2007 Buell Lightning: Chassis 2-51
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12. Move the front fork and the FORK TUBE HOLDER TOOL
in the vise from the horizontal position to the vertical.
NOTE
The recommended fork oil is hydraulic fork oil Type “E” (Part
No. HD-99884-80).
13. Pour 8 oz. (236.5 cc) into the fork pipe.
14. Pump the damper rod approximately 12 to 15 times or
until resistance is felt.
15. Place the damper rod in the fully bottomed position and
compress fork completely.
16. Pour 8 oz. (236.5 cc) more fork oil into the slider fork.
17. See Figure 2-73. Adjust fork oil level with FRONT FORK
OIL LEVEL GAUGE (Part No. B-59000A) to the specified
level below the top of the fork tube. Refer to Table 2-14.
18. See Figure 2-69. Install spring (17) and collar (15).
19. Move fork assembly from holding tool to the FORK
SPRING COMPRESSION TOOL.
20. See Figure 2-68. Install preload washer (4) and slider
piston (5).
21. See Figure 2-71. Hold damper rod assembly (3) and
install fork cap (1) on damper rod assembly (3) tightening
to 38-42 ft-lbs (51-57 Nm).
NOTE
See Figure 2-68. Careful not to damage preload pins (2)
while holding damper rod assembly (3).
22. Remove the fork assembly from the FORK SPRING
COMPRESSION TOOL and install in the FORK TUBE
HOLDER and install in vise.
23. See Figure 2-69. Thread fork cap (3) into fork tube (18)
and tighten to 22-30 ft-lbs (29.8-40.6 Nm).
24. Apply fork oil or light grease to o-rings on preload
adjuster and install preload adjuster (3).
25. Install snap ring (2).
Table 2-14. Fork Oil Levels
Model Inch MM
XB9SX, XB12S, XBSs 4.21 107
XB12Scg 4.29 109
Figure 2-73. Measuring Fork Oil Level
b0666x2x
3
2
1. Outer tube
2. Adjuster
3. Damper assembly
4. Fork oil level
1
4
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