2-78 2006 Buell Lightning: Chassis
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FRONT MODULES 2.28
REMOVAL
1. Remove seat. See 2.43 SEAT.
11WARNING1WARNING
To protect against accidental start-up of vehicle and pos-
sible personal injury, disconnect the negative battery
cable before proceeding. Inadequate safety precautions
could cause a battery explosion, which could result in
death or serious injury.
2. Disconnect battery by unthreading fastener removing
negative cable (black) from battery first. See 1.4 BAT-
TERY MAINTENANCE.
3. Remove windscreen. See 2.42 WINDSCREEN.
4. Remove headlight assembly and support bracket. See
2.27 HEADLIGHT ASSEMBLY AND SUPPORT
BRACKET.
5. Disconnect and remove instrument module. See 7.19
INSTRUMENT MODULE.
6. Remove ignition switch. See 7.3 IGNITION/HEADLIGHT
KEY SWITCH.
NOTE
See Figure 2-108. Once the ignition switch has been removed
there will be two remaining fasteners.
7. See Figure 2-108. Remove fastener attaching p-clamp to
rear side of right front module.
NOTE
See Figure 2-109. Once the clamp load has been released on
the final fastener securing the right front module to the upper
triple clamp, the left front module can be removed.
8. See Figure 2-108. Loosen but do not remove final fas-
tener securing the right front module to upper triple clamp.
9. See Figure 2-109. Remove the left front module.
10. See Figure 2-108. Remove the final fastener and the right
front module.
INSTALLATION
1. See Figure 2-108. Install right front module leaving single
fastener loose.
2. After installing the left front module and aligning with
holes in upper triple clamp, tighten previously installed
single fastener to 12-14 ft-lbs (16.3-19 Nm).
3. Attach front brake line p-clamp to rear of right front mod-
ule and tighten fastener to 36-60 in-lbs (4.1-6.8 Nm).
4. Install ignition switch. See 7.3 IGNITION/HEADLIGHT
KEY SWITCH.
5. Install and connect instrument module. See 7.19
INSTRUMENT MODULE.
6. Install headlight assembly and support bracket. 2.27
HEADLIGHT ASSEMBLY AND SUPPORT BRACKET.
7. Install windscreen. See 2.42 WINDSCREEN.
11WARNING1WARNING
Always connect the positive battery cable first. If the posi-
tive cable should contact ground with the negative cable
installed, the resulting sparks may cause a battery explo-
sion which could result in death or serious injury.
8. Install battery by threading positive cable (red) into
threaded hole first tightening to 72-96 in-lbs (8-11 Nm).
See 1.4 BATTERY MAINTENANCE.
11WARNING1WARNING
After installing seat, pull upward on front of seat to be
sure it is in locked position. While riding, a loose seat can
shift causing loss of control, which could result in death
or serious injury. (00070a)
9. Install seat. See 2.43 SEAT.
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