Buell 2006LIGHTNING MODELS, Service Manual, Page: 503 / 638

2006 Buell Lightning: Drive/Transmission 6-5
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PRIMARY CHAIN ADJUSTER
REPLACEMENT
1. See Figure 6-4. Remove locknut (3) from adjuster screw
(2). Turn adjuster screw out of threaded boss in primary
cover (4).
2. Remove chain adjuster as an assembly.
3. See Figure 6-4. Inspect primary chain adjuster shoe (1).
If badly worn or damaged, it must be replaced.
4. Replace adjuster shoe as an assembly.
5. Position adjuster inside primary cover (4) with closed
side of shoe against cover. Thread adjuster screw (2) all
the way into tapped boss at bottom of primary cover.
6. At outside of cover, thread locknut (3) onto adjuster
screw with nylon sealing surface toward cover. A 1/4-inch
allen wrench may be inserted into end of adjuster screw
to hold it while threading lock nut.
INSTALLATION
1. Remove foreign material from magnetic drain plug. Apply
LOCTITE 565 thread sealant and install plug and tighten
to 14-30 ft-lbs (19-40.7 Nm).
2. Wipe gasket surface clean. Install new gasket on pri-
mary cover.
3. Install primary cover and gasket onto left crankcase half
using mounting bolts.
4. See Figure 6-5. Tighten fasteners to 100-120 in-lbs
(11.3-13.5 Nm) in sequence shown.
5. See Figure 6-3. Install new shifter lever oil seal.
6. See Figure 6-6. Fit coupling (2) over cable end (1) with
rounded side inboard and the ramp connector button out-
board. With retaining ring side of ramp assembly facing
inward, place hook of ramp (3) around coupling button
and rotate assembly counterclockwise until tang on inner
ramp fits in slot of primary cover.
7. Thread nut on adjustment screw until slot of screw is
accessible with a screwdriver. Fit nut hex into recess of
outer ramp and turn adjustment screw counterclockwise.
8. Adjust clutch. See ADJUSTMENT under 1.8 CLUTCH.
9. Adjust primary chain tension. See 1.10 PRIMARY
CHAIN .
Figure 6-4. Primary Chain Adjuster
b1051x6x
1. Shoe, chain adjuster
2. Chain adjuster screw
3. Chain adjuster locknut
4. Primary cover
1
2
3
1
2
8800
3
4
Figure 6-5. Primary Cover Tightening Sequence
Figure 6-6. Clutch Release Mechanism
8801
6
1
7
8
9
11
10
2
12
3
13
4
5
3
2
1
b1055x6x
1. Cable end
2. Coupling
3. Outer ramp and hook
4. Lockplate
5. Spring
5
4