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BUELL LIGHTNING X1 (1999-2000) - SERVICE MANUAL

- English Service Manual to vehicles Buell 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