2-80 2007 Buell Lightning: Chassis
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HANDLEBARS 2.30
REMOVAL
1. Remove seat. See 2.44 SEAT.
11WARNING1WARNING
To prevent accidental vehicle start-up, which could
cause death or serious injury, disconnect negative (-)
battery cable before proceeding. (00048a)
2. Disconnect battery negative cable.
3. On XB9SX models, remove deflectors. See 2.25
DEFLECTORS/HANDLEBARS (XB9SX).
4. Remove left handlebar switch housing. See 7.17 HAN-
DLEBAR SWITCHES. Cut left handlebar grip and
remove.
5. Detach clutch hand control from handlebars. See 2.26
CLUTCH CONTROL/CABLE.
6. Remove front brake master cylinder. See 2.10 FRONT
BRAKE MASTER CYLINDER AND HAND LEVER.
7. Loosen screws on right handlebar switch housing, but do
not detach throttle grip assembly from handlebar. See
2.24 THROTTLE CONTROL.
8. Remove clutch lever assembly. See 2.26 CLUTCH CON-
TROL/CABLE.
9. See Figure 2-112. Remove the four screws holding
upper handlebar clamp.
NOTE
Right hand control assembly may now be removed from
detached handlebar.
10. Remove handlebars without stretching throttle cables.
11. See Figure 2-112. Remove endcaps.
INSTALLATION
1. Slide handlebars into throttle grip assembly. Fasten right
handlebar switch housing to handlebar. See 2.24
THROTTLE CONTROL.
2. See Figure 2-112. Attach handlebars.
a. Position handlebar on lower clamp.
b. Place the upper handlebar clamp in position and
thread the four screws in place after applying Loctite
271 (Red).
c. Tighten both front screws to 10-12 ft-lbs (14-16 Nm).
d. Then tighten both rear screws (2) 10-12 ft-lbs (14-16
Nm).
3. Install clutch hand control. Tighten but do not torque. See
2.26 CLUTCH CONTROL/CABLE.
4. Install left switch housing. See 7.17 HANDLEBAR
SWITCHES.
5. Check control wire routings. See D.1 HOSE AND WIRE
ROUTING.
a. Route right hand control wires between the lower
clamp and fork tube and on the outside of the clutch
cable.
b. Route left hand control wires between the lower
clamp and fork tube.
6. Install a new left hand grip.
7. Position clutch hand lever to rider preferences and
tighten fastener (1) to 60-84 in-lbs (6.8-9.5 Nm). See
2.26 CLUTCH CONTROL/CABLE.
8. Install front brake master cylinder. See 2.10 FRONT
BRAKE MASTER CYLINDER AND HAND LEVER.
9. On XB9SX models, install end caps and deflectors. See
2.25 DEFLECTORS/HANDLEBARS (XB9SX).
10. Check steering motion range to both fork stops.
11WARNING1WARNING
Connect positive (+) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explo-
sion, which could result in death or serious injury.
(00068a)
11. 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)
12. Install seat. See 2.44 SEAT.
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