2-56 2006 Buell Lightning: Chassis
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INSTALLATION
1. See Figure 2-76. Install the lower fork clamp (6) into the
steering stem bore and install the upper fork clamp (4).
2. Install steering stem capnut (1). Tighten but do not
torque.
11WARNING1WARNING
Carefully install the fork into the upper fork clamp. Forc-
ing the fork into the upper fork clamp could move the
stopper ring out of the groove which will not allow the
correct clamp load causing a possible loss of control of
the motorcycle which could result in death or serious
injury.
3. Install one front fork assembly into lower fork clamp (6).
4. See Figure 2-70. Slide the stopper ring (19) over top of
fork assembly and into groove.
5. Install fork assembly into upper fork clamp. Tighten but
do not torque lower fork clamp pinch fasteners.
6. Repeat previous two steps on second fork assembly.
7. Tighten steering stem capnut to 38-42 ft-lbs (52-57 Nm).
8. Install steering stem pinch bolt applying LOCTITE 272
(red) and tightening to 20-22 ft-lbs (27.1-29.8 Nm) for all
models except for the XB9SX which should be tightened
to 23-25 ft-lbs (31.2-33.8 Nm).
11WARNING1WARNING
Both forks should display the same number of alignment
lines. Forks that are not properly aligned can lead to loss
of control, which could result in death or serious injury.
(00124a)
NOTE
For additional information, see 2.16 FRONT FORK.
9. See Figure 2-75. Position both forks with same number
alignment lines (4) visible and reflectors facing to the
sides. Do not tighten.
10. Use LOCTITE 272 (red) on upper fork clamp fasteners
and tighten to 23-25 ft-lbs (31.2-33.8 Nm).
11. Use LOCTITE 272 (red) on lower fork clamp fasteners
and tighten to 20-22 ft-lbs (27.1-29.8 Nm).
12. Repeat torque sequence in steps 10 and 11 to verify
proper clamp load.
13. Install front modules. See 2.28 FRONT MODULES.
14. Install handlebars. See 2.29 HANDLEBARS.
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