2-96 2007 Buell Lightning: Chassis
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ASSEMBLY
NOTE
See Figure 2-126. There are two threaded plastic lugs (14) on
the trunk pan that are used for manufacturing purposes only.
1. Install trunk pan assembly (11) from left side of vehicle.
2. Install fastener (8) securing right front trunk pan to right
side tail section and tighten to 12-36 in-lbs (1.3-4 Nm).
3. Install right side passenger footrest support assembly.
See 2.33 FOOTPEG, HEEL GUARD AND MOUNT.
4. Install two fasteners (12) securing trunk pan to center tail
section and leave loose.
5. Install left tail section (5) onto vehicle.
a. Install fastener (8) attaching left front trunk pan to
left side tail section and tighten to 72-96 in-lbs (8-
10.8 Nm).
b. Apply LOCTITE 271 and install fasteners (4) attach-
ing left rear tail section to center tail section and
tighten to 102-114 in-lbs (11.5-12.8 Nm).
c. Apply LOCTITE 271 and install fasteners (1) attach-
ing left tail section to main frame/fuel tank assembly
and tighten to 21-23 ft-lbs (28.5-31.2 Nm).
d. Install fasteners securing battery tray to side cast-
ings and tighten to 48-72 in-lbs (5.4-8 Nm).
6. Tighten fasteners (12) securing trunk pan to center tail
section to 48-72 in-lbs (5.4-8 Nm).
7. Install left side passenger footrest support assembly. See
2.33 FOOTPEG, HEEL GUARD AND MOUNT.
8. Move rear main harness and shock absorber reservoir
back to left side of vehicle.
9. See Figure 2-125. Connect:
● Wire harness ground (2) [GRD 2].
● Rear brake light switch connector (5) [121].
● ECM connectors (7) [10, 11] and [164] (on XB12
models).
● BAS (bank angle sensor) connector (9) [134].
● Right turn signal connector (11) [18].
● Left turn signal connector (10) [19].
● License plate lamp connector (12) [45]
● Tail light connectors (13) [93].
● Ground terminals on right side tail section (6) [GRD
1] & [GRD 3].
10. Attach cable strap loosely securing the BAS harness to
the seat latch cable.
11. Install the rear shock absorber reservoir into bracket and
tighten fastener. See 2.23 REAR SHOCK ABSORBER.
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)
12. Install battery by threading positive cable (red) into
threaded hole first tightening to 72-96 in-lbs (8-
10.8 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)
13. Install seat. See 2.44 SEAT.
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