Buell S1 Lightning User Manual

3-3
ITEM NEW COMPONENTS SERVICE WEAR LIMITS
GEARCASE
Cam gear shaft in
bushing (loose)
0.0007-0.0022 in. 0.018-0.056 mm 0.003 in. 0.08 mm
Cam gear shaft end play
(min) (except rear intake)
0.005-0.024 in. 0.13-0.61 mm 0.025 in. 0.64 mm
Rear intake cam gear shaft
end play (min)
0.006-0.024 in. 0.15-0.61 mm 0.040 in. 1.02 mm
FLYWHEEL
Runout
Flywheels at rim 0.000-0.010 in. 0.00-0.25 mm 0.010 in. 0.25 mm
Shaft at
flywheel end
0.000-0.002 in. 0.00-0.05 mm 0.002 in. 0.05 mm
End play 0.001-0.005 in. 0.025-0.13 mm 0.005 in. 0.13 mm
SPROCKET SHAFT BEARING
Outer race fit in
crankcase (tight)
0.0004-0.0024 in. 0.010-0.061 mm
Bearing inner race fit
on shaft (tight)
0.0002-0.0015 in. 0.005-0.038 mm
PINION SHAFT BEARINGS
Pinion shaft jounal diameter 1.2496-1.2500 in. 31.740-31.750 mm 1.2496 in. (min) 31.375 mm (min)
Outer race diameter in
right crankcase
1.5646-1.5652 in. 39.741-39.756 mm 1.5672 in. (max) 39.807 mm (max)
Bearing running clearance 0.00012-0.00088 in. 0.0030-0.0224 mm
Fit in cover bushing
(loose)
0.0023-0.0043 in. 0.058-0.109 mm 0.0050 in. 0.127 mm

Buell S1 Lightning Specifications

General

Transmission	5-speed
Rear Brakes	Single 230mm disc, single-piston caliper
Compression Ratio	10.0:1
Ignition	Electronic
Engine Type	Air-cooled, four-stroke, 45° V-twin
Rear Suspension	Showa monoshock, adjustable preload, compression and rebound damping
Front Brakes	Single 340mm disc, 6-piston caliper
Seat Height	775 mm
Bore x Stroke	88.8 mm x 96.8 mm
Fuel System	Carburetor
Frame	Tubular steel
Tires	Front: 120/70 ZR17, Rear: 170/60 ZR17