Buell 2004 XB9S, Service Manual, Page: 78 / 597

2004 Buell Lightning: Maintenance 1-29
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PRIMARY CHAIN 1.11
INSPECTION
See Figure 1-26. Measure primary chain tension through the
inspection cover opening. Adjust primary chains not meeting
vertical free play specifications.
1. See Figure 1-26. Remove two fasteners with captive
washers and primary chain inspection cover with gasket
from primary cover.
2. See Figure 1-27. Check primary chain tension by mea-
suring vertical free play.
a. Measure vertical free play through chain inspection
cover opening.
b. Rotate engine to move primary chain to a different
position on sprockets.
c. Measure vertical free play several times, each time
with primary chain moved so that the measurement
is taken with sprockets rotated to the tightest chain
position.
3. The tightest measurement taken in Step 2 must be within
the specifications listed in
Table 1-8. If necessary, adjust
as described under 1.11 PRIMARY CHAIN in ADJUST-
MENT.
NOTE
The initial primary chain vertical free play specification used
at the assembly plant is 1/4-1/2 in. (6.4-12.7 mm) with a cold
engine. The 1/4 in. (6.4 mm) minimum is only allowed at the
absolute tightest point in the drive, as measured with special-
ized factory equipment. If a chain has less than 1/4 in.
(6.4 mm) vertical free play (with a cold engine), adjust free
play to the “field” specification of 3/8-1/2 in. (9.5-12.7 mm).
The looser specification will avoid overtightening, which might
otherwise occur during adjustment using “non-factory” equip-
ment and methods.
4. See Figure 1-26. Install primary chain inspection cover
and new gasket to primary cover using two fasteners
with captive washers. Tighten fasteners to 40-60 in-lbs
(5-7 Nm).
Figure 1-26. Primary Chain Inspection Cover
Figure 1-27. Measuring Primary Chain Free Play
Table 1-8. Primary Chain Free Play
ENGINE
TEMPERATURE
in. mm
Cold 3/8-1/2 9.5-12.7
Hot (normal running
temperature)
1/4-3/8 6.4-9.5
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