SECTION IV–FUEL SYSTEM SUBJECT 1. 2. PAGE NO. Remote Idle Adjuster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 This section explains procedures unique to 1997 model S1 Lightnings. Any procedures not found in this supplement are covered in the 1996 S1 Lightning Service Manual (Part No. 99490-96Y).
NOTES 20
REMOTE IDLE ADJUSTER GENERAL b0291xox See Figure 16. The remote idle adjuster allows idle adjustments without use of tools. Idle speeds are listed in Table 2. Increase idle speed REMOVAL 1. Remove seat and fuel tank. See FUEL TANK, REMOVAL in Section 4 of the 1996 manual. 2. Remove cable strap holding adjuster to frame. 3. See Figure 17. Unthread adjuster assembly from bracket (4). Remove spring (3) and washer (2).
AIR CLEANER MODEL YEAR CHANGE 5705 1 All 1997 model year motorcycles use a modified air cleaner assembly. The new design increases serviceability. REMOVAL 1CAUTION Do not run engine without filter element in place. Debris could be drawn into the engine causing damage. 1. See Figure 19. Remove screw and nylon washer (1) on top of air cleaner cover. 2. Remove screw and locknut (2) at rear of air cleaner cover. 3. See Figure 20. Remove cover (3) with attached filter box (2) and filter (1). 4.
INSTALLATION 1. 5884 Install backplate. a. Apply HYLOMAR to threads of breather bolts. b. Install air cleaner support ring and backplate using breather bolts. Tighten breather bolts to 10-15 ft-lbs (13.6-20.3 Nm). c. Attach rear breather hose to rear breather bolt. 1 d. 2. See Figure 24. Install two bolts (1), washers (2) and nuts (3) through backplate into isolator mount. See Figure 21. Install breather hoses. a. Slide rear breather hose through backplate. b.
NOTES 24
SECTION V–ELECTRIC STARTER SUBJECT 1. PAGE NO. Starting System Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 This section explains procedures unique to 1997 model S1 Lightnings. Any procedures not found in this supplement are covered in the 1996 S1 Lightning Service Manual (Part No. 99490-96Y).
NOTES 26
STARTING SYSTEM DIAGNOSIS — BATTERY TESTS — ● ● VISUAL ● VOLTAGE LOAD Check Connections at Battery and Starter Components. INOPERATIVE Solenoid Clicks. Continued on Next Page Nothing Clicks. Relay Clicks. Perform Voltage Drop Tests Between Battery and “Relay” Terminal on Solenoid. Less Than 1 Volt? Test for Voltage at Solenoid Terminal. Is 12V Present When Starter Button is Pressed? NO YES NO YES 2 Perform Voltage Drop 2 Tests from Battery (Pos. +) to Starter “Motor”Terminal. Crank Engine.
Continued from Previous Page STARTER SPINS, BUT DOES NOT ENGAGE RUN-ON Disconnect Solenoid “Relay” Terminal from Solenoid. Is 12V Present at GN Wire Terminal with Starter Button NOT Pressed? Remove Starter. Disassemble Drive Housing Assembly. Inspect for Damage to Armature Gear or Idler Gear. Damage Present? YES NO Is 12V Present on Starter Relay Terminal 86 with Starter Button NOT Pressed? Replace Solenoid. YES NO Replace Starter Button. Replace Starter Relay.
SECTION VI–DRIVE/TRANSMISSION All drive/transmission procedures in the 1996 S1 Lightning Service Manual (Part No. 99490-96Y) apply to 1997 models.
NOTES 30
SECTION VII–ELECTRICAL SUBJECT 1. 2. 3. 4. PAGE NO. Handlebar Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTES 32
HANDLEBAR SWITCHES MODEL YEAR CHANGE b0279x7x All 1997 model year motorcycles use new handlebar switches. The switches feature new icons, connectors and a different pin numbering sequence. Ignition ON NOTE All HANDLEBAR SWITCHES, REMOVAL and HANDLEBAR SWITCHES, INSTALLATION procedures remain the same. The new switch assemblies are interchangeable between 1996 and 1997 models if the corresponding connector on the wiring harness is changed.
STARTER INTERLOCK SYSTEM INSPECTION NOTE The starter interlock system is designed to prevent unintended start-up and/or forward motion of the motorcycle with the vehicle’s side stand not retracted. Use the following two tests to check the system for proper operation. The STARTER CIRCUIT and IGNITION CIRCUIT tests should be performed in one continuous operation.
Ignition Circuit Remove W/BK wire from ignition coil. Connect a test light or voltmeter to the vehicle. a. Attach one end to W/BK wire terminal. b. Attach the other end to vehicle ground. Turn ignition switch to IGN. Set engine stop switch to RUN. Place motorcycle in neutral. Is current present? YES Check neutral switch and circuit. See NEUTRAL INDICATOR SWITCH in Section 7 of the 1996 manual. Repeat entire ignition portion of interlock circuit test when finished. NO Place motorcycle in first gear.
HORN MODEL YEAR CHANGE 5882 See Figure 27. All 1997 model year motorcycles have a new horn in a new location. NOTE For troubleshooting information, see HORN, TROUBLESHOOTING in Section 7 in the 1996 manual. REMOVAL 1. Remove seat and fuel tank. See FUEL TANK, REMOVAL in Section 4 of the 1996 manual. 2. See Figure 28. Detach horn wires. 3. a. Disconnect Y/BK power wire (5). b. Disconnect BK ground wire (6). Remove bolt (1), lockwasher (2) and washer (3) to detach horn and bracket from frame.
WIRING HARNESS MODEL YEAR CHANGE The following changes were made to the wiring harness for 1997 model year motorcycles. ● New connectors and a different pin numbering sequence for the right handlebar switch [P1] and the left handlebar switch [P6]. See HANDLEBAR SWITCHES on page 33. ● Longer wires leading to the horn to accommodate the new mounting position. Table 3.
38 b0245a7x BN BK RIGHT TURN FLASHER VACUUM SWITCH OIL PRESSURE TIMER AND PICKUP BK BK O/W HIGH BEAM W BK LEFT TURN V BK P7 2 1 BK R/W Y/BK HORN V/BN TN O BK V/W NEUTRAL BK V/W GN/W PK R/W BK/W W/BK SPEEDOMETER ELECTRONIC IGNITION GN/Y O O/W BK/W R/Y GN/Y TN GN/W IGN POWER IGN MODULE FROM (2) TO STARTER BE W/R GN/BK Y/R GY W/BK W/BK BK/R 4 3 2 1 P2 ACC POWER O/W TO STOPLIGHT R/Y O/W W/GN BK O PK TACHOMETER O/W R/Y 1 2 R/Y 8 7 6 5 4 3 2 1 BK V/W GN/W PK R/W BK/W W/BK
