Buell Lightning X1 (1999-2000) - Service Manual - Repair Manual

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BUELL LIGHTNING X1 (1999-2000) - SERVICE MANUAL


- English Service Manual to Buell Lightning X1 (1999-2000)


INDEX:


Intro

- maintenance
- chassis
- engine
- fuel system
- electric starter
- drive/transmission
- electrical
- 1999 information
- appendix

Section i–maintenance

- specifications
- side views
- fluid requirements
- general
- united states system
- metric system
- steering head bearing grease
- brake fluid
- front fork oil

- fuel
- engine oil
- table 1. Recommended oil grades
- primary drive/transmission lubricant
- clutch
- model year change
- rear preload adjustment
- general
- adjustment
- ignition timing
- model year change

Section ii–chassis

- vehicle identification number
- model year change
- front wheel
- model year change
- removal/installation
- front brake caliper
- tool information
- swingarm
- model year change
- assembly
- installation

Section iii–engine

Section iv–fuel system

- remote idle adjuster
- general
- removal
- installation
- table 2. Engine idle speed
- air cleaner
- model year change
- removal
- installation

Section v–electric starter

- starting system diagnosis

Section vi–drive/transmission

Section vii–electrical

- handlebar switches
- model year change
- right handlebar switch
- left handlebar switch
- starter interlock system
- inspection
- starter circuit
- ignition circuit
- horn
- model year change
- removal
- installation
- wiring harness
- model year change
- table 3. Electrical connectors

Foreword

- general
- how to use your service manual supplement
- preparation for service
- service bulletins

- use genuine replacement parts
- product references
- kent-moore products
- sealing and threadlocking products
- contents
- warnings and cautions

General

- servicing a new motorcycle
- safe operating maintenance
- shop practices
- repair notes
- safety
- removing parts
- cleaning
- disassembly and assembly
- repair and replacement procedures
- hardware and threaded parts
- wiring, hoses and lines
- instruments and gauges
- bearings
- bushings
- gaskets
- lip type seals
- o-rings (preformed packings)
- gears
- shafts
- part replacement
- cleaning
- part protection
- cleaning process
- rust or corrosion removal
- bearings
- tool safety
- air tools
- wrenches
- pliers/cutters/prybars
- hammers
- punches/chisels
- screwdrivers
- ratchets and handles
- sockets
- storage units

1996 s1 lightning specifications

Side views

Fluid requirements

- general
- united states system
- metric system
- steering head bearing grease
- brake fluid
- front fork oil
- fuel
- engine oil
- table 1-1. Recommended oil grades
- primary drive/transmission lubricant

Battery

- general
- charging
- table 1-3. Charging rates
- removal
- installation

Engine lubrication system

- checking engine oil level
- table 1-4. Recommended oil grades
- changing engine oil and filter

Brakes

- general
- bleeding brakes
- pads, rotors and linkage
- table 1-5. Brake system components

Tires and wheels

- tire inflation
- table 1-6. Tire pressures
- wheel bearings
- speedometer cable

Clutch

- transmission fluid
- production change
- adjustment

Rear belt deflection

- inspection
- adjustment
- cleaning

Primary chain

- inspection
- table 1-7. Primary chain tension
- adjustment

Rear preload adjustment

- general
- adjustment

Suspension

- adjustment
- table 1-8. Suspension settings
- rear shock

Front fork

- steering head bearings
- lubrication
- adjustment
- fork oil change

Spark plugs

- inspection

Air cleaner filter

- removal
- installation

Carburetor

- cable adjustment
- idle adjustment

Ignition timing

- inspection
- adjustment

Vacuum-operated electric switch (v.o.e.s)

- adjustment/testing
- timing mark method
- ohmmeter and vacuum pump method

Handlebars

- inspection
- adjustment

Headlamp

- inspection
- adjustment

Storage

- general
- removal from storage

Troubleshooting

- general
- engine
- starter motor does not operate or does not turn en- .
- engine turns over but does not start
- starts hard
- starts but runs irregularly or misses
- spark plug fouls repeatedly
- pre-ignition or detonation (knocks or pings)
- overheating
- valve train noise
- excessive vibration
- engine lubrication system
- oil does not return to oil tank
- engine uses too much oil or smokes excessively
- engine leaks oil from cases, push rods, hoses, etc- .
- electrical system
- alternator does not charge
- alternator charge rate is below normal
- fuel
- carburetor floods
- transmission
- shifts hard
- jumps out of gear
- clutch
- slips
- drags or does not release
- chatters
- chassis
- irregular/inadequate brake action
- handling irregularities

Specifications

- torque values

Tire specifications

- general
- table 2-1. Tire fitment – tubeless cast marchesini- .
- table 2-2. Tire fitment – tubeless aluminum p/m wh- .

Vehicle identification number

- general

Wheels

- general
- troubleshooting
- table 2-3. Wheel service

Front wheel

- removal
- disassembly
- cleaning, inspection and repair
- assembly
- installation

Rear wheel

- removal
- disassembly
- cleaning, inspection and repair
- assembly
- installation

Checking cast rim runout

- general
- rim lateral runout
- rim radial runout
- table 2-4. Wheel runout

Tires

- general
- removal
- cleaning, inspection and repair
- adjustment
- wheel balancing

Brakes

- general
- table 2-5. Brake troubleshooting

Front brake master cylinder

- removal
- installation

Front brake caliper

- removal/disassembly
- cleaning, inspection and repair
- assembly
- installation

Front brake line

- installation

Rear brake master cylinder

- adjustment
- brake pedal
- removal/disassembly
- cleaning, inspection and repair
- assembly/installation

Rear brake caliper

- removal/disassembly
- cleaning, inspection and repair
- assembly
- installation

Rear brake line and switch

- removal
- installation

Front fork

- general
- removal
- disassembly
- cleaning, inspection and repair
- assembly
- installation

Fork stem and bracket assembly

- cleaning, inspection and repair
- assembly/installation

Swingarm

- removal
- disassembly
- cleaning/inspection
- assembly
- installation

Rear shock absorber

- general
- removal
- disassembly
- assembly
- installation

Suspension theory

- definitions
- general

Suspension adjustments

- rear shock preload
- adjustments
- rear suspension adjustments
- front suspension adjustments
- troubleshooting
- table 2-6. Factory recommended table 2-6. Suspensi- .
- table 2-7. General suspension problems
- table 2-8. Rear suspension problems
- table 2-9. Front suspension problems
- table 2-10. Rider suspension preferences

Throttle control

- removal/disassembly
- cleaning, inspection and repair
- assembly/installation

Clutch control

- adjustment
- removal/disassembly

Speedometer and tachometer

- general

- removal
- speedometer
- tachometer
- instrument support
- installation
- speedometer
- tachometer
- instrument support
- speedometer cable

Handlebar

- removal
- installation

Exhaust system

- removal/disassembly
- muffler
- exhaust header
- assembly/installation
- muffler
- exhaust header

Footrests

- removal
- installation

Sprocket cover

- removal/disassembly
- assembly/installation

Fenders

- removal/installation
- front fender
- rear fender/lower belt guard
- frame heat shield

Tail section

- removal
- installation

Windscreen

- removal
- installation

Seat

- removal
- installation

Side stand

- general
- removal/disassembly
- assembly/installation

Specifications

- torque values

Engine

- general
- cylinder
- crankcase
- gearcase
- fuel
- gasoline/alcohol blends
- lubrication
- adjustment/testing
- general
- compression test procedure
- table 3-1. Compression test results
- cylinder leakage test
- table 3-2. Air leakage test
- diagnosing smoking engine or high oil consumption

Stripping motorcycle for engine repair

- disassembling engine for cylinder head repair
- removing engine crankcase or complete engine

Installing the engine

- engine crankcase installation
- engine installation after cylinder head repair

Cylinder head

- removal
- disassembly
- cleaning, inspection and repair
- rocker arms and bushings
- replacing valve guides
- table 3-3. Valve stem clearances
- grinding valve faces and seats
- replacing valve seats
- lapping valve faces and seats
- assembly
- installation
- table 3-4. Push rod selection table
- table 3-5. Rocker arm cover hardware

Cylinder and piston

- removal/disassembly
- cleaning, inspection and repair
- checking gasket surface
- measuring cylinder bore
- table 3-6. 1200cc cylinder bore…
- measuring piston
- fitting cylinder to piston
- boring and honing cylinder
- table 3-7. Final cylinder bore sizes
- fitting piston rings
- connecting rod bushing
- assembly/installation

Lubrication system

- checking and adding oil
- changing oil and filter
- winter lubrication

Oil hose routing

- general

Oil tank

- removal/disassembly
- assembly/installation

Oil pressure signal light switch

- general
- oil pressure signal light
- oil pressure
- table 3-8. Troubleshooting oil- .

Crankcase breathing system

- general

Oiling system (color foldout)

Oil pump

- general
- removal/disassembly
- cleaning, inspection and repair
- assembly/installation

Oil filter mount

- general
- disassembly
- cleaning/inspection
- assembly


Valve tappets

- general
- removal
- cleaning/inspection

Valve tappets

- installation

Gearcase cover and cam gears

- general
- removal/disassembly
- cleaning, inspection and repair
- cam and pinion gear identification, inspection, an- .
- table 3-9. Cam and pinion gear color code and diam- .
- bushing inspection and removal
- table 3-10. Gear shaft specifications
- bushing installation
- bushing reaming
- assembly/installation

Crankcase

- general
- adjustment/testing
- flywheel end play
- table 3-11. Flywheel end play - .
- disassembly
- crankcase halves
- flywheels
- cleaning/inspection
- replacing flywheel washers
- lapping connecting rod races
- fitting rod bearings
- table 3-12. Race diameter- .
- fitting sprocket bearings
- fitting pinion bearings
- table 3-13. Pinion shaft bearing selection
- lapping engine main bearing races
- assembly
- flywheels
- crankcase halves

Internal engine passages

Specifications

- torque values

Carburetor

- general
- table 4-1. Fuel system troubleshooting
- table 4-1. Fuel system troubleshooting (cont.)
- table 4-2. Vacuum piston assembly troubleshooting
- operation
- enrichener
- fuel supply system
- starting circuit
- idleand low-speed circuit
- mid-range slide position
- high-speed circuit slide position
- accelerator pump system
- adjustment
- idle
- enrichener control
- float level
- operation check – vacuum piston
- opening malfunction
- closing malfunction
- removal
- carburetor
- carburetor manifold
- disassembly
- vacuum piston chamber
- carburetor body
- accelerator pump
- cleaning, inspection and repair
- vacuum piston components
- accelerator pump
- assembly
- vacuum piston chamber
- carburetor body
- accelerator pump
- installation
- carburetor manifold
- carburetor
- carburetor drain hose routing

Air cleaner

- general
- removal
- installation

Fuel tank

- general
- removal
- disassembly/assembly
- cleaning, inspection and repair
- installation

Fuel supply valve

- general
- removal
- cleaning, inspection and repair
- installation

Evaporative emissions control california models


- general
- troubleshooting
- removal
- vent valve
- canister
- installation
- vent valve
- canister
- hose routing
- carburetor
- canister hose routings

Specifications

- torque values

Electric starter system

- general
- wiring diagrams
- starter relay
- operation
- table 5-1. Troubleshooting
- table 5-1. Troubleshooting (continued)

Starter activation circuits

Diagnostics/troubleshooting

- general
- voltage drops

Starter system testing

- “on-motorcycle” tests
- starter relay test
- starter current draw test

Starter

- removal
- testing assembled starter
- starter solenoid
- solenoid pull-in test

Starter

- testing assembled starter
- solenoid hold-in test
- solenoid return test
- disassembly, inspection and repair
- assembly
- installation

Starter solenoid

- general
- disassembly
- assembly

Specifications

- torque values

Primary chain

- general
- adjustment/lubrication
- removal
- primary cover
- primary chain adjuster
- installation
- primary chain adjuster
- primary cover

Secondary drive belt

- general
- removal
- installation

Clutch

- general
- table 6-1. Clutch troubleshooting

Clutch release mechanism

- adjustment
- disassembly
- cleaning, inspection and repair
- assembly

Primary drive/clutch

- removal
- disassembly
- inspection/repair
- assembly
- installation

Transmission

- general
- lubrication

Transmission case

- general
- removal
- cleaning, inspection and repair
- neutral indicator switch

Shifter forks and drum

- disassembly
- cleaning, inspection and repair
- assembly

Mainshaft and countershaft

- disassembly
- cleaning, inspection and repair
- assembly

Main drive gear

- removal
- disassembly
- assembly
- installation

Access door bearings

- removal
- mainshaft and countershaft bearings
- shift drum bushing
- installation
- mainshaft and countershaft bearings
- shift drum bushing

Right transmission case bearings

- removal
- installation
- mainshaft 5th gear ball bearing
- countershaft needle bearing
- shift drum needle bearing

Transmission installation and shifter pawl adjustm- .

Specifications

- torque values

Ignition system

- general
- ignition module
- vacuum-operated electric switch
- rotor and sensor plate
- troubleshooting
- check for ignition spark
- no ignition spark
- continuous or no spark at plug
- intermittent ignition problem–vibration
- intermittent ignition problem–temperature
- ignition resistance test–ignition module
- ignition resistance test–ignition module harness

Vacuum-operated electric switch (v.o.e.s)

- adjustment/testing
- removal
- installation

Ignition/headlamp switch

- general
- removal
- table 7-1. Ignition positions
- table 7-2. Indicator markers
- installation

Ignition module

- general

- removal
- installation

Ignition sensor plate and rotor

- general
- removal
- installation

Ignition coil

- general
- troubleshooting
- table 7-3. Ignition coil winding resistance
- removal
- installation

Spark plug cables

- general
- removal
- inspection
- installation

Starter interlock

- general
- starter circuit
- ignition circuit
- table 7-4. Starter interlock troubleshooting
- testing/replacement
- side stand switch
- clutch switch

- diodes
- ignition relay
- starter relay
- main circuit breaker
- ignition fuse

Charging system

- general
- alternator
- voltage regulator
- troubleshooting
- battery
- wiring
- voltage regulator inspection
- charging system troubleshooting
- testing
- voltage regulator bleed test
- milliampere draw test
- total current draw test
- current and voltage output test
- voltage output test
- stator check
- ac output check

Alternator

- removal/disassembly
- rotor
- stator
- cleaning, inspection and repair
- assembly/installation

Voltage regulator

- general
- removal
- installation

Battery

- general

Headlamp

- removal
- headlamp and bulbs
- headlamp housing and brackets
- installation
- headlamp brackets and housing
- headlamp and bulbs

Tail lamp

- removal/disassembly
- tail lamp
- tail lamp bracket
- assembly/installation
- tail lamp bracket
- tail lamp

Turn signals

- removal
- front
- rear
- installation
- front
- rear

Turn signal flasher

- removal
- installation

Handlebar switches

- removal
- right side
- left side
- installation
- right side
- left side

Horn

- removal
- installation
- troubleshooting

Neutral indicator switch

- general
- testing
- removal/installation

Fuses and circuit breakers

- general
- fuses
- circuit breakers

Electrical connectors

- general
- table 7-5. Electrical connectors

Deutsch electrical connectors

- general
- removing/installing sockets
- removing/installing pins
- assembly/installation
- crimping instructions

Amp multilock electrical connectors

- removing socket/pin terminals
- installing socket/pin terminals
- crimping instructions

Wiring diagram

Metric conversions

- table b-1. Metric conversions

Fastener torque values

- table b-2. English torque values
- table b-3. Metric torque values