2 SPECIFICATIONS DIMENSIONS IN. MM 55 1397 Overall Length 79.5 Overall Width Wheel Base Seat Height CHASSIS U.S. LITERS Fuel Tank (including reserve) 4.0 gallons 15.14 2019 Reserve 0.6 gallons 2.27 30 762 Oil Tank 2.0 quarts 1.89 29.5 749 Transmission 1.0 quart 0.95 IN. MM Road Clearance 5.2 132 Front Wheel Travel 4.7 119.4 Rear Wheel Travel 4.9 124.5 Trail 3.
ITEM Clutch cable, primary cover fitting TORQUE NOTES 3-5 ft-lbs 4-6.87 Nm turn clockwise to install, page 2-45 Clutch clamp screw 30-33 in-lbs 3.4-4.0 Nm metric, page 2-45 Drive support fastener 30-35 ft-lbs 40.7-47.4 Nm page 2-53 Exhaust manifold nuts 6-8 ft-lbs 8.1-10.8 Nm page 2-50 Fender mounting screw, lower 10-15 in-lbs 1.1-1.7 Nm page 2-54 Fender mounting screw, upper 20-25 in-lbs 2.3-2.8 Nm metric, page 2-54 Front axle nut 48-53 ft-lbs 65.1-71.
ITEM Rear axle nut TORQUE NOTES 66-73 ft-lbs 89.5-98.9 Nm metric, page 2-6, page 2-13 9.5-12.5 ft-lbs 12.9-17.0 Nm metric, page 2-26, page 2-27 Rear brake caliper bleeder valve 6-9 ft-lbs 8.1-12.2 Nm metric, page 2-26, page 2-27 Rear brake caliper mounting screw 18-22 ft-lbs 24.4-29.8 Nm metric, page 2-26 7-8 ft-lbs 9.5-10.8 Nm LOCTITE SEALANT WITH TEFLON, page 2-27 10-12 ft-lbs 13.6-16.2 Nm page 2-27 Rear brake reservoir mounting screw 12-15 in-lbs 1.4-1.
TIRE SPECIFICATIONS GENERAL 1WARNING Tires must be correctly matched to wheel rims. Only the tires listed in the fitment tables below can be used for replacement. Mismatching tires and rims can cause damage to the tire bead during mounting. Using tires other than those specified can adversely affect motorcycle handling and may result in personal injury. Tire sizes are molded on the sidewall. Rim size and contour are marked on the rim’s exterior surface. Example: MT 3.5 x 17.
VEHICLE IDENTIFICATION NUMBER GENERAL 5711 A 17-digit serial number, or Vehicle Identification Number (V.I.N.), is stamped on the right side of the steering head (ex., 4MZSS11J1T3200001). Also affixed to the steering head at this location is an information plate bearing the V.I.N. code. See Figure 2-1. An abbreviated V.I.N. is stamped on the front left side of the crankcase. NOTE Always give the V.I.N. or abbreviated V.I.N. when ordering parts or making inquiries about your Buell motorcycle. Figure 2-1.
WHEELS GENERAL b0195x2x Good handling and maximum tire mileage are directly related to the care of wheels and tires. Regularly inspect wheels and tires for damage and wear. If handling problems occur, check the TROUBLESHOOTING guide in Section 1 or see the table below for a list of probable causes. See TIRES AND WHEELS in Section 1. Keep tires inflated to the recommended air pressure. Always balance the wheel after replacing a tire.
1WARNING To prevent personal injury, use the following guidelines when installing a new tire or repairing a flat: 1. Always locate and eliminate the cause of the original tire failure. 2. Do not patch or vulcanize a tire casing. These procedures weaken the casing and increase the risk of a blowout. 3. The use of tires other than those specified can adversely affect handling resulting in personal injury. 4. Tires and wheels are critical safety items.
FRONT WHEEL REMOVAL 5680 1. See Figure 2-4. Raise front wheel off floor using FRONT WHEEL SUPPORT STAND (Part No. B-41395) and S1 LIFT ADAPTER (Part No. B-41686). 2. Remove front brake caliper. See FRONT BRAKE CALIPER, REMOVAL/DISASSEMBLY on page 2-20. NOTE Do not operate front brake lever with front wheel removed or caliper pistons may be forced out. Reseating pistons requires caliper disassembly. 3. See Figure 2-5.
b0196x2x 3 5 2 1 4 6 8 7 10 12 9 11 1. 2. 3. 14 20 21 13 18 16 15 19 17 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. Nut (metric) Washer Speedometer drive spacer Speedometer drive Left axle spacer Wheel bearing Wheel Valve stem Wheel weight Spacer Wheel bearing Right axle spacer Front axle Locknut (6) Front brake carrier Screw (5) Front brake rotor Brake drive pin (6) Screw (6) Spring washer (6) Washer (6) Figure 2-6.
INSTALLATION 1. Apply LOCTITE ANTI-SEIZE LUBRICANT to axle. 2. Position wheel between forks with brake rotor on right side of vehicle. With pinch screws (metric) loose, insert threaded end of axle through right side fork. Push axle through fork and wheel hub until axle begins to emerge from left side of hub. b0197x2x Speedometer drive tab Speedometer drive 1CAUTION Speedometer drive tab must be properly inserted or damage to the unit will occur. If drive tab is damaged, it must be replaced. 3.
REAR WHEEL REMOVAL 1. 5574 Raise rear wheel off floor using REAR WHEEL SUPPORT STAND (Part No. B-41174). 2. Remove rear fender. See FENDERS, REMOVAL/ INSTALLATION on page 2-54. 3. Remove rear brake caliper. See REAR BRAKE CALIPER, REMOVAL/DISASSEMBLY on page 2-25. Rear axle nut (metric) NOTE Do not operate rear brake pedal with rear wheel removed or caliper piston may be forced out. Reseating piston requires caliper disassembly. 4. See Figure 2-8. Loosen rear axle nut (metric). 5.
DISASSEMBLY 1. See Figure 2-10. Move wheel to bench area. On the brake rotor side of the wheel, remove bearing using BUSHING AND BEARING PULLER (Part No. HD95760-69A) and 1 1/8 in. COLLET (Part No. HD-9576969). 2. Remove two bearings from sprocket side of wheel. 3. See Figure 2-9. Remove four screws (1) (metric) to remove rear brake rotor (2) from hub. 4. Remove five bolts (17) and washers (16) on belt sprocket (15). Remove belt sprocket from wheel. 4878 CLEANING, INSPECTION AND REPAIR 1.
INSTALLATION 1. Place wheel centrally in the swingarm with the brake rotor in the caliper. Slide wheel far enough forward to slip belt over sprocket and then slide wheel back. 2. See Figure 2-9. Apply LOCTITE ANTI-SEIZE LUBRICANT to axle (3). 3. Insert axle (3) through washer (4), left side of swingarm, rear brake caliper mount, wheel assembly, spacer (11) and right side of swingarm. 4. Install washer (12), lockwasher (13), and axle nut (14) (metric) on right side of axle.
CHECKING CAST RIM RUNOUT GENERAL f1378x2x Check wheels for lateral and radial runout before installing a new tire. Wheel Truing and Balancing Stand (Part No. HD-99500-80) Rim Lateral Runout 1. See Figure 2-11. Install truing arbor in wheel hub and place wheel in WHEEL TRUING AND BALANCING STAND (Part No. HD-99500-80). 2. Tighten arbor nuts so hub will turn on its bearings. 3. Check rim lateral runout by placing a gauge rod or dial indicator near the rim bead.
TIRES GENERAL b0198x2x Tires should be inspected for punctures, cuts, breaks and wear at least weekly. 1WARNING Always check both tire sidewalls for arrows indicating forward rotation. Some tires require different tire rotation depending on whether tire is used on front or rear wheel. Installing a tire with the wrong rotation could result in personal injury. Some tires have arrows molded into the tire sidewall.
INSTALLATION ● ● b0087x2x 1WARNING Only install original equipment (stock) tire valves and valve caps. A valve or valve and cap combination that is too long may interfere with (strike) adjacent components, damage the valve and cause rapid tire deflation. Rapid tire deflation could cause loss of control and personal injury. Tire lateral runout 0.080 in. (2.
ADJUSTMENT Wheel Balancing Wheel balancing is recommended to improve handling and reduce vibration, especially at high road speeds. In most cases, static balancing using WHEEL TRUING AND BALANCING STAND (Part No. HD-99500-80) will produce satisfactory results. However, dynamic balancing, utilizing a wheel spinner, can be used to produce finer tolerances for best high-speed handling characteristics. Follow the instructions supplied with the balance machine you are using.
BRAKES 1WARNING GENERAL ● Clean brake system components using denatured alcohol. Do not use mineral-base cleaning solvents, such as gasoline or paint thinner. Use of mineralbase solvents causes deterioration of rubber parts that continues after assembly. This could result in improper and unsafe brake operation which may cause personal injury. ● Always test motorcycle brakes at low speed after servicing or bleeding system.
FRONT BRAKE MASTER CYLINDER REMOVAL 1 NOTE The front master cylinder contains no user serviceable parts. Do not remove the master cylinder unless problems are being experienced. Replace the entire assembly when necessary. 1. Remove mirror mounting hardware (metric, left hand threads). 2. Open bleeder nipple cap on front caliper. Install end of a length of plastic tubing over caliper bleeder valve, while placing free end in a suitable container. Open bleeder valve about 1/2-turn.
FRONT BRAKE CALIPER REMOVAL/DISASSEMBLY 5712 NOTE Step 1 (draining fluid) is not required for caliper removal. Drain brake fluid only when disassembling caliper. 1. See Figure 2-19. Remove banjo bolt (4) and gaskets to disconnect brake line from caliper. Drain brake fluid into a clean, suitable container. Discard gaskets. 2. Remove cotter and support pins (1). 3. Remove center caliper bolt (2) and spacer. 4. Remove brake pads from front brake caliper.
1WARNING When using air pressure to remove pistons from caliper, pistons may be ejected with considerable force. Wear safety glasses, heavy gloves and hold caliper with heavy towel to prevent personal injury. 5737 1CAUTION Exercise care to avoid dropping piston on hard surface. Any damage requires piston replacement. 9. See Figure 2-21. Use BRAKE CALIPER PISTON REMOVER (Part No. B-42079) to remove caliper pistons. 10. See Figure 2-20.
FRONT BRAKE LINE REMOVAL 1. b0203x2x Top right sidemaster cylinder Open bleeder nipple cap on front brake caliper. Install end of a length of plastic tubing over caliper bleeder valve, while placing free end in a suitable container. Open bleeder valve about 1/2-turn. Pump brake hand lever to drain brake fluid. 2. See Figure 2-22. Remove screw (4) to detach brake line clamp (5) from lower triple clamp (right side). 3. Slide brake line out of wire guide (6) on front fender. 4.
REAR BRAKE MASTER CYLINDER ADJUSTMENT 5569 Brake Pedal 1. See Figure 2-23. Brake pedal must have 1/8 in. (3.2 mm) pushrod freeplay. If adjustment is necessary, hold pushrod (1) and loosen locknut (2) (metric). 2. Rotate pushrod to increase or decrease freeplay. 3. Tighten locknut. 1 2 NOTE If you alter pedal height, always check pushrod freeplay. 6 REMOVAL/DISASSEMBLY NOTE Do not disassemble the master cylinder unless problems are experienced. Discard all seals during the disassembly procedure.
ASSEMBLY/INSTALLATION 1. 2. See Figure 2-24. Mount reservoir assembly on frame with screw. Tighten screw to 12-15 in-lbs (1.4-1.7 Nm). Clamp reservoir hose to rear master cylinder with a new clamp and HOSE CLAMP PLIERS (Part No. HD-41137). 5559 Upper mark Lower mark Attach rear master cylinder to frame with two screws and locknuts. Tighten to 8-10 ft-lbs (10.8-13.6 Nm).
REAR BRAKE CALIPER REMOVAL/DISASSEMBLY NOTE Do not remove piston from caliper unless there are signs of hydraulic fluid leakage or piston is not operating properly. If piston must be removed, proceed to Step 7. NOTE Step 1 (draining fluid) is not required for caliper removal. Drain brake fluid only when disassembling caliper. 1. See Figure 2-26. Open bleeder nipple cap on rear caliper.
CLEANING, INSPECTION AND REPAIR 1WARNING Clean brake system components using denatured alcohol. Do not use mineral-base cleaning solvents, such as gasoline or paint thinner. Use of mineral-base solvents causes deterioration of rubber parts that continues after assembly. This could result in improper and unsafe brake operation which may cause personal injury. 1. 2. Clean brake system components using denatured alcohol. Blow dry using compressed air. Carefully inspect all components.
REAR BRAKE LINE AND SWITCH REMOVAL 1. Open bleeder nipple cap on rear caliper. Install end of a length of plastic tubing over caliper bleeder valve, while placing free end in a suitable container. Open bleeder valve (metric) about 1/2-turn. Pump rear brake pedal to drain brake fluid. 2. See Figure 2-27. Remove banjo bolt (metric) and two gaskets to detach brake line from rear brake caliper. Discard gaskets. 3. See Figure 2-28.
