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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