Buell 2004 XB9S, Service Manual

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2004 Buell Lightning: Maintenance 1-23
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CLUTCH 1.9
TRANSMISSION FLUID
Transmission fluid capacity is approximately 1.0 quart
(0.95 liter). For best results, drain fluid while hot.
1. On level surface, stand vehicle upright (not leaning on
sidestand) to prevent chaincase lubricant from draining
out of clutch cover opening when refilled.
2. See Figure 1-20. Position a suitable container under
drain plug. Remove plug and drain fluid.
3. Wipe any foreign material from the magnetic drain plug
and apply Loctite 592 Thread Sealant. Reinstall plug and
tighten to 11-15 ft-lbs (14.9-20.3 Nm).
4. Remove three fasteners and washers from clutch inspec-
tion cover. Remove clutch inspection cover with gasket
from primary cover.
CAUTION
Do not overfill the transmission with fluid. Overfilling
may cause rough clutch engagement and incomplete dis-
engagement, clutch drag and/or difficulty finding neutral
at engine idle.
5. See Figure 1-21. Add SPORT-TRANS FLUID (Part No.
99896-88 quart size; Part No. 99895-88 gallon size) as
required until fluid level (3) is even with bottom of clutch
diaphragm spring (2).
NOTE
Each time the clutch inspection cover is removed the gasket
must be replaced.
6. Install new clutch cover gasket.
7. See Figure 1-19. Install clutch inspection cover tighten-
ing three fasteners and washers to 84-108 in-lbs (10-
12 Nm).
8. Clean up any fluid that may have spilled on muffler.
Figure 1-19. Clutch Inspection Cover
Figure 1-20. Primary Drain Plug
Figure 1-21. Fluid Level
8356
8376
b1144x1x
1. Clutch diaphragm spring
2. Clutch adjusting screw
3. Primary cover
4. Correct chaincase lubricant level
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3
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