2006 Buell Lightning: Chassis
2-85
HOME
ASSEMBLY/INSTALLATION
Exhaust Header
1.
See
Figure 2-113.
Install exhaust ring (4), retaining ring
(5) and new port gasket (6).
2.
Install exhaust header (2). Tighten mounting fasteners
(3) to 72-96 in-lbs (8-11 Nm).
NOTE
Tighten header nuts gradually, alternating between studs to
insure that exhaust rings are flush with engine.
3.
Install oxygen sensor. See
4.33 OXYGEN SENSOR
.
4.
Rotate engine up. See
3.3 ENGINE ROTATION FOR
SERVICE
.
Rear Muffler Bracket
1.
See
Figure 2-112.
Slide rear muffler bracket (10) over oil
line.
2.
Install rear muffler bracket fasteners (11) and tighten to
32-36 ft-lbs (43-49 Nm).
3.
Install oil line to swingarm. See
3.9 OIL HOSE ROUTING
AND OIL RESERVOIR and 3.10 OIL LINE FITTINGS.
4.
Fill swingarm/oil tank with 2.5 quarts (3.3 liters) oil. See
Draining Oil
in
1.5 ENGINE LUBRICATION SYSTEM
.
5.
Install muffler.
Front Muffler Mount
1.
See
Figure 2-112.
Install front muffler mount bushings
(8).
2.
Install new strap on front muffler mount (6).
3.
Install front fastener (7) loosely. Do not tighten.
4.
Install muffler.
Muffler and Straps
NOTES
●
For details on assembly of components on XB12 models
with interactive exhaust systems, see
INSTALLATION
under
7.6 INTERACTIVE EXHAUST SYSTEM (XB12
MODELS).
●
Torca muffler clamps have eliminated the need for sili-
cone or graphite tape during assembly. To ensure sealing
integrity of muffler clamps and prevent the possibility of
leakage, Buell recommends that muffler clamp assem-
blies be discarded and replaced each time they are
removed.
1.
Install muffler and new Torca clamp onto header.
NOTE
If necessary, use a fiber hammer to fit muffler on header.
2.
See
Figure 2-112.
Loosely install new front and rear
muffler straps (2, 4).
NOTES
●
Never re-use front muffler strap. Always replace front
muffler strap with a new strap when removed from sys-
tem.
●
It is important that the front muffler mount is tightened
last in order to ensure proper alignment of the exhaust
system.
●
When rear muffler straps have been installed, it is impor-
tant that strap fasteners do not contact idler pulley
bracket.
●
On the front muffler mount fastener, torque is applied to
the head and not to the nut.
3.
Tighten front strap fastener and alternately tighten rear
muffler strap fasteners evenly till fasteners are tightened
to:
a.
Front: Tighten around the muffler until snug.
b.
Rear: Tighten rear muffler strap to 48-60 in-lbs (5-
7 Nm).
c.
Front: Tighten front muffler strap fasteners to 108-
120 in-lbs (12-14 Nm). Back off fastener two full
turns and then retighten to 108-120 in-lbs (12-
14 Nm).
4.
See
Figure 2-113.
Tighten the Torca clamp (1) to 28-
30 ft-lbs (38-40.6 Nm).
5.
Install front muffler mount fastener and tighten 16-18 ft-
lbs (21.7-24.4 Nm).
6.
Install idler pulley. See
6.6 DRIVE BELT SYSTEM
.
7.
Install front sprocket cover. See
2.33 SPROCKET
COVER
.
8.
Install chin fairing. See
2.36 CHIN FAIRING
.
Figure 2-113. Exhaust Header
b0973a2x
1
1.
Torca clamp
2.
Header
3.
Header mount fastener
4.
Exhaust ring
5.
Exhaust retaining ring
6.
Exhaust port gasket
2
4
5
6
3
Содержание 2006LIGHTNING MODELS
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