Harley Davidson 1996-97 Buell S1 Lightning Workshop Service Manual on 2040-parts.com
Moscow, default, Russian Federation
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DESCRIPTION THIS IS FOR A PDF DOWNLOAD ONLY, NOT A PAPER MANUAL! This item is for a complete factory service repair manual for 1996-97 Buell S1 LIGHTNING in PDF format. All major topics are covered, complete Step-by-step instruction, diagrams, illustration, and specifications to repair and troubleshoot. This service repair manual can easily help you with any repairs that you may need to do. This is the exact same manual used by the technicians at the dealerships to maintain, service, diagnose and repair your vehicle. This is a must for DO-It-Yourself. You will now be able to do the repairs and services that you pay hundreds for yourself. Save money with this guide! This High Quality PDF Includes 353pages the following: MAINTENANCE General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1996 S1-Lightning Specifications . . . . . . . . . . . . . . . . . . . 1-5 Side Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Fluid Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 Regular Maintenance Intervals (table) . . . . . . . . . . . . . . . 1-9 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 Rear Belt Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 Primary Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22 Rear Preload Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24 Front Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 Air Cleaner Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29 Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 Vacuum-Operated Electrical Switch (V.O.E.S.) . . . . . . . . 1-32 Handlebars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33 Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36 CHASSIS Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Vehicle Identification Number . . . . . . . . . . . . . . . . . . . . . 2-5 Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Front Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Rear Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Checking Cast Rim Runout . . . . . . . . . . . . . . . . . . . . . . . 2-14 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 Front Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . 2-19 Front Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 Front Brake Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 Rear Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . 2-23 Rear Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 Rear Brake Line and Switch . . . . . . . . . . . . . . . . . . . . . . 2-27 Front Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 Fork Stem and Bracket Assembly . . . . . . . . . . . . . . . . . . 2-32 Swingarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 Rear Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 Suspension Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 Suspension Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 Throttle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43 Clutch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 Speedometer and Tachometer . . . . . . . . . . . . . . . . . . . . 2-46 Handlebars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50 Footrests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-52 Sprocket Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53 Fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54 Tail Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55 Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56 Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57 Side Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-58 ENGINE Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Stripping Motorcycle For Engine Repair . . . . . . . . . . . . . 3-8 Installing The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Cylinder and Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 Oil Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 Oil Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 Oil Pressure Signal Light Switch . . . . . . . . . . . . . . . . . . . 3-31 Crankcase Breathing System . . . . . . . . . . . . . . . . . . . . . 3-32 Oiling System (Color Foldout) . . . . . . . . . . . . . . . . . . . . . 3-33 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Oil Filter Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Valve Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 Gearcase Cover and Cam Gears . . . . . . . . . . . . . . . . . . 3-40 Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48 FUEL SYSTEM Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Fuel Supply Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Evaporative Emissions Control-California Models . . . . . 4-23 ELECTRIC STARTER Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Electric Starter System . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Diagnostics/Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 5-9 Starter System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Starter Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 DRIVE/TRANSMISSION Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Primary Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 Secondary Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Clutch Release Mechanism . . . . . . . . . . . . . . . . . . . . . . . 6-9 Primary Drive/Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 Transmission Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16 Shifter Forks and Drum . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18 Mainshaft and Countershaft . . . . . . . . . . . . . . . . . . . . . . 6-20 Main Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26 Access Door Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 Right Transmission Case Bearings . . . . . . . . . . . . . . . . . 6-29 Transmission Installation and Shifter Pawl Adjustment . 6-30 ELECTRICAL Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 Vacuum-Operated Electrical Switch (V.O.E.S.) . . . . . . . . 7-10 Ignition/Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . 7-11 Ignition Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13 Ignition Sensor Plate and Rotor . . . . . . . . . . . . . . . . . . . . 7-14 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16 Spark Plug Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18 Starter Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29 Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32 Headlamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33 Tail Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35 Turn Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37 Turn Signal Flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38 Handlebar Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41 Neutral Indicator Switch . . . . . . . . . . . . . . . . . . . . . . . . . 7-42 Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . 7-43 Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44 Deutsch Electrical Connectors . . . . . . . . . . . . . . . . . . . . 7-46 Amp Multilock Electrical Connectors . . . . . . . . . . . . . . . . 7-48 APPENDIX Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Metric Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 PAYMENT PayPal is what eBay allows. Payment as soon as possible, but certainly within 5 days. If you have difficulties with payment, tell me please. Thanks. SHIPPING FREE WORLDWIDE I WILL EMAIL YOU A PDF LINK TO DOWNLOAD THE SERVICE MANUAL THE SAME DAY I RECEIVE PAYPAL PAYMENT. FILE PDF IS EMAILED TO YOUR EBAY EMAIL UNLESS YOU NOTIFY ME OTHERWISE. RETURNS NO RETURNS FEEDBACK Your positive feedback is important to us. As well as being an attribute to our online reputation it also assures us that you have received your item and are happy with your purchase and service. If, for any reason, you are not completely happy with any aspect of your transaction please let us know ASAP so I can resolve the problem - I know we can fix it. I will repay your feedback promptly with our own. CONTACT US eBay Message, quick respond from MON-FRI 8.00 AM to 11.00 PM (Local time + 4 GMT) |
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