1-44 2007 Buell Lightning: Maintenance
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INTERACTIVE EXHAUST CABLE 1.16
ADJUSTMENT
1. Remove intake cover assembly. See 2.38 INTAKE
COVER ASSEMBLY.
NOTES
● The actuator cover used on models with Translucent
body panels does not need to be removed in order to
adjust cable.
● When the ignition/light switch is turned off with the inter-
active exhaust valve in motion, the valve will stop par-
tially open which will cause an inaccurate adjustment.
For a description of the inactive exhaust operation, see
7.6 INTERACTIVE EXHAUST SYSTEM.
2. To close the valve in the muffler, cycle the actuator:
a. Hold the throttle wide open.
b. Turn the engine cut-off switch to RUN.
c. Turn the ignition/light key switch ON.
d. Watch the actuator cycle close/open/close.
3. See Figure 1-48. Loosen jam nut (3).
4. Remove cable (2) from bracket and cable wheel (4).
NOTE
For the next step in the procedure it will be necessary to
obtain a permanent marker.
5. Using a pair of pliers, fully open the exhaust valve in the
muffler by pulling the cable core by the ferule that was
disconnected from the cable wheel in the previous step
until resistance is felt. Be careful not to damage the cable
core.
6. Mark the cable core with the marker all the way around
where it comes out of the housing.
7. Release the cable core and reattach the cable to the
cable wheel and bracket.
8. Tighten jam nut.
CAUTION
Do not overtighten jam nut on interactive exhaust cable.
9. See Figure 1-49. Adjust interactive exhaust cable as fol-
lows:
a. See Figure 1-48. Move cable with your fingers from
side to side. There should be no more than 1/8 in.
(3.2 mm) side play in cable in either direction with
1/4 in. (6.4 mm) maximum overall side play.
b. Adjust cable as needed using cable adjuster (1).
Figure 1-48. Interactive Exhaust Cable
10513
1. Adjuster
2. Interactive exhaust cable
3. Jam nut
4. Cable wheel
4
3
1
2
10512a
Figure 1-49. Checking For 1/8 in. (3.2 mm) Maximum Free
Play In Either Direction For Proper Adjustment
10512a
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