1-54 2007 Buell Lightning: Maintenance
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TRANSMISSION
Shifts Hard
1. Clutch dragging slightly.
2. Shifter forks (inside transmission) damaged.
3. Corners worn off shifter clutch dogs (inside transmis-
sion).
Jumps Out of Gear
1. Shifter engaging parts (inside transmission) badly worn
and rounded.
2. Shifter forks bent.
3. Damaged gears.
CLUTCH
Slips
1. Clutch controls improperly adjusted.
2. Worn friction plates.
Drags or Does Not Release
1. Clutch controls improperly adjusted.
2. Clutch plates excessively warped.
Chatters
1. Friction or steel plates worn, warped or dragging.
CHASSIS
Irregular/Inadequate Brake Action
1. Master cylinder low on fluid.
2. Brake line contains air bubbles or moisture.
3. Master or wheel cylinder piston worn.
4. Brake pads covered with grease or oil.
5. Brake pads badly worn to minimum lining thickness.
6. Brake rotor badly worn or warped.
7. Brake pads dragging or excessive braking (brake fades
due to heat buildup).
8. Insufficient brake pedal or hand lever free play (brake
drags).
Handling Irregularities
1. Tires improperly inflated. See 1.7 TIRES AND WHEELS.
Do not overinflate.
2. Loose wheel axle. Tighten front axle to 39-41 ft-lbs (53-
56 Nm). Tighten rear axle to 48-52 ft-lbs (65-70 Nm).
3. Excessive wheel hub bearing play.
4. Rims and tires out-of-true side to side (lateral tire runout
should not be more than 0.080 in. (2.03 mm)).
5. Rims and tires out-of-round radially (tire runout should
not be more than 0.060 in. (1.5 mm)).
6. Irregular or peaked front tire tread wear.
7. Tire and wheel unbalanced or weights on wrong side of
wheel. (Front wheel weights must be on the brake rotor
side.)
8. Steering head bearings improperly tightened or worn.
See 1.12 STEERING HEAD BEARINGS. Check for
proper torque and replace worn bearings. See 2.17
FORK CLAMPS, UPPER AND LOWER.
9. Shock absorber or front forks not functioning normally
due to incorrect adjustment. See 1.11 SUSPENSION
DAMPING ADJUSTMENTS.
10. Heavy front end loading. Non-standard equipment on the
front end (such as heavy radio receivers, extra lighting
equipment or luggage) tends to cause unstable handling.
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