File 5
Contents
1. BATTERY GENERAL WARNING Batteries contain sulfuric acid which can cause severe burns Avoid contact with skin eyes or clothing Batteries produce explosive hydrogen gas at all 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 BATTERIES AND ACID OUT OF THE REACH OF CHIL DREN 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 The battery requires no additional fluid at any time Check the battery At every scheduled service interval When storing or removing the motorcycle for the season CHARGING The sealed low maintenance battery has a very slow dis charge rate See Figure 1 6 If you suspect a battery problem test as described below 1 Remove battery from motorcycle See BATTERY REMOVAL on page 1 14 2 Test battery voltage using a multimeter 3 If battery voltage is below 12 66 Volts use a 1 100 Amp 12 Volt charger on battery See Table 1 3 ADANGER EXPLOSIVE GASES Cigarettes flames or sparks could cause battery to explode resulting in personal injury Always shield eyes and face from battery Do not charge without proper instruction and training Securely co2. T i A N j ___ CAL CONTACT CLEANER Dry plug with com gt gt cat _ 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 Check air cleaner filter 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 AACAUTION Do not run engine without filter element in place Debris could be drawn into the engine causing damage 1 See Figure 1 39 Remove screw and nylon washer on top of air cleaner cover 2 Remove screw nylon washer and locknut at rear of air cleaner cover Remove cover See Figure 1 40 Remove filter box from snorkel tube Remove filter from filter box INSTALLATION 1 Replace filter element if damaged or if filter media cannot be adequately cleaned AWARNING L
3. connectors and battery terminals using a wire brush or sandpaper to remove any oxidation AWARNING Always connect positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explo sion resulting in personal injury CAUTION 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 CAUTION 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 Ibs 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 b0189x7x Battery positive terminal metric Battery negative om mete Battery strap Figure 1 7 Battery Hold cable during SS removal installation Tighten to 30 40 in lbs aK L 4 4 5 Nm Figure 1 8 Checking Battery Terminals ENGINE LUBRICATION SYSTEM CHECKING ENGINE OIL LEVEL Check engine oil level Atleast once every 500 miles 800 km At every service interval NOTE If engine uses more oil than normal or
4. gasket contacts mounting plate surface Apply another 1 2 3 4 turn by hand AWARNING Be sure no oil gets on tires when changing oil and filter Traction will be adversely affected which may lead to a loss of control and personal injury 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 WARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shift during vehicle operation and startle the rider causing loss of control and personal injury 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 Awarninc 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 Atthe 500 mile 800 km service interval At every 5000 mile 8000 km service interval
5. if vehicle is operated under harsh conditions check oil more frequently When checking or changing engine oil Warm vehicle to normal operating temperature Turn engine off Hold motorcycle upright not leaning on side stand on a level surface 1 Remove seat 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 AXCAUTION 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 stick add oil to tank Install filler cap dipstick Recommended viscosity depends upon ambient temper ature See Table 1 4 NOTE Difference between upper and lower dipstick marks is 0 5 quart 0 47 liter WARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shift during vehicle operation and startle the rider causing loss of control and personal injury 5 Install seat Oil pressure switch b P Lower mark Oil tank Figure 1 10 Checking Oil Tank Level Table 1 4 Recommended Oil Grades COLD HARLEY HARLEY LOWEST WEATHER DAVIDSON TYPE VISCOSITY D
6. items removed in Step 2 Load all cargo 6 Bounce a few times on the seat to be sure the suspen Figure 1 28 Adjusting Rear Preload 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 preload A cAuTION 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 a Increase the preload by tightening the nuts b Decrease the preload by loosening the nuts 1 23 SUSPENSION ADJUSTMENT 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
7. mm Hg is required to close the switch then the switch must be replaced Install V O E S See VACUUM OPERATED ELECTRIC SWITCH V O E S in Section 7 1 32 a V O E S 4 Ohmmeter probes V O E S leads 5 Vacuum pump Ohmmeter Figure 1 45 Checking V 0O E S Using Ohmmeter and Vacuum Pump HANDLEBARS INSPECTION Check handlebar adjustment Before every ride 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 ADJUSTMENT AACAUTION 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 TACHOMETER in Section 2 3 See Figure 1 47 Loosen clamp screws 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 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 s
8. 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 Table 1 8 Suspension Settings RANGE IN FACTORY ADJUSTMENT cticks SETTING E3 Front fork 28 20 1 29 compression Front fork 28 12 1 29 rebound Rear shock 7 3 1 30 rebound Rear shock 11 5 1 31 compression REAR SHOCK Check rear shock Atthe 500 mile 800 km service interval At every 5000 mile 8000 km service interval thereafter 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 1 24 Front fork compression damping adjuster a _ OA amp aA near o hockreoonmd i y damping adjuster Figure 1 30 Rear Shock Rebound Adjuster Rear shock compression damping adjuster Figure 1 31 Rear Shock Compression Adjuster FRONT FORK STEERING HEAD BEARINGS Check steering head bearings At the 500 mile 800 km service interval At every 5000 mile 8000 km service interval thereafter Lubricate every 10 000 mile 16 000 km service interval 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 Turn front wheel to full right lock Hook a spring scale into the axle hole and pull front wheel to center position It s
9. 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 11 Gearcase cover 24 Washer 2 12 Spark plug 2 25 Screw 2 13 Ignition coil b0223x7x Figure 1 44 Ignition System Components ADJUSTMENT With timing light aimed into inspection hole rotate sensor 1 See Figure 1 44 Remove outer cover pop rivets 1 outer timer cover 2 inner cover screws 3 inner cover 4 and gasket 5 Loosen timer plate studs 6 just enough to allow sensor assembly 8 to be rotated using a screwdriver in the plate s notch assembly 8 until front cylinder advance timing mark is centered in timing inspection hole Tighten timer plate studs 6 Install gasket 5 inner cover 4 inner cover screws 3 timer cover 2 and new outer cover rivets 1 Remove TIMING MARK VIEW PLUG from timing inspec tion hole Install hex socket timing plug 1 31 VACUUM OPERATED ELECTRIC SWITCH V 0 E S ADJUSTMENT TESTING Timing Mark Method Verify engine ignition timi
10. thereafter When storing or removing the motorcycle for the season Front brake hand lever and rear brake foot pedal must have a firm feel when brakes are applied If not bleed system as described BLEEDING BRAKES NOTE Hydraulic brake fluid bladder type pressure equipment can be 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 a Front brake caliper Figure 1 13 b Rear brake caliper Figure 1 14 2 Add D O T 5 SILICONE HYDRAULIC BRAKE FLUID to master cylinder reservoir Do not reuse brake fluid a Bring fluid level to within 1 8 in 8 2 mm of molded boss for front master cylinder reservoir b Bring fluid level between upper and lower marks for rear master cylinder reservoir 3 Depress and hold brake lever pedal to build up hydraulic pressure 4 Open bleeder valve about 1 2 turn counterclockwise 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 brake lever pedal to return slowly to its released position 5 Repeat Steps 2 4 until all air b
11. this is not the case turn adjuster 3 on idle control cable 2 shortening cable housing until throttle control functions properly Throttle control cable 4 Rubber boot 9 Tighten jam nut on idle control cable 2 adjuster 3 Idle control cable 5 Throttle cam stop Recheck operation of throttle control Step 7 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 Before every ride At every scheduled service interval See IGNITION TIMING on page 1 30 1 29 IGNITION TIMING INSPECTION m Check ignition timing Atevery 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 wise to decrease speed Use CARBURETOR IDLE AD
12. tires out of true sideways tire runout should not be more than 0 080 in 2 03 mm Rims and tires out of round or eccentric with hub tire runout should not be more than 0 090 in 2 29 mm 10 11 Irregular or peaked front tire tread wear Tire and wheel unbalanced Steering head bearings improperly adjusted Correct adjustment and replace pitted or worn bearings and races See FORK STEM AND BRACKET ASSEMBLY in Section 2 Shock absorber not functioning normally Heavy front end loading Non standard equipment on the front end such as heavy radio receivers extra lighting equipment or luggage tends to cause unstable handling
13. 0 km service interval Adjust at every 5000 mile 8000 km service interval thereafter 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 When check ing deflection have No rider or cargo weight on motorcycle Transmission in neutral Belt and sprockets at room temperature Motorcycle upright not on side stand See Figure 1 21 At the lower strand position A mid way between transmission sprocket and rear wheel sprocket apply 10 lbs 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 ADJUSTMENT 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 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 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
14. AVIDSON AMBIENT STARTS RATING BELOW 50 F SAE Below 40 F H D Multi Grade SAE Above 40 2owso ee wo H D Regular Heavy E HD 240 Eoy SAE Above 80 eet ero H D Extra Heavy CHANGING ENGINE OIL AND FILTER Change engine oil Drain hose L Atthe 500 mile 800 km service interval At every 5000 mile 8000 km service interval thereafter A i i Drain plug When storing or removing the motorcycle for the season 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 b0138a0x aer and compleie worn lank Apply a thin film of oil to new filter gasket and crankcase mounting plate Install drain hose on drain plug Tighten clamp 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
15. IGH beam position 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 b0008b7x 35 in 889 mm ANF IN Figure 1 49 Adjusting Headlamp STORAGE GENERAL If the motorcycle will not be operated for several months such as during the winter season there are several things which should be done to protect parts against corrosion to preserve the battery and to prevent the buildup of gum and varnish in the carburetor This work should be performed by your local Buell dealer following Service Manual procedures AWARNING Gasoline is flammable Do not store motorcycle having gasoline in tank within the home or garage where open flames pilot lights sparks or electric motors are present Inadequate safety precautions may cause an acci
16. JUSTMENT TOOL Part No HD 33413 and TIP SNAP ON Part No TMP23A as shown in Figure 1 43 a Onworld 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 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 Figure 1 42 Timing Inspection Hole speed is intended to alert the rider that the engine S 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 soeed Be aware that because there are variations in individual components it is
17. RK 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 5 WEIGHT to above red retaining cap AACAUTION See Figure 1 34 Raise outer tube no higher than 9 in 229 mm or fluid loss will occur 4 See Figure 1 35 Grasp damper assembly by the adjuster Pull damper assembly through several full strokes to bleed air from the fork j 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 1 26 9 in 229 mm maximum Figure 1 34 Maximum Outer Tube Lift Damper assembly Correct fork oil level is 4 33 in 110 mm below top of fork tube Use only WP FORK OIL 5 WEIGHT 1 Outer tube 3 2 Adjuster 4 Damper assembly Fork oil level Figure 1 36 Correct Fork Oil Level SPARK PLUGS INSPECTION 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
18. adjusted or filled with fuel a Ny TRANSMISSION Shifts Hard 1 Clutch dragging slightly 2 Shifter forks inside transmission damaged 3 Corners worn off shifter clutch dogs transmission inside Jumps Out of Gear 1 Shifter pawl improperly adjusted 2 Shifter engaging parts inside transmission badly worn and rounded 3 Shifter forks bent 4 Damaged gears CLUTCH Slips 1 Clutch controls improperly adjusted 2 Worn friction plates Drags or Does Not Release 1 Clutch controls improperly adjusted 2 Clutch plates excessively warped Chatters 1 Friction or steel plates worn warped or dragging CHASSIS lrregular Inadequate Brake Action Master cylinder low on fluid Brake line contains air bubbles Master or wheel cylinder piston worn Brake pads covered with grease or oil Brake pads badly worn 1 16 in 1 6 mm minimum lining thickness Brake rotor badly worn or warped 7 Brake pads dragging or excessive braking brake fades due to heat buildup 8 Insufficient brake pedal or hand lever freeplay brake drags Se uN o gt 1 37 Handling Irregularities 1 38 Tires improperly inflated Check TIRES AND WHEELS on page 1 18 Do not overinflate Loose wheel axle nuts Tighten front nut to 48 53 ft lbs 65 1 71 9 Nm Tighten rear nut to 66 73 ft lbs 90 99 Nm Excessive wheel hub bearing play Rear wheel out of alignment with frame and front wheel Rims and
19. 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 sion b Turn counterclockwise to increase belt deflection decrease tension Turn each adjuster nut exactly the same number of turns to maintain rear wheel alignment 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 b0086x6x Apply 10 Ibs 4 5 kg A of upward force B Belt deflection should be 7 8 1 in 22 2 25 4 mm Figure 1 21 Checking Belt Deflection Figure 1 22 Rear Axle Measure each side to check wheel alignment Figure 1 23 Checking Rear Wheel Alignment Right Side Shown 1 21 PRIMARY CHAIN INSPECTION Check primary chain Atthe 500 mile 800 km service interval At every 5000 mile 8000 km service interval thereafter 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 3 See Figure 1 25 Check primary chain tension by mea suring vertical freeplay measuring midway between sprockets several times each time with p
20. dent resulting in personal injury 1 Fill fuel tank and add a gasoline stabilizer Use one of the commercially available gasoline stabilizers following the manufacturer s instructions Run engine until gasoline has had a chance to reach carburetor float bowl Turn fuel supply valve OFF 2 Fill the oil tank Pinch off or remove and plug the line leading from the oil tank bottom to the oil pump feed fitting This prevents oil from seeping past the check ball into the oil pump and filling the engine flywheel compartment 3 Remove the spark plugs inject a few squirts of engine oil into each cylinder and crank the engine 5 6 revolutions Reinstall spark plugs Adjust primary chain Adjust secondary drive belt Check tire inflation If the motorcycle will be stored for an extended period of time securely support the motorcycle under the frame so that all weight is off the tires WARNING Do not apply any oil to brake rotors or brake pads Oil on brake pads degrades braking efficiency and can result in an accident causing personal injury 7 Wash painted and chrome plated surfaces Apply a light film of oil to exposed unpainted surfaces 8 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 REMOVAL FROM STORAGE WARNING After extended periods of storage and prior to starting vehicle place transmission in
21. ections 5 Fouled spark plugs 6 Loose or shorting spark plug cables or connections 7 Ignition timing badly out of adjustment 8 Loose wire connection at coil or battery connection or plug between ignition sensor and module 9 Ignition coil not functioning 10 Ignition module not functioning 11 Ignition sensor not functioning 12 Sticking or damaged valve or valves 13 Engine flooded with gasoline as a result of overchoking 14 Engine oil too heavy winter operation Starts Hard 1 Spark plugs in bad condition have improper gap or are partially fouled 2 Spark plug cables in bad condition and shorting Battery nearly discharged Loose wire connection at one of the battery terminals at coil or at plug between ignition sensor and module Carburetor controls not adjusted correctly Ignition coil not functioning Engine oil too heavy winter operation Ignition not timed properly See dealer Vapor vent valve plugged or carburetor fuel line closed off restricting fuel flow 10 Water or dirt in fuel system and carburetor 11 Enrichener valve inoperative 12 Air leak at intake manifold 13 Valves sticking a ONDT 1 36 Starts But Runs Irregularly or Misses Spark plugs in bad condition or partially fouled Spark plug cables in bad condition and shorting Spark plug gap too close or too wide Ignition coil not functioning Ignition module not functioning Ignition sensor not functioning Ba
22. en frame 4 Primary chain badly worn or links tight as a result of insufficient lubrication 5 Wheels not aligned and or tires worn 6 Internal engine problem ENGINE LUBRICATION SYSTEM Oil Does Not Return To Oil Tank Oil tank empty Return pump gears damaged Oil feed pump not functioning Restricted oil lines or fittings 2 YS Engine Uses Too Much Oil or Smokes Excessively 1 Piston rings badly worn or broken 2 Valve stem seals worn or damaged 3 Valve guides worn Engine Leaks Oil From Cases Push Rods Hoses Etc 1 Loose parts 2 Imperfect seal at gaskets push rod cover washers etc To aid locating leaks use BLACK LIGHT LEAK DETECTOR Part No HD 35457 3 Restricted oil return line to tank 4 Restricted breather passage s to air cleaner ELECTRICAL SYSTEM Alternator Does Not Charge Regulator rectifier module not functioning Rectifier not grounded Engine ground wire loose or broken Loose or broken wires in charging circuit Stator not functioning Rotor not functioning oo a ON S Alternator Charge Rate Is Below Normal Regulator rectifier module not functioning Stator not functioning Rotor not functioning Weak battery Loose connections oe A NS FUEL Carburetor Floods Excessive pumping of throttle control grip Inlet valve sticking Inlet valve and or valve seat worn or damaged Dirt or other foreign matter between valve and its seat Float mis
23. f 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 Check throttle cable adjustment Before every ride At every scheduled service interval Check throttle cable adjustment with engine running Turn handlebars through full range of travel If engine speed changes during this maneuver adjust throttle cables as fol lows 1 Remove air cleaner See AIR CLEANER REMOVAL in Section 4 2 See Figure 1 41 Slide rubber boot 4 off cable adjusters 3 3 Loosen jam nut on each adjuster NOTE 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 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
24. gear disengage clutch and push vehicle back and forth a few times to ensure proper clutch disengagement Improper clutch disengagement could result in personal injury 1 Remove and inspect spark plugs Replace if necessary 2 Clean air filter element and lubricate if necessary 3 If fuel tank was drained fill fuel tank with fresh gasoline 4 If oil feed line was pinched off or plugged unplug it and reconnect 5 Start the engine and run until it reaches normal operating temperature Check fluids and refill to proper levels if required a Check engine oil level b Check the transmission lubricant level 6 Perform all of the checks in the PRE RIDING CHECK LIST in the Owner s Manual 1 35 TROUBLESHOOTING GENERAL The following check list can be helpful in locating most operating troubles Refer to the appropriate sections in this Service Manual for detailed procedures ENGINE Starter Motor Does Not Operate or Does Not Turn Engine Over 1 Engine stop switch in OFF position 2 Ignition key switch not ON 3 Discharged battery or loose or corroded connections Solenoid chatters 4 Starter control relay or solenoid not functioning 5 Electric starter shaft pinion gear not engaging or over running clutch slipping Engine Turns Over But Does Not Start eS Fuel tank empty Fuel supply valve turned OFF Fuel supply valve or filter clogged Discharged battery loose or broken battery terminal conn
25. hould take 3 5 5 5 Ibs 1 6 2 5 kg to pull front wheel to center NOTE Check that clutch and throttle cables do not bind when mea suring bearing resistance 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 See FORK STEM AND BRACKET ASSEMBLY in Section 2 for lubrication procedure ADJUSTMENT 1 Raise front wheel off floor using FRONT WHEEL SUP PORT STAND Part No B 41395 and S1 LIFT ADAPTER Part No B 41686 Turn front wheel to full right lock See Figure 1 32 Hook spring scale into front axle hole Pull front wheel to center position It should take 3 5 5 5 los 1 6 2 5 kg to pull front wheel to center Loosen pinch screws 7 on upper and lower triple clamps See Figure 1 33 Tighten or loosen fork stem bolt 1 to set proper tension Recheck tension using spring scale See Step 3 Tighten triple clamp pinch screws 7 to 18 20 ft lbs 24 4 27 1 Nm 3 5 5 5 Ibs 1 6 2 5 kg b0031a2x Fork stem bolt Upper triple clamp Dust shield 2 Roller bearing 2 Bearing cup 2 Lower triple clamp Screw 5 Steering head lock Steering lock key Figure 1 33 Steering Head Assembly 1 25 FORK OIL CHANGE Replace fork oil Atevery 10 000 mile 16 000 km service interval If fork should be submerged in water 1 Remove and disassemble front forks See FRONT FO
26. lutch inspection b0190x6x r Torx screw with washer 4 a 2 P m cover Uu A z Drain plug Figure 1 15 Primary Cover Clutch adjusting screw s W Quad ring S Diaphragm spring Lubricant level Figure 1 16 Lubricant Level New style Old style Figure 1 17 Ramp Change ADJUSTMENT Check clutch adjustment lt Atthe 500 mile 800 km service interval At every 5000 mile 8000 km service interval thereafter If clutch slips under load or drags when released first check control cable adjustment If cable adjustment is within specifi 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 See Figure 1 18 Slide rubber boot 1 upward to expose adjuster mechanism Loosen jam nut 3 from adjuster 4 Turn adjuster to shorten cable housing until there is a large amount of freeplay at clutch hand lever 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 place NOTE Quad ring removed from primary cover for illustrative pur poses only in Figure 1 19 4 Remove spring 4 and adjusting screw lockplate 5 Turn adjusting screw counterclockwise until it lightl
27. ng See IGNITION TIMING on 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 a On world models idle speed is 950 1050 RPM b On California models idle speed is 1150 1250 RPM 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 RPM should decrease Connect V O E S vacuum hose to carburetor fitting Tim ing mark should reappear and engine speed should increase to previous RPM 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 See Figure 1 45 Connect two ohmmeter leads to the two V O E S leads Connect vacuum pump to V O E S vacuum fitting 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
28. nnect cables to the proper terminals POISON CAUSES SEVERE BURNS Contains sulfuric acid Avoid contact with skin eyes and clothing In event of accident flush with water and call a physician immediately KEEP OUT OF REACH OF CHILDREN Figure 1 5 Battery Warnings b0188x0x 12 9 12 6 12 3 Open Circuit Volts State of Charge Figure 1 6 Open Circuit Voltage vs State of Charge No Charge Last 24 Hours Table 1 3 Charging Rates OPEN CIRCUIT VOLTAGE 12 00 to 11 40 to 12 66 Volts 11 99 Volts CHARGER OUTPUT CURRENT RATE Less than 11 40 Volts 48 hours 24 hours REMOVAL AWWARNING _ To avoid accidental start up of vehicle and possible per 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 tive cable installed the resulting sparks may cause a bat tery explosion producing personal injury AACAUTION See Figure 1 8 Hold battery cable when loosening bat tery terminal hardware Failure to hold cable will cause _ battery damage 1 Disconnect battery cables negative cable first 2 Remove battery strap locknut using 7 16 in flex socket SNAP ON Part No TMU141 and handle SNAP ON Part No TM62B NOTE On California models detach carbon canister from bracket before removing battery 3 Remove battery from left side INSTALLATION 1 Clean cable
29. ocknut to 20 25 ft lbs 27 1 33 9 Nm 1 22 2 83 Primary chain inspection cover b0085x6x Front sprocket Rear sprocket Figure 1 25 Measuring Primary Chain Tension Figure 1 26 Primary Chain Adjustment REAR PRELOAD ADJUSTMENT GENERAL Adjust rear preload When anew rider buys the motorcycle When there is a change in load luggage etc ON i BE _ Rear turn signal Before changing front fork or rear shock suspension ie 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 a on the S1 Lightning Improper preload will adversely affect siroaa Rear axle nut both the handling and motorcycle ride Correct preload set B ting will result in motorcycle handling that suits the rider s size and weight ADJUSTMENT 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 2 Remove all accessories from motorcycle including tank bag and or saddlebags 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 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 cycle 5 Install
30. or using REAR WHEEL 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 3 See Figure 1 15 Position a suitable container under transmission lubricant drain plug Remove drain plug and drain lubricant 4 Remove foreign material from magnetic drain plug Reinstall plug and tighten to 14 21 ft lbs 19 28 Nm 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 from primary cover AACAUTION Do not overfill the primary chaincase with lubricant Overfilling may cause rough clutch engagement and incomplete disengagement or clutch drag 6 Add SPORT TRANS FLUID Part No 98854 96 quart size Part No 98855 96 gallon size as required until lubricant is even with bottom of clutch diaphragm spring See Figure 1 16 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 possible contact between the coupler and the primary cover _ C
31. ow 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 2 Wash element in luke warm water with a mild detergent Dry the filter element using low pressure 32 psi 221 kPa 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 Tighten to 6 8 ft lbs 8 1 10 8 Nm 1 28 1 2 N as zy Screw and nylon washer Screw nylon washer and locknut Figure 1 39 Air Cleaner Cover Ni a Filter element Filter box Snorkel tube Figure 1 40 Snorkel Tube CARBURETOR CABLE ADJUSTMENT AwarninG 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 o
32. paced 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 WARNING 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 Check headlamp beam for proper height and lateral align ment as follows 1 Verify correct front and rear tire inflation pressure See TIRES AND WHEELS on page 1 18 2 Place motorcycle on level floor or pavement in an area 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 6 Stand motorcycle upright with both tires resting on floor and with front wheel held in straight alignment directly forward 7 Turn ignition switch to IGN Set handlebar headlamp switch to H
33. 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 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 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 w F off spark plug deposits at regular intervals VA Tighten to 11 18 4 If the plugs require cleaning between tune ups proceed i bids carnal lt as follows A E q a Degrease firing end of spark plug using ELECTRI
34. rimary chain moved by rotating engine to a different position on sprockets 4 Check primary chain tension against Table 1 7 If neces sary adjust as described below NOTE Measurements are taken with sprockets rotated to tight est chain position 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 adjustment using non factory equipment and methods Table 1 7 Primary Chain Tension ENGINE TEMPERATURE FREEPLAY Cold 3 8 1 2 in 9 5 12 7 mm Hot normal running temperature 1 4 3 8 in 6 4 9 5 mm 5 Install primary chain inspection cover Tighten screws to 40 60 in Ibs 4 5 6 8 Nm ADJUSTMENT NOTE 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 l
35. terval Check for proper front and rear tire pressures when tires are cold Compare pressure against Table 1 6 Table 1 6 Tire Pressures PRESSURE FOR SOLO RIDING PRESSURE TIRE AND POSITION AT GVWR Front Dunlop Sportmax 32 PSI 36 PSI Radial Il 120 70 ZR 17 2 2 bar 2 5 bar Rear Dunlop Sportmax 36 PSI 38 PSI Radial Il 170 60 ZR 17 2 5 bar 2 8 bar WHEEL BEARINGS Check wheel bearings Every time the wheel is removed Atevery 10 000 mile 16 000 km service interval When storing or removing the motorcycle for the season Check wheel bearings and axle spacers for wear and corro sion Excessive play or roughness indicates worn bearings Replace bearings in sets only SPEEDOMETER CABLE Check speedometer cable Inspect before every ride Lubricate at every 5000 mile 8000 km service interval Examine speedometer cable housing outer sheath for kinks or other damage Replace entire cable assembly if any dam age is noted Lubricate inner cable with a good quality graphite grease Wipe off excess grease CLUTCH TRANSMISSION FLUID Check transmission fluid Replace at the 500 mile 800 km service interval Inspect level at every 2500 mile 4000 km service interval Replace at every 5000 mile 8000 km service interval Primary chaincase lubricant capacity is approximately 1 0 quart 0 95 liter For best results drain lubricant while hot 1 Raise rear of vehicle off the flo
36. ttery nearly discharged Damaged wire or loose connection at battery terminals or coil 9 Intermittent short circuit due to damaged wire insulation 10 Water or dirt in fuel system and carburetor or filter 11 Fuel tank filler cap vent plugged or carburetor float bowl vent closed off 12 Carburetor controls improperly adjusted 13 Air leak at intake manifold or air filter 14 Damaged intake or exhaust valve 15 Weak or broken valve springs 16 Incorrect valve timing Sto aS eS a Spark Plug Fouls Repeatedly 1 Incorrect spark plug 2 Piston rings badly worn or broken 3 Fuel mixture too rich for conditions see CARBURETOR TROUBLESHOOTING 4 Valve stem seals worn or damaged 5 Valve guides badly worn Pre Ignition or Detonation Knocks or Pings 1 Excessive carbon deposit on piston head or combustion chamber Incorrect heat range spark plug Spark plugs not firing Ignition timing advanced Fuel octane rating too low Intake manifold vacuum leak DPY NP Overheating Insufficient oil supply or oil not circulating Leaking valves Heavy carbon deposit Ignition timing retarded gt 2 Valve Train Noise Hydraulic lifter not functioning properly Bent push rod Cam cam gears or cam bushings worn Rocker arm binding on shaft Valve sticking in guide oe eS a Excessive Vibration 1 Engine tie bars loose broken or improperly spaced 2 Lower mounting bolts loose 3 Brok
37. ubbles are purged 6 Tighten bleeder valves a Front bleeder valve to 4 6 ft lbs 5 4 8 1 Nm b Rear bleeder valve to 6 9 ft lbs 8 1 12 2 Nm 7 Verify master cylinder fluid level as described in Step 2 8 Tighten master cylinder reservoir cover screws to 9 13 in lbs 1 0 1 5 Nm Install cover on rear reservoir Bleeder valve metric Protective cap removed Figure 1 14 Rear Brake Caliper Bleeder Valve PADS ROTORS AND LINKAGE Check brake pads and rotors for minimum thickness See Table 1 5 See Section 2 for replacement procedures Atthe 500 mile 800 km service interval At every service interval thereafter Check rear brake pedal height and freeplay See Table 1 5 See Section 2 for adjustment procedures Before every ride At the 500 mile 800 km service interval At every 5000 mile 8000 km service interval thereafter Table 1 5 Brake System Components SPECIFICATION FRONT REAR O Minimum rotor thickness 0 17 in 0 19 in 4 4 mm 4 8 mm Minimum pad thickness 1 16 in 1 6 mm 1 8 in 8 2 mm maximum Hand lever pedal freeplay TIRES AND WHEELS TIRE INFLATION AwaRNING 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 Check tire pressure and tread Before every ride Atthe 500 800 km mile service interval At every scheduled service in
38. y bot toms Turn clutch adjusting screw 6 clockwise 1 4 turn Install lockplate 5 and spring 4 on adjusting screw flats If hex on lockplate does not align with recess in outer ramp rotate adjusting screw clockwise until it aligns Squeeze clutch lever to maximum limit three times to set ball and ramp mechanism Pull outer cable conduit and at the same time adjust cable adjuster to provide 1 16 1 8 in 1 6 3 2 mm freeplay at hand lever Adjust as follows 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 in 1 6 3 2 mm 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 Change or add transmission fluid if necessary Install clutch inspection cover 2 Tighten TORX screws with washers 1 in a crosswise pattern to 7 9 ft lbs 9 12 Nm Check clutch cable freeplay See Step 6 above 1 20 1 Rubber boot 3 2 Cable end Jam nut Adjuster b0152x6x 1 Torx screw with washer 4 Spring 2 Clutch inspection cover 5 Lockplate 3 Quad ring 6 Adjusting screw Figure 1 19 Clutch Release Mechanism Adjust for 1 16 1 8 in 1 6 3 2 mm gap between ferrule and bracket REAR BELT DEFLECTION INSPECTION Check rear belt deflection Inspect before every ride Adjust at the 500 mile 80
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