Name: Buell 2007 LIGHTNING
Brand: Buell
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2007 Buell Lightning: Chassis 2-71

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ASSEMBLY/INSTALLATION

Clutch Cable

1. Install new o-ring on the clutch cable ﬁtting before install-

ing.

2. Apply 565 thread sealer to ﬁtting on clutch cable and

screw the clutch cable ﬁtting into the primary cover and

tighten to 36-108 in-lbs (4-12 Nm).

3. See Figure 2-102. Install cable end into slot in coupling.

Install the outer ramp and hook (1) onto the cable end (3)

and coupling (2) and place assembly back into the clutch

inspection area in the primary cover. See 6.3 CLUTCH

RELEASE MECHANISM.

4. See Figure 2-104. Install rubber washer and engine shift

lever assembly (1).

5. See Figure 2-101. Install (9) bearings and (8) sleeve into

the shift lever.

6. After applying LOCTITE 271, install ﬂange bolt (6) and

shift pedal to primary cover, and tighten to 22-24 ft-lbs

(30-32.5Nm).

7. After applying LOCTITE 271 (red), tighten engine shift

lever pinch screw to 48-60 in-lbs (5.4-6.8 Nm).

8. See Figure 2-104. If the shift linkage assembly (7) was

removed for any reason, apply Loctite 271 to fasteners

and tighten to 36-60 in-lbs (4-6.8 Nm). Adjust to rider

comfort.

NOTE

See D.1 HOSE AND WIRE ROUTING in Appendix D.

9. Route clutch cable through clutch cable wire form and

upper triple clamp.

Figure 2-104. Installing Shift Linkage

1. Engine shift lever

2. Primary cover

3. Clutch inspection cover

4. Flange head bolt

5. Chain adjuster screw

6. Locknut

7. Shift linkage assembly

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Buell 2007 LIGHTNING Specifications

General