Buell 2006LIGHTNING MODELS, Service Manual, Page: 505 / 638

2006 Buell Lightning: Drive/Transmission 6-7
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CLUTCH RELEASE MECHANISM 6.3
DISASSEMBLY
NOTE
For clutch adjustment procedure, See 1.8 CLUTCH .
1. Remove seat. See 2.43 SEAT.
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WARNING
1
WARNING
To prevent accidental vehicle start-up, which could
cause death or serious injury, disconnect negative (-)
battery cable before proceeding. (00048a)
2. Disconnect negative battery cable.
3. Slide rubber boot on clutch cable adjuster upward to
expose adjuster mechanism. Loosen jam nut from
adjuster. Turn adjuster to shorten cable housing until
there is a large amount of free play at clutch hand lever.
See
1.8 CLUTCH .
4. See Figure 6-9. Remove three TORX screws with wash-
ers and clutch inspection cover.
5. Slide spring (4) with attached screw lockplate (5) from
flats of adjusting screw.
6. Turn adjusting screw clockwise to release ramp and cou-
pling mechanism (7). As the adjusting screw is turned,
ramp assembly moves forward. Unscrew nut (6) from
end of adjusting screw.
7. Remove hook of ramp from cable end coupling (10).
Remove cable end from slot in coupling.
8. Remove and discard retaining ring from ramp assembly
to separate inner and outer halves. Remove three balls
from ramp sockets.
CLEANING AND INSPECTION
1. Thoroughly clean all parts in cleaning solvent.
2. See Figure 6-9. Inspect three balls of release mecha-
nism and ball socket surfaces of inner and outer ramps
for wear, pitting, surface breakdown and other damage.
Replace parts as necessary.
3. Check hub fit of inner and outer ramps. Replace ramps if
excessively worn.
4. Check clutch cable for frayed or worn ends. Replace
cable if damaged or worn.
5. Change or add transmission fluid if necessary. See 1.8
CLUTCH .
Figure 6-9. Clutch Release Mechanism
b1057x6x
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2
3
4
7
11
8
5
6
10
1. TORX screw with washers (3)
2. Clutch inspection cover
3. Clutch cover gasket
4. Spring
5. Lockplate
6. Nut
7. Ramp assembly
8. Adjusting screw assembly
9. Primary cover
10. Coupling
11. Drain plug and o-ring
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