User Guide

ManualsBrandsBuell ManualsOtherS1 Lightning '97

4-1

SPECIFICATIONS

CARBURETOR JET SIZES

Main jet 195

Slow jet 42

FUEL TANK CAPACITY GALLONS LITERS

Total (including reserve) 4.0 15.14

Reserve 0.6 2.27

CARBURETOR ADJUSTMENTS

Engine fast idle speed

(using enrichener circuit)

2000 RPM

Engine speed for setting ignition

timing-world models

950-1050 RPM

Engine speed for setting ignition

timing-California models

1150-1250 RPM

ITEM TORQUE NOTES

Air cleaner backplate screw 7-9 ft-lbs 9.5-12.2 Nm LOCTITE THREADLOCKER 242 (blue), page 4-19

Air cleaner cover rear screw 6-8 ft-lbs 8.1-10.8 Nm page 4-19

Air cleaner front support screw 3-5 ft-lbs 4.1-6.8 Nm LOCTITE THREADLOCKER 242 (blue), page 4-19

Canister clamp screws 6-8 ft-lbs 8.1-10.8 Nm page 4-25

Cylinder head breather bolts 10-15 ft-lbs 13.6-20.3 Nm HYLOMAR, page 4-19

Fuel cap ﬂange screws 22-25

in-lbs

2.5-2.8 Nm special pattern to tighten, page 4-21

Fuel supply valve screws 34-37

in-lbs

3.8-4.2 Nm page 4-22

Fuel tank screw 9-11 ft-lbs 12.2-14.9 Nm page 4-21

Intake manifold screws 6-10 ft-lbs 8.1-13.6 Nm page 4-17

Snorkel tube screw 6-8 ft-lbs 8.1-10.8 Nm LOCTITE THREADLOCKER 242 (blue), page 4-19

Tie bar bolts 30-33 ft-lbs 40.7-44.7 Nm page 4-17

Torx ignition bracket screw 25-30 ft-lbs 33.9-40.7 Nm page 4-17

Summary of content (17 pages)

PAGE 1
4 SPECIFICATIONS CARBURETOR JET SIZES CARBURETOR ADJUSTMENTS Main jet 195 Slow jet 42 FUEL TANK CAPACITY Engine fast idle speed (using enrichener circuit) GALLONS LITERS Total (including reserve) 4.0 15.14 Reserve 0.6 2.27 ITEM 2000 RPM Engine speed for setting ignition timing-world models 950-1050 RPM Engine speed for setting ignition timing-California models 1150-1250 RPM TORQUE NOTES Air cleaner backplate screw 7-9 ft-lbs 9.5-12.
PAGE 2
CARBURETOR GENERAL 5609 See Figure 4-1. Buell motorcycles use a constant-velocity, gravity-fed carburetor. This carburetor features a float-operated inlet valve, a variable venturi, a throttle stop screw (for idle speed adjustment) and a fuel enrichment system (for starting). 1 Idle and transfer ports provide a balanced fuel mixture during the transition period from stop to mid-range. A vacuum piston controls venturi opening. The carburetor is specifically designed to control exhaust emissions.
PAGE 3
Table 4-1. Fuel System Troubleshooting OVERFLOW Remedy: 1. Correct restricted hose. Replace vapor vent valve. 2. Tighten screws. 3. Replace O-ring. 4. Replace float assembly. 5. Clean and clear cavity and fuel supply tract. 6. Clean or replace valve and clean seat. 7. Adjust float tab for correct fuel level. Check for: 1. Restricted fuel tank vent system. 2. Loose float bowl screws. 3. Damaged float bowl O-ring. 4. Damaged or leaking float assembly. 5. Particle contamination in fuel inlet fitting cavity.
PAGE 4
Table 4-1. Fuel System Troubleshooting (cont.) POOR PERFORMANCE ON ROAD Check for: 1. Idle speed improperly adjusted. 2. Inlet system air leak. 3. Restricted fuel tank vent system. 4. Dirty or damaged air cleaner element. 5. Enrichener valve not seated or leaking. 6. Restricted fuel supply tract. 7. Plugged bowl vent or overflow. 8. Loose or plugged fuel and air jets or passages. 9. Worn or damaged needle or needle jet. 10. Vacuum piston assembly malfunction. 11. Accelerator pump inoperative. Remedy: 1.
PAGE 5
OPERATION OMF3 Normal running position Enrichener The enrichener knob, next to the ignition switch, controls the opening and closing of the enrichener valve at the carburetor. Full out position 1CAUTION 1/2 way position Avoid idling with the enrichener knob in the full out position for periods longer than 30 seconds. Such operation may cause poor performance, erratic idle, poor fuel economy and spark plug fouling. Figure 4-2. Enrichener Knob Positions NOTE The 1996 C.V.
PAGE 6
Fuel Supply System When fuel is used by the running engine, the fuel level in the float chamber drops; this lowers the float and inlet valve, thereby causing the valve to open and the fuel flow to resume. See Figure 4-3. Fuel from the fuel tank passes through the carburetor inlet valve into the carburetor float chamber. The rising fuel level in the float chamber lifts the float, which in turn lifts the attached inlet valve closer to the valve seat.
PAGE 7
Starting Circuit See Figure 4-4. The starting circuit consists of a cable-actuated enrichener valve and converging fuel and air passages in the carburetor body. The enrichener air/fuel passage opens to the carburetor venturi, where low pressure exists when the engine is running. Fuel in the carburetor float bowl and air in the enrichener air inlet are vented to atmosphere and are at atmospheric pressure (greater pressure than in the carburetor venturi).
PAGE 8
Idle- and Low-Speed Circuit See Figure 4-5. At idle (with the throttle plate closed and the main air stream obstructed), engine idle speed is maintained by fuel metered through the slow jet. Air from the slow air jet mixes with the fuel and is delivered to the idle port at the low pressure side of the throttle plate.
PAGE 9
Mid-Range Slide Position See Figure 4-6. As the throttle plate is opened, air flow increases through the carburetor; this causes air pressure to decrease in the carburetor venturi (near the needle jet) and in the chamber above the diaphragm (which is vented to the venturi through a vacuum port and passage in the vacuum piston). The chamber beneath the diaphragm is vented to higher atmospheric pressure by a passage to the carburetor inlet.
PAGE 10
High-Speed Circuit Slide Position See Figure 4-7. As the throttle plate is opened, the pressure difference between the chambers above and below the diaphragm increases and the vacuum piston moves further upward. The venturi opening increases and the needle is lifted further out of the needle jet. The quantity of fuel and the volume of air are simultaneously increased and metered to the proportions of engine demand by the variable venturi and needle lift.
PAGE 11
Accelerator Pump System See Figure 4-8. The accelerator pump system uses sudden throttle openings (rapid acceleration) to quickly inject fuel into the carburetor venturi; the extra fuel provides for smooth acceleration. This fuel also assists engine operation during cold engine warm-up when the enrichener is turned off prematurely. Rapid throttle action, during the first third of throttle travel, causes the accelerator pump rod to depress the accelerator pump diaphragm.
PAGE 12
ADJUSTMENT 3. Install float and recheck setting. 4. Install float bowl. Install carburetor as described in CARBURETOR, INSTALLATION on page 4-17. Idle See IGNITION TIMING in Section 1. Enrichener Control See Figure 4-9. Check enrichener operation. Enrichener knob (1) should open (and remain open) and close without binding. Plastic nut (2), next to the enrichener knob, controls the sliding resistance of the enrichener control cable within the cable conduit.
PAGE 13
XLH0404 Start float position Pin Fuel inlet valve Float “Base” Correct float position Float 0.413-0.453 in. (10.49-11.51 mm) 15 to 20˚ Incorrect float position Pin return spring collapsed Float Greater than 20˚ Figure 4-11.
PAGE 14
REMOVAL 5751 3 Carburetor 1WARNING Gasoline can be extremely flammable and highly explosive. Do not smoke or allow open flame or sparks when refueling or servicing the fuel system. Inadequate safety precautions may result in personal injury. 1. Turn fuel supply valve OFF. 2. Remove air cleaner cover and backplate. See AIR CLEANER, REMOVAL on page 4-18. 3. Loosen rear breather bolt. Remove front breather bolt and washer. Remove air cleaner support ring.
PAGE 15
DISASSEMBLY 12. Clean all internal fuel/air passages and jets. Check that all passages and jets are open and free of obstruction. Vacuum Piston Chamber 13. Check needle jet holder (10). Clean bleed tube orifices. Replace holder if damaged. 1. See Figure 4-14. Remove screws (26, 25) and throttle cable bracket (24). 2. Remove three shouldered screws (2). Remove top cover (1) and spring (3). 3. Lift out vacuum piston (4) with jet needle (6) and spring seat (5). Remove loose parts from vacuum piston.
PAGE 16
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. b0005b4x 2 3 1 5 21 Top cover Shouldered screw (3) Spring Vacuum piston Spring seat Jet needle Fitting (V.O.E.S.) Fuel inlet fitting Needle jet Needle jet holder Main jet Slow jet Fuel inlet valve Pin 6 19 4 20 57 23 54 7 22 55 54 27 25 29 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41.
PAGE 17
3. 4. Insert needle jet holder (10) into main jet passage with needle inserted into center of holder. Thread holder into passage and tighten. Thread and tighten main jet (11) in tapped hole in needle jet holder (10). Carburetor 1. Place float assembly (16) into position with fuel inlet valve (13) inserted into valve seat and with pivot arm aligned with holes in mounting posts (at bottom of carburetor body). Insert pin (14) through float pivot arm and float mounting posts. 5.