Buell 2004 XB9S, Service Manual, Page: 153 / 597

2-50 2004 Buell Lightning: Chassis
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INSTALLATION
1. See Figure 2-63. Install one front fork assembly into
lower fork clamp.
2. Slide the stopper ring over top of fork assembly and into
groove.
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WARNING
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WARNING
Carefully install the fork into the upper fork clamp. Forc-
ing 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.
3. Install fork assembly into upper fork clamp.
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WARNING
1
WARNING
Both forks should display the same number of alignment
lines. Forks that are not properly aligned may lead to a
loss of control which could result in death or serious
injury.
4. See Figure 2-74. Position fork with alignment lines (4)
visible and reflector facing to the side and tighten the
lower fork clamp.
5. Repeat step 1 through 4 on second front fork.
6. Temporarily install front axle to the fork assemblies to
verify correct alignment.
7. Use LOCTITE 272 on upper fork clamp fasteners and
tighten to 17-19 ft-lbs (23-26 Nm).
8. Use LOCTITE 272 on lower fork clamp fasteners and
tighten to 13-15 ft-lbs (18-20 Nm).
9. Repeat torque sequence in steps 7 and 8.
10. Install front brake caliper onto caliper mount. See 2.12
FRONT BRAKE CALIPER .
11. Install front wheel. See 2.5 FRONT WHEEL .
12. Install front fender. See 2.32 FENDERS.
13. Check headlamp alignment. See 1.19 HEADLIGHTS .
14. Adjust front forks suspension to rider preferences. See
1.12 SUSPENSION DAMPING ADJUSTMENTS .
Figure 2-74. Front Fork Preload And Rebound Adjuster
1. Rebound adjuster screw
2. Preload adjuster nut
3. Four preload alignment lines visible
(factory setting)
4. Alignment lines
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9957
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3
4