Aluminum bushings from front exhaust mount. Pressure Plate Assembly 8815 Adjusting screw assembly Retaining ring Tab recesses Figure 6-20. Plastic materials that do not breathe promote the formation of condensation. Install connector on retaining device, either attachment or rosebud clip. Wire Harness Connectors in Figure 4-43. Tighten switch to 36-60 in-lbs 4-6. Push on wire end of lead to remove terminal.
Chin Fairing Assembly, Right Rear Fasteners Install chin fairing. Cylinder Head, Cylinder and Piston Assembly 3-48 2004 Buell Lightning: Engine. Repeat Steps 4-11 for the remaining valve. Remove swingarm brace by removing fasteners. Shock spring retainer kit Lower shock mount sleeve 12.
Fairing Support Bracket Assembly 2004 Buell Lightning: Chassis 2-69. Fastener with washer metric Positive battery cable ring terminal Solenoid wire Figure 5-9. Remove exhaust header 2 by removing mounting fasteners 3. Clutch diaphragm spring Clutch adjusting screw Primary cover Correct chaincase lubricant level Figure 1-21. B-42887 Brake Caliper Piston Remover Part No. Fastener with washer Positive battery cable Figure 7-40.
If horn switch is faulty, replace left handlebar switch. Starter Components 2004 Buell Lightning: Starter 5-15. Base plate assembly Interactive exhaust cable 15. Remove damper locknut 10 from damper rod assembly 11. Recheck operation of throttle control.
Rear master cylinder body Install new cotter pin 7. Left and right front modules Figure 2-95. Just print out the section you need and throw it away when you are done! Intake Air Temperature Sensor Circuit Table 4-23. Belt Guard Assembly 2004 Buell Lightning: Chassis 2-81. A new pulley wheel must be installed.
Advanced Timing b0963x1x Figure 1-51. Rear Brake Pedal Pushrod Adjustment 1-18 2004 Buell Lightning: Maintenance. Mainshaft Thrust washer Thrust washer Split bearing 10. Countershaft 4th Countershaft 1st Thrust washer 15. Refer to wiring diagrams for more information. Rear caliper mounting fasteners Retainer, Rear caliper pin plug Rear caliper hanger pin Figure 1-16. Lower Bearing 2-54 2004 Buell Lightning: Chassis.
Ring gaps are not to be within 10° of the thrust face centerline. This manual contains maintenance and repair details: - Mechanical specifications of the vehicle - Technical specifications of the vehicle - Introductory Mechanics - Equipment elevation - Collisions - Products and supplies - Painting. This file holds of high quality diagrams and instructions on how to service and repair your Buell. Valve guide brush Part No. Sidestand Assembly Extended 2004 Buell Lightning: Engine 3-23.
Pull-in winding Starting circuit-see 11. Pivot end of pin to depress tang. This Service Manual has easy-to-read text sections with top quality diagrams and instructions. Exhaust valve seat Figure 3-65. B-45524 Valve Guide Installer Part No. Bearing closed end countershaft Figure 6-60.
Do not over tighten cable strap. Repeat process for remaining cylinder head. Speed should not exceed 50 mph 80 tire failure. Install clutch inspection cover and new Figure 1-24. All diagnostic Refer to diagnostic codes are listed on page 4-13 in Table 4-7. Gasket push rod cover 21. Clutch Cable Wire form and clutch adjuster.