FRONT FORK 2.16 GENERAL REMOVAL HOME. 4. See Figure Loosen upper and lower fork clamp pinch fasteners (1, 4).

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1 FRONT FORK.6 GENERAL The XRScg model utilizes a mm fork assembly while all other models have changed to the mm fork assembly. The front fork consists of two telescoping outer tube/inner slider assemblies. Each assembly has an internal compression spring which supports the forward weight of the vehicle and rider. The compression spring extends and retracts to cushion the ride over rough or irregular road surfaces. An oil filled damping mechanism controls the telescoping action of each tube/slider assembly.. See Figure -6. Loosen upper and lower fork clamp pinch fasteners (, ). b099xx See. SUSPENSION DAMPING ADJUSTMENTS for more information. REMOVAL. Remove front fender. See. FENDERS.. Remove front wheel. See.5 FRONT WHEEL.. Remove caliper mounting fasteners. See. FRONT BRAKE CALIPER. b6ax Figure -6. Stopper Ring 5. See Figure -6. Remove fork from upper fork clamp and slide the stopper ring up and over the top of the fork. 6. See Figure -6. Remove fork from lower fork clamp (). 7. Repeat through 6 on opposite side. 5. Screw, pinch fastener. Steering stem pinch fastener. Triple clamp, upper. Triple clamp assembly, lower 5. Screw, pinch fastener Figure -6. Upper and Lower Fork Clamp Assembly Buell Lightning: Chassis

2 DISASSEMBLY 898 Record rider suspension settings before disassembly.. Remove front fork. See REMOVAL in.6 FRONT FORK. f905xx 898 Figure -66. Removing Preload Adjuster. See Figure -66. Remove preload adjuster by turning counterclockwise. After fully unthreading preload adjuster, gently pull on adjuster Fork tube holder. Snap ring. Preload adjuster. Front fork assembly Figure -65. Fork Tube Holder (HD-77). See Figure -65. Clamp the FORK TUBE HOLDER TOOL () (Part No. HD-77) in a vise and install the upper part of the front fork in the holding tool.. Remove snap ring (). Figure -67. Removing Fork Cap From Outer Tube 5. See Figure -67. Remove fork cap from outer tube. 006 Buell Lightning: Chassis -7

3 b5xx Figure -68. Fork Spring Compressing Tool (HD-5966) 6. See Figure -68. Move the fork assembly from the holding tool and compress fork in the FORK SPRING COM- PRESSION TOOL. S FORK SPRING COMPRESSING TOOL (HD-5966) comes with a cup and screw that are for FLT models only and not to be used with Buell. When using the FORK SPRING COMPRESSING TOOL be sure not to bind the outer fork tube on the tool.. Fork cap. Preload pins. Damper rod assembly. Preload washer 5. Slider piston Figure -69. Holding Damper Rod Assembly 7. See Figure -69. Hold damper rod assembly () and remove fork cap (). Careful not to damage preload pins while holding damper rod assembly. 8. Remove preload washer () and slider piston (5). 9. See Figure -68. Expand fork and remove from FORK SPRING COMPRESSION TOOL Buell Lightning: Chassis

4 b099ax Preload adjuster. Preload adjuster o-rings. Fork cap. Fork cap o-ring 5. Preload washer 6. Slider piston 7. Inner slider piston o-ring 8. Snap ring 9. Rebound adjuster assembly 0. Damper locknut. Damper rod assembly. Centering plate. Ceiling washer. Center bolt 5. Collar 6. Spring joint 7. Spring 8. Outer tube 9. Stopper ring 0. Reflector assembly. Slide bushing. Guide bushing. Seal spacer. Oil seal 5. Oil seal stopper ring 6. Dust seal 7. Slider fork Figure -70. Front Fork Assembly 006 Buell Lightning: Chassis -9

5 0. See Figure -70. Over drain pan, spring collar (5), remove spring (7) and drain fork oil.. Drain remaining fork oil by pumping the damping rod () approximately 8 to 0 times or until damping rod moves freely.. Clamp fork upside down in the FORK TUBE HOLDER TOOL (Part No. HD-77) over drain pan allowing fork oil to drain. Be careful not to drop damping rod assembly into oil pan when removing center bolt.. Remove center bolt () to release damping rod assembly ().. Remove centering plate () from dampening rod (). CLEANING AND INSPECTION. Thoroughly clean and inspect all parts. Replace any parts that are bent, broken or damaged.. See Figure -70. Check the slider fork (7) and outer tube (8) for score marks, scratches and excessive or abnormal wear. Replace if worn or damaged.. Check the slide bushing () and the guide bushing () for excessive wear or scratches. Replace if damaged or worn.. Replace the stopper ring (9) if distorted. 5. Measure spring (7) free length. Replace springs shorter than service wear limit of 0.9 in. (77.5 mm) in mm front fork assemblies and. in. (6.6 mm) in mm fork assemblies. 6. See Figure -7. Measure slider fork runout. Replace pipe if runout exceeds the service wear limit of in. (0. mm). WARNING WARNING Be careful not to scratch the slider fork or the outer tube. Improperly operating forks may lead to a loss of control which could result in death or serious injury. b0776xx 5. Remove dust seal (6) to access oil seal stopper ring (5). 6. Release the oil seal stopper ring (5) out from the outer tube with a small pry tool. 7. Using a slide hammer action, remove the slider fork (7) from the outer tube (8). 8. Remove the slide bushing () from slider fork by prying the slide bushing at the split. Careful not to over expand slide bushing. Figure -7. Slider fork Runout 9. Remove guide bushing (), seal spacer (), oil seal (), stopper ring (5) and dust seal (6). Damper Rod Disassembly S See Figure -70. Disassembly of damper rod is not required unless damper locknut (0) has been moved. If damper rod needs servicing refer to the Parts Catalog for kit information. If damper locknut has been moved, proceed with the following disassembly and assembly procedures for setting the correct range of motion.. See Figure -70. Lightly turn the rebound adjuster screw on top of the rebound adjuster assembly (9) counter clockwise till it stops.. Holding the damper locknut (0), unscrew the rebound adjuster assembly (9) and remove from damper rod assembly ().. Remove damper locknut (0) from damper rod assembly () Buell Lightning: Chassis

6 ASSEMBLY Damper Rod Assembly Note Skip to fork assembly if damper rod assembly was not disassembled.. See Figure -70. Fully thread the damper rod locknut (0) on to damper rod () clockwise till it lightly bottoms. Set both forks to the exact same suspension settings.. Adjust rebound assembly for proper range of motion. a. Lightly turn the rebound adjuster screw on top of the rebound adjuster assembly (9) counter clockwise till it stops. b. Turn the rebound adjuster screw three full turns clockwise.. Fully thread rebound adjuster assembly (9) onto the damper rod assembly () until it lightly bottoms. Do not tighten. Fork Assembly. See Figure -70. Wrap the end of the slider fork (7) and the slide bushing channel with tape to avoid damaging the oil seal lip when installing.. Install a new dust seal (6) and stopper ring (5) onto the slider fork (7).. Coat the sealing lips of the new oil seal () with fork oil or sealing grease and install onto the slider fork with its marked side facing the dust seal (6).. Remove the tape from the slider fork end. 5. Install the seal spacer (), the guide bushing () and the slide bushing () onto the slider fork (7). 6. Coat the slide bushing () and the guide bushing () with fork oil. The outer tube can move freely up and down on the slider fork. Always hold both the slider fork and outer tube to prevent damage to bushings and seals. b7. Thread the damper locknut (0) until bottoms lightly on the rebound adjuster assembly. Do not tighten 5. Turning the rebound adjuster screw (9) counter clockwise three full turns or until stops. 879 Figure -7. Fork Seal Driver (B-7) mm Fork Seal Driver (B-57) mm 7. See Figure -70. Drive the guide bushing () with the seal spacer () and oil seal () into position in the outer tube using a FORK SEAL DRIVER (Part No. B- 7/mm) and (Part No. B-57/mm). See Figure Install the oil seal stopper ring (5) and a new dust seal (6).. Fork cap assembly. Rebound assembly 9. Place the fork in the FORK TUBE HOLDER TOOL (Part No. HD-77) and clamp into vise horizontally. Figure -7. Rebound Assembly and Fork Cap Assembly 6. See Figure -7. Tighten the damper locknut (0) to - 0 ft-lbs (0-0 Nm). 7. Repeat for other fork assembly. 0. See Figure -70. Install the centering plate () onto the damper assembly () and insert the damper assembly into the slider fork (7).. Replace the sealing washer () and center bolt () (metric). Tighten the center bolt to -0 ft-lbs (0-0 Nm). 006 Buell Lightning: Chassis -5

7 . Move the front fork and the FORK TUBE HOLDER TOOL in the vise from the horizontal position to the vertical. The recommended fork oil is hydraulic fork oil Type E (Part No. HD ).. Pour 8 oz. (6.5 cc) into the fork pipe.. Pump the damper rod approximately to 5 times or until resistance is felt. 5. Place the damper rod in the fully bottomed position and compress fork completely. 6. Pour 8 oz. (6.5 cc) more fork oil into the slider fork. 7. See Figure -7. Adjust fork oil level with FRONT FORK OIL LEVEL GAUGE (Part No. B-59000A) to the specified level below the top of the fork tube. Refer to Table -5. Table -5. Fork Oil Levels b0666xx Model Inch MM XB9SX, XBS, XBSs. 07 XBScg See Figure -70. Install spring (7) and collar (5). 9. Move fork assembly from holding tool to the FORK SPRING COMPRESSION TOOL. 0. See Figure -69. Install preload washer () and slider piston (5).. See Figure -7. Hold damper rod assembly () and install fork cap () on damper rod assembly () tightening to -0 ft-lbs (0-0 Nm). See Figure -69. Careful not to damage preload pins () while holding damper rod assembly ().. Remove the fork assembly from the FORK SPRING COMPRESSION TOOL and install in the FORK TUBE HOLDER and install in vise.. See Figure -70. Thread fork cap () into fork tube (8) and tighten to 5 ft-lbs (.89 Nm).. Apply fork oil or light grease to o-rings on preload adjuster and install preload adjuster (). 5. Install snap ring ().. Outer tube. Adjuster. Damper assembly. Fork oil level Figure -7. Measuring Fork Oil Level Buell Lightning: Chassis

8 INSTALLATION. See Figure -6. Install one front fork assembly into lower fork clamp.. Slide the stopper ring over top of fork assembly and into groove WARNING WARNING Carefully install the fork into the upper fork clamp. Forcing the fork into the upper fork clamp could move the stopper ring out of the groove which will not allow the correct upper fork clamp load resulting in possible loss of control of the motorcycle and could result in death or serious injury.. Install fork assembly into upper fork clamp. WARNING WARNING Both forks should display the same number of alignment lines. Forks that are not properly aligned can lead to loss of control, which could result in death or serious injury. (00a). Rebound adjuster screw. Preload adjuster nut. Four preload alignment lines visible (factory setting). Alignment lines Figure -75. Front Fork Preload And Rebound Adjuster. See Figure -75. Position fork with alignment lines () visible and reflector facing to the side and tighten the lower fork clamp. 5. Repeat step through on second front fork. 6. Temporarily install front axle to the fork assemblies to verify correct alignment. 7. Use LOCTITE 7 on upper fork clamp fasteners and tighten to -5 ft-lbs (.-.8 Nm). 8. Use LOCTITE 7 on lower fork clamp fasteners and tighten to 0- ft-lbs (7.-0 Nm). 9. Repeat torque sequence in steps 7 and Install front brake caliper onto caliper mount. See. FRONT BRAKE CALIPER.. Install front wheel. See.5 FRONT WHEEL.. Install front fender. See. FENDERS.. Check headlamp alignment. See.8 HEADLIGHTS.. Adjust front forks suspension to rider preferences. See. SUSPENSION DAMPING ADJUSTMENTS. 006 Buell Lightning: Chassis -5

9 S Buell Lightning: Chassis