hose 3. Fuel hose

HOSE ROUTING 2. Canister vent hose 4. Drain hose
Figure 4-28. Emissions Hose Routing at Carburetor

Carburetor
See Figure 4-28. Route the evaporative emissions control

hoses at the carburetor as shown. To gain access to the
V.O.E.S. and hoses, remove the fuel tank and/or air cleaner/
backplate assembly if necessary.
Canister Hose Routings
1. See Figure 4-25. Connect one end of the canister clean

air inlet hose to the carbon canister.
2. Connect overflow vent hose and canister vent hose to fit-

tings on carbon canister. Canister vent hose attaches to
top fitting. Route both hoses towards fresh air hose on
rear of canister.
3. Cable strap the three hoses where the hose connector

attaches the two pieces of fresh air hose.
4. Route the smaller hoses forward along the top left frame
tube. The vent and overflow hoses run together until the
vent hose turns between the cylinders. Connect vent
hose to elbow fitting on carburetor. Connect overflow
vent hose to vent valve fitting using a new cable strap.
5. Route fresh air hose upward and forward along the left
frame tube. Continue running hose to air cleaner back-
plate fitting. Secure hose using new cable straps.
4-25
5
SPECIFICATIONS
STARTER SERVICE WEAR LIMITS IN. MM
Free speed 3000 RPM (min.) @ 11.5 V Brush length minimum 0.433 11.0
Free current 90 amp (max.) @ 11.5 V Commutator diameter
1.141 28.98
minimum
Stall current 400 amp (max.) @ 2.4 V
Stall torque 8.1 ft-lbs (11.0 Nm) (min.) @ 2.4 V
ITEM TORQUE NOTES
Battery terminal hardware 30-40 in-lbs 3.4-4.5 Nm hold cable when loosening/tightening, page 5-17
Starter mounting bolts 13-20 ft-lbs 17.6-27.1 Nm page 5-17
5-1
ELECTRIC STARTER SYSTEM
GENERAL OPERATION
The starter is made up of an armature, field winding assem-
bly, solenoid, drive assembly, idler gear and drive housing. See Figure 5-1. The starter relay is activated when the starter
switch is pushed. This allows battery current to flow into the
The starter motor torque is increased through gear reduction. pull-in winding and also into the hold-in winding to ground. The
The gear reduction consists of the drive pinion on the arma- magnetic forces of the pull-in and hold-in windings in the sole-
ture, an idler gear and a clutch gear in the drive housing. The noid push the plunger causing it to shift to the left. This action
idler gear is supported by rollers. The clutch gear is part of engages the pinion gear with the clutch ring gear. At the same
the overrunning clutch/drive assembly. time, the main solenoid contacts are closed, so battery current
flows directly through the field windings to the armature and to
The overrunning clutch is the part which engages and drives ground. Simultaneously, the pull-in winding is shorted. The cur-
the clutch ring gear. It also prevents the starter from overrun- rent continues flowing through the hold-in winding keeping the
ning. The field windings are connected in series with the main solenoid contacts closed. At this point, the starter begins
armature through brushes and commutator segments. to crank the engine. After the engine has started, the pinion
gear turns freely on the pinion shaft through the action of the
Wiring Diagrams overrunning clutch. The overrunning clutch prevents the clutch
ring gear (which is now rotating under power from the engine)
from turning the armature too fast.
For additional information concerning the starting system cir-
cuit, see the wiring diagram at the end of Section 7, ELEC-
TRICAL.
When the starter switch is released, the current of the hold-in
winding is fed through the main solenoid contacts and the
Starter Relay direction of the current in the pull-in winding is reversed. The
solenoid plunger is returned to its original position by the
The starter relay is a non-repairable part that must be return spring, which causes the pinion gear to disengage
replaced as a unit if it fails. from the clutch ring gear.
5-2
b0164x5x
STARTER AT MOMENT STARTER SWITCH IS CLOSED Armature
Field winding
Brush
Idler gear
Pinion gear
Ball bearing
Plunger
Main
contacts
Overrunning Hold-in
clutch winding Pull-in
winding
Battery
Start circuit –
Clutch ring See wiring
gear diagram
Armature
STARTER DURING CRANKING
Field winding
Brush
Idler gear
Pinion gear
Ball bearing
Plunger
Main
contacts
Overrunning Hold-in
clutch winding Pull-in
winding Battery
Clutch ring
gear Start circuit –
See wiring
diagram
Figure 5-1. Starter Operation
5-3
5-4
b0207x5x
TN
NEUTRAL O
TN
P1
IGN POWER BE 1 GY
2
3
TO STARTER Y/O 4 BK/R
NEUTRAL
12 11 10 9 8 7 6 5 4 3 2 1 P3 SWITCH
TN
O
BK TN/W
P14 2 1
BK W
S2
SIDE STAND
SWITCH
S1
TN
S13 S12
MAIN CHASSIS GROUND
S11 TN/GN TN
S10 R BK
TN/GN TN/GN
MASTER
30A CIRCUIT
BREAKER
S7
TN/GN
S14
P5 S15 GN
R/BK
R
TO GROUND BK 2 BK
GY TN/W
P13
P8
A
B
C
D
CLUTCH SWITCH VIEW FROM FUSE BK/R TN/GN
P12
R/B K
GN
INSERTION SIDE BK
R
BK
IGNITION
GY/O
15A
R/BK
COLOR CODE: LT.BE LIGHT BLUE GY/O INSTRUMENTS
O
BK BLACK O ORANGE V VIOLET TN/W

LIGHTS 86 85
86 85 BK/R TN/GN
DIODE GY/O TN/W
15A
87 R/BK GN
30
GN GREEN R RED Y YELLOW CONNECTION 15A 87A
87A
R/BK
FUSE BLOCK R OFF
P9 LOCK
BATTERY
1996 BUELL S1-LIGHTNING STARTING CIRCUIT
Figure 5-2. Electric Starting System Circuit

Table 5-1. Troubleshooting
SOURCE OF
PROBLEM PROBABLE CAUSE SOLUTION
PROBLEM
1. Starter does 1.1 Battery. 1.1.1 Voltage drop due to 1.1.1 Charge battery.
not run or runs discharged battery.
at very low
1.1.2 Short-circuited or open 1.1.2 Replace battery.
speeds.
between electrodes.
1.1.3 Poor contact condition of 1.1.3 Clean and retighten.
battery terminal(s).
1.2 Wiring. 1.2.1 Disconnection between 1.2.1 Repair or replace wire.
starter switch and solenoid
terminal.
1.3 Starting 1.3.1 Poor contact condition or 1.3.1 Replace.
switch or poor connection.
starter relay.
1.4 Solenoid. 1.4.1 Poor contact condition. 1.4.1 Polish contact surface or
caused by burnt contact. replace solenoid assembly.
1.4.2 Contact plate removed. 1.4.2 Repair.
1.4.3 Pull-in winding open or short- 1.4.3 Replace solenoid assembly.
circuited.
1.4.4 Hold-in winding open. 1.4.4 Replace solenoid assembly.
1.5 Starting motor. 1.5.1 Poor contact condition of 1.5.1 Check brush spring tension.
brushes.
1.5.2 Commutator burnt. 1.5.2 Correct on lathe or replace.
1.5.3 Commutator high mica. 1.5.3 Correct by undercutting.
1.5.4 Field winding grounded. 1.5.4 Replace.
1.5.5 Armature winding grounded 1.5.5 Replace.
or short-circuited.
1.5.6 Reduction gears damaged. 1.5.6 Replace.
1.5.7 Insufficient brush spring 1.5.7 Replace.
tension.
1.5.8 Disconnected lead wire 1.5.8 Repair or replace lead wire.
between solenoid and field
windings.
1.5.9 Ball bearing sticks. 1.5.9 Replace bearing.
5-5
Table 5-1. Troubleshooting (Continued)
SOURCE OF
PROBLEM PROBABLE CAUSE SOLUTION
PROBLEM
2. Pinion does not 2.1 Battery. 2.1.1 Voltage drop due to 2.1.1 Charge battery.
engage with discharged battery.
ring gear while
2.1.2 Short-circuited or open 2.1.2 Replace battery.
starter is
between electrodes.
running or
engine cannot 2.1.3 Poor contact condition of 2.1.3 Clean and retighten.
be cranked. battery terminal(s).
2.2 Wiring. 2.2.1 Disconnection between 2.2.1 Repair or replace wire.
starter switch and solenoid
terminal.
2.3 Overrunning 2.3.1 Overrunning clutch 2.3.1 Replace overrunning clutch.
clutch. malfunction (rollers or
compression spring).
2.3.2 Pinion teeth worn out. 2.3.2 Replace overrunning clutch.
2.3.3 Pinion does not run in 2.3.3 Replace overrunning clutch.
overrunning direction.
2.3.4 Poor sliding condition of 2.3.4 Remove foreign materials,
spline teeth. dirt, or replace overrunning
clutch.
2.3.5 Reduction gears damaged. 2.3.5 Replace overrunning clutch
and idler gear.
2.4 Ring gear. 2.4.1 Excessively worn teeth. 2.4.1 Replace ring gear.
3. Starter does 3.1 Solenoid. 3.1.1 Return spring worn. 3.1.1 Replace solenoid.
not stop
3.1.2 Coil layer shorted. 3.1.2 Replace solenoid.
running.
3.1.3 Contact plate melted and 3.1.3 Replace solenoid.
stuck.
3.2 Starting 3.2.1 Unopened contacts. 3.3.1 Replace starting switch or
switch or starter relay.
starter relay.
3.2.2 Poor returning. 3.3.1 Replace starting switch or
starter relay.
5-6
BATTERY TESTS
• Visual • Voltage
INOPERATIVE Check connections at battery

and starter components
Nothing clicks Relay clicks Solenoid clicks STARTER SPINS, BUT STARTER STALLS OR
RUN-ON DOES NOT ENGAGE SPINS TOO SLOWLY
Check for Test relay Perform voltage drop

power at relay tests between battery Sticky Contaminated Starter clutch Damaged gear & Perform voltage drop tests
Sticking
Test wiring to starter switch (water failure. Replace armature. from battery to solenoid,
from button and solenoid relay ter- relay
relay and button in button) starter clutch Replace starter solenoid to motor, battery
minals (less than 1 volt)
ground to motor ground
solenoid
NO YES Does starter motor

High voltage NO turn if jumped? Starter motor current
Test solenoid
draw test (on vehicle)
Check Check
for for YES
Test starter YES NO
power ground Starter motor
at button at relay motor
free draw (bench test)
Back track to pinpoint

Perform Test starter
Correct connections or switch
solenoid motor for Test starter Inspect
NO YES NO relay problems hold-in & opens, shorts motor for engine,
ground pull-in tests or grounds opens, shorts primary
or grounds drive
Check
for Substitute
power to good relay
button
NO Repair wiring
YES Replace switch assembly
Figure 5-3. Electric Starting System Diagnosis

5-7
STARTER ACTIVATION CIRCUITS
b0157x5x
Start
switch ITEM A Start
switch ITEM B
0.1A 0.1A 0.1A 0.1A
20A 20A
Ignition Ignition
circuit Relay circuit Relay
breaker breaker
Ignition Ignition OV
20A 20A
switch switch
Main VDC Main VDC

circuit circuit
breaker breaker
150A 150A 150A 150A
Battery Solenoid Starter Battery Solenoid Starter
IDEAL CLOSED CIRCUIT
Start
switch ITEM C Start
switch ITEM D
0.1A 0.1A 0.1A 0.1A
20A 20A 20A

Ignition Ignition
circuit Relay circuit Relay
breaker breaker VDC
12V Ignition OV
Ignition 20A
switch switch
Main VDC Main

circuit circuit
breaker breaker
150A 150A 150A 150A
Battery Solenoid Starter Battery Solenoid Starter
OPEN CIRCUIT GROUND CIRCUIT
Figure 5-4. Typical circuity. Refer to wiring diagrams for more information.
5-8
DIAGNOSTICS/TROUBLESHOOTING
GENERAL 7. If the voltage drop is greater, back track through the con-
nections until the source of the potential difference is
The TROUBLESHOOTING table, starting on page 5-5, con- found.
tains detailed procedures to solve and correct problems. Fol-
low the ELECTRIC STARTING SYSTEM DIAGNOSIS The benefit of doing it this way is speed.
diagram on page 5-7 to diagnose starting system problems.
The VOLTAGE DROPS procedure below will help you to
locate poor connections or components with excessive volt- a. Readings aren’t as sensitive to real battery voltage.
age drops.
b. Readings show the actual voltage dropped, not just
the presence of voltage.
VOLTAGE DROPS
Check the integrity of all wiring, switches, circuit breakers and c. This tests the system as it is actually being used. It
connectors between the source and destination. is more accurate and will display hard to find poor
connections.
The voltage drop test measures the difference in potential or
the actual voltage dropped between the source and destina- d. This approach can be used on lighting circuits, igni-
tion. tion circuits, etc. Start from most positive and go to
1. See ITEM A in Figure 5-4. Attach your red meter lead to most negative (the destination or component).
the most positive part of the circuit, which in this case
would be the positive post of the battery. 8. See ITEM D in Figure 5-4. The negative or ground circuit
can be checked as well. Place the negative lead on the
2. See ITEM B in Figure 5-4. Attach the black meter lead to
most negative part of the circuit (or the negative battery
the final destination or component in the circuit (solenoid
post). Remember, there is nothing more negative than
terminal from relay).
the negative post of the battery. Place the positive lead to
3. Activate the starter and observe the meter reading. The the ground you wish to check.
meter will read the voltage dropped or the difference in
potential between the source and destination. 9. Activate the circuit. This will allow you to read the poten-
4. An ideal circuit’s voltage drop would be 0 volts or no volt- tial difference or voltage dropped on the negative or
age dropped, meaning no difference in potential. ground circuit. This is very effective for identifying poor
grounds due to powdered paint. Even the slightest con-
5. See ITEM C in Figure 5-4. An open circuit should read 12
nection may cause an ohmmeter to give a good reading.
volts, displaying all the voltage dropped, and the entire
However, when sufficient current is passed through, the
difference in potential displayed on the meter.
resistance caused by the powdered paint will cause a
6. Typically, a good circuit will drop less than 1 volt. voltage drop, or potential difference in the ground circuit.
5-9
STARTER SYSTEM TESTING
“ON-MOTORCYCLE” TESTS b0208x5x
Starter Relay Test

Starter relay
1. See Figure 5-5. Locate starter relay. The relay is
attached to the frame near the oil tank’s feed hose.
Unplug relay connector.
2. To test relay, proceed to Step 3. If installing a new starter

relay, remove old relay. Secure new relay to frame using
screw and washer. Attach relay connector plug.
3. See Figure 5-6. Obtain a 12 volt battery and a continuity

tester or ohmmeter. Connect positive battery lead to the
86 terminal. Connect negative battery lead to the 85 ter-
minal to energize relay. Check for continuity between the
30 and 87 terminals. A good relay shows continuity, con-
tinuity tester lamp “on” or a zero ohm reading on the
ohmmeter. A malfunctioning relay will not show continuity Figure 5-5. Starter Relay Location
and must be replaced.
b0159x5x Ohmmeter
4. If starter relay is functioning properly, proceed to
STARTER CURRENT DRAW TEST.
Starter Current Draw Test 87

OO
86 85
NOTE Battery 87A
30
● Engine temperature should be stable and at room tem-
perature.
1. Attach battery positive lead to 86 terminal.
2. Attach battery negative lead to 85 terminal.
● Battery should be fully charged.
3. Test for continuity between 30 and 87 terminals.
A good relay shows continuity or 0 ohms.
Check starter current draw with an induction ammeter before
disconnecting battery. Proceed as follows: Figure 5-6. Starter Relay Test
1. See Figure 5-7. Verify that transmission is in neutral. Dis- b0160x5x

connect spark plug wires from spark plug terminals. Induction
ammeter
2. Clamp induction ammeter over positive battery cable
next to starter.
3. With ignition key switch ON, turn engine over by pressing

starter switch while taking a reading on the ammeter.
Disregard initial high current reading which is normal
when engine is first turned over.
● Typical starter current draw will range between 140-

180 amperes. Battery
4. If starter current draw exceeds 180 amperes, then the
problem may be in the starter or starter drive. Remove
starter for further tests. See STARTER, REMOVAL on Typical starter current draw is 140-180 amperes.
page 5-11.
Figure 5-7. Starter Draw Test
5-10
STARTER
REMOVAL 3550a
1WARNING
sonal injury, disconnect the battery cables before per-
forming any of the following procedures. Always
disconnect the negative cable first. If the positive cable
should contact ground with the negative cable installed,
the resulting sparks may cause a battery explosion
Mounting bolts
resulting in personal injury.
and washers
1CAUTION
ware. Failure to hold cable will cause battery damage.
1. Remove primary cover. See PRIMARY CHAIN in Section 6.
2. See Figure 5-8. Remove the starter mounting bolts and
washers.
NOTE
A ball hex driver may be required to gain access to the starter
mounting bolts.
Figure 5-8. Starter Mounting
3. Remove positive battery lead and solenoid wire from
starter.
b0161x5x
4. Remove starter and gasket from right side of motorcycle.
“C” terminal
“50” terminal
TESTING ASSEMBLED STARTER
Starter Solenoid
NOTE
Do not disassemble solenoid. Before testing, disconnect field
wire from terminal “C,” as shown in Figure 5-9.
1CAUTION
Each test should be performed for only 3-5 seconds to Battery
prevent damage to solenoid.
NOTE
The solenoid Pull-in, Hold-in, and Return tests must be per-
formed together in one continuous operation. All three tests
are conducted one after the other in the sequence given with- Figure 5-9. Pull-In Test
out interruption.
Solenoid Pull-in Test

See Figure 5-9. Using a 12 volt battery, connect three sepa-
rate test leads as follows:
a. Solenoid housing to battery negative.
b. Solenoid “C” terminal to battery negative.
c. Solenoid “50” terminal to battery positive.
Starter pinion should pull in strongly if solenoid is working
properly. If pinion does not pull in, solenoid should be
replaced.
5-11
5
Solenoid Hold-in Test DISASSEMBLY, INSPECTION

See Figure 5-10. With test leads still connected in the manner AND REPAIR
specified in the previous SOLENOID PULL-IN TEST, discon-
nect solenoid “C” terminal/battery negative test lead at
battery negative end only; reconnect loose end of this 1. See Figure 5-14. Remove field wire (22).
test lead to battery positive, instead. If pinion remains in
pull-in position, solenoid is working properly. If pinion does
not remain in pull-in position, solenoid should be replaced. 2. See Figure 5-12. Remove thru-bolts.
b0162x5x
“C” terminal 4860
“50” terminal
Battery
Thru-bolts
Figure 5-10. Hold-In Test
Solenoid Return Test Figure 5-12. Removing the Thru-Bolts
See Figure 5-11. With test leads still connected in the manner
specified at the end of the previous SOLENOID HOLD-IN
3. See Figure 5-13. Remove two end cover screws, O-rings,
TEST, disconnect solenoid “50” terminal/battery positive
and end cover.
test lead at either end. If pinion returns to its original posi-
tion, the solenoid is working properly. If pinion does not return
to its original position, solenoid should be replaced.
3548a
b0163x5x
“C” terminal
“50” terminal
End cover
screws (2)
Battery
End cover
Figure 5-11. Return Test Figure 5-13. Removing End Cover
5-12
b0004o5x
3
4 2
23
5
7
1
23
6
22
8
14
13 17
15
11
18
12
16
9
12. Drive assembly/overrunning
21 10 clutch
13. Idler gear
14. Idler gear roller (5)
19 15. Idler gear bearing cage
20 16. O-ring
17. Return spring
1. Thru-bolt (2) 7. Field frame 18. Ball
2. End cover screw (2) 8. Armature bearings 19. Gasket
3. End cover 9. Drive housing mounting bolt 20. Washer (2)
4. Brush holder and lockwasher (2) 21. Mounting bolt (2)
5. Brush spring (4) 10. Drive housing 22. Field wire
6. Armature 11. Solenoid housing 23. O-ring (2)
Figure 5-14. Starter Assembly
5-13
4. See Figure 5-15. Use a wire hook to pull upward on
brush springs, and lift brushes out of holder. Remove 3540a
brush holder.
5. Check brush length. Replace all four brushes if length of
any one brush is less than 0.433 in. (11.0 mm).
Replace brushes in sets of four only.
6. See Figure 5-14. Remove armature (6) and field frame (7).
Brush holder
7. Place armature in lathe or truing stand and check runout
of commutator. Commutators with more than 0.016 in.
(0.41 mm) of runout should be replaced, or machined on
a lathe. Commutators should be replaced when diameter
is less than 1.141 in. (28.98 mm).
Figure 5-15. Removing Brush Holder
b0136x5x
Mica must not be left with a

thin edge next to segments Mica
Segments
Starting groove in mica
with 3 cornered file
Wrong way
Mica must be cut away

clean between segments Mica
Segments
Commutator
Undercutting mica with piece

of hacksaw blade Right way
Figure 5-16. Undercutting Mica Separators
5-14
1CAUTION
1783a
Do not use sandpaper or emery cloth to remove burrs on
commutator. Otherwise, abrasive grit may remain on
commutator segments; this could lead to excessive
brush wear. Use only the recommended crocus cloth.
8. Check depth of mica on commutator. If undercut is less
than 0.008 in. (0.20 mm), use an undercutting machine
to undercut the mica to 1/32 in. (0.79 mm) deep. The
slots should then be cleaned to remove any dirt or cop- Armature Commutator
per dust. See Figure 5-16. If an undercutting machine is core
not available, undercutting can be done satisfactorily
using a thin hacksaw blade. After undercutting, lightly
sand the commutator with crocus cloth to remove any
burrs.
9. See Figure 5-17. Check for SHORTED ARMATURE with
a growler. Place armature on growler. Hold a thin steel
strip (hacksaw blade) against armature core and slowly
turn armature. A shorted armature will cause the steel
strip to vibrate and be attracted to the core. Replace
armatures if shorted. Replace armatures showing continuity
Figure 5-18. Grounded Armature Test

1782a
Growler
Thin steel strip 1784a
Commutator
Replace armature if no continuity at any test point

Replace armatures which vibrate
Figure 5-19. Open Armature Test

Figure 5-17. Shorted Armature Test Using Growler
10. See Figure 5-18. Check for a GROUNDED ARMATURE 3542a

Brush on
with an ohmmeter or continuity tester. Touch one probe
field coil
to any commutator segment. Touch the other probe to
the armature core. There should be no continuity (infinite
ohms). If there is continuity, then the armature is
grounded. Replace grounded armatures.
11. See Figure 5-19. Check for OPEN ARMATURE with an
ohmmeter or continuity tester. Check for continuity
between all commutator segments. There should be con-
tinuity (0 ohms) at all test points. No continuity at any test
point indicates armature is open and must be replaced.
12. See Figure 5-20. Check for GROUNDED FIELD COIL
with an ohmmeter or continuity tester. Touch one probe Field frame
to the frame. Touch the other probe to each of the
brushes attached to the field coil. There should be no Replace field frames if continuity is found
continuity (infinite ohms). If there is any continuity at
either brush, then the field coil(s) are grounded and the
Figure 5-20. Grounded Field Test
field frame must be replaced.
5-15
3538a 1787a
Field wire
Positive brush
Brush on
holder (insulated)
field coil
Replace field frame if no continuity is found
Figure 5-21. Open Field Test
13. See Figure 5-21. Check for OPEN FIELD COILS with an
ohmmeter or continuity tester. Touch one probe to the
field wire. Touch the other probe to each of the brushes
attached to the field coils. There should be continuity. If Holder plate
there is no continuity at either brush, then the field coil(s)
are open and the field frame must be replaced.
Replace brush holder assembly if continuity is found
14. See Figure 5-22. Test BRUSH HOLDER INSULATION
with an ohmmeter or continuity tester. Touch one probe Figure 5-22. Brush Holder Insulation Test
to holder plate. Touch the other probe to each of the pos-
itive (insulated) brush holders. There should be no conti-
nuity (infinite ohms). If there is continuity at either brush 3549a
Drive housing
holder, replace the brush holder assembly.
15. See Figure 5-14. Check armature bearings (8) and

replace if necessary.
16. See Figure 5-23. Remove two drive housing mounting

screws (with washers and lockwashers). Remove drive
housing from solenoid housing.
17. See Figure 5-24. Remove drive (1), idler gear (2), idler
gear bearing (3), and O-ring (4) from drive housing (O-
ring is located in drive housing groove). Solenoid housing
Figure 5-23. Removing Starter Drive Housing

ASSEMBLY
1. See Figure 5-24. Clean, inspect and lubricate drive
assembly components. Lubricate parts with high temper-
ature grease, such as LUBRIPLATE 110.
2. See Figure 5-14. When installing drive assembly compo-

nents, open end of idler bearing cage (15) faces toward
solenoid.
5-16
3. When installing drive housing (10) to solenoid housing
(11), use new O-ring (16). Be sure to install return spring 3530a
(17) and ball (18). 5

4. Lubricate armature bearings (8) with high temperature
grease, such as LUBRIPLATE 110. Install armature (6)
and field frame (7) to solenoid housing (11).
5. Install brushes and brush holder (4).
6. Install end cover (3) with end cover screws (2) and O-
rings (23).
7. Install thru-bolts (1). 4 3

8. Install solenoid wire to terminal.
2
INSTALLATION
1. Install starter and starter gasket from right side of motor-
cycle.
2. Install positive battery cable and solenoid wire to sole- 1

noid.
3. See Figure 5-8. Install the starter mounting bolts and

washers. Tighten mounting bolts to 13-20 ft-lbs (17.6-
27.1Nm).
4. Install primary cover. See PRIMARY CHAIN in Section 6. 1. Drive 4. O-ring

2. Idler gear 5. Drive housing
5. Fill primary chaincase/transmission with proper lubricant.
3. Idler gear bearing
See CLUTCH, TRANSMISSION FLUID in Section 1.
Figure 5-24. Starter Drive Assembly
1WARNING
1CAUTION
ware. Failure to hold cable will cause battery damage.
6. Connect battery cables, positive cable first. Tighten bat-

tery terminal hardware to 30-40 in-lbs (3.4-4.5 Nm).
5-17
STARTER SOLENOID
GENERAL ASSEMBLY
See Figure 5-25. The starter solenoid is a switch that is
designed to open and close the starting circuit electromagnet- 1. See Figure 5-25. Replace wire connection hardware as
ically. The switch consists of contacts and a winding around a necessary.
hollow cylinder containing a movable plunger.
2. Install plunger (5) in solenoid housing (6).
DISASSEMBLY
3. Install new gasket (4) onto cover (3).
1. See Figure 5-25. Remove screws (1) and clip (2).
2. Remove cover (3) and gasket (4). Discard gasket. 4. Position cover with gasket onto solenoid housing. Install
3. Remove plunger (5) from solenoid housing (6). clip (2) and screws (1).
b0158x5x
3 1
2
4
6
5
1CAUTION
Do not tighten nut (7) without
removing items 1-5. Movement will
cause damage to the contact.
7 1. Screw (3)
2. Clip
3. Cover
4. Gasket
5. Plunger
6. Solenoid housing
7. Nut
Figure 5-25. Starter Solenoid
5-18
6
SPECIFICATIONS
TRANSMISSION PRIMARY DRIVE (ENGINE-TO-TRANSMISSION)
Transmission Type 5 forward speed, foot shift Engine sprocket 35 teeth

Clutch Type Wet – multiple disc Clutch sprocket 56 teeth
Clutch fluid capacity 1.0 quart 0.95 liter Ratio 1.60: 1
Fluid part no.-quart 98854-96
Fluid part no.-gallon 98855-96 FINAL DRIVE (TRANSMISSION-TO-REAR WHEEL)
Transmission sprocket 27 teeth

Rear wheel sprocket 61 teeth
TRANSMISSION GEAR RATIOS FINAL* OVERALL**
Secondary drive belt 128 teeth
First (Low) Gear 2.69 9.717
Ratio 2.26:1
Second Gear 1.97 7.118
Third Gear 1.43 5.180
Fourth Gear 1.18 4.269
Fifth (High) Gear 1.00 3.615

NEW COMPONENTS SERVICE WEAR LIMITS

CLUTCH PLATE NUMBER
THICKNESS REQUIRED
IN. MM IN. MM
Friction plate (fiber) 8 0.0866 + 0.0031 2.200 + 0.079 0.006 0.15

Steel plate 6 0.0629 + 0.0020 1.598 + 0.051 0.006 0.15
Clutch pack 0.661 16.79
minimum minimum
NOTE
Service wear limits are given as a guideline for measuring components that are not new. For measurement specifications not
given under SERVICE WEAR LIMITS, see NEW COMPONENTS.
6-1
ITEM TORQUE NOTES
Access door mounting bolts 13-17 ft-lbs 18-23 Nm LOCTITE THREADLOCKER 242 (blue), page 6-30
Clutch inspection cover
7-9 ft-lbs 9-12 Nm page 6-3
TORX screws with washers
LOCTITE THREADLOCKER 262 (red), left hand
Clutch mainshaft nut 70-80 ft-lbs 95-108 Nm
threads, page 6-13
Countershaft retainer
13-17 ft-lbs 18-23 Nm LOCTITE THREADLOCKER 242 (blue), page 6-25
TORX screw
Engine sprocket nut 150-165 ft-lbs 203-224 Nm LOCTITE THREADLOCKER 262 (red), page 6-13
135.6-149.1
Isolator bolts 100-110 ft-lbs LOCTITE THREADLOCKER 262 (red), page 6-7
Nm
Primary chain adjuster locknut 10-12 ft-lbs 14-16 Nm on interior of chaincase, page 6-4
Primary chain adjuster locknut 20-25 ft-lbs 27-34 Nm on exterior of chaincase, page 6-4
Primary chain inspection
40-60 in-lbs 4.5-6.8 Nm page 6-3
cover screws
Primary cover bolts 80-110 in-lbs 9.0-12.4 Nm 3 lengths, page 6-5
Rear shock mounting bolts 40-45 ft-lbs 47.5-61.0 Nm metric, page 6-7
100-120
Shift lever pinch screw 11.3-13.6 Nm page 6-5
in-lbs
Shifter shaft assembly nuts 90-110 in-lbs 10.2-12.4 Nm same torque for top and bottom nuts, page 6-30
Tie bar bolts 30-33 ft-lbs 40.7-44.7 Nm page 6-7
Transmission detent plate nut 13-17 ft-lbs 18-23 Nm page 6-19
Transmission drain plug 14-21 ft-lbs 19-28 Nm page 6-5
LOCTITE THREADLOCKER 262 (red), left hand
Transmission sprocket nut See note
threads, special torque turn method, page 6-30
Transmission sprocket screws 90-110 in-lbs 10.2-12.4 Nm replace after 3 removals, page 6-31
6-2
PRIMARY CHAIN
GENERAL REMOVAL
An opening between the primary drive and transmission com- Primary Cover
partments allows the same lubricant supply to lubricate mov-
ing parts in both compartments. 1WARNING
Since the primary chain runs in lubricant, little service will be
required other than checking lubricant level and chain ten-
sion. If, through hard usage, the primary chain does become
worn, it must be replaced. Remove and install the chain fol-
lowing the procedure under PRIMARY DRIVE/CLUTCH,
REMOVAL on page 6-10. 1. Raise rear wheel off floor using REAR WHEEL
SUPPORT STAND (Part No. B-41174).
2. Remove muffler. See EXHAUST SYSTEM in Section 2.
ADJUSTMENT/LUBRICATION
3. See Figure 6-1. Place a drain pan under the engine.
See PRIMARY CHAIN in Section 1 for inspection and adjust- Remove drain plug (9) and drain lubricant from primary
ment procedures. drive.
4. Remove shift lever assembly (12) and rubber washer
See CLUTCH, TRANSMISSION FLUID in Section 1 for com- (13). Do not to scratch primary cover (15).
plete lubrication service on the primary chain. 5. Add freeplay to clutch cable. See CLUTCH in Section 1.
b0152a6x
1. TORX screw with washers (4)
2. Clutch inspection cover
3. Spring
4. Lockplate 15 16
5. Nut 17
6. Coupling
7. Ramp assembly 12
8. Quad ring
9. Drain plug 14
10. Locknut
11. Chain adjuster screw 13
12. Shift lever assembly (includes
pinch screw and washer)
13. Rubber washer
11
14. Oil seal
15. Primary cover 7
16. Primary chain
inspection cover
10
17. Clutch adjusting screw 5
4
3
8 9
6
2
NOTE
1 Depending upon vehicle production date, configuration
of items 6 and 7 may vary. See CLUTCH in Section 1.
Figure 6-1. Primary cover
6-3
6. Loosen locknut (10). Turn chain adjuster screw (11) coun-
3547
terclockwise (outward) to relax primary chain tension.
1
7. Remove four TORX screws with washers (1) and clutch
inspection cover (2). Remove and discard Quad ring (2)
from groove in primary cover.
8. Slide spring (3) with attached hex lockplate (4) from flats
of clutch adjusting screw (17). 4
6 5
9. Turn clutch adjusting screw (17) clockwise to release
ramp and coupling mechanism. As the adjusting screw is
turned, ramp assembly (7) moves forward. Unscrew nut 2
(5) from end of adjusting screw.
3
10. Remove hook of ramp from button to the rear of cable 1. Primary cover 4. Locknut (interior)
end coupling (6). Remove cable end from slot in cou- 2. Locknut (exterior) 5. Plate
pling. Remove coupling and ramp assembly. 3. Chain adjuster screw 6. Shoe
Figure 6-2. Removing Primary Chain Adjuster

11. Remove screws which secure primary cover. Remove
cover and gasket. Discard gasket.
b0133x6x
12. Remove and discard shift lever oil seal (14). Open 6
side
Primary Chain Adjuster
4
1. See Figure 6-2. Remove primary cover (1).
7
2. Remove locknut (2) from chain adjuster screw (3). Turn 5
adjuster screw out of threaded boss in primary cover. Threaded 3
boss
3. Slide shoe (6) off plate (5) (shoe must be slid off plate
toward closed or blind side of shoe). Remove locknut (4)
and plate (5).
INSTALLATION 1
Primary Chain Adjuster Nylon sealing

2
surface
1. See Figure 6-3. If shoe (6) is badly worn, replace it or
adjust assembly. 1. Primary cover 5. Plate
2. Locknut (exterior) 6. Shoe
2. Install plate (5) over top of chain adjuster screw (3). 3. Chain adjuster screw 7. Spacer
Place spacer (7) over top of adjuster screw next to plate. 4. Locknut (interior)
Secure plate and spacer to adjuster screw by threading Figure 6-3. Primary Chain Adjuster
on locknut (4). Tighten locknut to 10-12 ft-lbs (14-16 Nm).
3. Place plate into slots at open end of shoe (6). Slide shoe
over plate until locknut at top end of adjuster screw is
against closed (blind) side of shoe.
4. Position adjuster inside primary cover (1) with closed

side of shoe against cover. Thread adjuster screw into
tapped boss at bottom of primary cover. At outside of
cover, install locknut (2) onto adjuster screw with nylon
sealing surface toward cover.
5. Install primary cover.
6-4
Primary Cover x0023a6x
2 1
1. Remove foreign material from magnetic drain plug. Install 1
plug and tighten to 14-21 ft-lbs (19-28 Nm).
2 2
2. Wipe gasket surface clean. Install new gasket on primary
cover.
3. See Figure 6-4. Install primary cover and gasket onto left
crankcase half using mounting bolts. Tighten bolts to 80-
110 in-lbs (9.0-12.4 Nm). 1 1
3
4. See Figure 6-1. Install new shift lever oil seal (14). 1. 1/4-20 x 1-3/4 in. bolt with washers (7)
2. 1/4-20 x 2-1/4 in. bolt with washers (4)
5. Fit coupling (6) over clutch cable end. Place hook of 3. 5/16-18 x 3-1/2 in. bolt with washers (2)
ramp (7) around coupling button and rotate assembly
counterclockwise until tang on inner ramp fits in slot of Figure 6-4. Install Primary Cover Bolts
primary cover.
5583
6. Thread nut (5) on adjusting screw (17) until slot of screw Primary chain
is accessible with a screwdriver. Fit nut hex into recess of inspection cover
outer ramp and turn adjusting screw counterclockwise.
7. Fill transmission to proper level with fresh lubricant. See

CLUTCH, TRANSMISSION FLUID in Section 1.
8. Adjust clutch. See CLUTCH, ADJUSTMENT in Section 1.
9. Adjust primary chain tension. See PRIMARY CHAIN,

ADJUSTMENT in Section 1. Shift lever
10. Install rubber washer (13) and shift lever assembly (12).
Shift lever must bisect primary chain inspection cover.
See Figure 6-5. Tighten pinch screw to 100-120 in-lbs
(11.3-13.6 Nm).
11. Install muffler. See EXHAUST SYSTEM in Section 2. Figure 6-5. Shift Lever
1WARNING
sion producing personal injury.
1CAUTION
6-5
SECONDARY DRIVE BELT
GENERAL 5673
The secondary drive belt should be checked for unusual
wear, cracking or loss of teeth. Check the belt sprocket for
unusual wear, broken teeth or damaged flange.
See REAR BELT DEFLECTION in Section 1 for inspection, Attach straps
adjustment and cleaning procedures. to frame
Floor hoist
REMOVAL
Belt removal requires special lifts to support the motorcycle. If
you do not have the proper equipment, have your Buell dealer
perform the repair.
1. Lift and secure the motorcycle.
a. Place vehicle on a lift and anchor front wheel in
place.
b. Raise rear wheel off lift using REAR WHEEL SUP- Figure 6-6. Floor Hoist
2. Drain oil tank. See ENGINE LUBRICATION SYSTEM in
5674
Section 1.
1WARNING
1CAUTION
ware. Failure to hold cable may cause battery damage. Jack under
crankcase
3. Disconnect both battery cables, negative cable first.
4. Remove rear fender. See FENDERS in Section 2.
Crating strap
5. Remove rear caliper. See REAR BRAKE CALIPER,
REMOVAL/DISASSEMBLY in Section 2.
Figure 6-7. Crating Strap
6. Remove lower belt guard and sprocket cover. See
SPROCKET COVER and FENDERS in Section 2.
13. Remove muffler and exhaust header. See EXHAUST
7. Remove seat, fuel tank and tail section. See TAIL SEC- SYSTEM in Section 2.
TION, REMOVAL in Section 2.
14. Detach feed, vent and return hoses from oil tank.
REMOVAL in Section 4. 15. See Figure 6-7. Place a jack underneath the rear swing-
9. Detach belt from rear sprocket. arm and underneath the front of the crankcase.
a. Loosen rear axle nut (metric). 16. Place a crating strap over swingarm and around lift.
b. Loosen both rear axle adjuster nuts on swingarm. Tighten crating strap until snug.
c. Slide wheel forward. 17. Detach tie bars from frame mounts in the following
sequence. Do not remove tie bars from engine.
d. Remove belt from rear sprocket.
10. Remove both rider footrests from frame. a. Rear tie bar. Use a swivel socket.
11. See Figure 6-6. Place a floor hoist behind the lift. Attach b. Top tie bar.
straps to frame and hoist. Raise hoist until straps tighten.
c. Front tie bar and clutch cable clamp.
12. Remove rear shock mounting bolt (metric) from swing-
arm. Allow rear shock to hang from front mount. 18. Remove isolator bolts and washers on each side.
6-6
19. Slowly raise floor hoist until rubber isolators can be 10. Install muffer and exhaust header. See EXHAUST SYS-
removed. Frame will rise while swingarm and engine TEM in Section 2.
remain secured to lift by crating strap.
11. Align belt and rear wheel. See REAR BELT DEFLEC-
NOTE TION in Section 1.
Rubber isolators align with a frame mounted metal pin.
12. Install rider footrests. See FOOTRESTS, INSTALLATION
20. Remove belt through gap between frame and swingarm in Section 2.
mount block.
13. Install air cleaner. See AIR CLEANER, INSTALLATION in
Section 4.
INSTALLATION
14. Install sprocket cover and rear belt guard. See
1. Install new belt over sprockets. SPROCKET COVER and FENDERS in Section 2.
2. Install rubber isolators.
15. Install rear fender. See FENDERS, REMOVAL/INSTAL-
a. Align metal pin on frame with hole in isolator.
LATION in Section 2.
b. Slowly lower floor hoist to drop frame and isolators
around swingarm mount block. 16. Install rear caliper. See REAR BRAKE CALIPER, INSTAL-
NOTE
If isolator fit is troublesome, place a flat tool such a disposable 1WARNING
putty knife between swingarm mount block and isolator. As After installing seat, pull upward on front of seat to be
frame lowers, withdraw tool when edge of isolator slides sure it is locked in position. If seat is loose, it could shift
around edge of mount block. during vehicle operation and startle the rider, causing
3. Apply LOCTITE THREADLOCKER 262 (red) to isolator loss of control and personal injury.
bolts. Install isolator bolts and washers through isolators
and into swingarm mount block. Tighten bolts to 100-110 17. Install tail section, fuel tank and seat. See TAIL SEC-
ft-lbs (135.6-149.1 Nm). TION, INSTALLATION in Section 2.
4. Attach tie bars to frame in the following order. 1WARNING
a. Place clutch cable clamp on front tie bar bolt. Clamp Always connect positive battery cable first. If the positive
should hold cable on air cleaner side of motor. Insert cable should contact ground with the negative cable
bolt from front through frame and tie bar. Fasten with installed, the resulting sparks may cause a battery explo-
flat washer and nut. Tighten to 30-33 ft-lbs (40.7- sion resulting in personal injury.
44.7 Nm).
b. Insert bolt through top tie bar, washer, spacer and 1CAUTION
frame tab. Secure with locknut. Tighten to 30-33 ft- Hold battery cable when tightening battery terminal hard-
lbs (40.7-44.7 Nm). ware. Failure to hold cable may cause battery damage.
c. Rear tie bar must be horizontal and below frame tab.
Insert bolt upwards through tie bar and frame. Fas- 18. Connect both battery cables, positive cable first.
ten with nut. Tighten to 30-33 ft-lbs (40.7-44.7 Nm). 19. Perform the following tests.
5. Remove crating strap from lift and swingarm.
a. Check license plate lamp illumination.
6. Remove jacks from underneath swingarm and crank-
case. b. Check oil level after starting vehicle and allowing
7. Attach rear shock to swingarm with bolt (metric) and nut. motorcycle to reach normal operating temperature.
Tighten to 40-45 ft-lbs (47.5-61.0 Nm). 20. Remove supports.
8. Remove floor hoist straps from frame.
a. Remove REAR WHEEL SUPPORT STAND.
9. Connect and fill lubrication system. See ENGINE LUBRI-
CATION SYSTEM in Section 1. b. Free front wheel and remove motorcycle from lift.
6-7
CLUTCH
GENERAL When the clutch is engaged (clutch lever released), the dia-
phragm spring (11) applies strong inward force against the
pressure plate (17); the pressure plate then presses the
See Figure 6-9. The purpose of the clutch is to smoothly dis- clutch plates (18, 19 and 20) together, allowing no slippage
engage and engage the engine from the rear wheel for start- between the plates and causing the plates to turn as a single
ing, stopping and shifting gears. unit. The result is that the rotational force of the clutch shell
(26) is fully transmitted through the “locked” clutch plates to
The clutch is a wet, multiple-disc clutch with six steel plates the clutch hub (23). As long as the transmission is set in a for-
(19), one spring plate (20), and eight fiber (friction) plates (18) ward gear, power from the engine will be transmitted to the
stacked alternately in the clutch shell (26). The order of plate rear wheel.
assembly, from inboard to outboard, is as follows:
When the clutch is disengaged (clutch lever pulled to left han-
F - St - F - St - F - St - F - Sp - F - St - F - St - F - St - F dlebar grip), the pressure plate (17) is pulled outward (by
clutch cable action) against the diaphragm spring (11),
thereby compressing the diaphragm spring. With the pressure
(F = Friction plate, St = Steel plate, Sp = Spring plate)
plate retracted, strong inward force no longer squeezes the
clutch plates (18, 19 and 20) together. The friction plates (18)
The friction plates (clutch driving plates) are keyed to the are now free to rotate at a different relative speed than that of
clutch shell (26), which is driven by the engine through the the steel and spring plates (19, 20) (i.e. – slippage between
primary chain. The steel plates (clutch driven plates) and the the clutch plates occurs). The result is that the rotational force
centrally located spring plate (also a clutch driven plate) are of the clutch shell (26) is no longer fully transmitted through
keyed to the clutch hub (23), which drives the rear wheel the “unlocked” clutch plates to the clutch hub (23). The engine
through the transmission and secondary drive belt. is free to rotate at a different speed than the rear wheel.
Table 6-1. Clutch Troubleshooting

SYMPTOM CAUSE (CHECK IN FOLLOWING ORDER) REMEDY
Clutch slips. Incorrect clutch release adjustment. Check and adjust clutch release mechanism.
Worn clutch plates. Check service wear limits. Replace plates.
Clutch drags. Incorrect clutch release adjustment. Check and adjust clutch release mechanism.
Worn clutch release ramps or balls. Replace release ramps and/or balls.
Warped clutch steel plates. Replace clutch steel plates.
Blade worn or damaged clutch gear splines. Replace clutch gear or hub as required.
Overfilled primary. Drain lubricant to correct level.
6-8
CLUTCH RELEASE MECHANISM
ADJUSTMENT CLEANING, INSPECTION

See CLUTCH, ADJUSTMENT in Section 1. AND REPAIR
1. Thoroughly clean all parts in cleaning solvent.
DISASSEMBLY
2. See Figure 6-8. Inspect three balls (7) of release mecha-
1WARNING nism and ball socket surfaces of inner and outer ramps
for wear, pitting, surface breakdown and other damage.
To avoid accidental start-up of vehicle and possible per- Replace parts as necessary.
ceeding. Always disconnect the negative cable first. If 3. Check hub fit of inner (15) and outer (6) ramps. Replace
the positive cable should contact ground with the nega- ramps if excessively worn.
tive cable installed, the resulting sparks may cause a bat- 4. Check clutch cable for frayed or worn ends. Replace
tery explosion producing personal injury. cable if damaged or worn.
1. Pull clutch cable ferrule (end of cable housing) away from 5. Change or add transmission fluid if necessary. See
clutch hand lever bracket. Gap between ferrule and CLUTCH, TRANSMISSION FLUID in Section 1.
bracket should be 1/16-1/8 (1.6-3.2 mm). Adjust freeplay ASSEMBLY
by turning cable adjuster.
1. See Figure 6-8. Apply multi-purpose grease to balls (7)
2. See Figure 6-8. Remove four TORX screws with washers and ramps (6, 15). Insert balls in sockets of outer ramp.
(1) and clutch inspection cover (2). Install inner ramp on hub of outer ramp with tang 180°
3. Slide spring (3) with attached screw lockplate (4) from from hook of outer ramp. Install retaining ring in groove of
flats of adjusting screw (12). outer ramp hub.
2. Fit coupling (16) over cable end. Place hook of ramp
4. Turn adjusting screw (12) clockwise to release ramp and around coupling button and rotate assembly counter-
coupling mechanism. As the adjusting screw is turned, clockwise until tang on inner ramp fits in slot of primary
ramp assembly moves forward. Unscrew nut (5) from end cover (11).
of adjusting screw.
3. Thread nut (5) on adjusting screw (12) until slot of screw
5. Remove hook of ramp from cable end coupling (16). is accessible with a screwdriver. Fit nut hex into recess of
Remove cable end (10) from slot in coupling. outer ramp and turn adjusting screw counterclockwise
6. Remove retaining ring (13) from ramp assembly to sepa- until resistance is felt.
rate inner and outer halves. Remove three balls (7) from 4. Adjust clutch release mechanism. See CLUTCH,
ramp sockets. ADJUSTMENT in Section 1.
1. TORX screw with washer (4) 11 b0131x6x
2. Clutch inspection cover

3. Spring
12
4. Adjusting screw lockplate 10
5. Nut
6. Outer ramp
7. Ball (3)
8. O-ring 9
9. Cable end fitting
10. Clutch cable end
11. Primary cover
8
12. Clutch adjusting screw 7
assembly 6
13. Retaining ring 5
2 4
14. Quad ring 3
15. Inner ramp 13
16. Coupling 1
14
15
NOTE
16 Depending upon vehicle production date,
configuration of items 6 and 16 may vary.
See CLUTCH in Section 1.
6-9
PRIMARY DRIVE/CLUTCH
REMOVAL 1WARNING
See Figure 6-10. Do not attempt to disassemble the
1WARNING clutch without SPRING COMPRESSING TOOL (Part No.
HD-38515-A), CLUTCH SPRING FORCING SCREW (Part
No. HD-38515-91) and proper eye protection. Otherwise,
the highly compressed diaphragm spring could fly out
with great force, possibly causing personal injury.
tive cable installed, the resulting sparks may cause a bat- 2. Thread the CLUTCH SPRING FORCING SCREW (Part
tery explosion producing personal injury. No. HD-38515-91) (item 1, Figure 6-10.) onto the clutch
adjusting screw (item 16, Figure 6-9.) Place the bridge
NOTE
(item 2, Figure 6-10.) of SPRING COMPRESSING TOOL
See Figure 6-9. If replacement of clutch pack (friction plates (Part No. HD-38515-A) against diaphragm spring (item
[18], steel plates [19], and spring plate [20]) is the only ser- 10, Figure 6-9.) Thread the tool handle (item 3, Figure 6-
vice work to be performed, perform REMOVAL Step 1 only, 10.) onto end of forcing screw.
and then proceed to DISASSEMBLY, NOTE.
1CAUTION
1. Remove primary cover. See PRIMARY CHAIN on See Figure 6-9. Turn compressing tool handle only the
page 6-3. amount required to remove spring seat (10) and snap
2. Install SPROCKET LOCKING LINK (Part No. HD- ring (9). Excessive compression of diaphragm spring
38362). Remove the engine sprocket nut. Loosen, but do could damage clutch pressure plate.
not remove, engine sprocket. If necessary, use the slot- 3. See Figure 6-10. With a wrench on the clutch spring forc-
ted portion of TWO CLAW PULLER (Part No. HD-97292- ing screw flats to prevent the forcing screw from turning,
61) and two bolts to loosen the engine sprocket. turn handle clockwise until tool relieves pressure on snap
3. Remove retaining ring (12). Remove adjusting screw ring (9) and spring seat (10).
assembly (13, 14, 15 and 16) from pressure plate (17). 4. Remove snap ring (9) and spring seat (10) from the
groove in clutch hub (23) prongs. Remove the assembly
1CAUTION of diaphragm spring (11), pressure plate (17), adjusting
Clutch hub nut (21) has left-hand threads. To prevent screw components, and compressing tool.
damage, turn nut clockwise to loosen and remove from
mainshaft. 5. Turn the compressing tool handle counterclockwise until
the clutch spring forcing screw disconnects from the
4. Remove nut (21) and washer (22). Remove the clutch clutch adjusting screw (16). Remove snap ring (9), spring
assembly, primary chain, and engine sprocket as an seat (10), and diaphragm spring (11) from pressure plate
assembly from the vehicle. (17) assembly.
5. If primary chain is damaged or excessively worn, remove 6. Remove retaining ring (12) and adjusting screw assem-
it from engine sprocket and clutch assembly; replace bly (13, 14, 15 and 16) from pressure plate (17). If neces-
original primary chain with a new one. sary, disassemble adjusting screw assembly by removing
retaining ring (14), and then separating the remaining
adjusting screw components (13, 15 and 16).
DISASSEMBLY 7. Remove the clutch pack, which consists of eight friction
plates (18), six steel plates (19), and a spring plate (20),
NOTE from the clutch hub (23).
See Figure 6-9. If replacement of clutch pack (friction plates
[18], steel plates [19], and spring plate [20]) is the only ser- 1CAUTION
vice work to be performed, perform DISASSEMBLY Steps 2, Due to the possible damage to the bearing (25), the
3, 4, 5 and 7 only, and then proceed to INSPECTION AND clutch hub (23) and shell (26) assembly should not be
REPAIR, NOTE. Observe all 1WARNING and disassembled unless the bearing, hub, or shell require
1CAUTION statements which apply to the steps speci- replacement. If the assembly is pressed apart, the bear-
fied. ing must be replaced.
1. See Figure 6-9. With clutch assembly removed from pri- 8. Remove retaining ring (27) from inboard end of clutch
mary chaincase, reinstall adjusting screw assembly (13, hub (23). Using an arbor press, separate clutch hub (23)
14, 15 and 16) into pressure plate (17), noting that two from assembly of clutch shell (26), bearing (25), and
tabs on perimeter of release plate (13) must be inserted retaining ring (24).
into corresponding recesses in pressure plate (17). 9. Remove retaining ring (24) from groove in clutch shell
Secure the adjusting screw assembly with retaining ring (26). Press on the inboard side of bearing (25) outer race
(12). to remove bearing from clutch shell.
6-10
b0009b6x
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8 7
1. Spring 5
2. Locking plate
3. Well nut
4. Coupling 3
5. Outer ramp 2
6. Ball (3) 1
7. Inner ramp
8. Retaining ring 6
9. Snap ring
10. Spring seat 4
11. Diaphragm spring 17. Pressure plate 23. Clutch hub
12. Retaining ring 18. Friction plate (8) 24. Retaining ring
13. Release plate 19. Steel plate (6) 25. Bearing NOTE
14. Retaining ring 20. Spring plate 26. Clutch shell Depending upon vehicle production date,
15. Bearing 21. Mainshaft nut 27. Retaining ring configuration of items 4 and 5 may vary. See
16. Adjusting screw 22. Washer CLUTCH in Section 1.
Figure 6-9. Clutch Assembly
6-11
6. Check the primary chain sprocket and the starter ring
3555 gear on the clutch shell (26). If either sprocket or ring
gear are badly worn or damaged, replace the clutch
shell.
7. Check the slots that mate with the clutch plates on both
clutch shell and hub. If slots are worn or damaged,
replace shell and/or hub.
8. Check the diaphragm spring (11) for cracks or bent tabs.
3 Install a new spring if either condition exists.
2
ASSEMBLY
NOTE
See Figure 6-9. If replacement of clutch pack (friction plates
[18], steel plates [19], and spring plate [20]) is the only ser-
vice work to be performed, perform ASSEMBLY Steps 2, 5, 6,
1 7, and 8 only, and then proceed to INSTALLATION, NOTE.
Observe all 1WARNING and 1CAUTION statements
which apply to the steps specified.
1. See Figure 6-9. If the assembly of the clutch hub (23)

and shell (26) was disassembled, press new bearing
(25) in clutch shell; secure bearing with a new retaining
1. Clutch spring 2. Bridge
ring (24). Press inboard end of clutch hub into shell bear-
forcing screw 3. Tool handle
ing; secure with new retaining ring (27) on end of hub.
Figure 6-10. Compressing Clutch Diaphragm Spring 2. Install the clutch pack, which consists of eight friction
plates (18), six steel plates (19), and a spring plate (20),
INSPECTION/REPAIR into the clutch hub (23). The order of plate assembly,
from inboard to outboard, is as follows:
NOTE F- St -F- St -F- St -F- Sp -F- St -F- St -F- St -F
If replacement of clutch pack (friction plates [18], steel plates
[19], and spring plate [20]) is the only service work to be per- INBOARD ............................................................OUTBOARD
formed, perform all INSPECTION AND REPAIR steps (except
Step 5), and then proceed to ASSEMBLY, NOTE. F = Friction plate
St = Steel plate
See Figure 6-9. Wash all parts, except the friction (driven) Sp = Spring plate
plates (18) and bearing (25), in cleaning solvent. Blow dry
with compressed air. Examine the clutch components as fol- If disassembled, assemble bearing (15) and adjusting screw
lows: (16) in release plate (13); secure with new retaining ring (14).
1. Check for worn lining surface. 3. Install adjusting screw assembly (13, 14, 15 and 16) into
2. Inspect for checked or chipped lining. pressure plate (17), noting that two tabs on perimeter of
release plate (13) must be inserted into corresponding
3. Inspect each steel (drive) plate (19) for grooves. Also, recesses in pressure plate (17). Secure the adjusting
check each steel plate for flatness in several places using screw assembly with retaining ring (12).
a feeler gauge; the plate must be placed on a surface
plate or flat surface. Replace any plates that are dam- 4. Position diaphragm spring (11), with its concave side fac-
aged or that are warped more than 0.006 in. (0.15 mm). ing inboard (toward pressure plate), onto pressure plate
(17) assembly. Position spring seat (10), with its flat,
4. Wipe the lubricant from the eight friction plates, and larger O.D. side facing inboard (toward diaphragm
stack them on top of each other. Measure the thickness spring), and a new snap ring (9) onto convex (outboard)
of the eight stacked friction plates with a dial caliper or side of diaphragm spring (11).
micrometer. The minimum thickness must be 0.661 in.
5. Thread the CLUTCH SPRING FORCING SCREW (Part
(16.79 mm). If the thickness is less than specified, the
No. HD-38515-91) (item 1, Figure 6-10.) onto the clutch
friction plates and steel plates must be discarded, and a
adjusting screw (item 16, Figure 6-9.). Place the bridge
new set of both friction and steel plates must be
(item 2, Figure 6-10.) of SPRING COMPRESSING TOOL
installed.
(Part No. HD-38515-A) against diaphragm spring (item
5. Check the bearing (25) for smoothness by rotating the 10, Figure 6-9.). Thread the tool handle (item 3, Figure 6-
clutch shell while holding the clutch hub. If bearing is 10.) onto end of forcing screw. Do not tighten compress-
rough or binds, it must be replaced. ing tool against diaphragm spring at this time.
6-12
6. See Figure 6-9. Align square openings of pressure plate 2. Install SPROCKET LOCKING LINK (Part No. HD-
(17) and diaphragm spring (11) so that the assembly can 38362). Apply two or three drops of LOCTITE THREAD-
be installed over prongs of clutch hub (23). Place assem- LOCKER 262 (red) onto threads of sprocket shaft. Install
bly of spring seat, snap ring, diaphragm spring, pressure the engine sprocket nut. Tighten nut to 150-165 ft-lbs
plate, adjusting screw components, and compressing (203-224 Nm).
tool onto clutch hub (23), and against clutch pack.
1CAUTION 1CAUTION
Turn compressing tool handle only the amount required
Washer (22) must be installed with the word “out” facing
to install spring seat (10) and snap ring (9). Excessive
the mainshaft nut (21) or transmission may be damaged.
compression of diaphragm spring (11) could damage
clutch pressure plate.
3. Apply two or three drops of LOCTITE THREADLOCKER
7. Place a wrench on the clutch spring forcing screw flats to 262 (red) onto threads on end of mainshaft. Install
prevent the forcing screw from turning. Turn compressing washer (22) and nut (21) (left-hand threads) on main-
tool handle clockwise until diaphragm spring (11) com- shaft. Tighten nut (21) to 70-80 ft-lbs (95-108 Nm).
presses just enough to install spring seat (10) and snap
ring (9) into the groove in clutch hub (23) prongs. With 4. Install adjusting screw assembly (13, 14, 15 and 16) in
snap ring positioned against flange face (outboard side) the pressure plate (17), noting that two tabs on perimeter
of spring seat, and fully seated in groove of clutch hub, of release plate (13) must be inserted into corresponding
carefully loosen and remove compression tool. recesses in pressure plate (17). Secure assembly with a
8. Remove retaining ring (12). Remove adjusting screw new retaining ring (12).
assembly (13, 14, 15 and 16) from pressure plate (17).
5. Install primary cover. See PRIMARY CHAIN on page 6-5.
INSTALLATION 1WARNING
NOTE
See Figure 6-9.If replacement of clutch pack (friction plates cable should contact ground with the negative cable
[18], steel plates [19], and spring plate [20]) was the only ser- installed, the resulting sparks may cause a battery explo-
vice work performed, perform INSTALLATION Step 5 only. sion resulting in personal injury.
1. Install the engine sprocket, clutch assembly, and primary
chain as a unit into primary chaincase. 6. Connect battery cables, positive cable first.
6-13
TRANSMISSION
GENERAL LUBRICATION
See Figure 6-11. The transmission is a five-speed constant- Drain transmission and refill to correct level with fresh, clean
mesh type housed in an extension of the crankcase. The lubricant at least once each year or every 5000 miles (8000
transmission permits the rider to vary the ratio of engine km), whichever comes first. For best results, drain lubricant
speed-to-rear driving wheel speed in order to meet the vary- while hot.
ing conditions of operation.
See CLUTCH, TRANSMISSION FLUID in Section 1 for more
The transmission is foot-operated by the gear shifter lever, information.
which transmits the force through a gear shifter shaft. The
shifter shaft actuates a pawl and a shifter fork drum. The
shifter fork drum moves shifter forks, which slide a series of
shifter clutch gears, on the mainshaft and countershaft, into
and out of mesh with the other gears.
6-14
XLH transpower flow
Neutral 1st Gear

Mainshaft Mainshaft
4 1 3 2 5 4 1 3 2 5
Countershaft Out Countershaft In
3rd Gear 2nd Gear

Mainshaft In Mainshaft
4 1 3 2 5 4 1 3 2 5
Countershaft Out Countershaft In
5th Gear 4th Gear

Mainshaft Mainshaft
Out In In Out
4 1 3 2 5 4 1 3 2 5
Countershaft Countershaft
– Sliding member – Power flow
Figure 6-11. Transmission Power Flow
6-15
TRANSMISSION CASE
GENERAL
The rear compartment of the left and right crankcase halves
form the transmission case. An access cover (door) allows
removal of transmission components without removing the Axle nut (metric)
engine or disassembling (splitting) the crankcase.
Axle adjuster nut
REMOVAL
2. Remove rear fender. See FENDERS in Section 2.
3. See Figure 6-12. Loosen rear axle nut (metric). Reduce

tension on secondary drive belt by turning axle adjuster
nuts on each side of swingarm an equal number of turns
counterclockwise. Move rear wheel as far forward as
possible.
4. Remove muffler. See EXHAUST SYSTEM in Section 2. Figure 6-12. Secondary Drive Belt Adjustment
Place a drain pan under the engine. Remove drain plug
and drain lubricant from primary drive/transmission.
b0249x6x
5. Remove swingarm/drive support screws and retaining 1 2
nut. Remove sprocket cover, washer and spacer.
6. See Figure 6-13. Place transmission in first gear.
Remove two socket head screws (5) and lockplate (4).
1CAUTION 3
Transmission sprocket nut has left-hand threads. To pre-
vent damage, turn nut clockwise to loosen and remove
from main drive gear shaft.
7. Remove transmission sprocket nut (3) from main drive
gear shaft (1).
8. Remove secondary drive belt from transmission sprocket
(2). Remove transmission sprocket from main drive gear
shaft (1).
9. Remove primary cover. See PRIMARY CHAIN on page 6-3.
10. Remove clutch assembly, primary chain and engine
sprocket. See PRIMARY DRIVE/CLUTCH on page 6-10. 5 4
11. See Figure 6-14. Lock transmission in gear. Remove
countershaft TORX screw and retainer. 1. Main drive gear shaft 4. Lockplate
2. Transmission sprocket 5. Socket head
12. See Figure 6-15. Detach spring (1) from groove in 3. Transmission sprocket screw (2)
post (2). nut (left hand threads)
13. Remove retaining ring (10) and detent plate (9). You will
need to use a new retaining ring for installation. Figure 6-13. Transmission Sprocket
14. Remove two locknuts (3) and washers (11) which attach
shifter shaft assembly (6) to studs at transmission case.
Remove shifter shaft assembly.
15. Remove five access door bolts (7) and washers (8).
Remove transmission assembly by pulling it straight out-
ward, away from transmission case.
6-16
b0153x6x
3557 7,8
Retainer TORX screw 5

3 11
2 7,8
1
6 4
Figure 6-14. Countershaft Retainer 9
10
1. Spring 7. Bolt (5)
CLEANING, INSPECTION 2. Post 8. Washer (5)
AND REPAIR 3. Locknut (2) 9. Detent plate
Thoroughly clean transmission compartment with cleaning 4. Detent arm screw 10. Retaining ring
solvent. Blow parts dry with compressed air. Inspect parts to 5. Pawl 11. Washer (2)
determine if any must be replaced. Replace all parts that are 6. Shifter shaft assembly
badly worn or damaged.
Figure 6-15. Shifter Shaft Assembly
Neutral Indicator Switch
3553
See Figure 6-16. The neutral indicator switch is threaded into
the transmission portion of the right crankcase half. See
NEUTRAL INDICATOR SWITCH in Section 7 for testing,
removal and installation procedures.
Neutral indicator
switch
Figure 6-16. Neutral Indicator Switch
6-17
SHIFTER FORKS AND DRUM
DISASSEMBLY 2. See Figure 6-17. Remove nut (10), washer (14), screw
(18), drum lock plates (8, 9), detent arm (16), and
1. Remove transmission assembly. See TRANSMISSION spring (17).
CASE, REMOVAL on page 6-16. Mount transmission
assembly in vise with protected jaws. 3. Remove and discard the three fork cotter pins (4).
b0128x6x
1
5
Flat side
6
4
3 7
2 5
4 4
5
10
14
9
11 8
21
12
17
16 20 19
18
13
15
1. Shifter fork 3rd and 5th gear 8. Plate, shifter drum locating 15. Bowed snap ring
2. Shifter fork 1st and 2nd gear 9. Plate, reinforcing 16. Detent arm
3. Shifter fork 4th gear 10. Nut (2) 17. Spring
4. Cotter pin 11. Shifter shaft assembly 18. Screw, detent
5. Pin, shifter fork 12. Nut 19. Bearing, mainshaft
6. Pin, neutral indicator 13. Plate, detent 20. Bearing countershaft
7. Shifter fork drum 14. Washer 21. Washer
Figure 6-17. Shifter Mechanism
6-18
4. Remove three shift fork pins (5). A small magnet is useful
b0154x6x
in freeing the fork pins (5).
7 b0156x6x
5. Slide shifter drum (7) away from access door, through 11
shifter forks. The neutral switch pin prevents removal in 8
the other direction. 8 7
6. Remove shift forks (1, 2 and 3).
CLEANING, INSPECTION 9
5 9 10
AND REPAIR 10
1. See Figure 6-17. Clean all parts except bearings (19, 20)
with solvent.
2. Inspect bearings (19, 20) and shifter drum ends. If ends
of shifter drum are pitted or grooved, replace the shifter
drum and bearings. If replacing bearings, see ACCESS
6
DOOR BEARINGS on page 6-28.
3. Inspect shifter drum (7) for cracks or wear. Replace if 4
5
necessary. 3 5. Casting, detent
2
1 6. Post
ASSEMBLY 7. Plate, shifter drum
1. Bowed snap ring 8. Plate, reinforcing
1. See Figure 6-18 for shifter fork identification. See Figure 2. Plate, detent 9. Washer
6-17. Lubricate the shaft bore in fork (1) with SPORT- 3. Screw, detent 10. Nut
TRANS FLUID. Place 3rd and 5th gear shifter fork (1) in 4. Spring 11. Pin
the fork groove of mainshaft 2nd gear. Be sure the flat
side of fork is facing the access cover. Figure 6-19. Detent Plate Mounting
5. Align the hole through the top of each shifter fork with the
b0155x6x appropriate cam groove in the shifter drum. Lubricate
pins (5) with SPORT-TRANS FLUID. Drop pins (5)
4th gear 1st and 3rd and through the holes in shifter forks. With a small screw-
2nd gear 5th gear driver press on the pins while manipulating the forks back
and forth until the pin seats in the drum groove. Secure
pins in place with new cotter pins (4).
1CAUTION
The cotter pins must be inserted through the shifter forks
as shown in the inset of Figure 6-17 to prevent possible
damage to cotter pins (4).
NOTE
Figure 6-18. Shifter Fork Identification
See Figure 6-19. Detent plate (2) and bowed snap ring (1) are
2. Lubricate the shaft bore in fork (2) with SPORT-TRANS not installed at this time. These parts are installed during
FLUID. Place 1st and 2nd gear shifter fork (2) in the fork transmission installation after the final shifter pawl adjustment
groove of countershaft 3rd gear. Be sure the flat side of is made. See TRANSMISSION INSTALLATION AND
fork is facing away from the access door. SHIFTER PAWL ADJUSTMENT on page 6-30.
3. Lubricate the shaft bore in fork (3) with SPORT-TRANS
FLUID. Place 4th gear shifter fork (3) in the fork groove of 6. At the inside of the access door, place the shifter drum
mainshaft 1st gear. Be sure the flat side of fork is facing plate (7) in the groove of the drum shaft. See inset Figure
away from the access door. 6-19. Take care to correctly align the drum plates (7) and
4. See Figure 6-17. Position the shifter drum shaft so that (8) with the pin pressed in the drum plate. Take detent
the neutral indicator switch activator pin (6) is upward. screw (3) and insert it through detent arm (5), access
The shaft is then in the neutral position. Insert the pin door, shift drum plate (7), drum reinforcement plate (8),
end of drum shaft (7) through the hubs of shifter forks (1, and washer (9). Thread nut (10) on detent screw and
2 and 3) and through the bearing in access cover. tighten to 13-17 ft-lbs (18-23 Nm).
6-19
6
MAINSHAFT AND COUNTERSHAFT
DISASSEMBLY 3552
1. Remove transmission assembly. See TRANSMISSION

CASE, REMOVAL on page 6-16. Remove shifter forks
and drum as described under SHIFTER FORKS AND
DRUM on page 6-18.
2. See Figure 6-20. Clamp transmission assembly in vise,

with protective jaws, as shown, to work on disassembly.
Use protective jaws

when clamping in vise
Figure 6-20.
3559
NOTE
As the transmission runs, each part develops a certain wear
pattern and a kind of “set” with its mating parts. For this rea-
son, it is important that each component be reinstalled in its
original location and facing its original direction.
3. See Figure 6-21. As each component is removed, place

it on a clean surface in the exact order of removal.
Figure 6-21.
xlh0626
See Figure 6-22. Using RETAINING RING PLIERS (Part No.

J-5586) remove and discard retaining ring (5) next to counter-
shaft 5th gear (12). Slide countershaft 5th (12), mainshaft 2nd
(22) and countershaft 2nd (11) off end of shafts. Remove split
bearing (7) that was under gear (11) and thrust washer (6) on
the countershaft. Figure 6-22.
6-20
b0129x6x
14
15
16
17 18
19
37
13
30
20
21
20 22
5
5 5
12 6
11 7
6
23
7
5
24
5
25
6 7
26
6
27
10 5
9 36
5
1. Bearing 6
2. Door, access 8
3. Spacer, bevel 7 28
6 29
4. Gear, countershaft 4th
5. Ring, retaining (7) 4 35
3
6. Washer, thrust (6)
7. Bearing, split (4) 2
8. Gear, countershaft 1st
9. Countershaft
10. Gear, countershaft 3rd 24. Gear, mainshaft 1st 1
11. Gear, countershaft 2nd 25. Gear, mainshaft 4th 33 31 34
12. Gear, countershaft 5th 26. Spacer 32
13. Bearing, closed (countershaft) 27. Mainshaft
14. Sprocket, chain/belt 28. Bearing
15. Seal, oil 29. Ring, retaining
16. Spacer (belt drive) 30. Seal
17. Ring, Quad 31. Retention collar
18. Ring, retaining 32. Torx screw
19. Bearing, ball 33. Ring, retaining
20. Bearing, needle 34. Nut, mainshaft
21. Gear, mainshaft 5th 35. Washer, spring
22. Gear, mainshaft 2nd 36. Bushing
23. Gear, mainshaft 3rd 37. Bearing closed (shifter shaft)
Figure 6-23. Transmission Assembly
6-21
4. See Figure 6-24. Remove retaining ring (5) next to coun-
xlh0628
tershaft 3rd gear (10). Slide countershaft 3rd gear (10)
off free end of shaft.
5. At mainshaft, between mainshaft 1st gear (24) and main-

shaft 3rd gear (23), expand retaining ring (5) and move
next to mainshaft 1st gear along with thrust washer (6).
Move mainshaft 3rd gear as far as possible toward main-
shaft 1st gear (24). Expand retaining ring (5) at opposite
side of mainshaft 3rd gear and slide off end of shaft.
Remove mainshaft 3rd gear (23) and its split bearing (7).
6. Slide thrust washer (6) off end of mainshaft. Expand

retaining ring (5), which is next to mainshaft 1st gear
(24), and slide off end of shaft.
Figure 6-24.
xlh0629
Press
Mandrel
7. See Figure 6-25. Place COUNTERSHAFT GEAR SUP-

PORT PLATE (Part No. HD-37404) under countershaft Support
4th gear (4). Place assembly on press with suitable metal plate
blocks under the support plate. Place a socket or man-
drel, smaller than inside diameter of bearing, and press
countershaft free of access cover. Slide mainshaft 1st Blocks
gear (24) off mainshaft.
Figure 6-25.
xlh0630
8. See Figure 6-26. Remove beveled spacer (3) and coun-

tershaft 4th gear (4).
9. Expand retaining ring (5) located next to countershaft 1st

gear (8). Remove retaining ring (5) and thrust washer (6).
Slide countershaft 1st gear off end of shaft. Remove split
bearing (7).
10. Remove thrust washer (6). Expand remaining retaining

ring (5) and slide off shaft. This completes disassembly
of countershaft. Figure 6-26.
6-22
11. See Figure 6-27. Place mainshaft and access door
xlh0631
assembly on arbor press with support under mainshaft
4th gear (25). Press on end of shaft until mainshaft is
free of access door bearing. Remove spacer (26), Press
mainshaft 4th gear (25) and split bearing (7).
12. Remove thrust washer (6). Expand and remove remain-

ing retaining ring (5).
Blocks
AND REPAIR
1. Clean all parts (except bearings) in cleaning solvent and

blow dry with compressed air.
2. Check gear teeth for damage. If gears are pitted, scored, Figure 6-27.
rounded, cracked or chipped, they should be replaced.
xlh0632
3. Inspect the engaging dogs on the gears. Replace the
gears if dogs are rounded, cracked, battered, chipped or
dimpled.
4. Discard all retaining rings that were removed.
ASSEMBLY
1CAUTION
During assembly, the split bearings (7) and the internal
bores of the gears must be lubricated with SPORT-
TRANS FLUID prior to assembly. Leaving these parts dry
could accelerate wear at start-up. Press
1. Find a section of pipe that matches the inner race of

bearing (28). See Figure 6-28. Place the door assembly,
outside downward, on a press with the inner race of
bearing (28) resting on the section of pipe. Insert the
splined end of the shaft through the bearing and hold in a Figure 6-28.
vertical position. Press the shaft into the bearing until the
bearing bottoms against the shaft shoulder.
6-23
2. See Figure 6-29. Place spacer (26) over mainshaft and
xlh0633
position next to bearing (28). Position split bearing (7)
into machined seat next to spacer (26). Locate mainshaft
4th gear (25), which can be identified by the two radial
grooves at one side. Slide gear (25) onto shaft with radial
grooves facing door. Position gear over bearing next to
spacer (26).
3. Install thrust washer (6) and retaining ring (5) next to

gear (25). It will be necessary to push the retaining ring
into final position with a screwdriver.
4. Slide mainshaft 1st gear (24) onto mainshaft with the 2 grooves
locking dogs facing gear (25).
Figure 6-29.
5. See Figure 6-30. Install retaining ring (5). Position retain-
ing ring in the second ring groove from the end with inter- xlh0634
nal threads. Install thrust washer (6) next to retaining
ring. Install split bearing (7) in seat next to washer (6).
6. Locate countershaft first gear (8). Gear (8) has a ring

groove at one side of the gear. Install gear (8) over split
bearing (7).

gear (8).
1 groove
8. Locate countershaft 4th gear (4). This gear is splined and
has a single radial groove at one side. Position gear next
to retaining ring (5). Place beveled washer (3) over end
of shaft with beveled side away from gear (4).
Figure 6-30.
xlh0635
Press
Mandrel
9. See Figure 6-31. Stand countershaft assembly on press

with small end (end with threaded hole) upward. Place
access cover and mainshaft assembly on top of counter-
shaft with bearing (1) in access cover over end of coun-
tershaft. Place a socket or section of pipe on inner race
of bearing (1). Hold assembly straight, making sure gear
teeth on countershaft are engaged with gear teeth on
mainshaft, and press bearing onto shaft until beveled
spacer bottoms against bearing.
NOTE Blocks
When correctly installed, countershaft 4th gear should have

zero end play. Figure 6-31.
6-24
10. See Figure 6-32. At mainshaft, install retaining ring (5)
xlh0636
and thrust washer (6). Install split bearing (7) in seat next
to thrust washer (6).
11. Install mainshaft 3rd gear (23) onto shaft over bearing
(7).
gear (23).
13. Install countershaft 3rd gear (10) onto shaft.
Figure 6-32.
xlh0637
14. See Figure 6-33. Install retaining ring (5) and thrust
washer (6). Install split bearing (7) into seat next to thrust
washer (6).
15. Install countershaft 2nd gear (11) over bearing (7).
16. Install mainshaft 2nd gear (22) onto shaft.
17. Install countershaft 5th gear (12).
Figure 6-33.
18. Expand retaining ring (5) and slide into groove next to
countershaft 5th gear (12).
3557
31
32
19. See Figure 6-34. At outside of access door, position

retention collar (31) next to end of countershaft with bev-
eled side facing outward. Apply a few drops of LOCTITE
THREADLOCKER 242 (blue) to the threads of TORX
screw (32). Insert TORX screw (32) through retention
collar, and thread into end of shaft. Place transmission in
gear, and tighten TORX screw to 13-17 ft-lbs (18-23 Nm). Figure 6-34.
6-25
MAIN DRIVE GEAR
REMOVAL
3563
1. Remove transmission. See TRANSMISSION CASE, Cross Plate (Part
REMOVAL on page 6-16. No. HD-35316-91)
2. See Figure 6-35. From inside case tap out seal (3) at end
of mainshaft 5th gear (1). Discard seal (3).
3. See Figure 6-36. Use MAIN DRIVE GEAR REMOVER
AND INSTALLER (Part No. HD-35316-A) with CROSS
PLATE (Part No. HD-35316-91). Take support bracket (1)
and insert pins, at one side, into holes which are now
exposed under access cover.
4. See Figure 6-37. Insert bolt (2) through support bracket
(1) and 5th gear (3).
1CAUTION
When removing the main drive gear, the gear is pressed
out against the resistance of the bearing inner race. With-
out any support at the inner race, the bearing is
destroyed. Whenever the main drive gear is removed the Figure 6-36. Support Bracket Mounting
main drive gear bearing will also have to be replaced.
5. At outside of case, place driver (4) and thrust washer (5)

over end of bolt (2). Install and tighten nut (6) until 5th
gear (3) is free.
xlh0639
For inner bearing 0.080 in.

0.315-0.285 in. (2.03 mm)
(8.001-7.239 mm)
For outer bearing xlh0641
For seal
0.06-0.03 in.
(1.5-0.7 mm)
1. Support bracket 4. Driver

1. Main drive gear 3. Seal 2. Bolt 5. Thrust washer
2. Needle bearing 3. 5th gear 6. Nut
Figure 6-35. Main Drive Gear Assembly Figure 6-37. Removing Main Drive Gear
6-26
DISASSEMBLY 3554
Ram
Drive out needle bearings, from inside bore of main drive
gear. Do not reuse bearings after removal.
Main drive gear
ASSEMBLY Needle bearing

installation tool
1. Use INNER/OUTER MAIN DRIVE GEAR NEEDLE

BEARING INSTALLATION TOOL (Part No. HD-37842A).
See Figure 6-38. The tool is stamped 0.080 in. (2.032
mm) for the end of the tool to be used for driving the
bearing into the inner end and 0.315 in. (8.001 mm) for
the outer end bearing.
2. Place main drive gear on a press. With the bearing instal-

lation tool, press in the outer bearing to a depth of 0.315-
0.285 in. (8.001-7.239 mm). Press in the inner bearing to
Figure 6-38. Needle Bearing Installation Tool
a depth of 0.080 in. (2.032 mm). The installation tool will
automatically bottom on the gear when the correct depth
is reached.
xlh0643
INSTALLATION
1. Replace main drive gear bearing. See ACCESS DOOR
BEARINGS, INSTALLATION on page 6-28.
2. Use MAIN DRIVE GEAR REMOVER AND INSTALLER

TOOL. See Figure 6-39. Take bolt (2) and place washer
(5) followed by main drive gear (4) over end of bolt. From
inside of case insert bolt and main drive gear through
inner race of ball bearing.
3. Insert threaded end of bolt (2) through installer cup (3)

and thrust washer (1). Thread nut (6) onto end of bolt (2). 1. Thrust washer 4. 5th gear
Tighten nut (6) until shoulder on gear (4) bottoms against 2. Bolt 5. Washer
inner race of bearing. 3. Installer cup 6. Nut
Figure 6-39. Main Drive Gear Installation

4. See Figure 6-35. Tap in new seal (3) at threaded end of
5th gear.
6-27
ACCESS DOOR BEARINGS
REMOVAL INSTALLATION
Mainshaft and Countershaft Bearings Mainshaft and Countershaft Bearings
1. Lay access door on press with inside surface of door

1. Remove transmission assembly. See TRANSMISSION downward.
CASE, REMOVAL on page 6-16. Remove shifter forks
and drum as described under SHIFTER FORKS AND 2. Lay bearing squarely over bore with printed side of bear-
DRUM on page 6-18. Remove countershaft and main- ing upward. Place section of pipe or tubing (slightly
shaft. See MAINSHAFT AND COUNTERSHAFT starting smaller than outside diameter of bearing) against outer
on page 6-20. race. Press bearing into bore until bearing bottoms
against shoulder.
2. Inspect the mainshaft and countershaft ball bearings for
pitting, scoring, discoloration or other damage. 3. Install new retaining ring with beveled side facing away
from bearing.
3. See Figure 6-40. If bearing replacement is required,
remove retaining rings (1, 2). Press out bearings (3, 4) Shift Drum Bushing
from the inside of the door.
1. Lay access door on press with outside surface of door

downward.
Shift Drum Bushing
2. See Figure 6-41. Lay bushing squarely over bore. Locate
1. Inspect the shifter drum bushing for pitting, scoring, dis- socket or pipe that is slightly larger than diameter of
coloration or excessive wear. If bushing requires replace- bushing. Place socket or pipe on bushing and press into
ment press bushing out of door from either side. bore until bushing is flush with or 0.020 in. (0.51 mm)
below inside surface. If using a pressing tool larger than
diameter of bushing, the pressing tool will bottom against
door when bushing is flush with top surface.
b0181x6x
b0182x6x
Assemble bushing flush

to 0.020 in. (0.51 mm)
3 recess from this surface
4 Shift drum bushing
1. Retaining ring 3. Bearing, mainshaft

2. Retaining ring 4. Bearing, countershaft
Figure 6-40. Ball Bearing Assembly Figure 6-41. Shift Drum Bushing Assembly
6-28
RIGHT TRANSMISSION CASE BEARINGS
REMOVAL 3563
Cross Plate (Part
1. Remove transmission assembly. See TRANSMISSION
No. HD-35316-91)
CASE, REMOVAL on page 6-16. Remove main drive 5th
gear. See MAIN DRIVE GEAR on page 6-26.
2. At outside of case remove seal next to 5th gear bearing
retainer. Remove retaining ring.
3. From inside transmission case drive bearings (5th gear,
countershaft or shifter shaft) out of bores. Carefully tap
bearings free by working around bearing diameter to
keep bearing from skewing.
INSTALLATION
Mainshaft 5th Gear Ball Bearing
1. Locate MAIN DRIVE GEAR REMOVER AND
INSTALLER (Part No. HD-35316-A). See Figure 6-42.
Place support bracket pins in appropriate holes in trans- Figure 6-42. Cross Plate Mounting
mission case.
2. See Figure 6-43. Insert bolt (2) through support bracket xlh0647
(1), new bearing (3), driver (4) and thrust bearing (5).
Thread nut (6) on end of bolt. Tighten nut carefully until
bearing is started in bore squarely. Tighten nut (6) until
bearing is seated against shoulder in bore.
3. At outside of case install beveled retaining ring in groove
inside bearing bore with beveled side facing outside of
case.
4. Lubricate bearing with SPORT-TRANS FLUID.
Countershaft Needle Bearing

1. Find a suitable bearing driver 1-1/4 in. (31.75 mm) in
diameter.
2. From the outside of the case place the needle bearing
open end first next to the bearing bore. Hold the driver
squarely against the closed end of the bearing and tap
the bearing into place. The bearing is properly positioned
when it is driven inward flush or 0.030 in. (0.76 mm) 1. Support bracket 4. Driver
below the outside surface of the case. 2. Bolt 5. Thrust bearing
3. Lubricate bearing with SPORT-TRANS FLUID. 3. Bearing 6. Nut
Figure 6-43. Installing Mainshaft Ball Bearing

Shift Drum Needle Bearing
1. Find a suitable bearing driver 13/16 in. (20.64 mm) in
diameter.
2. From the outside of the case place the needle bearing,
open end first, next to the bearing bore. Hold the driver
squarely against the closed end of the bearing and tap
the bearing into place. The bearing is properly positioned
when driven inward flush or 0.030 in. (0.76 mm) below
the outside surface.
3. Lubricate bearing with SPORT-TRANS FLUID.
6-29
TRANSMISSION INSTALLATION AND
SHIFTER PAWL ADJUSTMENT
Verify that all parts have been properly installed, as described
b0135x6x
earlier in this section under RIGHT TRANSMISSION CASE 1 2
BEARINGS, MAIN DRIVE GEAR, MAINSHAFT AND COUN-
TERSHAFT, and SHIFTER FORKS AND DRUM. 4
1. Carefully insert transmission into case opening. Position
the assembly so that the mainshaft enters fifth gear, and
so that the countershaft and drum shifter shaft enter their
respective bearings.
2. See Figure 6-15. Apply a few drops of LOCTITE
THREADLOCKER 242 (blue) to the threads of the five
access door mounting bolts (7). Insert the bolts with
washers (8) through holes in access door, and thread
into tapped holes in right transmission case. Tighten
bolts to 13-17 ft-lbs (18-23 Nm).
No. 32 drill bit (0.116 in. dia.)
3. Lift pawl (5) over drum pins, and place shifter shaft
assembly (6) on studs at transmission case. Loosely
install a washer (11) and locknut (3) on each stud.
4. Attach the loop of spring (1) over and into groove in post (2).
5. Place detent plate (9) over drum pins. Rotate plate until
2
blind holes in plate align with pins in end of drum shaft.
Install new retaining ring (10) using SHIFT DRUM 3
RETAINING RING INSTALLER (Part No. HD-39151).
Verify that retaining ring is fully engaged with drum
groove.
6. See Figure 6-44. Place transmission in third gear. Place 5
a No. 32 drill bit (0.116 in. dia.) through hole in detent
plate (3), and between pawl (2) and drive pin at end of
shifter drum shaft. Push down top of crank (4) to remove Drill bit
all clearance between pawl and drill bit; this will correctly
align pawl to shift drum pins (do not push down with too 1. Nut 4. Crank
great a force, as this might cause the shifter drum to 2. Pawl 5. Shifter drum pin
rotate). With bit in place, tighten shifter shaft assembly 3. Detent plate
bottom nut (1) first to 90-110 in-lbs (10.2-12.4 Nm).
Then, tighten shifter shaft assembly top nut (1) to the Figure 6-44. Shifter Shaft Assembly Alignment
same torque. Remove drill bit.
11. Increase belt deflection by loosing rear axle and moving
7. See Figure 6-23. Place new quad ring (17) over rear wheel forward. Turn the nut counterclockwise to
threaded end of fifth gear (21), and position next to the install it onto main drive gear shaft.
gear taper. Install spacer (16) over threaded end of fifth
gear with chamfered end toward quad ring. Slide spacer a. Use SPROCKET HOLDING TOOL (Part No. HD-
up against bearing (19). 41321) and MAINSHAFT LOCKNUT WRENCH
8. Coat lips of seal (15) with SPORT-TRANS FLUID. Posi- (Part No. HD-94660-37B) and a torque wrench.
tion seal over spacer (16) with lips of seal toward case. Tighten nut to 50 ft-lbs (68 Nm) INITIAL torque,
Gently tap seal into bore of case until the outside of seal ONLY.
is flush with outer edge of bore. It is acceptable to recess
seal to about 0.030 in. (0.76 mm) below outer edge of b. See Figure 6-46. Scribe a line on the transmission
bore; seal recession will be limited by seal bottoming sprocket nut and continue the line on the transmis-
against retaining ring (18). sion sprocket as shown.
9. See Figure 6-45. Install transmission sprocket (2) with c. Tighten the transmission sprocket nut an additional
secondary drive belt onto main drive gear shaft (1). 30°-40°.
10. Place transmission in neutral. Apply a few drops of LOC-
TITE THREADLOCKER 262 (red) to the left-hand d. See Figure 6-45. Install lockplate (4) over nut (3) so
threads of transmission sprocket nut (3). Position nut that two of lockplate’s four drilled holes (diagonally
with washer-faced side facing transmission sprocket. opposite) align with sprocket’s (2) two tapped holes.
6-30
NOTE
b0249x6x
1 2
The lockplate has four screw holes and can be turned to
either side, so you should be able to find a position without
having to additionally tighten the nut. If you cannot align the
screw holes properly, the nut may be additionally TIGHT-
3
ENED until the screw holes line up, but do not exceed 45° as
specified above. Never LOOSEN nut to align the screw holes.
e. See Figure 6-46. If lockplate will not align with holes,

tighten nut to 45° maximum.
1CAUTION
Maximum allowable tightening of sprocket nut is 45° of
counterclockwise rotation, after initially tightening to 50 ft-
lbs. Do not loosen sprocket nut while attempting to align
5 4
the screw holes. If you cannot align lockplate and sprocket
screw holes, nut may be additionally tightened 45° as 1. Main drive gear shaft 4. Lockplate
specified above. Tightening too much or too little may 2. Transmission sprocket 5. Socket head
cause the nut to come loose during vehicle operation. 3. Transmission sprocket screw (2)
nut (left hand threads)
12. If you cannot align lockplate and sprocket screw holes,
Figure 6-45. Transmission Sprocket
nut may be additionally tightened until screw holes align.
i00077-
13. Install two socket head screws (5) through aligned holes Transmission
Transmission sprocket
of lockplate and into tapped holes of sprocket. Tighten
sprocket nut
NOTE
The original equipment socket head screws (5) have thread-

locking compound applied to them. Since this compound
remains effective for about three removal/installation cycles,
the original screws may be reused up to three times. After the
third removal/installation cycle, replace both screws with new 45°
screws identical to the original.
30°
14. Install the remaining removed components in the reverse

order of the removal procedures. See the procedures
listed in the respective component sections.
Line scribed on nut and sprocket
15. Adjust drive belt tension. See REAR BELT DEFLECTION
in Section 1. Figure 6-46. Aligning Transmission Sprocket
16. Fill transmission to proper level with fresh lubricant. See

CLUTCH, TRANSMISSION FLUID in Section 1.
6-31
7
SPECIFICATIONS
BATTERY IGNITION TIMING SPARK OCCURRENCE
Size 12 VDC V.O.E.S.

Idle
Type Sealed Connected Disconnected
World models Approximately
20˚ BTDC
950-1050 RPM 7.5˚ BTDC
California models Approximately
SPARK PLUGS 20˚ BTDC
1150-1250 RPM 7.5˚ BTDC
Size 12 mm
Style 6R12
Gap 0.038-0.045 in. 0.96-1.14 mm
IGNITION COIL RESISTANCE
Torque value 11-18 ft-lbs 14.9-24.4 Nm
Primary winding 2.5-3.1 Ohms
Secondary winding 10,000-12,500 Ohms
ALTERNATOR
AC voltage output 19-26 VAC per 1000 engine RPM

Stator coil resistance 0.2-0.4 Ohms ELECTRICAL SYSTEM AMPERES
Main circuit breaker 30

Ignition fuse 15
REGULATOR Light fuse 15
Voltage output @ 75°F 13.8-15 VDC Accessory fuse 15
Amperes @ 3600 RPM 22 Amps Instrument fuse 15
BULB CHART
Number Of
Lamp Description (All Lamps 12 V) Specifications
Bulbs Required
Headlamp High/low replaceable bulb 1 60 W/55 W
Position lamp 1 14 W
Marker lamps Tail/stop lamp 1 5 W/21 W
Turn signal lamp-front and rear, 1 bulb per lamp 4 10 W
License plate lamp 1 5W
Indicator lamps on High beam indicator 1 0.07 Amps/2 C.P.
instrument support
Turn signal indicator 2 0.07 Amps/2 C.P.
Oil pressure indicator 1 0.07 Amps/4 C.P.
Neutral indicator 1 0.07 Amps/4 C.P.
Instruments Speedometer 2 0.22 Amps/2 C.P.
Tachometer 1 0.22 Amps/2 C.P.
7-1
ITEM TORQUE NOTES
Headlamp housing screws 5-7 ft-lbs 6.8-9.5 Nm metric, page 7-34, page 7-37
Ignition coil mounting screws 2-6 ft-lbs 2.7-8 Nm page 7-17
Inner cover screws 12-20 in-lbs 1.4-2.3 Nm page 7-15
Neutral indicator switch 3-5 ft-lbs 4.0-6.8 Nm LOCTITE THREADLOCKER 242 (blue), page 7-42
Rotor mounting bolts 90-110 in-lbs 10.2-10.4 Nm LOCTITE THREADLOCKER 242 (blue), page 7-30
Spark plugs 11-18 ft-lbs 14.9-24.4 Nm page 7-1
T-27 Torx with retaining compound, replace after
Stator mounting screws 30-40 in-lbs 3.4-3.5 Nm
removal, page 7-30
left side
right side
Timer plate studs 12-20 in-lbs 1.4-2.3 Nm page 7-15
Trigger rotor bolt 75-80 in-lbs 8.5-9.0 Nm LOCTITE THREADLOCKER 242 (blue), page 7-15
7-2
IGNITION SYSTEM
GENERAL Ignition Module

The vehicle uses a breakerless inductive-discharge ignition The ignition module is mounted to the vehicle frame under a
system. The system has both a primary and secondary cir- protective cover; it is located to the right of the battery. The
cuit. The primary circuit consists of the battery, ignition switch, ignition module has two functions. First, it computes the spark
primary coil winding, computerized ignition timer and associ- advance for proper ignition timing. Second, it opens and
ated wiring. The secondary circuit consists of the secondary closes the low-voltage circuits between the battery and igni-
coil, spark plugs and associated wiring. See Figure 7-1. tion coil to produce high-voltage discharge to the spark plugs.
The computerized ignition system contains three assemblies.

9. Trigger rotor 22. Ignition module connector [P10]
10. Seal 23. Ignition module 17
12. Spark plug (2) 25. Screw (2)
13. Ignition coil 16 22
23
15 14
18
24
19 25
21
13 20
12
10 9
8
11
3
7 6 1
5
b0223x7x
4
2
Figure 7-1. Ignition System Components
7-3
Vacuum-Operated Electric Switch TROUBLESHOOTING
The vacuum-operated electric switch (V.O.E.S.) is attached to
Perform the following tests if the engine will not start, or if
the carburetor. The V.O.E.S. senses intake passage vacuum
hard starting or missing indicates a faulty operating ignition
through a carburetor hose connection. The switch is open
system.
during acceleration and high engine load conditions (low vac-
uum) and is closed during deceleration and low engine load
conditions (high vacuum). The ignition module is programmed
with two spark advance curves to meet varying engine loads.
The high-vacuum curve, selected for maximum spark Check for Ignition Spark
advance under normal light-load cruising conditions, provides
improved fuel economy and performance. The low-vacuum 1. Disconnect spark plug cables from spark plugs. Check
curve (retarded spark) minimizes spark knock while maintain- condition of plugs and cables. Clean or replace as nec-
ing performance under high-load conditions (acceleration and essary.
highway driving).
2. Insert a conductive adapter into spark plug cable end
The ignition module selects the proper curve when it receives
and establish a 3/16 in. (4.8 mm) gap between adapter
an open or closed electrical signal from the V.O.E.S. This sys-
and cylinder head. Turn on ignition and “engine stop”
tem ensures correct timing to suit starting and high-speed
switches. With transmission in neutral, press “engine
requirements.
start” button. Check for a spark across plug electrode
A single ignition coil fires both spark plugs simultaneously. gap. If a spark is produced, problem is not in electronic
The spark plug in the front cylinder fires at the end of that cyl- system or coil – check carburetion, enrichener and spark
inder’s compression stroke, thereby igniting the air/fuel mix- plugs. If no spark is produced, check battery voltage and
ture. At the same instant, the spark in the rear cylinder fires battery connection condition. Battery voltage must be 11-
ineffectually during the end of that cylinder’s exhaust stroke. 13 VDC. Charge battery if voltage is low.
During the next engine revolution, the simultaneous firing of
the spark plugs will occur during the middle of the front cylin- 3. Verify that the ground strap from swingarm mount block
der’s exhaust stroke and at the end of the rear cylinder’s com- to below the circuit breakers is in good condition. If there
pression stroke (thereby igniting the air/fuel mixture in the is still no spark, then perform the tests under NO IGNI-
rear cylinder). TION SPARK below.
Rotor and Sensor Plate No Ignition Spark

The rotor and sensor plate are located in the gearcase cover
on the right side of the motorcycle. The rotor is mounted on See Figure 7-2. To conduct the following tests, it will be nec-
the camshaft and operates at one-half crankshaft speed. As essary to assemble a set of jumper wires. Cut two wires of
the rotor turns, slots in its outside diameter break the mag- ample length to reach from a good ground connection to the
netic field of a Hall-effect device mounted on the sensor plate. negative terminal of the coil primary. If a suitable capacitor is
The output of the Hall-effect device is a logic-type signal that not available, use a condenser (such as the type used in ear-
corresponds to the timing information from the spinning rotor. lier breaker point ignition systems). When conducting Steps 3
This technique gives accurate timing information down to “0” and 5 of the following spark tests, connect a spare spark plug
speed. to one of the plug wires and lay the spark plug on the engine
cylinder head. During the testing procedures, check for spark
The ignition system produces a spark near top dead center across the spark plug electrodes.
(TDC) for starting. At RPM’s and loads above this, the system
produces a spark 5˚-40˚ before TDC. The whole timing pro-
gram can be shifted by mechanical rotation of the sensor
plate. See IGNITION TIMING in Section 1. xlhinsert1
The ignition module contains all the solid-state components

used in the ignition system. The dwell time for the ignition coil 0.33 MFD capacitor
is also calculated by the microprocessor and is dependent
upon engine speed. The programmed dwell is an added fea-
ture to keep battery drain to a minimum and to adequately
charge the coil at all speeds. The ignition module has added
16 ga. wire
protection against transient voltages, continuous reverse volt-
age protection and damage due to jump starts. The system
will operate down to 5.7 VDC. The ignition module is fully
enclosed to protect it from vibration, dust, water and oil. The
unit is not repairable–it must be replaced if it fails.
See the wiring diagrams at the end of this section for addi-
tional information on ignition system circuits. Figure 7-2. Test Jumper
7-4
b0241x7x
ELECTRONIC IGNITION
VACUUM SWITCH
TIMER AND PICKUP BK
BK
TN
NEUTRAL
P7 2 1
V/W
BK
GN/W
BK/W
W/BK
BK
PK
V/W
R/W
R/W BK/W
TN
GN/W
P10 8 7 6 5 4 3 2 1
P1
IGN POWER BE 1 GY
GN/W
BK/W
W/BK
BK
PK
V/W
R/W
FROM (2) GN/BK 3 W/BK A B C P16
NEUTRAL
12 11 10 9 8 7 6 5 4 3 2 1 P3 SWITCH
TN
S8
BK TN/W
P14 2 1
BK W
SIDE STAND
SWITCH
S2
S1
TN
S13 S12
MAIN CHASSIS GROUND
S11 TN/GN TN
S10 R BK
TN/GN TN/GN
MASTER
30A CIRCUIT
BREAKER
S7
TN/GN
S14
P5 S15 GN
R/BK
R
TO GROUND BK 2 BK
GY TN/W PK
P13
P8
A
B
C
D
P12
R/B K
GN
INSERTION SIDE BK
R
W/BK
COIL IGNITION BK
GY/O R/BK
15A
R/BK
COLOR CODE: LT.BE LIGHT BLUE GY/O
REAR PLUG INSTRUMENTS
R/BK

86 85
DIODE GY/O TN/W
15A
87 R/BK GN
30
87A
R/BK
FUSE BLOCK R OFF
P9 LOCK
BATTERY
1996 BUELL S1-LIGHTNING WIRING DIAGRAM
7-5
Figure 7-3. Ignition System Circuit

Continuous or No Spark at Plug
b0077x7x
STEP 1
1. Ignition switch on.
2. Multimeter red wire to white wire terminal, IF NO POWER

black wire to ground.
Check circuit breaker, ignition relay,
loose wires, switches.
3. Meter should register 12 VDC ± 1.0 volt. If
meter is correct, proceed to STEP 2. To tach
STEP 2 b0078x7x
1. Remove pink (module) wire from coil

terminal.
IF NO POWER
3. Multimeter red wire alternately to white
wire terminal and to pink wire terminal. Check coil resistance. See COIL
later in this section.
4. Meter should register 12 VDC at both
If resistance is OK check spark.
terminals. If meter is correct, proceed
See STEP 3.
to STEP 3.
STEP 3 b0079x7x
1. Pink (module) wire disconnected.

3. Jumper wire – connect capacitor wire to
IF NO SPARK
pink wire terminal.
Replace coil.
4. Connect both wires to common ground.
5. Momentarily touch ground wire to pink wire
terminal. When you remove the wire, there Jumper
should be a spark at plug. If spark occurs,
proceed to STEP 4.
STEP 4 x0043ax7x
1. Reconnect pink wire to coil.
2. Ignition switch on. B A

IF NO POWER
3. Disconnect sensor. Check module ground and power
C
wire to module for loose connec-
4. Connector from module–multimeter red tions. See Resistance Test which
wire to red wire socket and multimeter follows. Check spark, STEP 5.
black wire to black/white pin. Should regis- A. Green
ter 12 VDC ± 0.5 volts. If meter is correct, B. Black/white pin
proceed to STEP 5. C. Red from module
7-6
b0044a7x
STEP 5
1. Ignition on.
2. Momentarily place screwdriver across IF NO SPARK

black/white and green connector pins.
Since the ignition module ignores the first Check module resistance. See
A B IGNITION RESISTANCE TEST-
four sensor inputs, repeat this step six to
IGNITION MODULE. Replace mod-
ten times. ule if resistance is bad.
C
3. Strong evidence of spark at spark plug
when screwdriver is removed. If there is a A. Red from module
spark, sensor is suspect. Install known, B. Green
good sensor and test again. C. Black/white pin
Intermittent Ignition Problem–Vibration

b0224x7x
1. Check battery connections. Disconnect
module ground (scrape paint, add star
washer).
2. Disconnect white wire at coil terminal PROBLEM NOT ELIMINATED

(not module feed).
Problem is vibration, possibly loose
3. Connect 16 ga. jumper wire from battery connections at safety switches or
positive terminal to white wire. defective ignition relay in starter
circuit.
4. Operate vehicle to see if problem is
eliminated.
NOTE
Vehicle no longer has an engine stop switch.
Engine must be stopped by removing jumper
wire.
Intermittent Ignition Problem–Temperature

d0018x8x
1. Remove outer timing cover.
2. Remove inner timing cover and gasket. Sensor
3. Start engine.
4. Spray sensor plate with refrigerant (obtain- IF ENGINE KILLS
able at electronic supply houses) to see if
Problem is temperature sensitive
engine kills.
sensor or module. Replace sensor
5. With engine hot, at operating temperature or module.
and cover off, apply heat (blow dryer) to
nose of sensor and see if engine kills.
6. Apply heat (blow dryer) to module and see if
engine kills.
7-7
Ignition Resistance Test-Ignition Module
1CAUTION
If a resistance test is performed on a “live” circuit, the multimeter will be damaged. Turn off ignition and disconnect
the battery before doing a resistance test.
METER
TEST PROBE 1 PROBE 2 METER READING AT MODULE
SETTING
0-1 Ohm Good
Check for To black/white To chassis Check harness for opens. See next
RX1 More than
grounds wire in harness ground page. If harness checks OK, replace
1 Ohm
module.
2
b0080b3x
3 4
V
5 W
4
A B
Chassis
ground
C
1. Ignition sensor plate

2. Ignition module
3. Ignition coil
4. Spark plug (2)
5. Vacuum-operated electric switch (V.O.E.S.)
7-8
Ignition Resistance Test-Ignition Module Harness
TEST CONDITIONS: Engine stop switch on right handlebar must be in OFF position and 8-place ignition module
connector [P10] and 3-place sensor connector [P16] must be disconnected for these tests. Shake or wiggle the
harness to detect any breaks in the wiring.
METER
TEST PROBE 1 PROBE 2 METER READING AT HARNESS
SETTING
0-1 Ohm Good.
Check for To pin 8 on To chassis
RX1 More than
grounds connector [P10] ground Repair/clean ground connection.
1 Ohm
All pins except Infinity Good.
Check for To chassis
RX1 pin 8 on Any
grounds ground Locate and repair short to ground.
connector [P10] resistance
All pins except Opposite end of 0-1 Ohm Good.
Continuity RX1 pin 8 on each of the 6 More than Repair broken wire or loose/dirty
connector [P10] leads 1 Ohm connection
IGNITION MODULE CONNECTOR [P10]

PIN NO. 1 2 3 4 5 6 7 8
COLOR CODE W BK/W R PK GN V/W BK open
1. Ignition sensor plate

2. Ignition module
3. Ignition coil
4. Spark plug 8-pin black ignition
5. Vacuum-operated electric module sensor [P10]
switch (V.O.E.S.) Chassis
4 3 2 1
ground
2 5 6 7 8
3-pin black ignition
Unplug sensor [P16]
A B
1
C
3 A. Red
4 B. Green
5 C. Black
f1143b8x 4
7-9
VACUUM-OPERATED ELECTRIC SWITCH (V.O.E.S)
ADJUSTMENT/TESTING b0225x7x
ELECTRONIC
See VACUUM-OPERATED ELECTRIC SWITCH (V.O.E.S) in IGNITION MODULE VACUUM
Section 1. SWITCH
TIMER
AND PICKUP BK
BK
P7 2 1
REMOVAL
V/W
BK
GN/W
BK/W
W/BK
BK
PK
V/W
R/W
R/W BK/W
1. Remove seat and fuel tank. See FUEL TANK, REMOVAL GN/W
P10 8 7 6 5 4 3 2 1
in Section 4.
GN/W
BK/W
W/BK
BK
PK
V/W
R/W
A B C P16
2. See Figure 7-4. Disconnect V.O.E.S. connector [P7] from
main wiring harness.
3. Remove V.O.E.S. from carburetor.
[P7] WIRE TERMINATION

INSTALLATION 1 Ignition module
2 Splice number one
1. See Figure 7-4. Place a new V.O.E.S. on carburetor.
Figure 7-4. V.O.E.S. Connector [P7]

2. Attach V.O.E.S. connector [P7] to main wiring harness.
1WARNING

TION in Section 4.
7-10
IGNITION/HEADLAMP SWITCH
GENERAL 5755
1 2
1WARNING 3
DO NOT modify the ignition/headlamp switch wiring to
circumvent the automatic-on headlamp feature. Visibility
is a major concern for motorcyclists. Failure to have
proper headlamp operation could lead to personal injury.
See Figure 7-5. The three-position combination ignition/head- 4

lamp switch is not repairable. Replace the unit if it fails.
Switch positions are explained in Table 7-1. 5

1CAUTION
When turning off the ignition, verify that the key is
removed in the LOCK position or that the lights are not 1. LOCK position 4. Switch face nut
left on. If the rider stops the engine and inadvertently 2. OFF position 5. Ignition switch
removes the key in the OFF position, the battery will be 3. IGNITION position bracket
drained of its charge if the vehicle is left standing too
long. Figure 7-5. Ignition/Headlamp Switch
NOTE
The key locks the ignition system and is removable in both the
LOCK and OFF positions. The OFF position is located Table 7-1. Ignition Positions
between the LOCK and IGNITION positions and allows the
rider to remove the key while leaving the lights on. When the REMOVE
LABEL NAME IGN. LAMPS
key is placed in the OFF position, several indicator markers KEY
are or can be activated. See Table 7-2.
LOCK locked off off yes
OFF markers off See note & yes
REMOVAL Table 7-2.
IGN ignition on no
in Section 4.
1WARNING
To avoid accidental start-up of vehicle and possible per- Table 7-2. Indicator Markers
ceeding. Always disconnect the negative cable first. If ITEM OFF IGN
tive cable installed, the resulting sparks may cause a bat- Headlamp position marker on on
tery explosion producing personal injury. Headlamp high/low beam off on
1CAUTION License plate lamp on on
Hold battery cable when loosening battery terminal hard- Speedometer illumination lamp on on
Tachometer illumination lamp off on
Stop lamp can be activated
3. Cut cable strap securing main wiring harness to frame.
Front and rear turn signals can be activated
4. See Figure 7-6. Disconnect ignition connector [P8] from
main wiring harness. Horn can be activated
5. See Figure 7-5. Remove ignition switch face nut.

6. Remove ignition switch.
7-11
1. Insert ignition switch into hole of switch bracket. The

word “TOP” stamped on the switch body should face
upward toward the lettering on the switch position decal.
Loosely install face nut.
2. See Figure 7-6. Attach ignition switch connector [P8] to
R/BK
R/GY
main wiring harness.
R
R/BK
IGN
P8
A
B
C
D
3. Tighten face nut to secure switch within cover. R/GY
R OFF
R/B K
R/GY
4. Secure main wiring harness to frame with a new cable
R
LOCK
strap.
1WARNING
Always connect the positive battery cable first. If the pos-
itive cable should contact ground with the negative cable
KEY SWITCH
1CAUTION
Hold battery cable when tightening battery terminal hard- [P8] WIRE TERMINATION
A Master circuit breaker
5. Install battery cables, positive cable first. B Accessories fuse in fuse block
C Ignition fuse in fuse block
TION in Section 4. D Empty
1WARNING Figure 7-6. Ignition Switch Connector [P8]
Check for proper headlamp operation before riding

motorcycle. Visibility is a major concern for motorcy-
clists. Failure to have proper headlamp operation could
lead to personal injury.
7. Check ignition/headlamp switch for proper operation.
7-12
IGNITION MODULE
GENERAL 5682
See Figure 7-7. The ignition module is located on a plate Ignition module
which is a portion of the frame. The ignition module is not
repairable. Replace the unit if it fails.
See IGNITION SYSTEM on page 7-3 for information on the
function and testing of the ignition module.
REMOVAL
1WARNING
ceeding. Always disconnect the negative cable first. If Figure 7-7. Ignition Module
tive cable installed, the resulting sparks may cause a bat- b0225x7x
1CAUTION ELECTRONIC
IGNITION MODULE VACUUM
Hold battery cable when loosening battery terminal hard- TIMER
SWITCH
ware. Failure to hold cable may cause battery damage. AND PICKUP BK
BK

3. Cut cable strap which secures main wire harness to side P7 2 1
V/W
frame member.
BK
GN/W
BK/W
W/BK
BK
PK
V/W
R/W
4. See Figure 7-8. Disconnect ignition module connector R/W BK/W
GN/W
[P10] from main wiring harness. P10 8 7 6 5 4 3 2 1
5. See Figure 7-7. Remove screws and washers to detach

GN/W
BK/W
W/BK
BK
PK
V/W
R/W
module from frame. A B C P16
INSTALLATION
1. See Figure 7-7. Fasten module to frame using screws
and washers.
2. See Figure 7-8. Attach ignition module connector [P10]
to main wiring harness. [P10] WIRE TERMINATION
3. Secure main wiring harness to frame member with a 1 Splice number eight
new cable strap.
2 Timer and pickup
1WARNING
Always connect the positive battery cable first. If the pos- 3 Timer and pickup
4 Coil
sion producing personal injury and/or property damage. 5 Timer and pickup
1CAUTION 6 Vacuum-operated switch
7 Splice number two
8 Empty
4. Install battery cables, positive cable first.
1WARNING
After installing seat, pull upward on front of seat to be Figure 7-8. Ignition Module Connector [P10]
5. Install tail section and seat. See TAIL SECTION, INSTAL-
6. Test engine for proper ignition system operation.
7-13
IGNITION SENSOR PLATE AND ROTOR
GENERAL REMOVAL
See Figure 7-9. The ignition sensor plate assembly (8) and
trigger rotor (9) are located in the gearcase cover (11) on the
1WARNING
right side of the vehicle. The rotor is mounted on the camshaft
and operates at one-half crankshaft speed. The sensor plate
wiring is connected to the ignition module (23) wiring har-
ness. See IGNITION SYSTEM on page 7-3 for information on
the function, testing and adjustment of the ignition sensor
plate and trigger rotor assembly.
1CAUTION

9. Trigger rotor 22. Ignition module connector [P10] 17
10. Seal 23. Ignition module
12. Spark plug (2) 25. Screw (2) 16 22
13. Ignition coil
23
15 14
18
24
19 25
21
13 20
12
10 9
8
11
3
7 6 1
5
b0223x7x
4
2
Figure 7-9. Ignition Components
7-14
2. Remove sprocket cover. See SPROCKET COVER in
Section 2. 5630
3. Cut cable straps holding sensor plate wiring at the follow- Timer plate stud
ing locations:
a. Top of starter.
b. Edge of gearcase cover.
c. Oil line. Sensor plate wiring
4. See Figure 7-9. Disconnect sensor plate (8) wiring at
connector (20) [P16] located below the starter motor.
5. Note position of each sensor plate wiring terminal in plug
end of connector (20).
6. Remove terminals. See DEUTSCH ELECTRICAL CON-
NECTORS on page 7-46.
7. Drill off heads of outer timer cover pop rivets (1) using a
3/8 in. (9.525 mm) drill bit. Tap remaining rivet shafts
inboard through holes in timer cover (2) and inner cover Sensor plate
(4). Remove timer cover. Timer plate stud
8. Remove inner cover screws (3), inner cover (4) and igni-
tion gasket (5). Carefully remove any remaining pieces of
rivets from gearcase cover timer bore.
Figure 7-10. Marking Ignition Timing
9. See Figure 7-10. To obtain approximate ignition timing
during installation, mark position of timer plate studs on 5. Install sensor plate wiring terminals into correct positions
sensor plate. in plug end of connector (20) [P16]. Red, green and black
10. See Figure 7-9. Remove timer plate studs. Carefully wires of plug end (from sensor plate) must match same
remove sensor plate. Remove bolt (7) and trigger rotor (9). color wires in receptacle end of connector (from ignition
module wiring harness). See Figure 7-4. Install terminals
11. Carefully remove camshaft oil seal (10) if damaged or if
following procedure outlined under DEUTSCH ELECTRI-
there is any evidence of oil leakage past the seal.
CAL CONNECTORS on page 7-46.
6. Connect sensor plate (8) wiring to wiring harness con-

INSTALLATION nector (20) [P16].
1. See Figure 7-9. With the lipped side facing inboard,
install new camshaft oil seal (10) into gearcase cover 7. Check ignition timing. See IGNITION TIMING in Section 1.
(11), if removed. Press seal into position until flush with
8. Final tighten timer plate studs (6) to 12-20 in-lbs (1.4-2.3
surface of timer bore.
Nm).
2. Position trigger rotor (9) onto end of camshaft aligning
notch with camshaft slot. Apply LOCTITE THREAD- 9. Install gasket (5) and inner cover (4) using screws (3).
LOCKER 242 (blue) to bolt (7). Install bolt to secure Tighten screws to 12-20 in-lbs (1.4-2.3 Nm).
rotor. Tighten bolt to 75-80 in-lbs (8.5-9.0 Nm).
3. Install sensor plate (8) and timer plate studs (6). Rotate
1CAUTION
sensor plate to its previously marked position to obtain Use only H-D Part No. 8699 rivets to secure outer timing
approximate ignition timing. cover. These rivets are specially designed so that no rivet
end falls off into the timing compartment. Use of regular
1CAUTION rivets can damage ignition system components and may
Route sensor plate wires about 1-1/2 in. (38 mm) forward allow water to enter the timing compartment.
of gearcase cover rear edge. If wires are routed too far to
the rear of this position, they could contact the moving 10. Secure timer cover (2) to inner cover using new rivets.
secondary drive belt and/or sprocket resulting in damage
to sensor plate wiring. 1WARNING
4. Route sensor plate wiring leads. Always connect the positive battery cable first. If the pos-
a. Downward through hole (7 o’clock position) in timer itive cable should contact ground with the negative cable
bore of gearcase cover (11). installed, the resulting sparks may cause a battery explo-
b. Upward through bottom opening between right
crankcase half and rear of gearcase cover. 1CAUTION
c. Route wiring around tower shaft behind gearcase Hold battery cable when tightening battery terminal hard-
cover. Route wires upward to starter motor. ware. Failure to hold cable may cause battery damage.
d. Cable strap sensor plate wiring. See Step 3 of
REMOVAL. 11. Install battery cables, positive cable first.
7-15
IGNITION COIL
GENERAL dyn808
The ignition coil is mounted on the frame underneath the fuel

tank and behind the steering neck. Ignition coil primary
circuit test
See Figure 7-9. The ignition coil (13) is a pulse-type trans-
former. Internally, the coil consists of primary and secondary
windings with a laminated iron core. The contents are sealed
in a waterproof insulating compound. The ignition coil is not
repairable. Replace the unit if it fails.
The low-voltage ignition primary circuit consists of the coil pri-

mary winding, ignition module (23) and battery. When the cir-
cuit is closed, current flows through the coil primary winding
creating a strong magnetic field in the iron core of the ignition
coil.
Ignition coil secondary
When the ignition module receives a signal from the ignition
circuit test
sensor plate (8) and trigger rotor (9), the ignition module inter-
rupts (opens) the ignition primary circuit, which causes the
magnetic field in the coil core to collapse suddenly.
The collapsing magnetic field induces a high-voltage electri-

cal discharge in the ignition secondary circuit, which consists
of the coil secondary winding, spark plug cables and spark
plugs (12). The high-voltage discharge produces a spark to
bridge the electrode gap of each spark plug. Figure 7-11. Test Ignition Coil Resistance Tests
The ignition coil fires both spark plugs simultaneously. In one

spark plug, the spark jumps from the center electrode to the Table 7-3. Ignition Coil Winding Resistance
outer electrode, but on the other plug, the spark jumps in the
reverse direction (from the outer electrode to the center elec- IGNITION COIL OHMMETER NORMAL RESISTANCE
trode). WINDING SCALE RANGE (IN OHMS)
Primary RX1 2.5-3.1
TROUBLESHOOTING Secondary RX1K 10,000-12,500
Follow the troubleshooting procedures listed under IGNITION NOTE

SYSTEM if the engine will not start, is difficult to start or runs ● A low resistance value indicates a short in the coil wind-
roughly. Also check condition of spark plug cables. Insulation ing-replace coil.
on cables may be cracked or damaged allowing high tension
● A high resistance value might indicate that there is some
current to short to metal parts. This problem is most notice-
corrosion/oxidation of the coil terminals. Clean the termi-
able when cables are wet.
nals and repeat resistance test. If resistance is still high
after cleaning terminals, replace coil.
If poor starting/running condition persists, check resistance of
ignition coil primary and secondary windings using an ohm- ● An infinite ohms (∞ or no continuity) resistance value
meter. See Figure 7-11. Resistance values should be within indicates an open circuit (a break in the coil winding)-
the limits shown in Table 7-3. replace coil.
7-16
REMOVAL 5731
1WARNING
2
sonal injury, disconnect the battery cables before pro- 3 4
ceeding. Always disconnect the negative cable first. If 1
1CAUTION
Hold battery cable when loosening battery terminal hard- 5
ware. Failure to hold cable may cause battery damage. 7
6
in Section 4.
3. See Figure 7-12. Disconnect spark plug cables from igni- 1. Ignition coil 5. Pink wire coil post
tion coil. 2. Screws (2) 6. White wire coil post
4. Remove nuts and lockwashers to detach pink and white 3. Mounting plate 7. Washer
wires from coil posts. 4. Horn bracket
5. Remove two screws (2). Mounting plate (3), coil (1), horn Figure 7-12. Ignition Coil
bracket (4) and washer (7) will drop from frame.
INSTALLATION
1. See Figure 7-12. Place horn mounting bracket (4) on top
of coil. Attach coil to frame with screws (2), washer (7)
and mounting plate (3). Tighten screws (1) to 4-6 ft-lbs
(5.4-8 Nm).
2. Connect ring terminal of pink wires to forward post. Con-
nect ring terminals of white wires to rear post. Secure
wires with nuts and lockwashers.
3. Connect spark plug cables to ignition coil. Longer cable
attaches to rear post and rear cylinder spark plug.
1WARNING

TION in Section 4.
1WARNING
Always connect the positive battery cable first. If the pos-
1CAUTION
5. Install battery cables, positive cable first.
7-17
SPARK PLUG CABLES
GENERAL INSPECTION
Resistor-type high-tension spark plug cables have a carbon- 1. Inspect spark plug cables. Replace cables that are worn
impregnated fabric core (instead of solid wire) for radio noise or damaged.
suppression and improved reliability of electronic compo-
a. Check for cracks or loose terminals.
nents. Use the exact replacement cable for best results.
b. Check for loose fit on ignition coil and spark plugs.
REMOVAL 2. Check cable boots/caps for cracks or tears. Replace

boots/caps that are worn or damaged.
1WARNING 3. Check spark plug cable resistance with an ohmmeter.
Never disconnect a spark plug cable with the engine run- Resistance must be 1625-3796 ohms for 6-1/2 in. (165
ning. If you disconnect a spark plug cable with the mm) cable, and 5000-11,680 ohms for 20 in. (508 mm)
engine running, you may receive a potentially fatal elec- cable. Replace cables that do not meet resistance speci-
tric shock from the ignition system. fications.
1CAUTION
When disconnecting each spark plug cable from its INSTALLATION
spark plug terminal, always grasp and pull on the rubber
boot at the end of the cable assembly (as close as possi- Connect spark plug cables to ignition coil and spark plugs.
ble to the spark plug terminal). Do not pull on the cable Make sure boots/caps are secured properly; this will provide
portion itself. Pulling on the cable will damage the the necessary moisture-proof environment for the ignition coil
cable’s carbon core. and spark plug terminals.
Disconnect spark plug cables from ignition coil and spark plug NOTE
terminals. See Section 1 for spark plug information.
7-18
STARTER INTERLOCK
GENERAL Ignition Circuit

The ignition circuit prevents the motorcycle from operating
The starter interlock system is designed to prevent unin-
unless a ground is established at the ignition relay. If this
tended start-up and/or forward motion of the motorcycle with
ground is not established, the ignition system will be not
the vehicle’s side stand not retracted.
turned on and the motorcycle will not run. Grounds may be
established three ways.
Two circuits make up the starter interlock system.
a. By retracting the side stand and grounding through
the side stand switch.
Starter Circuit
b. By placing the motorcycle in neutral and grounding
through the neutral switch.
The starter circuit prevents the motorcycle from being started
unless a ground has been established at the starter relay. c. By disengaging the clutch and grounding through
This ground may come from one of two sources. the clutch lever switch.
Note that the ignition circuit allows operation in gear with the
a. By placing the motorcycle in neutral and grounding side stand extended if the clutch is disengaged. However, if
through the neutral switch. the motorcycle is in gear with the side stand extended, and
the clutch is released, the ignition ground is lost and the igni-
b. By disengaging the clutch and grounding through tion system is turned off. This system will prevent operation of
the clutch lever switch. the vehicle if forward motion is attempted with the side stand
down.
Once the starter circuit is grounded and the starter button
See Figure 7-13.
pushed, the starter relay can be energized. The energized
relay then permits the starter motor to crank the engine.
Table 7-4. Starter Interlock Troubleshooting

PROBLEM CHECK FOR CORRECTION
Electric starter will not crank. Battery problems. See BATTERY in Section 1.
Inappropriate gear selected. Place vehicle in neutral.
Clutch lever not disengaged. Pull in clutch lever.
Starter relay problems. Listen for starter relay “click”. If click is not heard,
perform starter relay tests.
Follow starter troubleshooting in Section 5.
Electric starter cranks, but vehicle Side stand not retracted. Retract side stand.
will not start.
Motorcycle will not start with side Clutch lever not disengaged. Pull in clutch lever.
stand retracted.
Motorcycle will not start with side Ignition relay problems. Listen for relay “click”. If click is not heard, perform
stand retracted or clutch disengaged. ignition system tests.
Motorcycle will not start after starter No spark at spark plug. Check for 12 VDC at coil white/black wire.
relay tests.
Follow ignition system troubleshooting on page 7-6.
7-19
7-20
b0241x7x
ELECTRONIC IGNITION
VACUUM SWITCH
TIMER AND PICKUP BK
BK
TN
NEUTRAL
P7 2 1
V/W
BK
GN/W
BK/W
W/BK
BK
PK
V/W
R/W
R/W BK/W
TN
GN/W
P10 8 7 6 5 4 3 2 1
P1
IGN POWER BE 1 GY
GN/W
BK/W
W/BK
BK
PK
V/W
R/W
FROM (2) GN/BK 3 W/BK A B C P16
NEUTRAL
12 11 10 9 8 7 6 5 4 3 2 1 P3 SWITCH
TN
S8
BK TN/W
P14 2 1
BK W
SIDE STAND
SWITCH
S2
S1
TN
S13 S12
MAIN CHASSIS GROUND
S11 TN/GN TN
S10 R BK
TN/GN TN/GN
MASTER
30A CIRCUIT
BREAKER
S7
TN/GN
S14
P5 S15 GN
R/BK
R
TO GROUND BK 2 BK
GY TN/W PK
P13
P8
A
B
C
D
P12
R/B K
GN
INSERTION SIDE BK
R
W/BK
COIL IGNITION BK
GY/O R/BK
15A
R/BK
COLOR CODE: LT.BE LIGHT BLUE GY/O
REAR PLUG INSTRUMENTS
R/BK

86 85
DIODE GY/O TN/W
15A
87 R/BK GN
30
87A
R/BK
FUSE BLOCK R OFF
P9 LOCK
BATTERY
4/18/96
Figure 7-13. Starter Interlock System

TESTING/REPLACEMENT b0244x7x
Side Stand Switch Side stand up

switch closed
See Figure 7-14. The side stand switch is a simple spring (0 ohms)
loaded plunger. The switch completes a path to ground for the
ignition relay when the side stand is in the retracted position.
Test the switch as follows. Side stand down
switch open
1. Unplug the 2-place side stand switch connector [P14]. (infinite ohms)
2. Test the switch using an ohmmeter.
a. When the switch is open (side stand down), the
switch should show ∞ ohms (infinite ohms).
b. When the switch is closed (side stand up), the switch
should show 0 ohms or little resistance.
3. Replace the assembly with a new switch if necessary.
Remove side stand switch from frame by turning counter-
clockwise.
Clutch Switch Connector [P14]
See Figure 7-15. The clutch switch attaches to the clutch con-
trol lever bracket. The switch completes a path to ground for Figure 7-14. Side Stand Switch
the ignition relay and the starter relay when the clutch is dis-
engaged. Test the switch as follows.
b0243x7x
1. Unplug the 2-place clutch switch connector [P5].
2. Test the switch using an ohm meter.
a. When the switch is open (clutch engaged), the
switch should show ∞ ohms (infinite ohms).
b. When the switch is closed (clutch disengaged), the
switch should show 0 ohms or little resistance.
3. Replace the assembly with a new switch if necessary.
a. Remove small Phillips screw.
b. Depress clutch lever and hold.
c. Detach switch by depressing switch trigger button
and pulling switch towards the end of the handlebar.
d. Install new switch. Trigger button
Diodes Clutch disengaged

switch closed
The main wiring harness contains two diodes along the left (0 ohms)
side frame tube. The harness sheath has a white mark show-
ing the location of the diodes. A diode acts as a one way
switch which permits current flow in one direction, but not in
the other. Test the diodes as follows. Clutch engaged
switch open
TESTING DIODE S12/S13 (infinite ohms)
1. Disconnect the following connectors:
Connector [P5]
a. Instruments and indicator lamps [P3].
b. Clutch switch [P5].
Figure 7-15. Clutch Switch
c. Ignition relay [P12].
2. Test for continuity in both directions between wire 1 (TN/
GN) on [P5] and wire 8 (TN) on [P3]. Ohmmeter should
show continuity in one direction, but not the other.
Replace the diode with a new diode if necessary.
3. Attach connectors separated in Step 1.
7-21
TESTING DIODE S14/S15
5732
1. Disconnect the following connectors:
a. Instruments and indicator lamps [P3].
b. Clutch switch [P5].
c. Ignition relay [P12].
2. Test for continuity in both directions between ignition
relay [P12] wire 85 (TN/W) and clutch switch [P5] wire 1
(TN/GN). Ohmmeter should show continuity in one direc- Ignition relay
tion, but not the other. Replace the diode with a new
diode if necessary.
Circuit breaker
3. Attach connectors separated in Step 1.
Ignition Relay
See Figure 7-16. The ignition relay is under the tail section
along the right side frame tube. Test the relay as follows.
1. Remove seat and fuel tank. See FUEL TANK, REMOVAL Figure 7-16. Ignition Relay and Circuit Breaker
in Section 4.
2. Remove mounting bolt to detach relay from frame. b0242x7x
VIEW FROM FUSE
3. Disconnect the 4-place connector [P12]. INSERTION SIDE
4. Test the relay in the same fashion as the starter relay. IGNITION
See Section 5. GY/O R/BK
15A
5. Replace the relay with a new relay if necessary. O INSTRUMENTS
O R/BK
Starter Relay 15A
LIGHTS R/BK
The starter relay is on the left side forward of the oil tank. See BE
15A
STARTER SYSTEM TESTING in Section 5.
ACCESSORIES
Main Circuit Breaker O/W

O/W 15A
R/GY
See Figure 7-16. Attached to the frame above the battery, the SPARE
FUSE
main circuit breaker is between the ignition key switch and the
battery. The main circuit breaker can be removed as follows. FUSE BLOCK
P11
in Section 4. NOTE
2. Remove battery negative terminal from frame. Depending upon vehicle production date, there may be
3. Remove nuts and wire leads from circuit breaker studs. one or two blue wires exiting the LIGHTS socket of the
fuse block. Early 1996 vehicles have a blue wire without
4. Remove circuit breaker from circuit breaker clip.
a terminating connection.
Ignition Fuse
See Figure 7-17. The ignition fuse is in the fuse block under Figure 7-17. Fuse Block
the right side of the tail section. Always replace the fuse with
another 15 ampere fuse.
7-22
7
CHARGING SYSTEM
GENERAL 5682
Voltage regulator
The charging system consists of the alternator and regulator.
See page 7-25 for charging system circuits.
Alternator
The alternator consists of two main components: the rotor
which is mounted on the engine sprocket shaft, and the sta-
tor, which is bolted to the engine crankcase.
Voltage Regulator
See Figure 7-18. The voltage regulator is a series regulator
with shunt control. The circuit combines the functions of recti-
fying and regulating.
Figure 7-18. Voltage Regulator
TROUBLESHOOTING
When the charging system fails or does not charge at a satis-
factory rate, it is recommended that the following checks be
made.
Battery
Check for a weak or dead battery. See BATTERY in
Section 1. Battery must be fully charged in order to perform
any electrical tests.
Wiring
Check for corroded or loose connections in the charging cir-
cuit. See Figure 7-19.
Voltage Regulator Inspection

The voltage regulator base must have a clean, tight connec-
tion for proper grounding. Check by using an ohmmeter with
one lead on a known good ground, such as battery ground
cable, and the other on the regulator base.
Connector plug to engine crankcase must be clean and tight.
7-23
Charging System Troubleshooting
NOTE
Whenever a charging system component fails a test and is SYMPTOM:
BATTERY BECOMES DISCHARGED
replaced, the system must be re-tested to be sure problem
has been corrected.
Test battery.
Charge or replace as required. See
BATTERY in Section 1.
Pass
Inspect regulator.
Correct as required. Fail See REGULATOR INSPECTION.
Pass
Test regulator.
Replace regulator. Fail See REGULATOR BLEED TEST.
Pass
Isolate damaged Fail Perform MILLIAMP DRAW TEST (If applicable).

component or wiring.
Pass
Isolate damaged wiring or Perform TOTAL CURRENT DRAW TEST.

excessive accessories. Fail
Record measurement.
Pass
Perform
Replace stator. Fail STATOR Fail Perform CURRENT OUTPUT TEST.
CHECK. Record measurement and compare with
TOTAL CURRENT DRAW TEST before
proceeding.
Pass
Pass
Perform
Inspect AC
Fail rotor. Fail Perform VOLTAGE OUTPUT TEST. Fail
OUTPUT
TEST.
Replace
Replace Pass Pass
regulator.
rotor. Pass
System tests good up to this point.
Replace
stator. Replace regulator. Suspect:
1. Accessories on for long periods when
vehicle is parked and not running.
Damaged or 2. Accessories on when vehicle is ridden
Fail Perform CURRENT OUTPUT
slipping rotor. very slowly for long periods.
TEST.
3. Battery self-discharge and/or acces-
sory draw because vehicle was not
operated for a long period.
7-24
b0240x7x
BK
MASTER
30A CIRCUIT
BREAKER
BK
VOLTAGE REGULATOR
BK
BK
BK
1 2 P17
BK
BK
BATTERY STATOR
COLOR CODE: LT.BE LIGHT BLUE
BE BLUE GY GRAY TN TAN

DIODE
BN BROWN PK PINK W WHITE
NO CONNECTION
GN GREEN R RED Y YELLOW CONNECTION
XX XX PIN CONNECTOR
CABLE COLOR STRIPE COLOR SOCKET CONNECTOR
Figure 7-19. Charging System Circuit
7-25
TESTING flt0808 3 milliamperes
maximum
Voltage Regulator Bleed Test
Be sure regulator is connected to battery. Unplug regulator
Amp
connector to engine crankcase. Use a trouble light and touch
one probe to a known good ground and the other to the regu-
lator pins, one at a time. If light glows, replace regulator. 12 VDC
battery
Battery
Milliampere Draw Test negative
Ignition
cable
NOTE OFF
Be sure accessories are not wired so they stay on at all times.

Check for this by connecting ammeter between negative bat- Figure 7-20. Milliampere Draw Test
tery terminal and battery.
d0004x8x
See Figure 7-20. Connect ammeter between negative battery
terminal and battery. With this arrangement, you will also pick Load tester
up any regulator drain. With ignition switch and all lights and
accessories turned to LOCK, amperage reading should be 3
milliamperes maximum. A higher reading indicates excessive
current draw.
Any accessories must be considered and checked for exces-

sive drain.
This condition could drain battery completely if vehicle is

parked for a long time.
NOTE
A battery with a surface discharge condition could suffer a
static drain. Correct by cleaning battery case.
Total Current Draw Test

See Figure 7-21. If battery runs down during use, the current
draw of the motorcycle components and accessories may
exceed output of the charging system. To check for this condi-
tion, place load tester induction pickup or current probe
pickup over battery negative cable.
Figure 7-21. Check Current Draw (Ignition Switch On)
With ignition and all continuously running lights and accesso-
ries turned on (headlamp on high beam), wait 10 seconds,
and then read the total current draw. Compare this reading to
the reading obtained in CURRENT AND VOLTAGE OUTPUT
TEST. The current output should exceed current draw by 6.5
amps, minimum (3 amps for ignition and 3.5 amps for battery
maintenance). If not, there may be too many accessories for
the charging system to handle.
NOTE
Rider’s habits may require output test at lower RPM.
7-26
Current and Voltage Output Test d0005x8x
Load tester
1. See Figure 7-22. Connect load tester.
a. Connect negative and positive leads to battery ter-

minals.
b. Place load tester induction pickup over positive reg- To circuit breaker
ulator cable. (DC output)
2. Run the engine at 2000 RPM. Increase the load as

required to obtain a constant 13.0 VDC.
3. The current output should be 19-23 amps. Make note of

measurement.
Voltage Output Test

See Figure 7-22. After removing the load, read the load tester
voltage meter. Voltage to the battery must not be more than
15 VDC. If voltage is higher, regulator is not functioning prop- To stator
erly or connections are loose or dirty.
Figure 7-22. Current and Voltage Output Test
1CAUTION
Do not leave any load switch turned on for more than 20
5683
seconds or overheating and tester damage are possible.
Stator Check
1. Turn ignition to LOCK.
2. Disconnect stator wiring from voltage regulator wiring at

connector [P17].
3. See Figure 7-23. Connect an ohmmeter on the RX1

scale between crankcase and either stator socket. Test
for continuity.
a. A good stator will show no continuity (∞ ohms)

across either test point.
b. Any other reading indicates a grounded stator which

Figure 7-23. Test for Grounded Stator
must be replaced.
4. See Figure 7-24. Check the resistance using an ohmme-

5684
ter set on the RX1 scale.
a. Resistance across the stator sockets or pins should

be 0.2-0.4 ohms.
b. If the resistance is lower, the stator is damaged and

must be replaced.
Figure 7-24. Check for Stator Resistance
7-27
AC Output Check 5685a
1. See Figure 7-25. Test AC output.
a. Disconnect voltage regulator wiring at connector

[P17].
b. Connect an AC voltmeter across both stator sockets.
c. Run the engine at 2000 RPM. The AC output should

be 38-52 volts AC.
2. Compare test results to specifications.
a. If the output is below specifications, charging prob-

lem could be a faulty rotor or stator.
b. If output is good, charging problem might be faulty

regulator/rectifier. Replace as required. Figure 7-25. Check Stator AC Voltage Output
3. Check the output again as described under Current and

Voltage Output Test.
7-28
ALTERNATOR
Rotor
1WARNING Blocking

ceeding. Always disconnect the negative cable first. If
1CAUTION
1. Disconnect battery cables, negative cable first. Sprocket
2. Remove primary cover. See PRIMARY CHAIN in Section 6.

Figure 7-26. Removing Rotor From Sprocket
3. Remove clutch assembly, primary chain and engine
sprocket/rotor assembly as a unit. Refer to PRIMARY b0082x7x
DRIVE/CLUTCH in Section 6. Remove/disassemble
rotor and/or stator, as required. Refer to the following 1
procedures.
Rotor
5
1. Remove bolts which secure alternator rotor to engine 3
sprocket.
2
2. See Figure 7-26. Position blocking under rotor. Press 4
sprocket free of rotor.
NOTE
Resistance to sprocket/rotor disassembly is due in part to the 1. Stator 4. Stator wiring
magnetic force of the permanent rotor magnets. 2. Torx screw (4) 5. Connector [P17]
3. Grommet
Stator Figure 7-27. Stator Assembly
1. See Figure 7-27. Disconnect stator wiring (4) from volt-
age regulator wiring at connector (5) [P17].
2. Remove cable straps holding stator wire to frame.
3. Withdraw stator wiring (4) from below starter.
4. Remove and discard the four Torx screws (2) which
secure stator (1) to left crankcase half.
1CAUTION
Stator TORX screws contain a thread locking compound.
Do not reuse existing screws. Always use new screws
with the proper thread locking compound. Loss of torque
on TORX fasteners could result in alternator damage.
5. Remove stator wiring grommet (3) from left crankcase

half.
6. Withdraw stator wiring (4) from grommet hole in left
crankcase half. Remove stator (1).
7-29
CLEANING, INSPECTION 3560
Pipe
AND REPAIR section Rotor
1CAUTION
Do not strike or drop alternator rotor or damage to mag-
net adhesive may occur. Magnet adhesive damage can
result in rotor failure.
1. Clean rotor with a petroleum-base solvent. Remove all
foreign material from rotor magnets. Replace rotor if rotor
magnets are cracked or loose.
2. Clean stator by wiping with a clean cloth.
3. Examine stator leads for cracked or damaged insulation.
NOTE
Sprocket
The rotor and stator can be replaced individually if either is
damaged.
Figure 7-28. Pressing Rotor onto Sprocket
ASSEMBLY/INSTALLATION 7. See Figure 7-28. Attach rotor to sprocket.
Depending on whether the rotor, the stator, or both the rotor
a. Position rotor on sprocket. Align holes in sprocket
and stator were removed/disassembled, perform the applica-
with holes in rotor.
ble procedures which follow:
b. Apply a drop of LOCTITE THREADLOCKER 242
1. See Figure 7-27. Feed stator wiring (4) with attached
(blue) to threads of each mounting bolt. Insert
grommet (3) into open grommet hole in left crankcase
mounting bolts through rotor and start bolts into
half.
tapped holes in sprocket.
2. Apply a light coating of clean engine oil or chaincase
lubricant to grommet. Install grommet into hole in left c. Position a section of pipe with an inside diameter
crankcase half. larger than the sprocket mounting hub over center of
rotor. Press rotor onto sprocket. Tighten bolts to 90-
1CAUTION 110 in-lbs (10.2-12.4 Nm).
Stator TORX screws contain a thread locking compound.
Do not reuse existing screws. Always use new screws 8. Install clutch assembly, primary chain and engine
with the proper thread locking compound. Loss of torque sprocket/rotor assembly as a unit. See PRIMARY
on TORX fasteners could result in alternator damage. DRIVE/CLUTCH in Section 6.
9. Install primary cover. See PRIMARY CHAIN in Section 6.
3. Position stator (1) on left crankcase half. Secure stator
using four new Torx screws (2). Tighten screws to 1WARNING
30-40 in-lbs (3.4-3.5 Nm).
Always connect positive battery cable first. If the positive
4. Route stator wiring (4) below starter to frame upright. cable should contact ground with the negative cable
NOTE installed, the resulting sparks may cause a battery explo-
Temporarily attach a thin flexible “feed” or mechanic’s wire to sion resulting in personal injury.
the connector end of the stator wiring to assist in the routing 1CAUTION
of the wiring
5. Route stator wiring upward along side of frame upright. ware. Failure to hold cable may cause battery damage.
Connect stator wiring connector [P17] to voltage regulator.
6. Secure stator wiring, along with any other wires and
hoses routed in the same location, to frame using cable 11. Test charging system. See CHARGING SYSTEM on
straps. page 7-23.
7-30
VOLTAGE REGULATOR
GENERAL b0227x7x
The voltage regulator is on the right side next to the battery. R BK
The voltage regulator is not repairable. Replace the unit if it MASTER

30A CIRCUIT
fails. BREAKER
BK
REMOVAL VOLTAGE REGULATOR
1WARNING
To avoid accidental start-up of vehicle and possible per- GN
sonal injury, disconnect the battery cables before pro- BK

BK
ceeding. Always disconnect the negative cable first. If BK
the positive cable should contact ground with the nega- 1 2 P17

tery explosion producing personal injury. BK
1CAUTION BK

BATTERY STATOR
1CAUTION Figure 7-29. Voltage Regulator Connector [P17]
When disconnecting the alternator stator wiring, pull
apart the connector by firmly grasping both connector
halves. Do not pull on leads or damage to the wires and/ b0072a7x
1 8
or terminals may result.
2. See Figure 7-29. Disconnect voltage regulator connector 3
[P17] from alternator stator wiring.
2
7
3. Disconnect charging wire (black) from gold terminal on 4
the main circuit breaker.
4. See Figure 7-30. Remove screws (1, 3), washers (2) and
lockwasher (5). Detach and remove groundstrap from
long screw (1).
5
5. Remove and discard voltage regulator (3). 6
1. Screw (long) 5. Lockwasher

INSTALLATION 2. Washer (2) 6. Charging wire
1. See Figure 7-30. Install new voltage regulator with 3. Screw (short) 7. Connector [P17]
longer screw (1) next to battery. Attach groundstrap 4. Voltage regulator 8. Cable-strap
under voltage regulator mount.
Figure 7-30. Voltage Regulator
2. Connect voltage regulator connector [P17] to alternator
stator wiring.
3. Route charging wire to gold post on main circuit breaker.
Attach wire to frame with new cable straps.
1WARNING
Always connect positive battery cable first. If the positive
1CAUTION
5. Test charging system. See CHARGING SYSTEM on
page 7-23.
7-31
BATTERY
GENERAL b0228x7x
1WARNING 1
● Batteries contain sulfuric acid which can cause severe
burns. Avoid contact with skin, eyes or clothing.
3
● Batteries produce explosive hydrogen gas at all 2
times, especially when being charged. Keep ciga-
rettes, open flame and sparks away from the battery
at all times. Ventilate area when charging battery.
Always protect hands and protect eyes with shield or
goggles when working near a battery or acid. KEEP
8
BATTERIES AND ACID OUT OF THE REACH OF CHIL- 7
DREN!
5
See Figure 7-31. The battery is below the seat in the center of
the vehicle. The battery can be removed from the left side of
the motorcycle without removing the tail section or fuel tank. 6 4
NOTE
The battery requires no additional fluid at any time. See BAT- 1. Positive cable 5. Locknut
TERY in Section 1 for removal/installation and charging pro- 2. Bolt 6. Bottom pad
cedures. 3. Negative cable 7. Battery
4. Battery strap 8. Rear pad
Figure 7-31. Battery
7-32
HEADLAMP
REMOVAL b0231x7x
13
Headlamp and Bulbs 3 4 5 12
1. See Figure 7-32. Loosen screw (10) at bottom of head- 11
lamp.
2. Pry headlamp (9) from headlamp housing (13).
3. See Figure 7-33. Press retaining clip (4) and remove 7
position lamp bulb (3) from headlamp. Twist bulb to
remove from harness. 2 8
1
1WARNING 6
The bulb contains Halogen gas under pressure. Handle
bulb careful and wear eye protech to avoid possible per- 9 10
sonal injury.
1CAUTION 1. Screw (2) (metric) 8. Headlamp bulb

Never touch the bulb with your fingers. Fingerprints will 2. Washer (2) 9. Headlamp
etch the glass and cause the bulb to fail. Always wrap the 3. Locknut (4) 10. Captured screw
bulb in paper or a clean, dry cloth during handling. 4. Bracket (2) 11. Ground wire
5. Bolt (4) (2 sizes) 12. Position lamp bulb
4. Remove headlamp bulb (6). 6. Connector [P4] 13. Headlamp housing
a. Detach headlamp bulb connector. 7. Headlamp bulb
connector
b. Open the wire retaining latch (1).
Figure 7-32. Headlamp Assembly
c. Pull bulb housing from headlamp housing.
5. Disconnect ground wire from headlamp.
5733
Headlamp Housing and Brackets

1. See Figure 7-32. Remove screw (1) (metric) and washer
(2) on each side. 1
6
2. Detach speedometer cable from headlamp housing clip.
3. Remove seat and fuel tank. See FUEL TANK, REMOVAL 2
in Section 4.
5
4. See Figure 7-34. Cut as many cable straps as necessary 3
to access headlamp connector [P4] along right side 4
frame tube. Detach connector [P4] from wiring harness.
5. Remove headlamp housing from vehicle. 1. Wire retaining latch 4. Retaining clip
6. Remove headlamp brackets. 2. Headlamp 5. Ground connection
3. Position lamp bulb 6. Headlamp bulb
a. Remove front turn signals. See TURN SIGNALS,
REMOVAL on page 7-37. Figure 7-33. Headlamp Bulbs
b. Remove windscreen mounting brackets.
c. See Figure 7-32. Remove four bolts (5) and locknuts
(3).
d. Remove front forks and headlamp brackets (4). See
FRONT FORK, REMOVAL in Section 2.
NOTE
Lower bolt on right headlamp bracket is longer than the three
other bolts. A wire guide and two washers are installed on this
bolt. The wire guide keeps cables away from the forks.
7-33
RIGHT FRONT R/BK BN
TURN SIGNAL
Headlamp Brackets and Housing BE BK
1. Install headlamp brackets.

a. Install front forks through triple clamps and brackets.
See FRONT FORK, INSTALLATION in Section 2. HEADLAMP
CONNECTOR
b. See Figure 7-32. Install four bolts (5) and locknuts POSITION LMP
HIGH BEAM
O/W
W
1
2
O/W
W
S9
LOW BEAM Y 3 Y
(3). Wire guide and two washers go on lower bolt on LMP GROUND BK 4 BK
right headlamp bracket. Place wires into wire guide. P4
c. Place windscreen brackets on the inside of the S4

HEADLAMP
headlamp brackets.
d. Install front turn signals. See TURN SIGNALS,
S5
INSTALLATION on page 7-37. LEFT FRONT LT.BE V
TURN SIGNAL
BE BK
2. See Figure 7-34. Route headlamp wire harness between

front forks and along right side frame tube. Attach con-
nector [P4] to wiring harness. Fasten wiring harness to
frame with new cable straps. [P4] WIRE TERMINATION
3. See Figure 7-32. Install headlamp housing using two
1 Splice number six
screws (1) (metric) and washers (2). Tighten to 6-8 ft-lbs
(8.1-10.8 Nm). 2 Splice number nine
4. Install fuel tank and seat. See FUEL TANK, INSTALLA- 3 Splice number four
TION in Section 4.
4 Splice number one
5. Attach speedometer cable to headlamp housing clip.
1WARNING Figure 7-34. Headlamp Connector [P4]
Check for proper headlamp operation before riding
clists. Failure to have proper headlamp operation could
6. Check ignition/headlamp switch for proper operation.
Headlamp and Bulbs

1WARNING
The bulb contains Halogen gas under pressure. Handle
bulb careful and wear eye protech to avoid possible per-
sonal injury.
1CAUTION
Never touch the bulb with your fingers. Fingerprints will
etch the glass and cause the bulb to fail. Always wrap the
bulb in paper or a clean, dry cloth during handling.
1. See Figure 7-33. Install headlamp bulb (6).
a. Align tabs on bulb housing with tabs on headlamp.
Insert bulb.
b. Close the wire retaining latch (1).
c. Connect the headlamp bulb connector.
NOTE
When replacement is required, see your Buell dealer. Not
using the specified bulb may cause charging system problems.
2. Insert position lamp bulb (3).
3. Connect ground wire (5).
4. See Figure 7-32. Place headlamp in housing (13).
Tighten screw (10).
5. Align headlamp. See HEADLAMP in Section 1.
7-34
TAIL LAMP
Tail Lamp 3
1
1. See Figure 7-35. If necessary, remove tail lamp bulb (3).
a. Remove two screws (1) to detach tail lamp lens. 4
b. Turn bulb counterclockwise and remove.
2. Remove two locknuts (7) (metric) and washers (6). 2 5
3. Disconnect the three terminals and remove tail lamp.
6
Tail Lamp Bracket
2. See Figure 7-36. Cut cable straps holding tail lamp wiring 7
harness to rear frame. Detach connector [P11] from main
wiring harness.
3. See Figure 7-35. Remove seat wing screw (9).
8
9
4. Remove bolt (4) to detach bracket from frame.
5. Remove turn signals. See TURN SIGNALS, REMOVAL 10
on page 7-37.
6. Remove tail lamp.
7. Remove reflectors (8).
1. Screw (2) 6. Washer (2)
2. Tail lamp 7. Locknut (2) (metric)
ASSEMBLY/INSTALLATION 3. Tail lamp bulb 8. Reflector (2)
4. Bolt 9. Wing screw
5. Tail lamp bracket 10. Tail lamp connector [P11]
Tail Lamp Bracket
Figure 7-35. Tail Lamp
1. See Figure 7-35. Install reflectors (8).
2. Install tail lamp with washers (6) and locknuts (7) (metric).
3. Install turn signals. See TURN SIGNALS, INSTALLA-
TION on page 7-37.
4. Attach bracket (5) to frame with bolt (4) and seat wing
screw (9).
5. Use new cable straps to secure tail lamp wiring harness
to rear frame. Attach connector [P11] to main wiring har-
ness. See Figure 7-36.
6. Install tail section and seat. See TAIL SECTION, INSTAL-
1WARNING
Check for proper tail lamp and turn signal operation
before riding motorcycle. Visibility is a major concern for
motorcyclists. Failure to have proper lamp operation
could lead to personal injury.
7. Check tail lamp and turn signals for proper operation.
8. Use new cable straps to bundle the tail lamp wiring har-
ness under the tail section.
7-35
Tail Lamp b0230x7x
1. See Figure 7-37. Install the three tail lamp wires. BN LT.BE RIGHT REAR
BK BE
TURN SIGNAL
NOTE
TAIL LAMP AND
Early 1996 models may have a blue wire in slot 7 of connector REAR TURN SIGNALS
[P11]. This wire does not have a terminating connection. BN
O/W
1
2
BN
O/W
V 3 V
Cable strap this wire to the other harness wires. BK
BK
4
5
BK
BK
R/Y 6 R/Y
7
2. See Figure 7-35. Attach tail lamp to bracket with two BK 8 BK
R/Y
P11 BK
locknuts (7) (metric) and washers (6). S2 O/W
P15
3. If removed, install tail lamp bulb. BE
BK
1
2
BE
BK
Y
BK
LICENSE PLATE
a. Turn bulb clockwise to install. LIGHT
TAIL LAMP
b. Install tail lamp lens with two screws (1).
1WARNING V
BK
R/BK
BE
LEFT REAR
TURN SIGNAL
Check for proper tail lamp and turn signal operation
before riding motorcycle. Visibility is a major concern for
motorcyclists. Failure to have proper lamp operation
could lead to personal injury. 1 Splice number four
4. Check tail lamp and turn signals for proper operation. 2 Accessory fuse in fuse block [P9]
5. Use new cable straps to bundle the tail lamp wiring har-
ness under the tail section. 3 Splice number five
4 Splice number two
5 Splice number two
6 Rear stoplight switch
7 Unused
8 Splice number two
Figure 7-36. Tail Lamp Connector [P11]
b0246x7x
3
1 2
1. Black
2. Orange with white tracer
3. Red with yellow tracer
Figure 7-37. Tail Lamp Bulb Wires
7-36
TURN SIGNALS
REMOVAL b0232x7x
Front
1. Remove headlamp mounting screws (metric) and washers.
2. See Figure 7-38. Disconnect bullet connectors (5).
3. Remove screws (1) (metric) and locknuts (6) (metric).
4. Remove turn signals and standoffs (4). 8
Rear
1. See Figure 7-38. Cut cable straps to access bullet con-
nectors under tail section. Disconnect bullet connectors.
7
2. Remove screws (9) (metric) and nuts (6) (metric).
3. Remove turn signals from tail lamp bracket (7). 6
9
INSTALLATION
NOTE
New turn signal bulbs may be installed by removing screw on 5
turn signal lens. 1 4
Front
1. See Figure 7-38. Install turn signals and standoffs using 3
screws (1) (metric) and nuts (6) (metric).
2
NOTE
Install turn signal with lens drain hole facing downward.
1. Screw (2) (metric) 6. Locknut (4) (metric)
2. Attach bullet connectors to wiring harness as shown in 2. Bulb (4) 7. Tail lamp bracket
Figure 7-34. 3. Turn signal (right 8. Turn signal (left front or
3. Install headlamp housing using two screws (metric) and front or left rear) right rear)
washers. Tighten to 5-7 ft-lbs (6.8-9.5 Nm). 4. Turn signal standoff 9. Screw (2) (metric)
(2, front signals only)
1WARNING 5. Bullet connectors
Check for proper turn signal operation before riding (2 per signal)
clists. Failure to have proper turn signal operation could Figure 7-38. Turn Signals
3. Cable strap turn signal wires into a bundle beneath the
4. Check turn signals for proper operation.
tail section.
Rear
1WARNING
1. See Figure 7-38. Install turn signals using screws (9)
(metric) and nuts (6) (metric). Check for proper turn signal operation before riding
NOTE clists. Failure to have proper turn signal operation could
Install turn signal with lens drain hole facing downward.
2. Attach bullet connectors to wiring harness as shown in
Figure 7-36. 4. Check turn signals for proper operation.
7-37
TURN SIGNAL FLASHER
REMOVAL 5682
Flasher
NOTE
The turn signal flasher is not repairable. Replace the unit if it
fails.
2. See Figure 7-39. Remove screw from clamp.
3. Remove turn signal flasher and detach both wires.
INSTALLATION
1. See Figure 7-39. Connect both wires to flasher.
2. Place flasher inside clamp so prongs on flasher face
inside and down.
3. Install on flasher and clamp on frame with screw.
Figure 7-39. Turn Signal Flasher
1WARNING
Check for proper turn signal operation before riding
clists. Failure to have proper turn signal operation could
4. Check turn signals for proper operation.
7-38
HANDLEBAR SWITCHES
REMOVAL b0235x7x
NOTE
The individual handlebar switches are not repairable. Replace
the switch assembly upon switch failure.
Right Side
1. See Steps 1-5 of THROTTLE CONTROL, REMOVAL/
DISASSEMBLY in Section 2.
in Section 4.
3. See Figure 7-40. Cut as many cable straps as necessary
RIGHT HANDLEBAR
to access right handlebar switch connector [P1] along SWITCH CONNECTOR
right side frame tube. Detach connector [P1] from wiring P1
IGN POWER
harness. IGN MODULE
BE
W/R
1
2
GY
W/BK
FROM (2) GN/BK 3 W/BK
Left Side TO STARTER Y/O 4
P2
BK/R
ACC POWER
1. Remove three screws (metric) from handlebar switch. TO STOPLIGHT
O/W
R/Y
1
2
O/W
R/Y
2. Separate switch housings and remove from handlebar. BRAKE SWITCH

in Section 4.
4. See Figure 7-41. Cut as many cable straps as necessary
to access left handlebar switch connector [P6] along right [P11] WIRE TERMINATION
side frame tube. Detach connector [P6] from wiring har-
ness. 1 Ignition relay [P12]
2 Splice number eight
INSTALLATION 3 Splice number eight
4 Starter relay [P13]
Right Side
1. See Steps 1-3 of THROTTLE CONTROL, ASSEMBLY/
Figure 7-40. Right Handlebar Switch Connection [P1]
INSTALLATION in Section 2.
2. Position housings on right handlebar by engaging stud
on front housing with hole in handlebar. Fasten housings
with two screws (metric). Tighten to 12-17 in-lbs (1.4-
1.9 Nm).
3. See Figure 7-40. Route switch housing wiring harness
between front forks and along right side frame tube.
Attach connector [P1] to wiring harness. Fasten wiring
harness to frame with new cable straps.
TION in Section 4.
5. Adjust throttle cables as described under CARBURE-
TOR, CABLE ADJUSTMENT in Section 1.
1WARNING
Check all handlebar switch operations before riding
motorcycle. Handlebar switches not operating properly
6. Check handlebar switch for proper operation.
7-39
Left Side
LEFT HANDLEBAR
1. Attach switch housing to handlebar with three screws SWITCH CONNECTOR
(metric). Tighten screws to 25-33 in-lbs (2.8-3.7 Nm). P6
LOW BEAM W 1 Y
2. See Figure 7-41. Route switch housing wiring harness HIGH BEAM BK 2 W
LIGHT POWER BN 3 BE
between front forks and along right side frame tube. RIGHT TURN LT.BE 4 BN
Attach connector [P6] to wiring harness. Fasten wiring LEFT TURN
FROM FLASHER
O 5 V
BE 6 V/BN
harness to frame with new cable straps. HORN GN 7 Y/BK
HORN POWER GY 8 O/W
TION in Section 4. P5
FROM IGN RLY R/BE 1 TN/GN
1WARNING TO GROUND BK 2 BK
Check all handlebar switch operations before riding CLUTCH SWITCH

motorcycle. Handlebar switches not operating properly
4. Check handlebar switch for proper operation.
1 Headlamp connector [P4]

2 Splice number nine
3 Splice number three
4 Splice number four
5 Splice number five
6 Turn signal flasher
7 Horn
8 Splice number six
Figure 7-41. Left Handlebar Switch Connection [P6]
7-40
HORN
REMOVAL b0081a7x
1. Remove ignition coil to detach horn bracket from frame.

See IGNITION COIL, REMOVAL on page 7-17.
2. See Figure 7-42. Remove power wire (6) from spade
connection.
3. Detach ground wire (4) from horn by removing locknut (1)
(metric) and washer (3).
6
INSTALLATION 1
1. See Figure 7-42. Install horn on bracket with ground wire
(4), washer (3) and locknut (1) (metric). 2 3
4
2. Attach power wire (6).
3. Install horn and ignition coil. See IGNITION COIL,
INSTALLATION on page 7-17. 5
TROUBLESHOOTING 1. Locknut (metric) 4. Internal tooth washer

2. Horn mounting 5. Horn
1. If the horn does not sound or fails to function satisfacto- bracket 6. Power wire
rily, check for the following conditions. 3. Ground connection
a. Discharged battery.
Figure 7-42. Horn Assembly
b. Loose, frayed or damaged wiring leading to horn ter-
minal.
2. If battery has a satisfactory charge and wiring appears to
be in good condition, check for the following.
a. Poor ground to frame through mounting hardware or
ground wire (see Steps 3-5 below).
b. Inoperative horn switch (see Steps 3-5 below).
3. Remove terminal clips from connections.
4. Connect a voltmeter as follows.
a. Positive (+) lead to wire terminal.
b. Negative (–) lead to ground.
5. Turn ignition switch to IGN. Depress horn switch. If bat-
tery voltage is present, horn or horn grounding is faulty. If
battery voltage is not present, either horn switch or wiring
to horn is faulty.
a. If horn is faulty, then it must be replaced as an
assembly. The horn is not repairable.
b. If horn switch is faulty, replace left handlebar switch.
See HANDLEBAR SWITCHES, REMOVAL on
page 7-39.
7-41
NEUTRAL INDICATOR SWITCH
GENERAL xlh0733
See Figure 7-43. The neutral indicator switch (1) is threaded

into the transmission portion of the right crankcase half (2); it
is immediately forward of the main drive gear shaft (3). The
sprocket cover must be removed to test the switch. If switch
requires replacement, secondary drive belt and transmission
sprocket must also be removed; there is not enough clear-
ance to allow the removal of the switch without first removing
the transmission sprocket.
A pin on the shifter drum contacts the neutral indicator switch 3553
plunger, completing the neutral indicator circuit. The switch is
not repairable. Replace the switch if it malfunctions.
TESTING
Section 2.
2. See Figure 7-43. Disconnect wire lead from neutral indi- 2
cator switch (1).
3. With ignition switch ON, touch the neutral indicator wire
lead to a suitable ground.
a. If indicator lamp lights, then problem is at indicator
switch. Replace switch.
1
b. If indicator lamp does not light, then problem is else-
where in circuit (i.e. indicator lamp burned out, loose
3
connection, or faulty wiring).
c. After testing, connect wire lead to indicator switch.
4. Install sprocket cover. See SPROCKET COVER in Sec-
tion 2.
REMOVAL/INSTALLATION
1. Verify that the ignition/headlamp switch is turned to 1. Neutral indicator 4. Transmission sprocket
LOCK. switch 5. Transmission sprocket
2. Right crankcase half nut (LH threads)
3. Main drive gear 6. Lockplate
Section 2.
shaft 7. Socket head screw (2)
3. See Figure 7-43. Place transmission in first gear.
Remove two socket head screws (7) and lockplate (6). Figure 7-43. Neutral Indicator Switch
1CAUTION 7. Apply a light coating of LOCTITE THREADLOCKER 242
Transmission sprocket nut has left-hand threads. Turn (blue) to new neutral indicator switch (1) threads. Install
nut clockwise to loosen and remove from main drive gear switch in crankcase, and tighten switch to 3-5 ft-lbs (4.0-
shaft. Transmission sprocket nut will be damaged if 6.8 Nm). Connect wire lead to switch.
turned counterclockwise to remove.
8. Install transmission sprocket (4) (with secondary drive
4. Remove transmission sprocket nut (5) from main drive belt) onto main drive gear shaft (3). See TRANSMIS-
gear shaft (3). SION INSTALLATION AND SHIFTER PAWL ADJUST-
5. Decrease secondary drive belt tension by loosening axle MENT in Section 6.
adjusting nuts. See REAR BELT DEFLECTION in Sec-
tion 1. Remove transmission sprocket (4) (with second- 9. Install sprocket cover. See SPROCKET COVER in Sec-
ary drive belt) from main drive gear shaft (3). tion 2.
6. Remove wire lead from neutral indicator switch (1). 10. Adjust secondary drive belt tension. See REAR BELT
Remove switch from right crankcase half (2). DEFLECTION in Section 1.
7-42
FUSES AND CIRCUIT BREAKERS
GENERAL 5682
The S1 Lightning features two components which protect the Fuse block
electrical system.
1WARNING
To avoid accidental start-up of vehicle and possible
personal injury, disconnect the battery cables before
servicing motorcycle. Always disconnect the negative
cable first. If the positive cable should contact ground
with the negative cable installed, the resulting sparks
Spare fuse
may cause a battery explosion producing personal injury.
Fuses
See Figure 7-44. Four replaceable fuses are located in the
fuse block on the right side of the frame. A spare fuse is Figure 7-44. Fuse Block
attached to the fuse block.
The ignition, lights and accessory circuit breakers are each 5732
rated at 15 amperes.
Always investigate the cause of blown fuses before replacing

them. See your Buell dealer for more information.
Circuit Breakers
See Figure 7-45. The main circuit breaker is on the frame
beneath the tail section. The main circuit breaker is rated at
30 amperes.
Circuit breaker
Circuit breakers prevent electrical overload of a circuit. The
circuit breaker electrical contacts remain closed (completing
the circuit) as long as current (amperage) flowing through the
circuit does not exceed the ampere rating of the breaker. If
the circuit current exceeds the breaker ampere rating, then
the circuit breaker contacts open and the current flow in the
circuit is interrupted. Figure 7-45. Circuit Breaker
Since the circuit breakers are of the automatic-reset type, the
bimetallic breaker contacts automatically close (completing
the circuit) once they have cooled down from the initial over-
load. If the overload condition still exists, the breaker contacts
will again open to interrupt current flow. This cycling effect, or
opening and closing of the breaker contacts, continues as
long as the current circuit overload condition exists.
7-43
ELECTRICAL CONNECTORS
GENERAL
The following table provides a brief description of the connec-
tors found on the S1 Lightning. Approximate locations of each
connector are shown in Figure 7-46.
Connector numbers are listed in [brackets] in this manual.
Table 7-5. Electrical Connectors

CONNECTOR
DESCRIPTION COMPONENT(S) ALSO SEE
NUMBER
right handlebar switch housing-

[P1] 4-place Amp Multilock page 7-39
ignition power, module and starter
[P2] 2-place Amp Multilock front brake switch page 7-51
[P3] 12-place Amp Multilock instruments and indicator lamps page 7-51
[P4] 4-place Amp Multilock headlamp page 7-34
[P5] 2-place Amp Multilock clutch switch page 7-21
left handlebar switch housing-

[P6] 8-place Amp Multilock page 7-40
horn, turn signals, lights
[P7] 2-place Deutsch vacuum-operated electric switch page 7-10
[P8] 4-place PED ignition/headlamp switch page 7-12
four 15 amp fuses for ignition,

[P9] 4-slot fuse block page 7-43
instruments, lights and accessories
[P10] 8-place Deutsch ignition module page 7-13
[P11] 8-place Amp Multilock tail lamp and rear turn signals page 7-36
[P12] 4-place relay ignition relay page 7-22
[P13] 4-place relay starter relay page 7-22
[P14] 2-place Amp Multilock side stand switch page 7-21
[P15] 2-place Amp Multilock license plate light page 7-36
[P16] 3-place Deutsch timer and pickup page 7-13
[P17] 2-place plug voltage regulator page 7-31
7-44
b0222x7x
NOTE
27 Only three wires are used to connect the tail lamp
28 (28). See TAIL LAMP, ASSEMBLY/INSTALLATION
on page 7-35.
Approximate diode location.

See DIODES on page 7-21.
29 26
22
25
18
20 19
24 21 17
23 16 15
14
30
31 13
12
11
1 10
2 6
4 8
3
5
9
7
1. Voltage regulator/stator [P17] 12. Brake switch [P2] 25. Ignition module [P10]
2. Starter relay [P13] 13. Vacuum switch [P7] 26. Tail lamp and turn
3. Timer and pickup [P16] 14. Horn power wire signals [P11]
4. Battery positive cable 15. Horn ground 27. Rear right turn signal
5. Starter 16. Ignition coil 28. Tail lamp
6. Left handlebar switch 17. Instruments [P3] 29. Rear left turn signal
housing [P6] 18. Headlamp [P4] 30. Fuse block
7. Oil pressure switch 19. Clutch switch [P5] 31. Rear brake lamp switch
8. Neutral indicator switch 20. Ignition switch [P8]
9. Right front turn signal 21. Ignition relay [P12]
10. Left front turn signal 22. Master circuit breaker
11. Right handlebar switch 23. Battery negative cable
housing [P1] 24. Turn signal flasher
Figure 7-46. Wiring Harness
7-45
DEUTSCH ELECTRICAL CONNECTORS
GENERAL b0070x3x
The Deutsch Connector features a superior seal to protect

electrical contacts from dirt and moisture in harsh environ- 8
ments. The connector also provides better pin retention than
11
7 6
previous connectors. 10
9 5
Three and eight pin connectors are of similar construction
with one exception: eight pin connectors use two external 4
latches on the socket side. 2
NOTE 1
The DEUTSCH TERMINAL CRIMP TOOL (Part No. HD- 3
39965) is used to install Deutsch pin and socket terminals on
wires. If new terminals must be installed, follow the instruc- Socket Side Pin Side
tions included with the crimping tool or see CRIMPING 1. Socket terminal 7. Secondary locking
INSTRUCTIONS on page 7-47. 2. Wire seal wedge
3. Socket housing 8. Latch cover
4. External latch 9. Pin housing
REMOVING/INSTALLING SOCKETS 5. Internal seal 10. Wire seal
1. See Figure 7-47. Remove the secondary locking 6. Secondary locking 11. Pin terminal
wedge (6). Insert the blade of a small screwdriver wedge
between the socket housing and locking wedge inline
with the groove (inline with the pin holes if the groove is Figure 7-47. 3-Pin Connector
absent). Turn the screwdriver 90° to pop the wedge up
2. Gently depress terminal latches inside socket housing REMOVING/INSTALLING PINS
(3) and back out socket terminals (1) through holes in
1. See Figure 7-47. Remove the secondary locking wedge
rear wire seal (2).
(7). Use the hooked end of a stiff piece of mechanic’s
3. Fit rear wire seal (2) into back of socket housing, if wire or a needle nose pliers, whichever is most suitable.
removed. Grasp socket terminal approximately 1 in.
(25.4 mm) behind the contact barrel. Gently push sock- 2. Gently depress terminal latches inside pin housing (9)
ets through holes in wire seal into their respective cham- and back out pin terminals (11) through holes in wire seal
bers. Feed socket into chamber until it “clicks” in place. (10).
Verify that socket will not back out of chamber; a slight
3. Fit wire seal (10) into back of pin housing (9). Grasp
tug on the wire will confirm that it is properly locked in
crimped pin approximately 1 in. (25.4 mm) behind the
place.
contact barrel. Gently push pins through holes in wire
4. Install internal seal (5) on lip of socket housing, if seal into their respective numbered locations. Feed pin
removed. Insert tapered end of secondary locking wedge into chamber until it “clicks” in place. Verify that pin will
(6) into socket housing and press down until it snaps in not back out of chamber; a slight tug on the wire will con-
place. The wedge fits into the center groove within the firm that it is properly locked in place.
socket housing and holds the terminal latches tightly
closed. 4. Insert tapered end of secondary locking wedge (7) into
pin housing (9) and press down until it snaps in place.
NOTE The wedge fits in the center groove within the pin hous-
● The conical secondary locking wedge of the 3-pin con- ing and holds the terminal latches tightly closed.
nector must be installed with the arrow pointing toward
the external latch. See Figure 7-48.
● If the secondary locking wedge does not slide into the
installed position easily, verify that all terminals are fully Insert socket housing (3) into pin housing (9) until it snaps in
installed in the socket housing. The lock indicates when place. To fit the halves of the connector together, the latch (4)
terminals are not properly installed by not entering its on the socket side must be aligned with the latch cover (8) on
fully installed position. the pin side.
7-46
CRIMPING INSTRUCTIONS x0014x7x
1. See Figure 7-49. Squeeze the handles to cycle the

DEUTSCH TERMINAL CRIMP TOOL (Part No. HD-
39965) to the fully open position. Pin
housing
2. Raise locking bar by pushing up on bottom flange. With
the crimp tails facing upward and the rounded side of the
contact barrel resting on the concave split level area of
the crimp tool, insert contact (socket/pin) through middle Arrow points to
hole of locking bar. external latch
3. Release locking bar to lock position of contact. If the
crimp tails are slightly out of vertical alignment, the crimp
tool automatically rotates the contact so that the tails
face straight upward. When correctly positioned, the lock-
ing bar fits snugly in the space between the contact band Socket
and the core crimp tails. housing
4. Strip lead removing 5/32 in. (4.0 mm) of insulation. Insert

wires between crimp tails until ends make contact with
locking bar. Verify that wire is positioned so that short
pair of crimp tails squeeze bare wire strands, while long
pair folds over insulation material. Figure 7-48. 3-pin Locking Wedge Orientation
5. Squeeze handle of crimp tool until tightly closed. Tool

automatically opens when the crimping sequence is
complete. Raise up locking bar and remove contact.
NOTE
Inspect the quality of the core and insulation crimps. Distor-
tion should be minimal.
1. Insert contact through middle 2. Insert stripped lead until it 3. Close and squeeze crimp tool.
hole of locking bar. contacts locking bar.
Locking bar
4. Raise locking bar and 5. Inspect quality of core and

remove contact. insulation crimps.
Core crimp
Insulation crimp
x0007b7x
Figure 7-49. Deutsch Crimping Procedure
7-47
AMP MULTILOCK ELECTRICAL CONNECTORS
REMOVING SOCKET/PIN 5. See Figure 7-51. With the flat edge against the terminal,
insert the pick (Snap-On TT600-3) into the cavity until it
TERMINALS stops. Pivot the end of the pick away from the terminal
1. If necessary, cut any surrounding cable straps to gain and gently tug on wire to pull terminal from chamber. Do
access to the connector. not tug on the wire until the tang is released or the termi-
2. See Figure 7-50. Depress the button on the socket terminal will be difficult to remove. A “click” is heard if the tang
nal side of the connector (plug) and pull apart the pin and is engaged but then inadvertently released. Repeat the
socket halves.
step without releasing the tang.
3. Bend back the latch slightly and free one side of second-
ary lock, then repeat the step to release the other side. NOTE
Rotate the secondary lock outward on hinge to access
terminals in chambers of connector housing. An AMP TERMINAL CRIMP TOOL (Part No. HD-41609) is
4. Looking in the terminal side of the connector (opposite used to install Amp Multilock pin and socket terminals on
the secondary lock), take note of the cavity next to each wires. If new terminals must be installed, see CRIMPING
terminal. INSTRUCTIONS on page 7-50.
f1292x2x
Secondary lock open
Pin terminal
Latch
Secondary lock open
Button
Latch
Pin housing
Socket housing
Latch Socket terminal
Secondary lock open
Figure 7-50. Amp Multilock Connector (Exploded View)
7-48
INSTALLING SOCKET/PIN terminal (on the side opposite the crimp tails) must face
downward. On the socket side, tangs are at the top of each
TERMINALS chamber, so the socket terminal slot (on the same side as the
crimp tails) must face upward. Up and down can be deter-
NOTE mined by the position of the release button (used to separate
For wire location purposes, numbers are stamped into the the pin and socket halves), the button always being the top of
secondary locks of both the socket and pin housings. the connector.
1. See Figure 7-51. From the secondary lock side of the 2. Gently tug on wire end to verify that the terminal is locked
connector, insert the terminal into its respective num- in place and will not back out of chamber.
bered chamber until it snaps in place. For proper fit, the
slot in the terminal must face the tang in the chamber. 3. Rotate the hinged secondary lock inward until tabs fully
engage latches on both sides of connector.
NOTE
The tang in the chamber engages the slot to lock the terminal 4. Insert the socket housing (plug) into the pin housing
in position. On the pin side of the connector, tangs are posi- (receptacle) until it snaps in place.
tioned at the bottom of each chamber, so the slot in the pin 5. Secure wiring harness with new cable straps.
f1289x2x
Secondary lock open
4
Socket housing
Socket terminal
2
Pick tool
1
3
Secondary lock open
4
Pin terminal
2 Pick tool
3
Pin housing
1. Open secondary lock.

2. Insert pick into cavity on mating end of connector.
3. Pivot end of pick to release tang.
4. Gently tug on wire to remove terminal from housing.
Figure 7-51. Release Tang and Back Out Terminals
7-49
CRIMPING INSTRUCTIONS b0238x7x
1. See Figure 7-53. Squeeze the handles to cycle the AMP

TERMINAL CRIMP TOOL (Part No. HD-41609) to the
fully open position. 1. Raise locking bar and
seat contact on nest of
2. Raise locking bar by pushing up on bottom flange. With crimp tool. Release
the crimp tails facing upward, insert contact (socket/pin) locking tool.
through locking bar, so that the closed side of the contact
rests on the nest (concave split level area) of the crimp
tool). Use the front nest for 20 gauge wire, the middle for
16 gauge and the rear for 18 gauge.
3. Release locking bar to lock position of contact. When

correctly positioned, the locking bar fits snugly in the
space at the front of the core crimp tails.
4. Strip lead removing 5/32 in. (4.0 mm) of insulation. Insert

wires between crimp tails until ends make contact with
locking bar. Verify that wire is positioned so that short 2. Insert stripped lead
pair of crimp tails squeeze bare wire strands, while long until it contacts locking
pair folds over insulation material. bar.
5. Squeeze handle of crimp tool until tightly closed. Tool

automatically opens when the crimping sequence is
complete. Raise up locking bar and remove contact.
6. See Figure 7-52. Inspect the quality of the core and insu-
lation crimps. Distortion should be minimal.
b0239x7x
1
3. Close and squeeze
2 Pin terminal
3 crimp tool.
4. Raise locking bar and

1 remove contact
2 3 4 Socket terminal
1. Insulation crimp tail

2. Core crimp tail
3. Locking groove bar
4. Tang slot
Figure 7-52. Crimps Figure 7-53. Amp Multilock Crimping Procedure
7-50
b0245x7x
BN
RIGHT BK ELECTRONIC IGNITION
TURN FLASHER
VACUUM SWITCH
OIL GN/Y
O
TIMER AND PICKUP BK
BK
PRESSURE O/W
SPEEDOMETER NEUTRAL
TN
O
P7 2 1 BK
Y/BK
HORN
V/W
BK
W
V/BN
HIGH BEAM BK
GN/W
BK/W
W/BK
O/W
BK
PK
V/W
R/W
R/W BK/W
R/Y
TN GN/Y
GN/W
V R/Y
LEFT TURN BK P10 8 7 6 5 4 3 2 1
P1
IGN POWER BE 1 GY
GN/W
BK/W
W/BK
BK
PK
V/W
R/W
IGN MODULE W/R 2 W/BK O/W
FROM (2) GN/BK 3 W/BK W/GN A B C P16
TO STARTER Y/O 4 BK/R BK
O
P2 TACHOMETER PK
ACC POWER O/W 1 O/W NEUTRAL OIL PRESSURE REAR
TO STOPLIGHT R/Y R/Y
2
12 11 10 9 8 7 6 5 4 3 2 1 P3 SWITCH SWITCH STOPLIGHT
BRAKE SWITCH SWITCH
GN/Y
O/W
BK
BK
TN
PK
BN
O
O
V
W
S8
BK TN/W
P14 2 1
BK W
RIGHT FRONT R/BK BN
TURN SIGNAL
BE BK
S6 BN LT.BE RIGHT REAR
BK BE
TURN SIGNAL
SIDE STAND
SWITCH
BN 1 BN
O/W 2 O/W
V 3 V
P4 BK 4 BK
BK 5 BK
POSITION LMP O/W 1 O/W R/Y 6 R/Y
HIGH BEAM
LOW BEAM
W
Y
2
3
W
Y
S9 BK
7
8 BK
R/Y
LMP GROUND BK 4 BK
P11 BK
O/W
S2
P15
BE 1 BE Y
HEADLAMP S4 BK 2 BK BK
LICENSE PLATE TAIL LAMP

LIGHT
S1
LEFT FRONT LT.BE V S5 S3
TN
TURN SIGNAL
V
BK
R/BK
BE
LEFT REAR
BE BK TURN SIGNAL
S13 S12
MAIN CHASSIS GROUND
S11 TN/GN TN
S10 R BK
TN/GN TN/GN
MASTER
30A CIRCUIT
P6 BREAKER
LOW BEAM W 1 Y BK
HIGH BEAM BK 2 W
LIGHT POWER BN 3 BE S7
RIGHT TURN LT BE 4 BN
LEFT TURN O 5 V
FROM FLASHER BE 6 V/BN
HORN TN/GN
GN 7 Y/BK
HORN POWER GY 8 O/W S14 VOLTAGE REGULATOR
P5 S15 GN
R/BK
R/GY
R
TO GROUND BK 2 BK
GY TN/W PK
P13
P8
A
B
C
D
CLUTCH SWITCH PK
VIEW FROM FUSE BK/R TN/GN
P12
R/B K
R/GY
GN
INSERTION SIDE BK
R
W/BK
BK
COIL IGNITION BK
GY/O R/BK
15A
R/BK
COLOR CODE: LT.BE LIGHT BLUE GY/O O 1 2 P17
REAR PLUG O
INSTRUMENTS
R/BK

86 85
BE
DIODE GY/O TN/W
15A
BK
87 R/BK GN
30
GN GREEN R RED Y YELLOW CONNECTION O/W R/GY
O/W 15A 87A
87A
R/BK BK
FUSE BLOCK R OFF
P9 LOCK
BATTERY STATOR
3/28/96
7-51
Figure 7-54. 1996 S1 Lightning Wiring Diagram

A
APPENDIX A–TOOLS
Part No. B-35316-5 12 Inch Bolt. Part No. B-41177 Front Fork Holding Tool
Used with Part No. HD-39302.
Part No. B-41174 Rear Wheel Support Stand and Part No. B-41178-A Rear Shock Compressing Tool
Part No. B-41174-2 Replacement Pad
Part No. B-41175 Pivot Shaft Bearing Adjuster Part No. B-41395 Front Wheel Support Stand and
Part No. B-41686 S1 Lift Adapter
Part No. B-41176 Front Fork Bushing/Seal Installer Part No. B-42079 Brake Caliper Piston Remover
A-1
Part No. B-59000A Pro Level Oil Gauge Part No. HD-25070 Robinair Heat Gun
Part No. HD-01289 Rim Protectors Part No. HD-28700 Tire Bead Expander
Part No. HD-21000 Tire Spreader Part No. HD-33067 Wheel Bearing Packer
Part No. HD-23738 Vacuum Pump Part No. HD-33223-1 Cylinder Compression Gauge
A-2
Part No. HD-33413 Carburetor Idle Adjustment Tool Part No. HD-33813 Inductive Timing Light
Part No. HD-33416 Universal Driver Handle Part No. HD-34623A Piston Pin Retaining Ring Installer
Part No. HD-33418 Universal Puller Forcing Screw Part No. HD-34643A Shoulderless Valve Guide
Seal Installer
Part No. HD-33446A Cylinder Torque Plates Part No. HD-34723 Valve Guide Hone (8 mm)
and Torque Plate Bolts Part No. HD-33446-86
A-3
Part No. HD-34731 Shoulderless Valve Guide Part No. HD-34813 Rowe Flywheel Rebuilding Jig
Installation Tool
Part No. HD-34736B Valve Spring Compressor Part No. HD-34816 Oil Pressure Switch Wrench
Part No. HD-34740 Driver Handle and Remover. Used with Part No. HD-35102 Wrist Pin Bushing Hone (20 mm)
HD-34643A and HD-34731.
Part No. HD-34751 Nylon Valve Guide Brush Part No. HD-35316-A Main Drive Gear Remover/Installer
and Main Drive Gear Bearing Installer
A-4
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Part No. HD-35381 Belt Tension Gauge Part No. HD-35667 Cylinder Leakdown Tester
Part No. HD-35457 Black Light Leak Detector Part No. HD-35758 Neway Valve Seat Cutter Set
Part No. HD-35500A Digital Multi-Meter (FLUKE 23) Part No. HD-35801 Intake Manifold Screw Wrench
Part No. HD-35518 Internal/External Part No. HD-37047A Sprocket Bearing/Seal Installer
Retaining Ring Pliers
A-5
Part No. HD-37404 Countershaft Gear Support Plate Part No. HD-38125-8 Packard Terminal Crimp Tool
Part No. HD-37842A Inner/Outer Main Drive Gear Part No. HD-38361 Cam Gear Gauge Pin Set
Needle Bearing Installer (0.108 in. (2.74 mm) Diameter)
Part No. HD-38125-6 Packard Terminal Crimp Tool Part No. HD-38362 Sprocket Locking Link
(Sealed and non-sealed connectors)
Part No. HD-38125-7 Packard Terminal Crimp Tool Part No. HD-38515-A Clutch Spring Compressing Tool
(Sealed connectors) and Part No. HD-38515-91 Forcing Screw
A-6
13
40
CC
R
E
ST
T
OR
SP
Part No. HD-38871 Camshaft Bushing Plate Pilot Part No. HD-39458 Sprocket Shaft Bearing Outer
and Reamer Race Installer
Part No. HD-39151 Shift Drum Retaining Ring Installer Part No. HD-39565 Engine Sound Probe
Part No. HD-39301A Steering Head Bearing Part No. HD-39617 Inductive Amp Probe.
Race Remover Use with HD-35500A.
Part No. HD-39302 Steering Head Bearing Part No. HD-39621 Electrical Terminal Repair Kit
Race Installer
A-7
Part No. HD-39621-27 Socket Terminal Remover Part No. HD-39800 Oil Filter Crusher, Small
Part No. HD-39621-28 Pin Terminal Remover Part No. HD-39823 Oil Filter Crusher, Large
Part No. HD-39782 Cylinder Head Support Part No. HD-39847 Universal Ratcheting Tap/
Reamer Handle
Part No. HD-39786 Cylinder Head Holding Fixture Part No. HD-39932 (Steel) or HD-39932-CAR (Carbide)
Intake and Exhaust Valve Guide Reamer
A-8
Part No. HD-39964 Reamer Lubricant (Cool Tool) Part No. HD-41025 Tool Organizational System
Part No. HD-39965 Deutsch Terminal Crimp Tool Part No. HD-41137 Hose Clamp Pliers
Part No. HD-39969 Ultra-Torch UT-100 Part No. HD-41155 VHS Video Shelf
Part No. HD-39994 Paint Repair Kit Part No. HD-41183 Shrink Attachment
A-9
Part No. HD-41185 Hose Cutting Tool Part No. HD-41496 Main Drive Gear Seal Installer
Part No. HD-41185-1 Oil Hose Cutter Part No. HD-41506 Crankshaft Locking Tool
Part No. HD-41215 Oil Filter Wrench Part No. HD-41609 Amp Terminal Crimp Tool
Part No. HD-41321 Sprocket Holding Tool Part No. HD-41675 Oil Pressure Sending Unit Wrench
A-10
600 200
Made in USA
PP-9606- 0001
Part No. HD-42376 Battery/Charging System Part No. HD-94803-67 Rear Intake Camshaft
Load Tester Bushing Reamer
Part No. HD-94547-101 Crankshaft Bearing Outer Race Part No. HD-94804-57 Rocker Arm Bushing Reamer
Remover/Installer
Part No. HD-94660-37B Mainshaft Locknut Wrench Part No. HD-94812-1 Pinion Shaft Bushing Reamer.
Use with HD-94812-87.
Part No. HD-94800-26A Connecting Rod Bushing Part No. HD-94812-87 Pinion Shaft Reamer Pilot.
Reamers and Pilots Use with HD-94812-1.
A-11
Part No. HD-95017-61 Large External Retaining Part No. HD-95952-33A Connecting Rod
Ring Pliers Clamping Tool
Part No. HD-95635-46 All-Purpose Claw Puller Part No. HD-95970-32C Piston Pin Bushing Tool
Part No. HD-95637-46A Wedge Attachment for Part No. HD-96215-49 Small Internal Retaining
Claw Puller. Use with HD-95635-46. Ring Pliers
Part No. HD-95760-69A Bushing/Bearing Puller Tool Set. Part No. HD-96295-65D Timing Mark View Plug.
Set includes items 1-7. Items 8 (HD-95769-69), 9 (HD- Use with HD-33813.
95770-69) and 10 (HD-95771-69) are optional.
A-12
Part No. HD-96333-51B Piston Ring Compressor Part No. HD-96718-87 Pinion Bearing Outer Race
Lapping Kit
Part No. HD-96550-36A Valve Lapping Tool Part No. HD-96740-36 Connecting Rod Lapping Arbor
Part No. HD-96650-80 Flywheel Truing Stand Part No. HD-96796-47 Valve Spring Tester
Part No. HD-96710-40B Crankcase Main Bearing Part No. HD-96921-52A Oil Pressure Gauge
Lapping Tool
A-13
Part No. HD-96940-52A Oil Pressure Gauge Adapter. Part No. HD-99500-80 Wheel Truing
Use with HD-96921-52A. and Balancing Stand
Part No. HD-97087-65B Hose Clamp Pliers Part No. J-5586 Transmission Shaft
Retaining Ring Pliers
Part No. HD-97292-61 Two Claw Puller
A-14
<B=1> APPENDIX B–METRIC CONVERSIONS
Table B-1. Metric Conversions

MILLIMETERS to INCHES INCHES to MILLIMETERS
(mm x 0.03937 = inches) (inches x 25.40 = mm)
mm in. mm in. mm in. mm in. in. mm in. mm in. mm in. mm

.1 .0039 25 .9842 58 2.283 91 3.582 .001 .025 .6 15.240 1 15/16 49.21 3 5/16 84.14
.2 .0078 26 1.024 59 2.323 92 3.622 .002 .051 5/8 15.875 2 50.80 3 3/8 85.72
.3 .0118 27 1.063 60 2.362 93 3.661 .003 .076 11/16 17.462 2 1/16 52.39 3.4 86.36
.4 .0157 28 1.102 61 2.401 94 3.701 .004 .102 .7 17.780 2.1 53.34 3 7/16 87.31
.5 .0197 29 1.142 62 2.441 95 3.740 .005 .127 3/4 19.050 2 1/8 53.97 3 1/2 88.90
.6 .0236 30 1.181 63 2.480 96 3.779 .006 .152 .8 20.320 2 3/16 55.56 3 9/16 90.49
.7 .0275 31 1.220 64 2.519 97 3.819 .007 .178 13/16 20.638 2.2 55.88 3.6 91.44
.8 .0315 32 1.260 65 2.559 98 3.858 .008 .203 7/8 22.225 2 1/4 57.15 3 5/8 92.07
.9 .0354 33 1.299 66 2.598 99 3.897 .009 .229 .9 22.860 2.3 58.42 3 11/16 93.66
1 .0394 34 1.338 67 2.638 100 3.937 .010 .254 15/16 23.812 2 5/16 58.74 3.7 93.98
2 .0787 35 1.378 68 2.677 101 3.976 1/64 .397 1 25.40 2 3/8 60.32 3 3/4 95.25
3 .1181 36 1.417 69 2.716 102 4.016 .020 .508 1 1/16 26.99 2.4 60.96 3.8 96.52
4 .1575 37 1.456 70 2.756 103 4.055 .030 .762 1.1 27.94 2 7/16 61.91 3 13/16 96.84
5 .1968 38 1.496 71 2.795 104 4.094 1/32 .794 1 1/8 28.57 2 1/2 63.50 3 7/8 98.42
6 .2362 39 1.535 72 2.834 105 4.134 .040 1.016 1 3/16 30.16 2 9/16 65.09 3.9 99.06
7 .2756 40 1.575 73 2.874 106 4.173 .050 1.270 1.2 30.48 2.6 66.04 3 15/16 100.01
8 .3149 41 1.614 74 2.913 107 4.212 .060 1.524 1 1/4 31.75 2 5/8 66.67 4 101.6
9 .3543 42 1.653 75 2.953 108 4.252 1/16 1.588 1.3 33.02 2 11/16 68.26 4 1/16 102.19
10 .3937 43 1.693 76 2.992 109 4.291 .070 1.778 1 5/16 33.34 2.7 68.58 4.1 104.14
11 .4331 44 1.732 77 3.031 110 4.331 .080 2.032 1 3/8 34.92 2 3/4 69.85 4 1/8 104.77
12 .4724 45 1.772 78 3.071 111 4.370 .090 2.286 1.4 35.56 2.8 71.12 4 3/16 106.36
13 .5118 46 1.811 79 3.110 112 4.409 .1 2.540 1 7/16 36.51 2 13/16 71.44 4.2 106.68
14 .5512 47 1.850 80 3.149 113 4.449 1/8 3.175 1 1/2 38.10 2 7/8 73.02 4 1/4 107.95
15 .5905 48 1.890 81 3.189 114 4.488 3/16 4.762 1 9/16 39.69 2.9 73.66 4.3 109.22
16 .6299 49 1.929 82 3.228 115 4.527 .2 5.080 1.6 40.64 2 15/16 74.61 4 5/16 109.54
17 .6693 50 1.968 83 3.268 116 4.567 1/4 6.350 1 5/8 41.27 3 76.20 4 3/8 111.12
18 .7086 51 2.008 84 3.307 117 4.606 .3 7.620 1 11/16 42.86 3 1/16 77.79 4.4 111.76
19 .7480 52 2.047 85 3.346 118 4.645 5/16 7.938 1.7 43.18 3.1 78.74 4 7/16 112.71
20 .7874 53 2.086 86 3.386 119 4.685 3/8 9.525 1 3/4 44.45 3 1/8 79.37 4 1/2 114.30
21 .8268 54 2.126 87 3.425 120 4.724 .4 10.160 1.8 45.72 3 3/16 80.96 4 9/16 115.89
22 .8661 55 2.165 88 3.464 121 4.764 7/16 11.112 1 13/16 46.04 3.2 81.28 4.6 116.84
23 .9055 56 2.205 89 3.504 122 4.803 1/2 12.700 1 7/8 47.62 3 1/4 82.55 4 5/8 117.47
24 .9449 57 2.244 90 3.543 123 4.842 9/16 14.288 1.9 48.26 3.3 83.82 4 11/16 119.06
B-1
FASTENER TORQUE VALUES
Torque specifications for specific components are listed in each 1WARNING
section at the point of use. When converting to Newton-meters,
The quality fasteners used on Buell motorcycles have
use the formulas given under the metric chart. For all other
specific strength, finish and type requirements to
steel fasteners, use the values listed in one of the tables below.
perform properly in the assembly and the operating
In the English table, torque figures are listed in ft-lbs, except
environment. Use only genuine Buell replacement
those marked with an asterisk (*), which are listed in in-lbs. In
fasteners tightened to the proper torque. Substitution
the metric table, figures are listed in Newton-meters.
could cause fastener failure, which may result in vehicle
damage and/or personal injury.
B-2
Table B-2. English Torque Values
MINIMUM BODY SIZE OR OUTSIDE DIAMETER
FASTENER TYPE TENSILE MATERIAL # (number) in. (inches)
STRENGTH 2 3 4 5 6 8 10 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1
SAE 2 74,000 LOW
STEEL PSI CARBON 6 12 20 32 47 69 96 155 206 310
SAE 5 120,000 MEDIUM

STEEL PSI CARBON HEAT 14* 22* 10 19 33 54 78 114 154 257 382 587
TREAT

STEEL PSI CARBON 13 25 44 71 110 154 215 360 570 840
ALLOY

STEEL PSI CARBON 14 29 47 78 119 169 230 380 600 900
ALLOY

STEEL PSI CARBON 14 29 47 78 119 169 230 380 600 900
ALLOY
SOCKET 212,000 HIGH CARBON

SET PSI QUENCHED 9* 16* 30* 70* 140* 18 29 43 63 100 146
SCREW TEMPERED
STUDS Use SAE 2, 5 and 8 values when grade is known, with nut of sufficient strength.
*Torque values in in-lbs.
Table B-3. Metric Torque Values

MINIMUM BODY SIZE OR OUTSIDE DIAMETER
FASTENER TYPE TENSILE MATERIAL # (number) mm (millimeters)
STRENGTH 2 3 4 5 6 8 10 6.4 7.9 9.5 11.1 12.7 14.3 15.9 19.1 22.2 25.4
SAE 2 5,202 LOW
STEEL kg/cm2 CARBON 8.3 16.6 27.7 44.3 65.0 95.4 132.8 214.4 283.5 428.7
SAE 5 8,436 MEDIUM

STEEL kg/cm2 CARBON HEAT 1.6 2.5 13.8 26.3 45.6 74.7 107.9 157.7 213.0 355.4 528.3 811.8
TREAT
SAE 7 9,350 MEDIUM

ALLOY
SAE 8 10,545 MEDIUM

ALLOY
SAE 8 10,545 MEDIUM

ALLOY
SOCKET 14,904 HIGH CARBON

SET kg/cm2 QUENCHED 1.0 1.8 3.4 8.1 16.1 24.9 40.1 59.5 87.1 138.3 201.9
SCREW TEMPERED
STUDS Use SAE 2, 5 and 8 values when grade is known, with nut of sufficient strength.
foot-pounds (ft-lbs) x 1.356 = Newton-meters (Nm) inch-pounds (in-lbs) x 0.113 = Newton-meters (Nm)
B-3
Adobe Acrobat Reader Online Guide
This online guide contains information to help you use the Acrobat Reader pro-
gram. For installation instructions and system requirements, see the README
file accompanying your software. Click one of the following topics to go to an
explanation of that topic:
How to use this online guide
About Adobe Acrobat
The Acrobat Reader window
Status bar
Preferences
Using links
Using notes
Displaying documents in full-screen mode
Reading an article
How to upgrade
1
How to use this online guide
Use these procedures to navigate through this guide:
Topic
Click underlined text to go to the topic indicated. Underlined text
indicates text that is “linked” to another part of this guide.
Click the Go Back button in the tool bar to return to your previous
location.
Click the Next Page button in the tool bar to go to the next page of
the guide.
Click the First Page button in the tool bar to return to the opening
screen of this guide.
Distiller setu Click the bookmark name to go to the topic marked by that book-
How long
Compres mark. Click the triangle to the left of a bookmark to show and hide
About
subordinate bookmarks. The bookmarks for this guide provide a
complete list of topics.
Click the arrow button to go to the next screen of any continued
topic.
2
About Adobe Acrobat
The Adobe Acrobat product family consists of three products designed to bring
electronic document solutions to a wide-range of users:
• Acrobat 2.0 – all the software a business user requires for creating electronic
documents from common applications. Included in Acrobat 2.0 are Acrobat
Exchange and PDF Writer for creating electronic documents. New in Acrobat
2.0 is Acrobat Search for full-text searches of indexed PDF files. Also includes
the Acrobat Reader for Macintosh, Windows, DOS and UNIX.
• Acrobat Pro – Acrobat 2.0 plus Acrobat Distiller. Acrobat Distiller converts
any PostScript language file into PDF. Set up Acrobat Distiller to convert Post-
Script files on a local Macintosh or Windows computer, or to monitor directories
on a network file server, which provides Distiller conversion services to any
number of network users.
• Acrobat for Workgroups – everything a workgroup of ten requires: ten
licenses of Acrobat Exchange for Macintosh and Windows, Acrobat Distiller,
and Acrobat Catalog for creating indexes for full-text cross-document searches.
To find out how to order Acrobat products, click one of the following topics:
How to upgrade Order form
3
The Acrobat Reader window
You open a document in the Acrobat Reader window. You can display
bookmarks or thumbnails in an overview area to the left of the document.
Beneath the menu bar at the top of the window is the tool bar; at the bottom left
of the window is the status bar. At the right of the window is a vertical scroll bar
that enables you to scroll up and down through a document. The overview area
of the window includes an independent scroll bar that you can use to scroll
through bookmarks or thumbnails.
See these topics for more information about the Acrobat Reader window:
Status bar fields and controls
Tools and buttons
4
Tools and buttons
The tool bar contains tools for selecting and viewing documents. Select a tool
by clicking the tool icon. To hide or show the tool bar, choose Hide Tool Bar or
Show Tool Bar from the Window menu.
The tool bar contains the following tools and buttons:
Click the Page Only button to close the overview area of the window.
Click the Bookmarks and Page button to open the overview area and
display bookmarks created for the document. Click a bookmark’s name
to go to the location marked by that bookmark.
Click the Thumbnails and Page button to open the overview area and
display thumbnail images of each document page. Click a thumbnail to
go to the page marked by that thumbnail.
Use the hand tool to move a document page on-screen when it does not
fit within the window. Drag the hand tool in the direction you want to
move the page.
5
Use the zoom tools to magnify and reduce the page display by a
factor of 2.
Use the select text tool to select text in a document, which can then be
copied to the Clipboard using the Copy command. Choose select graph-
ics from the Tools menu to select graphics in a document.
The browse buttons advance the document to the first
or last page of a document, or forward or back one page
at a time.
Use the Go Back and Go Forward buttons to retrace your steps in
a document, moving to each view in the order visited. Go Back
also returns you to the original document after you click a link to
another document.
Click the Actual Size button to display the page at 100 percent.
Click the Fit Page button to scale the page to fit within the window.
6
Click the Fit Width button to scale the page width to fill the width of the
window. Pressing this button and the Option (Macintosh) or Control
(Windows) key fills the window with only the visible text and graphics
on the page.
The find tool searches for part of a word, a complete word, or
multiple words in a document.
7
Status bar fields and controls
The status bar contains the following fields and controls:
The window splitter adjusts the width of the overview and docu-
ment areas. Drag the control to where you want to divide the two
areas.
The page number box displays the current page number and lets
you go to a specified page in a multi-page document. Click the
page number box to display the Go to Page dialog box.
The magnification box displays the current page magnification
and lets you select various magnifications. Choose Other from the
menu to display the Zoom To dialog box.
The page size box shows the size of the current page using the
units specified in the Preferences dialog box.
8
Preferences
The Preferences items in the Edit menu allow you to set preferences that affect
all the Acrobat documents you view.
General preferences
The Preferences/General dialog box provides these options:
• Default Magnification is the magnification that Acrobat Exchange uses
when documents are opened.
• Max “Fit Visible” Magnification is the maximum magnification for Fit
Visible and for viewing articles.
• Display Large Images displays large images without replacing them as gray
boxes. A “large” image is an image that requires many bytes of storage and that
takes a long time to display.
• Use Page Cache may reduce the amount of time it takes to page through a
document.
• Greek Text below [_____] pixels displays the size of characters below
which Acrobat Exchange “greeks” characters (displays characters as gray
lines). Increasing the size of greeked characters speeds page display.
9
• Substitution Fonts controls which multiple master fonts Acrobat Exchange
substitutes for Type 1 fonts that are not available on your system.
• Page Units displays the units of measurement (inches, millimeters, or
points).
• Display Splash Screen at Startup
• Display Open Dialog at Startup
• Maximize Application on Opening (Windows only) the application
window is maximized to fill the entire display.
Full-Screen preferences
The Preferences/Full Screen dialog box provides these options:
• Change pages specifies mouse and keyboard control, or automatic advance-
ment every specified number of seconds.
• Loop displays the document continuously, looping from the first page to the
last.
• Background color specifies the window’s background color.
See Displaying documents in full-screen mode for instructions.
10
Displaying documents in full-screen mode
Select Full Screen from the View menu to make the PDF document fill
the entire monitor screen.
The characteristics of full-screen documents are set through the Full Screen
Preferences dialog box. See Full-screen preferences for more information.
The cursor remains active during full-screen mode so that viewers can click
links and open notes.Thumbnails and bookmarks are not accessible in full-
screen mode.
The following tools and commands are accessible through their command-key
shortcuts:
• All View menu commands except Page Only, Bookmarks and Page, and
Thumbnails and Page
• Tools menu: hand, Zoom-in, and Zoom-out
To exit from full-screen display mode, press the Escape key, or advance past the
last page.
11
Using links
Creators of PDF documents can create hypertext links that connect two parts of
a document. Links can also connect part of a PDF document to another PDF
document or to another application file, such as a spreadsheet or movie.
To use a link:
Click any text or graphics that is identified as a hypertext link. The pointer
changes to a pointing finger when positioned over a link.
To return from a link:

Click Go Back or choose Go Back from the View menu to return to the previous
page view.
12
Using notes
When you encounter a note in a PDF document, double-click it to open the note
window. To find the next note in the document, choose Find Next Note from the
Tools menu.
To close the note window, click the close box in the upper left corner of the note
(Macintosh users can also press Command-W).
13
Reading an article
Creators of PDF documents can define document articles that automatically
guide readers through sections of a document.
To read an article:
Select Articles from the View menu (the menu item is dimmed if no articles
exist in the document). The Articles dialog box appears.
Select the article you want to read from the title list and click View to go directly
to the beginning of the article, or click the beginning of the article with the hand
tool. Place the hand tool cursor on any box in the article.
If you start at the first article box, the cursor changes to Read Article, and
the status bar shows Read Article.
Click or press Enter to follow the article.
To return to the previous view of the article:

Hold down the Shift key and click.
To return to the beginning of the article:

Hold down Option/Ctrl and click.
14
To exit an article at any time:
• Select any navigation method other than pressing Enter or Return.
• Go to another article or page.
• Click +Shift + Option (Macintosh) or Shift +Ctrl + Click (Windows).
Note: If you exit an article by going to a specific page using Go To Page or the
toolbar buttons, the page is displayed with the Default Magnification prefer-
ence setting. The magnification in effect while you read the article is not used.
15
How to upgrade
You’re using Acrobat Reader to view a Portable Document Format file created
by someone else. But you can do much better with Acrobat 2.0 for just $195
U.S. (Outside North America, contact your local Adobe reseller.)
Acrobat 2.0 for Macintosh or Windows includes:

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Print or fax the order form to 1-408-655-6096. Or mail the order form to:
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16
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18
MAINTENANCE
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Rear Preload Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1996 S1-Lightning Specifications . . . . . . . . . . . . . . . . . . . 1-5 Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
Side Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Front Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
Fluid Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Regular Maintenance Intervals (table) . . . . . . . . . . . . . . . 1-9 Air Cleaner Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Vacuum-Operated Electrical Switch (V.O.E.S.) . . . . . . . . 1-32
Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 Handlebars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
Rear Belt Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
Primary Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
CHASSIS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Swingarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Rear Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36
Vehicle Identification Number . . . . . . . . . . . . . . . . . . . . . 2-5 Suspension Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Suspension Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Throttle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Rear Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Clutch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Checking Cast Rim Runout . . . . . . . . . . . . . . . . . . . . . . . 2-14 Speedometer and Tachometer . . . . . . . . . . . . . . . . . . . . 2-46
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Handlebars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Front Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . 2-19 Footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52
Front Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Sprocket Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Front Brake Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Rear Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . 2-23 Tail Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Rear Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Rear Brake Line and Switch . . . . . . . . . . . . . . . . . . . . . . 2-27 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Front Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Side Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58
Fork Stem and Bracket Assembly . . . . . . . . . . . . . . . . . . 2-32
ENGINE
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Oil Pressure Signal Light Switch . . . . . . . . . . . . . . . . . . . 3-31
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Crankcase Breathing System . . . . . . . . . . . . . . . . . . . . . 3-32
Stripping Motorcycle For Engine Repair . . . . . . . . . . . . . 3-8 Oiling System (Color Foldout) . . . . . . . . . . . . . . . . . . . . . 3-33
Installing The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Oil Filter Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Cylinder and Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Valve Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Gearcase Cover and Cam Gears . . . . . . . . . . . . . . . . . . 3-40
Oil Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
FUEL SYSTEM
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Fuel Supply Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Evaporative Emissions Control-California Models . . . . . 4-23
ELECTRIC STARTER
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Starter System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Electric Starter System . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Diagnostics/Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 5-9 Starter Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
DRIVE/TRANSMISSION
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Transmission Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Primary Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Shifter Forks and Drum . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Secondary Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Mainshaft and Countershaft . . . . . . . . . . . . . . . . . . . . . . 6-20
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Main Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Clutch Release Mechanism . . . . . . . . . . . . . . . . . . . . . . . 6-9 Access Door Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Primary Drive/Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Right Transmission Case Bearings . . . . . . . . . . . . . . . . . 6-29
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Transmission Installation and Shifter Pawl Adjustment . 6-30
ELECTRICAL
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Vacuum-Operated Electrical Switch (V.O.E.S.) . . . . . . . . 7-10 Tail Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Ignition/Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Turn Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
Ignition Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Turn Signal Flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Ignition Sensor Plate and Rotor . . . . . . . . . . . . . . . . . . . . 7-14 Handlebar Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41
Spark Plug Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 Neutral Indicator Switch . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
Starter Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . 7-43
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29 Deutsch Electrical Connectors . . . . . . . . . . . . . . . . . . . . 7-46
Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31 Amp Multilock Electrical Connectors . . . . . . . . . . . . . . . . 7-48
1997 INFORMATION
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Electric Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Drive/transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
APPENDIX
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Metric Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

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SECTION I–MAINTENANCE

SUBJECT PAGE NO.

DIMENSIONS IN. MM IGNITION SYSTEM

Wheel base 55 1397 Spark plugs No. 6R12

Type Constant Mesh, Foot Shift

CAPACITIES U.S. LITERS

S1 shipping weight 446 202 TRANSMISSION GEAR RATIOS FINAL* OVERALL**

Type 4-Cycle, 45 Degree V-Type Front-Dunlop Sportmax 32 PSI 36 PSI

Figure 1. 1997 S1 Lightning, Right Side View

Figure 2. 1997 S1 Lightning, Right Side View (Body Removed)

Figure 3. 1997 S1 Lightning, Left Side View

Figure 4. 1997 S1 Lightning, Left Side View (Body Removed)

GENERAL FRONT FORK OIL

● milliliters x 0.0338 = ﬂuid ounces (U.S.) SAE Above 40°

MODEL YEAR CHANGE

Figure 5. Ramp Change

Rear axle nut

4. See Figure 6. Measure the distance from the center of the 1

MODEL YEAR CHANGE 5853

Figure 8. Remote Idle Adjuster

SUBJECT PAGE NO.

Manufacturer: Buell Motorcycle Company

Sample V.I.N. as it appears on the steering head - 4MZSS11J1V3200001

Figure 9. Vehicle Identiﬁcation Number (V.I.N.)

MODEL YEAR CHANGE 5874

Figure 10. 1997 Rotor to Carrier Fastener

TOOL INFORMATION b0265x2x

Use the BRAKE CALIPER PISTON REMOVER (Part No. B-

Exercise care to avoid dropping piston on hard surface.

Figure 12. Inside Caliper Half

Figure 13. Using Air Pressure to Remove Pistons

MODEL YEAR CHANGE b0290a2x

All 1997 model year motorcycles use a revised swingarm

SUBJECT PAGE NO.

1. See Figure 17. Thread remote adjuster (1), spring (3)

Table 2. Engine Idle Speed

MODEL REGULAR IDLE FAST IDLE

World Model 950-1050 RPM Figure 18. Cable Strap

MODEL YEAR CHANGE 5705

All 1997 model year motorcycles use a modiﬁed air cleaner

1. See Figure 19. Remove screw and nylon washer (1) on

a. Detach rear breather hose (4) from tee ﬁtting (3).

Figure 21. Breather Hoses

a. Apply HYLOMAR to threads of breather bolts.

b. Install air cleaner support ring and backplate using 1

c. Attach rear breather hose to rear breather bolt. 1 3

Figure 22. Snorkel Ring

b. Attach front breather hose (5, with attached tee and

c. Connect rear breather hose (4) to tee ﬁtting (3).

4. See Figure 22. Apply LOCTITE THREADLOCKER 242

8. Install screw and locknut at rear mount. Tighten to 6-8 ft-

SUBJECT PAGE NO.

Check Connections at Battery

Check for Check for Battery Voltage from Starter

Substitute Inspect Starter Repair Wiring Check for Battery Voltage to

Motor terminal Replace Repair Wiring to

RUN-ON STARTER SPINS, BUT

Replace Starter Replace Starter

2 Perform Voltage Drop

SUBJECT PAGE NO.

MODEL YEAR CHANGE b0279x7x

All 1997 model year motorcycles use new handlebar

See WIRING HARNESS on page 37 for more information.