7

2005 buell lighting workshop repair manual download

LINK 1 ENTER SITE >>> Download PDF
LINK 2 ENTER SITE >>> Download PDF

File Name:2005 buell lighting workshop repair manual download.pdf
Size: 3129 KB
Type: PDF, ePub, eBook

Category: Book
Uploaded: 2 May 2019, 20:34 PM
Rating: 4.6/5 from 605 votes.

Status: AVAILABLE

Last checked: 14 Minutes ago!

In order to read or download 2005 buell lighting workshop repair manual download ebook, you need to create a FREE account.

Download Now!

eBook includes PDF, ePub and Kindle version

✔ Register a free 1 month Trial Account.

✔ Download as many books as you like (Personal use)

✔ Cancel the membership at any time if not satisfied.

✔ Join Over 80000 Happy Readers

2005 buell lighting workshop repair manual downloadBest Buell Lightning Service Repair ManualThis is the most complete Service Repair Manual for the 2005 Buell Lightning ever compiled byBest Buell Lightning Service Repair ManualThis is the most complete Service Repair Manual for the 2005 Buell Lightning ever compiled byThis DOWNLOAD contains of high quality diagrams and instructions on how to service andThis is a must for the Do-ItYourselfer. You will not be dissatisfied. Models Covers:Service Repair Manual Covers. Section 1: Maintenance. Section 2: Chassis. Section 3: Engine. Section 4: Fuel System. Section 5: Starter. Section 7: Electrical. Service repair manual are INSTANT DOWNLOAD saving you money on postage and packaging. AllFile Format: PDF. Language: English. The URL contains a typographical error. A custom filter or module, such as URLScan, restricts access to the file. Review the browser URL. Create a tracing rule to track failed requests for this HTTP status code and see which module is calling SetStatus. For more information about creating a tracing rule for failed requests, click here. Create the file or directory and try the request again. This component is part of the supply chain for many original equipment manufacturers (OEMs) of consumer-grade security cameras and IoT devices. Includes IoCs and a decryption script for detection. Just as important, asset owners need to adopt a post-breach mindset. His role is to help organizations do three core things: identify, assess, and. Includes IOCs. Read the blog and get the report to speed up your understanding of the current threat landscape. It also provides a sneak peek into our related (and groundbreaking!) talk about power system security at Black Hat USA 2019. Because of the significance of the malware, our Nozomi Networks Security Research team is evaluating it. Find out what is known about the malware to date.http://aquafilling.com/userfiles/dso1012a-manual.xml

Tags:
• 2005 buell lighting workshop repair manual download, 2005 buell lighting workshop repair manual downloads, 2005 buell lighting workshop repair manual download online, 2005 buell lighting workshop repair manual download pdf.

While the regulation is still in the review stage, some low-impact utilities are not waiting to improve their cyber security posture and get a head start on compliance. They are taking advantage of the latest innovation for cyber threat monitoring and detection systems. Vermont Electric Coop is one such entity, and they have realized multiple benefits from their proactive approach. Analyzing and monitoring this data to detect anomalies was very difficult. This article describes how our product, SCADAguardian does it, and gives an example of how it would detect and counter a cyberattack on a regional control center of an electric power utility. This article highlights the steps involved in the watershed 2015 Ukraine utility cyberattack as it moved from IT to OT systems and suggests ways of improving threat detection and mitigation. This component is part of the supply chain for many original equipment manufacturers (OEMs) of consumer-grade security cameras and IoT devices. Includes IoCs and a decryption script for detection. Includes IOCs. Read the blog and get the report to speed up your understanding of the current threat landscape. This component is part of the supply chain for many original equipment manufacturers (OEMs) of consumer-grade security cameras and IoT devices. Includes IoCs and a decryption script for detection. Just as important, asset owners need to adopt a post-breach mindset. Asset owners should act immediately to secure their SIS — and the information in our white paper will help. Let’s take a look at two examples of how a passive ICS anomaly detection and monitoring solution secures pipeline networks. Yet only 41 of companies continually monitor OT infrastructure to prioritize cyber threats and attacks. Let’s take a closer look at this innovative and useful development. And the collaboration doesn’t stop there. Read on to learn more.https://cyklokram.com/static_pages_files/dso5012a-user-manual.xml This component is part of the supply chain for many original equipment manufacturers (OEMs) of consumer-grade security cameras and IoT devices. Privacy and Legal Notices If you continue to use this site we will assume that you are happy with it. Ok. June 18, 2021 Limited Edition Cars: Are They Worth It. June 18, 2021 How to Increase Your Car’s Cargo Space June 17, 2021 5 Best Car Security Tips to Keep Your Ride Safe At All Times June 16, 2021 3 Ways LEDs are Lighting up Car Light Trends June 16, 2021 What to Do If Your Car Breaks Down June 16, 2021 Top 5 Factors to Consider When Choosing Towing Companies June 16, 2021 What Do I Do If I’m Locked Out of My Car. June 15, 2021 Search Motor Era. If all is correct, the vehicle is ready to go back to the PARTS CATALOG. customer. 2007 Buell Lightning: Maintenance. Part Replacement Bearings do not usually need to be removed. Only remove bearings if necessary. Always replace worn or damaged parts with new parts. 2007 Buell Lightning: Maintenance. Don’t pull on a tool cabinet; push it in front of you. Set the brakes on the locking casters after the cabinet has been rolled to your work. 2007 Buell Lightning: Maintenance. In freezing tempera- Buell motorcycles are designed to give the best performance tures, the water becomes slush or ice, which may clog oil using unleaded gasoline. The batteries are shipped pre-charged and ready to of battery condition. Check the voltage of the battery to verify be put into service. Use rec- ommended torque values. Over-tightening battery termi- nal bolts could result in damage to battery terminals. (00216a) 2007 Buell Lightning: Maintenance 1-11. Wipe dipstick clean. DO NOT OVER TIGHTEN. 1-12 2007 Buell Lightning: Maintenance. Tighten rear caliper bleeder valve (metric) to 36-60 in- lbs (4-7 Nm).Brake Pedal NOTE Brake pedal has no free play adjustment. 8349 Bottom of master cylinder Rod adjuster Locknut Clevis Clevis pin Figure 1-12. Rear Brake Pedal Pushrod Adjustment 2007 Buell Lightning: Maintenance 1-19. Check rotor surface. Replace if warped or badly scored. 2.12 FRONT BRAKE CALIPER 2.15 REAR BRAKE CALIPER for procedure. Figure 1-14. Front Brake Rotor 1-20 2007 Buell Lightning: Maintenance. Figure 1-17. Rear Brake Pad Spring 1-22 2007 Buell Lightning: Maintenance. Very Use only Buell approved tires. See a Buell dealer. Using high bearing speeds can damage unlubricated bearings.Correct chaincase lubricant level 10. Figure 1-22. Fluid Level 1-24 2007 Buell Lightning: Maintenance. Figure 1-23. Clutch Cable Adjuster Mechanism NOTE Spring installs on outboard side of hex lockplate. 8405 Diaphragm spring Lockplate Adjusting screw Figure 1-24. Clutch Adjustment 2007 Buell Lightning: Maintenance 1-25. Figure 1-20. Install clutch inspection cover and new Figure 1-25. Adjusting Clutch Free Play gasket using three fasteners and washers and tighten to 84-108 in-lbs (10-12 Nm). 1-26 2007 Buell Lightning: Maintenance. Clean the drive belt with a mild soap and water spray solution as required. Dry thoroughly. Do not immerse belt in solution. Do not direct pressurized water on belt. 2007 Buell Lightning: Maintenance 1-27. Tighten fasteners to 84-108 in-lbs (10-12 Nm).Counterclockwise (outward) to increase free play. Tighten locknut (1) to 20-25 ft-lbs (27-34 Nm). Locknut Adjusting Fastener Figure 1-29. Chain Tension Adjusting Fastener 1-32 2007 Buell Lightning: Maintenance. Using a screwdriver, turn the slotted dial clockwise until it stops. This is the maximum compression damping setting. Figure 1-31. Front Fork Compression Damping Adjuster 2007 Buell Lightning: Maintenance 1-35. This is the maximum rebound damping setting. Rear Shock Rebound Adjustment 1-36 2007 Buell Lightning: Maintenance. Buell dealer for repairs. Loose, worn or damaged steer- The desired resistance is between 1-7 lbs (0.5-3.2 kg). ing or suspension components can adversely affect sta-. A plug with a white, yellow, tan or rusty brown pow- dery deposit indicates balanced combustion. Clean off spark plug deposits at regular intervals. 2007 Buell Lightning: Maintenance 1-39. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 16. Install seat. See 2.44 SEAT. 1-40 2007 Buell Lightning: Maintenance. Figure 1-41. Actuator Cover for XB12 Models with translucent body panel. 2007 Buell Lightning: Maintenance 1-41. Installed Air Cleaner Filter Element Figure 1-45. Air Cleaner Baseplate Assembly 1-42 2007 Buell Lightning: Maintenance. Adjuster Interactive exhaust cable Jam nut Cable wheel Figure 1-48. Interactive Exhaust Cable Figure 1-48. Loosen jam nut (3). Remove cable (2) from bracket and cable wheel (4). NOTE 1-44 2007 Buell Lightning: Maintenance. This ensures the system is working prop- erly. If you do not see the mark, verify previous cable adjust- ment. 2007 Buell Lightning: Maintenance 1-45. Figure 1-52. If the static timing is correct, the screen will switch to HIGH - 5 volts at the precise moment the timing mark exactly centers in the inspection window. Figure 1-52. Correct Timing 1-46 2007 Buell Lightning: Maintenance. Retarded Timing Figure 1-53. Timer Cover 8391a Figure 1-54. Cam Position Sensor 2007 Buell Lightning: Maintenance 1-47. Figure 1-58. Headlamp Switch Adjust headlamp alignment. See ADJUSTMENT section. 1-48 2007 Buell Lightning: Maintenance. Once headlights are aligned, tighten fasteners to 48-72 in-lbs (5-8 Nm). 9950 Figure 1-59. Horizontal Headlamp Adjustment 9951 Figure 1-60. Vertical Headlamp Adjustment 2007 Buell Lightning: Maintenance 1-49. See ADJUSTMENT below. Connect vehicle to Digital Technician. Select Buell TPS zero tab. Select TP volts on screen. Figure 1-61. Back off idle adjustment until TP volts stop decreasing and then continue to back out one full turn. If motorcycle is to be covered, use a material that will breathe, such as light canvas. Plastic materials that do not breathe promote the formation of condensation. 2007 Buell Lightning: Maintenance 1-51. Oxygen sensor damaged or malfunctioning (bike running Internal engine problem. rich). See dealer. Wheels not balanced correctly. Air intake screen covered or restricted. 2007 Buell Lightning: Maintenance 1-53. Non-standard equipment on the front end (such as heavy radio receivers, extra lighting equipment or luggage) tends to cause unstable handling. 1-54 2007 Buell Lightning: Maintenance. 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. 2007 Buell Lightning: Maintenance 1-55. See a Buell dealer. Using non- approved tires can adversely affect stability, which could result in death or serious injury. (00133a) Figure 2-1. Tire sizes are molded on the sidewall. Rim size and contour are marked on the rim’s exterior surface. At the same time, inspect tire tread for punctures, cuts, breaks and other damage. Repeat the inspection before long trips. 2007 Buell Lightning: Chassis. Swingarm bearings. Check for proper torque and replace worn or damaged bearings. 2.19 ISWINGARM AND BRACE. 2007 Buell Lightning: Chassis. See a Buell dealer. Using non-approved tires can adversely affect stability, which could result in death or serious injury. (00133a) WARNING WARNING Tires are a critical safety component. Remove wheel. Figure 2-5. Front Wheel Removal 2-10 2007 Buell Lightning: Chassis. Hold the forcing screw (2), and turn the nut (3) clockwise until the bearing is free of the hub. 2007 Buell Lightning: Chassis 2-11. Improper brake operation could result in death or serious injury. (00111a) Inspect brake rotor and pads. See 1.6 BRAKE SYSTEM MAINTENANCE and 2.12 FRONT BRAKE CALIPER. 2-12 2007 Buell Lightning: Chassis. B-43993-9) and forcing screw. Figure 2-12. Install the Backing Plate (B-43993-12) and Forcing Screw 2007 Buell Lightning: Chassis 2-13. B-43993-10) and forcing screw. 16. Install the wheel. See INSTALLATION under 2.5 FRONT Forcing screw WHEEL. Spacer Figure 2-15. Install the Spacer 10. See Figure 2-15. Install the spacer. 2-14 2007 Buell Lightning: Chassis. Align reference dot on front rotor with the valve stem. CAUTION Do not re-use brake disc screws.Install right side fender fasteners. See 2.35 FENDERS. 8419 Axle (left handed thread) Front axle pinch fasteners (2) (metric) Figure 2-19. Front Wheel Mounting 2-16 2007 Buell Lightning: Chassis. See IDLER PULLEY REMOVAL 6.6 DRIVE REMOVER AND INSTALLER (Part No. HD-44060). BELT SYSTEM. Remove lower belt guard. See 2.36 BELT GUARDS. Remove rear wheel spacer (4). 2007 Buell Lightning: Chassis 2-17. Such contact can adversely affect braking ability, which could cause loss of control, resulting in death or serious injury. (00290a) 2-18 2007 Buell Lightning: Chassis. Install brake rotor (2) with new rotor mounting fas- teners (1) and tighten to 25-27 ft-lbs (34-37 Nm). 2007 Buell Lightning: Chassis 2-19. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) Figure 2-26. Rear Brake Caliper Carrier Fasteners 2-20 2007 Buell Lightning: Chassis. Wheel Rim Runout b0758x2x RUNOUT Maximum lateral 0.040 1.02 Maximum radial 0.030 0.76 Gauge rod Figure 2-28. Checking Cast Rim Radial Runout Using Wheel Truing and Balancing Stand (HD-99500-80) 2007 Buell Lightning: Chassis 2-21. Buell front and rear tires are not the same. Inter- changing front and rear tires can cause tire failure, which could result in death or serious injury. Buell front and rear tires are not the same. Inter- Figure 2-32. Starting Bead on Rim (Typical) changing front and rear tires can cause tire failure, which could result in death or serious injury. Checking Tire Radial Runout Table 2-11. Tire Runout RUNOUT Tire radial 0.060 1.52 Tire lateral 0.080 2.03 2-24 2007 Buell Lightning: Chassis. Install clevis pin (2). Rear master cylinder body Install new cotter pin (7). Clevis pin Pedal bushings (2) Shift brake pedal sleeve Brake pedal fastener Brake pedal Cotter pin Figure 2-36. Brake Pedal Assembly 2-26 2007 Buell Lightning: Chassis. Brake switch fastener 11. Brake switch 12. Brake switch terminal 13. Banjo bolt (metric) 14. Brake line 15. Copper washers 16. Pivot bolt Figure 2-37. Front Brake Hand Lever Assembly 2007 Buell Lightning: Chassis 2-27. Piston Assembly in Master Cylinder Figure 2-38. Depress piston assembly (1) and remove internal circlip (2) and discard. Figure 2-37. Remove piston assembly (6) from front master cylinder reservoir (4) and discard. 2-28 2007 Buell Lightning: Chassis. Assemble new piston components placing small end of spring (5) behind primary seal of piston (4). Lubricate master cylinder body and piston seals with special lubricant found in the service parts kit. 2007 Buell Lightning: Chassis 2-29. Replace the brake line if any damage is noted. P-clamp Brake line Wire form Bleeder valve Banjo bolt Figure 2-42. Front Brake Line 2007 Buell Lightning: Chassis 2-31. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) 2-32 2007 Buell Lightning: Chassis. Slide caliper down the rotor to clear fork lower and then remove off rotor. Figure 2-46. Removing Pistons (B-42887) 2007 Buell Lightning: Chassis 2-33. Install pistons (5) in each piston bore. Install new o-rings (8) between caliper halves. Clamp caliper together with caliper fasteners (11) and tighten to 15-19 ft-lbs (20-26 Nm). 2-34 2007 Buell Lightning: Chassis. Brake pads 11. Caliper fasteners Figure 2-47. Front Caliper Assembly 2007 Buell Lightning: Chassis 2-35. Rear Master Cylinder On Vehicle sembled. Prevent damage to seating surfaces by carefully Figure 2-49. Remove brake reservoir hose at master removing brake line components. cylinder. Remove seat. See 2.44 SEAT. 2-36 2007 Buell Lightning: Chassis. Cotter pin (1) from frame if necessary. 11. Rear master cylinder mount screw Figure 2-51. Rear Master Cylinder Assembly 2007 Buell Lightning: Chassis 2-37. If the circlip is not properly installed, improper brake operation could result in death or serious injury. Tuck rubber boot on rod assembly (3) into master cylin- der body (1). 2-38 2007 Buell Lightning: Chassis. Figure 2-50. Connect brake line switch connector under seat. Install heel guard. See 2.33 FOOTPEG, HEEL GUARD AND MOUNT. 2007 Buell Lightning: Chassis 2-39. Discard copper washer. 10. Remove brake line from motorcycle. 2-40 2007 Buell Lightning: Chassis. B-42887) with Figure 2-57. Rear Brake Caliper adaptor (2). Figure 2-57. Remove caliper mounting fasteners (6 Remove two o-rings from groove in caliper bore and dis- and 7). card. 2-42 2007 Buell Lightning: Chassis. Repeat 4 through 6 on opposite side. Screw, pinch fastener Steering stem pinch fastener Triple clamp, upper Triple clamp assembly, lower Screw, pinch fastener Figure 2-62. Upper and Lower Fork Clamp Assembly 2007 Buell Lightning: Chassis 2-45. Remove snap ring (2). Figure 2-66. Removing Fork Cap From Outer Tube Figure 2-66. Remove fork cap from outer tube. 2-46 2007 Buell Lightning: Chassis. Remove preload washer (4) and slider piston (5). Figure 2-67. Expand fork and remove from FORK When using the FORK SPRING COMPRESSING TOOL SPRING COMPRESSION TOOL. Spring joint 25. Oil seal stopper ring Snap ring 17. Spring 26. Dust seal Rebound adjuster assembly 18. Outer tube 27. Slider fork Figure 2-69. Front Fork Assembly 2-48 2007 Buell Lightning: Chassis. Holding the damper locknut (10), unscrew the rebound adjuster assembly (9) and remove from damper rod assembly (11). Remove damper locknut (10) from damper rod assembly (11). 2007 Buell Lightning: Chassis 2-49. Tighten the center bolt to 22-30 ft-lbs (30- Repeat for other fork assembly. 40 Nm). 2-50 2007 Buell Lightning: Chassis. Steering Stem Assembly 2007 Buell Lightning: Chassis 2-53. Tighten steering stem capnut to 38-42 ft-lbs (52-57 Nm). Install steering stem pinch bolt applying LOCTITE 271 (red) and tightening to 20-22 ft-lbs (27.1-29.8 Nm) for all models. 2-54 2007 Buell Lightning: Chassis. B-43993-12) Discard steering head bearings and replace with new. Steer- ing head bearings are not reusable. Figure 2-77. Steering Head Bearings Installation Tools 2007 Buell Lightning: Chassis 2-55. HD-39302) onto the forcing screw (1). Tighten the nut (6) by hand, until the bearing is started into the bore in the steering head. 2-56 2007 Buell Lightning: Chassis. Rear Wheel Mounting, Right Side (XB12Ss) Figure 2-83. Belt Guard and Rear Fender Assembly (XB12Ss) 2-58 2007 Buell Lightning: Chassis. Remove rear wheel. See 2.6 REAR WHEEL. Remove rear fenders. See 2.35 FENDERS. 13. Remove swingarm from vehicle. 2007 Buell Lightning: Chassis 2-59. The complete bearing assembly must be replaced as a unit when replacement is necessary. Do not intermix bearing components. 2-60 2007 Buell Lightning: Chassis. Install right side rider footpeg mount. Tighten fasteners to 132-144 in-lbs (15-16.2 Nm). See 2.33 FOOTPEG, HEEL GUARD AND MOUNT. Remove rear wheel support stand. 2007 Buell Lightning: Chassis 2-61. NOTE Hold wire form while tightening to prevent it from twisting. 2-62 2007 Buell Lightning: Chassis. Install tail frame. See 2.40 LEFT TAIL SECTION AND BATTERY PAN. Install exhaust header. See 2.32 EXHAUST SYSTEM. Rotate engine. See 3.3 ENGINE ROTATION FOR SER- VICE. 2007 Buell Lightning: Chassis 2-63. From the tacked corners, pivot the puck onto the frame keeping the directional point aligned with the horizontal crease. 2-64 2007 Buell Lightning: Chassis. Lower shock mount 11. Shock spring retainer kit 12. Rear shock spring Figure 2-92. Rear Shock Absorber Assembly 2007 Buell Lightning: Chassis 2-65. Rear Shock Absorber and Remove Reservoir Figure 2-94. Rear Shock Absorber Remote Reservoir (XB12Ss shown) Clamp (XB12S shown) and Compression Dial 2-66 2007 Buell Lightning: Chassis. Tighten to 25-33 in-lbs (3-4 Nm). Adjust cables. See 1.15 THROTTLE CABLE AND IDLE SPEED ADJUSTMENT. Install air cleaner assembly. See 4.44 AIR CLEANER ASSEMBLY. 2007 Buell Lightning: Chassis 2-67. Clutch hand lever Clutch adjuster Remove cable strap securing clutch cable to voltage reg- Clutch cable adjuster boot ulator wire. Clutch cable ferrule Figure 2-100. Clutch Hand Control Assembly 2007 Buell Lightning: Chassis 2-69. See Figure 2-102. Remove the outer ramp and hook (1) from the cable end (3) and coupling (2). Remove cable end from slot in coupling. See 6.3 CLUTCH RELEASE MECHANISM. 2-70 2007 Buell Lightning: Chassis. Figure 2-104. Installing Shift Linkage 2007 Buell Lightning: Chassis 2-71. Tighten screws in a crosswise pattern to 84-108 in-lbs (9.5-12.2 Nm). 2-72 2007 Buell Lightning: Chassis. XB9SX Headlight Grille 2007 Buell Lightning: Chassis 2-73. Left and right front modules Figure 2-107. Electrical Connectors Behind Windscreen 2-74 2007 Buell Lightning: Chassis. Headlight Assembly 2007 Buell Lightning: Chassis 2-75. Left and right front modules Figure 2-109. Electrical Connectors Behind Windscreen 2-76 2007 Buell Lightning: Chassis. Install windscreen. See 2.43 WINDSCREEN. 8998 Figure 2-110. Right Front Module Fastener and Brake Line P-Clamp Fastener (Typical) 2-78 2007 Buell Lightning: Chassis. Fairing Support Bracket Assembly 2007 Buell Lightning: Chassis 2-79. Tighten both front screws to 10-12 ft-lbs (14-16 Nm). Then tighten both rear screws (2) 10-12 ft-lbs (14-16 Nm). 2-80 2007 Buell Lightning: Chassis. Handlebar Assembly 2007 Buell Lightning: Chassis 2-81. Mirrors and Mounting Hardware (Typical) 2-82 2007 Buell Lightning: Chassis. Remove oxygen sensor. See 4.33 OXYGEN SENSOR. Figure 2-115. Remove exhaust header (2) by removing mounting fasteners (3). Remove exhaust ring (4), retaining ring (5) and port gas- ket (6). 2007 Buell Lightning: Chassis 2-83. Rider Footpeg, Mount and Heel Guard Assembly 2-86 2007 Buell Lightning: Chassis. Remove footpeg mount (3). Heel guard fasteners b0933a2x Heel guard Footpeg mount Spring Ball Detent plate Clip Footpeg 10. Footpeg mount fastener 11. Jam nut Figure 2-117. Passenger Footpeg, Mount and Heel Guard Assembly 2007 Buell Lightning: Chassis 2-87. Sprocket Cover 2-88 2007 Buell Lightning: Chassis. Front and Rear Fender 2007 Buell Lightning: Chassis 2-89. Belt Guard Assembly 2-90 2007 Buell Lightning: Chassis. Align left section (3) and loosely install left side fasteners and washers (4). Apply LOCTITE 271 (red) and tighten all fasteners to 36- 48 in-lbs (4-5 Nm). 2007 Buell Lightning: Chassis 2-91. Translucent Intake Cover Assembly 2-92 2007 Buell Lightning: Chassis. RAM Air Scoop, Engine Shroud, Oil Cooler 2007 Buell Lightning: Chassis 2-93. Because the surface is not bare polished aluminum, it must be cleaned using only mild soap and warm water. After washing, always dry the surface using a clean, soft cloth. 2-94 2007 Buell Lightning: Chassis. Left rear and right rear tail section fasteners (4) Fuse block and relay center Figure 2-125. Main Harness and Electrical Connectors Under Seat (Typical) 2007 Buell Lightning: Chassis 2-95. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 13. Install seat. See 2.44 SEAT. 2-96 2007 Buell Lightning: Chassis. Trunk pan assembly 12. Rear trunk pan fastener to center tail section (2) 13. Rear shock reservoir bracket 14. Plastic lugs (for manufacturing purposes only) Figure 2-126. Tail Frame and Trunk Pan Assembly 2007 Buell Lightning: Chassis 2-97. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) Install seat. See 2.44 SEAT. 2-98 2007 Buell Lightning: Chassis. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) Install seat. See 2.44 SEAT. 2007 Buell Lightning: Chassis 2-99. Right Side Frame Section (Typical) 2-100 2007 Buell Lightning: Chassis. Front Windscreen 2007 Buell Lightning: Chassis 2-101. Seat and Attachment (Inset XB12Ss seat) 2-102 2007 Buell Lightning: Chassis. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) Install seat. See 2.44 SEAT. 2007 Buell Lightning: Chassis 2-103. Latch bracket 11. Trunk pan Figure 2-130. Seat Lock Assembly 2-104 2007 Buell Lightning: Chassis. Remove sidestand spring (2) and spring extension plate (4) using SNAP-ON SPRING TOOL (Part No. HE-52B). Remove sidestand pivot pin circlip (7) and remove sidestand pivot pin (3). Extend sidestand leg (1) and remove. 2007 Buell Lightning: Chassis 2-105. Figure 2-134. Lubricating Points (Shaded Areas) 2-106 2007 Buell Lightning: Chassis. Your sion, it indicates the piston rings need replacing. Low motorcycle will run normally using this type of gas. Buell compression by itself, however, may indicate improperly recommends you use it when possible, as an aid to seated valves, in addition to or in lieu of worn piston rings. The following are some general instructions that apply to Buell motorcycle engines: Run engine until it reaches normal operating tempera- ture. 2007 Buell Lightning: Engine. Loosen clutch adjuster to release tension from hand lever. Remove clutch cable ferrule from hand lever. Wire form Clutch cable adjuster boot Figure 3-4. Clutch Cable Wire Form and Adjuster Boot 2007 Buell Lightning: Engine 3-11. Rear tie bar assembly 11. Fasteners for center tie bar mount (2) 22. Fasteners for rear tie bar assembly (2) Figure 3-5. Engine Mounting System 3-12 2007 Buell Lightning: Engine. Loosen rear isolator bolt (1). DO NOT REMOVE. 22. See Figure 3-7. Remove front isolator bolt (1). 23. Remove front isolator mount (2) from engine. 24. Rotate engine down. 2007 Buell Lightning: Engine 3-13. Remove scissors jack. 3-14 2007 Buell Lightning: Engine. Fuel Line and DDFI Electrical Connections (Typical) 3-18 2007 Buell Lightning: Engine. NOTE Remove the right side rider footrest and support plate, and 18. Remove left and right side rider footrests and support secure towards rear of vehicle. plates. See 2.33 FOOTPEG, HEEL GUARD AND MOUNT. 2007 Buell Lightning: Engine 3-21. Rear tie bar assembly 11. Fasteners for rear tie bar assembly (2) Figure 3-17. Engine Mounting System 3-22 2007 Buell Lightning: Engine. Remove front tie-bar (7) from “V” bracket. Remove front tie-bar (7) from engine. Unbolt “V” bracket from main frame and remove “V” bracket. 2007 Buell Lightning: Engine 3-23. Wire form retainer Clutch cable adjuster boot Lower retaining clamp Figure 3-20. Clutch Cable Wire Form Retainer, Retaining Clamp and Adjuster Boot 3-24 2007 Buell Lightning: Engine. Sidestand Assembly (Extended) 2007 Buell Lightning: Engine 3-25. Timer cover. Figure 3-28. Front Exhaust Mount Bushings (2 piece) Figure 3-29. Wire guard located under the sprocket cover. 12367 8724 12369a 8729 Figure 3-27. Removing Threaded Insert Figure 3-29. Wire Guard 2007 Buell Lightning: Engine 3-27. Figure 3-35. Apply LOCTITE 242 (blue) and install swingarm pivot shaft pinch bolt threaded insert. Figure 3-36. Front Exhaust Mount Bushings (2 piece) 2007 Buell Lightning: Engine 3-29. Rear tie bar assembly 11. Fasteners for rear tie bar assembly (2) Figure 3-42. Engine Mounting System 2007 Buell Lightning: Engine 3-31. Attach regulator wiring harness to clutch cable below clutch cable lower retaining clamp using a nylon cable strap. 18. Remove scissors jack. 3-32 2007 Buell Lightning: Engine. Orientation of return line should be approximately 6 o’clock Figure 3-49. Oil Cooler Feed and Return Oil Lines Location and Orientation 2007 Buell Lightning: Engine 3-37. Positive battery cable at starter.Electrical Connections and Throttle Cables (Typical) 2007 Buell Lightning: Engine 3-41. Push rod cover 22. Screw (4) 23. O-ring (push rod cover - 2) 24. Push rod 25. Washer (4) 26. Bolt (4) b1266x3x Figure 3-56. Rocker Arm and Push Rod Cover Assemblies 2007 Buell Lightning: Engine 3-43. Remove push rods. Figure 3-58. Removing Rocker Arm Shafts 3-44 2007 Buell Lightning: Engine. Repeat the above procedure for the other valves. Valve Spring Compressor (Part No. HD-34736B) 2007 Buell Lightning: Engine 3-45. Cylinder base gasket 15. Cylinder base stud 16. Exhaust valve 17. Exhaust valve seat Figure 3-61. Cylinder Head, Cylinder and Piston Assembly 3-46 2007 Buell Lightning: Engine. HD-94804-57). Repeat for other end of rocker arm. 8733 8734 Figure 3-69. Replacing Rocker Arm Bushings 3-50 2007 Buell Lightning: Engine. HD-34751) and hot soapy water. Valve guide brush (Part No. HD-39786) Figure 3-71. Cleaning Valve Guides 2007 Buell Lightning: Engine 3-51. Valve and Seat Dimensions 2007 Buell Lightning: Engine 3-53. Cylinder base gasket 15. Exhaust valve 17. Exhaust valve seat Figure 3-74. Cylinder Head, Cylinder and Piston Assembly 3-54 2007 Buell Lightning: Engine. Otherwise, dam- age to push rods or rocker arms may result. 2007 Buell Lightning: Engine 3-57. Figure 3-82. Tightening Head Screws Figure 3-82.Place a new lower gaskets on lower rocker cover. Tighten screws to 120-168 in- lbs (13.6-18.9 Nm). 3-60 2007 Buell Lightning: Engine. Piston Piston pin Retaining ring (2) Dowel and o-ring Cylinder Base gasket Cylinder stud (4) Connecting rod 10. Piston pin bushing Figure 3-85. Cylinder and Piston 2007 Buell Lightning: Engine 3-61. Figure 3-88. To remove piston rings spread outward until they clear grooves in piston and lift off. 3-62 2007 Buell Lightning: Engine. Try to insert a feeler gauge between the straight- edge and the gasket surface.The cylinder is now clean.See SPECIFICATIONS.