Buell 2007 LIGHTNING User manual

2007 BUELL LIGHTNING MODELS
SERVICE MANUAL
Part Number 99490-07Y
Section 1: Maintenance
Section 2: Chassis
Section 3: Engine
Section 4: Fuel System
Section 5: Starter
Section 6: Drive/Transmission
Section 7: Electrical
Appendices

SUBJECT PAGE NO.
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Fuel and Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.3 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.4 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.5 Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.6 Brake System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1.7 Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.8 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1.9 Drive Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
1.10 Primary Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
1.11 Suspension Damping Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
1.12 Steering Head Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
1.13 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
1.14 Air Cleaner Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41
1.15 Throttle Cable and Idle Speed Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43
1.16 Interactive Exhaust Cable (XB12 models) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44
1.17 Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-46
1.18 Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-48
1.19 Throttle Position Sensor (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-50
1.20 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51
1.21 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-52
MAINTENANCE 1
Table Of Contents

2007 Buell Lightning: Maintenance 1-1
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GENERAL 1.1
SERVICING A NEW MOTORCYCLE
1WARNING1WARNING
Perform the service and maintenance operations as indi-
cated in the regular service interval table. Lack of regular
maintenance at the recommended intervals can affect
the safe operation of your motorcycle, which could result
in death or serious injury. (00010a)
Service operations to be performed before customer delivery
are specified in the applicable model year PREDELIVERY
AND SETUP MANUAL.
The performance of new motorcycle initial service is required
to keep warranty in force and to ensure proper emissions sys-
tems operation. See 1.3 MAINTENANCE SCHEDULE for
details.
SAFE OPERATING MAINTENANCE
NOTES
●
Do not attempt to retighten engine head bolts. Retighten-
ing can cause engine damage.
●
During the initial break-in period, use only Harley-David-
son 20W50 engine oil. Failure to use the recommended
oil will result in improper break-in of the engine cylinders
and piston rings.
A careful check of certain equipment is necessary after peri-
ods of storage, and frequently between regular service inter-
vals, to determine if additional maintenance is required.
Check:
1. Tires for abrasions, cuts and correct pressure.
2. Secondary drive belt condition.
3. Brakes, steering and throttle for responsiveness.
4. Brake fluid level and condition. Check hydraulic lines and
fittings for leaks. Also, check brake pads and rotors for
wear.
5. Cables for fraying, crimping and free operation.
6. Engine oil and transmission fluid levels.
7. Headlamp, passing lamp, tail lamp, brake lamp and turn
signal operation.
SHOP PRACTICES
Repair Notes
NOTES
●
General maintenance practices are given in this section.
●
Repair = Disassembly/Assembly.
●
Replace = Removal/Installation.
All special tools and torque values are noted at the point of
use.
All required parts or materials can be found in the appropriate
PARTS CATALOG.
Safety
Safety is always the most important consideration when per-
forming any job. Be sure you have a complete understanding
of the task to be performed. Use common sense. Use the
proper tools. Protect yourself and bystanders with approved
eye protection. Don’t just do the job – do the job safely.
Removing Parts
Always consider the weight of a part when lifting. Use a hoist
whenever necessary. Do not lift heavy parts by hand. A hoist
and adjustable lifting beam or sling are needed to remove
some parts. The lengths of chains or cables from the hoist to
the part should be equal and parallel and should be posi-
tioned directly over the center of the part. Be sure that no
obstructions will interfere with the lifting operation. Never
leave a part suspended in mid-air.
1WARNING1WARNING
Be sure to check capacity rating and condition of hoists,
slings, chains and cables before use. Exceeding capac-
ity ratings or using lifting devices that are in poor condi-
tion can lead to an accident, which could result in death
or serious injury. (00466b)
Always use blocking or proper stands to support the part that
has been hoisted. If a part cannot be removed, verify that all
bolts and attaching hardware have been removed. Check to
see if any parts are in the way of the part being removed.
When removing hoses, wiring or tubes, always tag each part
to ensure proper installation.
Cleaning
If you intend to reuse parts, follow good shop practice and
thoroughly clean the parts before assembly. Keep all dirt out
of parts; the unit will perform better and last longer. Seals, fil-
ters and covers are used in this vehicle to keep out environ-
mental dirt and dust. These items must be kept in good
condition to ensure satisfactory operation.
Clean and inspect all parts as they are removed. Be sure all
holes and passages are clean and open. After cleaning,
cover all parts with clean lint-free cloth, paper or other mate-
rial. Be sure the part is clean when it is installed.
Always clean around lines or covers before they are removed.
Plug, tape or cap holes and openings to keep out dirt, dust
and debris.
Disassembly and Assembly
Always assemble or disassemble one part at a time. Do not
work on two assemblies simultaneously. Be sure to make all
necessary adjustments. Recheck your work when finished.
Be sure that everything is done.
Operate the vehicle to perform any final check or adjust-
ments. If all is correct, the vehicle is ready to go back to the
customer.

1-2 2007 Buell Lightning: Maintenance
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REPAIR AND REPLACEMENT
PROCEDURES
Hardware and Threaded Parts
Install helical thread inserts when inside threads in castings
are stripped, damaged or not capable of withstanding speci-
fied torque.
Replace bolts, nuts, studs, washers, spacers and small com-
mon hardware if missing or in any way damaged. Clean up or
repair minor thread damage with a suitable thread chaser.
Replace all damaged or missing lubrication fittings.
Use Teflon pipe sealant on pipe fitting threads.
Threadlocking Agents
Always follow specific service manual procedures when work-
ing with fasteners containing preapplied threadlocking agents
when fastener replacement is recommended.
When re-using fasteners containing threadlocking agents, be
sure to completely remove all existing threadlocking agent
from fastener threads with a wire brush or wire wheel. Also,
be sure to remove residual threadlocking agent from fastener
hole using an appropriate thread chasing device and com-
pressed air when using new or existing fasteners.
Always use the recommended threadlocking agent for your
specific procedure.
Wiring, Hoses and Lines
Replace hoses, clamps, electrical wiring, electrical switches
or fuel lines if they do not meet specifications.
Instruments and Gauges
Replace broken or defective instruments and gauges.
Bearings
Anti-friction bearings must be handled in a special way. To
keep out dirt and abrasives, cover the bearings as soon as
they are removed from the package.
Wash bearings in a non-flammable cleaning solution. Knock
out packed lubricant inside by tapping the bearing against a
wooden block. Wash bearings again. Cover bearings with
clean material after setting them down to dry. Never use com-
pressed air to dry bearings.
Coat bearings with clean oil. Wrap bearings in clean paper.
Be sure that the chamfered side of the bearing always faces
the shoulder (when bearings installed against shoulders).
Lubricate bearings and all metal contact surfaces before
pressing into place. Only apply pressure on the part of the
bearing that makes direct contact with the mating part. Install
bearings with numbered side facing out.
Always use the proper tools and fixtures for removing and
installing bearings.
Bearings do not usually need to be removed. Only remove
bearings if necessary.
Bushings
Do not remove a bushing unless damaged, excessively worn
or loose in its bore. Press out bushings that must be replaced.
When pressing or driving bushings, be sure to apply pressure
in line with the bushing bore. Use a bearing/bushing driver or
a bar with a smooth, flat end. Never use a hammer to drive
bushings.
Inspect the bushing and the mated part for oil holes. Be sure
all oil holes are properly aligned.
Gaskets
Always discard gaskets after removal. Replace with new gas-
kets. Never use the same gasket twice. Be sure that gasket
holes match up with holes in the mating part.
Lip Type Seals
Lip seals are used to seal oil or grease and are usually
installed with the sealing lip facing the contained lubricant.
Seal orientation, however, may vary under different applica-
tions.
Seals should not be removed unless necessary. Only remove
seals if required to gain access to other parts or if seal dam-
age or wear dictates replacement.
Leaking oil or grease usually means that a seal is damaged.
Replace leaking seals to prevent overheated bearings.
Always discard seals after removal. Do not use the same seal
twice.
O-Rings (Preformed Packings)
Always discard o-rings after removal. Replace with new o-
rings. To prevent leaks, lubricate the o-rings before installa-
tion. Apply the same type of lubricant as that being sealed.
Be sure that all gasket, o-ring and seal mating surfaces are
thoroughly clean before installation.
Gears
Always check gears for damaged or worn teeth.
Lubricate mating surfaces before pressing gears on shafts.
Shafts
If a shaft does not come out easily, check that all nuts, bolts
or retaining rings have been removed. Check to see if other
parts are in the way before using force.
Shafts fitted to tapered splines should be very tight. If shafts
are not tight, disassemble and inspect tapered splines. Dis-
card parts that are worn. Be sure tapered splines are clean,
dry and free of burrs before putting them in place. Press mat-
ing parts together tightly.
Clean all rust from the machined surfaces of new parts.
Part Replacement
Always replace worn or damaged parts with new parts.

2007 Buell Lightning: Maintenance 1-3
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CLEANING
Part Protection
Before cleaning, protect rubber parts (such as hoses, boots
and electrical insulation) from cleaning solutions. Use a
grease-proof barrier material. Remove the rubber part if it
cannot be properly protected.
Cleaning Process
Any cleaning method may be used as long as it does not
result in parts damage. Thorough cleaning is necessary for
proper parts inspection. Strip rusted paint areas to bare metal
before repainting.
Rust or Corrosion Removal
Remove rust and corrosion with a wire brush, abrasive cloth,
sand blasting, vapor blasting or rust remover. Use buffing cro-
cus cloth on highly polished parts that are rusted.
TOOL SAFETY
Air Tools
●
Always use approved eye protection equipment when
performing any task using air-operated tools.
●
On all power tools, use only recommended accessories
with proper capacity ratings.
●
Do not exceed air pressure ratings of any power tools.
●
Bits should be placed against work surface before air
hammers are operated.
●
Disconnect the air supply line to an air hammer before
attaching a bit.
●
Never point an air tool at yourself or another person.
●
Protect bystanders with approved eye protection.
Wrenches
●
Never use an extension on a wrench handle.
●
If possible, always pull on a wrench handle and adjust
your stance to prevent a fall if something lets go.
●
Never cock a wrench.
●
Never use a hammer on any wrench other than a STRIK-
ING FACE wrench.
●
Discard any wrench with broken or battered points.
●
Never use a pipe wrench to bend, raise or lift a pipe.
Pliers/Cutters/Prybars
●
Plastic- or vinyl-covered pliers handles are not intended
to act as insulation; don’t use on live electrical circuits.
●
Don’t use pliers or cutters for cutting hardened wire
unless they were designed for that purpose.
●
Always cut at right angles.
●
Don’t use any prybar as a chisel, punch or hammer.
Hammers
●
Never strike one hammer against a hardened object,
such as another hammer.
●
Always grasp a hammer handle firmly, close to the end.
●
Strike the object with the full face of the hammer.
●
Never work with a hammer which has a loose head.
●
Discard hammer if face is chipped or mushroomed.
●
Wear approved eye protection when using striking tools.
●
Protect bystanders with approved eye protection.
Punches/Chisels
●
Never use a punch or chisel with a chipped or mush-
roomed end; dress mushroomed chisels and punches
with a file.
●
Hold a chisel or a punch with a tool holder if possible.
●
When using a chisel on a small piece, clamp the piece
firmly in a vise and chip toward the stationary jaw.
●
Wear approved eye protection when using these tools.
●
Protect bystanders with approved eye protection.
Screwdrivers
●
Don’t use a screwdriver for prying, punching, chiseling,
scoring or scraping.
●
Use the right type of screwdriver for the job; match the tip
to the fastener.
●
Don’t interchange POZIDRIV
®
, PHILLIPS
®
or REED
AND PRINCE screwdrivers.
●
Screwdriver handles are not intended to act as insula-
tion; don’t use on live electrical circuits.
●
Don’t use a screwdriver with rounded edges because it
will slip – redress with a file.
Ratchets and Handles
●
Periodically clean and lubricate ratchet mechanisms with
a light grade oil. Do not replace parts individually; ratch-
ets should be rebuilt with the entire contents of service
kit.
●
Never hammer or put a pipe extension on a ratchet or
handle for added leverage.
●
Always support the ratchet head when using socket
extensions, but do not put your hand on the head or you
may interfere with the action of its reversing mechanism.
●
When breaking loose a fastener, apply a small amount of
pressure as a test to be sure the ratchet’s gear wheel is
engaged with the pawl.

1-4 2007 Buell Lightning: Maintenance
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Sockets
●
Never use hand sockets on power or impact wrenches.
●
Select the right size socket for the job.
●
Never cock any wrench or socket.
●
Select only impact sockets for use with air or electric
impact wrenches.
●
Replace sockets showing cracks or wear.
●
Keep sockets clean.
● Always use approved eye protection when using power
or impact sockets.
Storage Units
●
Don’t open more than one loaded drawer at a time.
Close each drawer before opening up another.
●
Close lids and lock drawers and doors before moving
storage units.
●
Don’t pull on a tool cabinet; push it in front of you.
●
Set the brakes on the locking casters after the cabinet
has been rolled to your work.

2007 Buell Lightning: Maintenance 1-5
HOME
FUEL AND OIL 1.2
FUEL
1WARNING1WARNING
Avoid spills. Slowly remove filler cap. Do not fill above bot-
tom of filler neck insert, leaving air space for fuel expan-
sion. Secure filler cap after refueling. Gasoline is
extremely flammable and highly explosive, which could
result in death or serious injury. (00028a)
Use a good quality unleaded gasoline (91 pump octane or
higher). Pump octane is the octane number usually shown on
the gas pump.
GASOLINE BLENDS
CAUTION
Do not use gasoline that contains methanol. Doing so
can result in fuel system component failure, engine dam-
age and/or equipment malfunction. (00148a)
Buell motorcycles are designed to give the best performance
using unleaded gasoline. Some fuel suppliers sell gasoline/
alcohol blends as a fuel. The type and amount of alcohol
added to the fuel is important.
●DO NOT USE GASOLINES CONTAINING METHANOL.
Using gasoline/methanol blends will result in starting and
driveability deterioration and damage to critical fuel sys-
tem components.
●DO NOT USE RACE GAS OR OCTANE BOOSTERS.
Use of these fuels will damage the fuel system.
●ETHANOL is a mixture of 10% ethanol (Grain alcohol)
and 90% unleaded gasoline. Gasoline/ethanol blends
can be used in your motorcycle if the ethanol content
does not exceed 10%.
●REFORMULATED OR OXYGENATED GASOLINES
(RFG): “Reformulated gasoline” is a term used to
describe gasoline blends that are specifically designed to
burn cleaner than other types of gasoline. Your motorcy-
cle will run normally using this type of gas.
You may find that some gasoline blends adversely affect the
starting, driveability or fuel efficiency of your bike. If you expe-
rience one or more of these problems, we recommend you try
a different brand of gasoline or gasoline with a higher octane
rating.
ENGINE OIL
Use the proper grade of oil for the lowest temperature
expected before the next oil change.
If it is necessary to add oil and Harley-Davidson oil is not
available, use an oil certified for diesel engines. Acceptable
diesel engine oil designations include CF-4, CG-4, CH-4 and
CI4. The preferred viscosities for the diesel engine oils, in
descending order, are 20W-50, 15W-40 and 10W-40. At the
first opportunity, see a Harley-Davidson dealer to change
back to 100 percent Harley-Davidson oil.
See 1.5 ENGINE LUBRICATION SYSTEM for all service
information.
WINTER LUBRICATION
Combustion in an engine produces water vapor. During start-
ing and warm-up in cold weather, especially in freezing tem-
peratures, the vapor condenses to water before the
crankcase is hot enough to exhaust it through the breather
system. If the engine is run long enough for the crankcase to
become thoroughly heated, the water returns to vapor and is
then exhausted.
An engine used for only short trips, and seldom allowed to
thoroughly warm up, accumulates increasing amounts of
water in the oil reservoir. Water mixed with oil forms a sludge
that causes accelerated engine wear. In freezing tempera-
tures, the water becomes slush or ice, which may clog oil
lines and result in engine failure.
Always change the engine oil more often in winter. If the
engine is used for short runs, change the oil even more fre-
quently. The farther below freezing the temperature drops the
more often the oil should be changed.

1-6 2007 Buell Lightning: Maintenance
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MAINTENANCE SCHEDULE 1.3
NOTES:
1. Should be performed by an authorized Harley-Davidson/Buell dealer, unless you have the proper tools, service data and
are mechanically qualified.
2. Change brake fluid every two (2) years.
Table 1-1. Regular Service Intervals For Buell Lightning Models
ITEM SERVICED PROCEDURE
1000
mi
1600
km
5000
mi
8000
km
10,000
mi
16,000
km
15,000
mi
24,000
km
20,000
mi
32,000
km
25,000
mi
40,000
km
NOTES
Engine oil and filter Replace XXXXXX
Oil lines and brake system Inspect for leaks XXXXXX 1
Air cleaner Inspect, service as required XXXX X
Replace X
Tires Check pressure, inspect tread XXXXXX
Transmission lubricant Replace X X X
Clutch Check adjustment XXXXXX 1
Primary chain Check adjustment XXXXXX 1
Rear belt, idler and sprockets Inspect XXXXXX 1
Throttle, brake, and clutch con-
trols, sidestand, active muffler
cable and active intake cable adj.
(if equipped)
Check, adjust and lubricate XXXXXX 1
Brake fluid Check levels and condition XXXXXX 1,2
Brake pads and discs Inspect for wear XXXXXX
Brake calipers and
master cylinders
Inspect for leaks XXXX1,2
Spark plugs Replace X X 1
Electrical equipment and switches Check operation XXXXXX
Engine idle speed Check adjustment XXXXXX 1
Ignition timing Check X X 1
Throttle position sensor (TPS) Zero X X X 1
Front fork oil Replace X X 1
Steering head bearings Perform resistance test XXXXX 1
Oil cooler fins Clean XXXXXX
Brake systems, oil lines, front
forks, rear shock, exhaust system,
exhaust system mounting, evapo-
rative emission system (if applica-
ble)
Inspect XXXXXX 1
Critical fasteners Check tightness X X 1
Engine mounts and stabilizer links Inspect X X 1
Road test Verify component and system functions XXXXXX

2007 Buell Lightning: Maintenance 1-7
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Table 1-2. Quick Reference Maintenance Chart
ITEM SERVICED SPECIFICATION DATA
Engine oil and filter Drain plug torque Apply Loctite 565 Thread Sealant and reinstall
plug and tighten to 26-29 ft-lbs (35-39 Nm)
Oil capacity 2.5 quarts (2.4 liters) and includes the 4.0 ounces
(0.12 liter) poured into the filter
Filter Hand tighten 1/2-3/4 turn after gasket contact
Black filter part number 63806-00Y
Primary chain tension Deflection with hot engine 1/4-3/8 in. (6.4-9.5 mm)
Deflection with cold engine 3/8-1/2 in. (9.5-12.7 mm)
Chain tensioner nut torque 20-25 ft-lbs (27-34 Nm)
Primary chain inspection cover torque 84-108 in-lbs (10-12 Nm)
Primary chain lubricant Lubricant capacity FORMULA+ TRANSMISSION AND PRIMARY
CHAINCASE LUBRICANT (Part No. 99851-05)
as required until fluid level is even with bottom of
clutch diaphragm spring
Primary chaincase drain plug torque Apply Loctite 565 Thread Sealant and reinstall
plug and tighten to 14-30 ft-lbs (19-40.7 Nm)
Clutch adjustment Free play at adjuster screw clockwise 1/4-1/2 turn
Free play at hand lever 1/16-1/8 in. (1.6-3.2 mm)
Clutch inspection cover torque 84-108 in-lbs (10-12 Nm)
Transmission lubricant Lubricant level FORMULA+ TRANSMISSION AND PRIMARY
CHAINCASE LUBRICANT (Part No. 99851-05)
as required until fluid level is even with bottom of
clutch diaphragm spring
Tire condition and pressure Pressure for solo rider Front: 34 psi (234 kPa)
Rear: 36 psi (248 kPa)
Pressure for rider and passenger Same as Solo
Wear Replace tire if 1/32 in. (0.8 mm) or less of tread
pattern remains
Brake fluid reservoir level D.O.T. 4 hydraulic brake fluid part nos. 99953-99A (12 oz.) 99973-05 (gal.)
Proper fluid level 1/8 in. (3.2 mm) from the top
Master cylinder reservoir cover torque 9-13 in-lbs (1.0-1.5 Nm)
Brake pad linings and discs Minimum brake pad thickness 0.040 in. (1.0 mm) or less
Minimum brake disc thickness 0.18 in. (4.5 mm) or less
Intake cover assembly Intake cover screw torque 12-36 in-lbs (1.3-4 Nm)

1-8 2007 Buell Lightning: Maintenance
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Clutch and throttle cables Lubricant LUBIT-8 TUFOIL®CHAIN AND CABLE LUBE
(Part No. HD-94968-85TV)
Handlebar clamp screw torque 60-84 in-lbs (6.8-9.5 Nm)
Handlebar switch housing screw torque 25-33 in-lbs (3-4 Nm)
Spark plugs Type 10R12A
Gap 0.035 in. (0.9 mm)
Torque 12-18 ft-lbs (16-24 Nm)
Engine idle speed Idle speed 1050-1150 RPM
Front fork oil Type: All models except XB12Scg HYDRAULIC FORK OIL (TYPE E)
Part No. 99884-80
4.21 in. (107 mm) from the top of the fork tube
XB12Scg HYDRAULIC FORK OIL (TYPE E)
Part No. 99884-80
4.29 in. (109 mm) from the top of the fork tube
Battery Lubricant ELECTRICAL CONTACT LUBRICANT
Part No. 99861-02 (1 oz.)
Battery terminal torque 72-96 in-lbs (8-11 Nm)
Table 1-2. Quick Reference Maintenance Chart
ITEM SERVICED SPECIFICATION DATA

2007 Buell Lightning: Maintenance 1-9
HOME
BATTERY MAINTENANCE 1.4
GENERAL
Buell motorcycle batteries are permanently sealed, mainte-
nance-free, valve-regulated, lead/calcium and sulfuric acid
batteries. The batteries are shipped pre-charged and ready to
be put into service. Do not attempt to open these batteries for
any reason.
Inspect the battery for damage or leaks and for clean, non-
corroded connections:
●At the 1000 mile (1600 km) service interval.
●At every scheduled service interval thereafter.
1WARNING1WARNING
Batteries contain sulfuric acid, which could cause severe
burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working
with batteries. KEEP BATTERIES AWAY FROM CHIL-
DREN. (00063a)
1WARNING1WARNING
A warning label is attached to the top of the battery. See
Figure 1-1. Never remove warning label attached to top of
battery. Failure to read and understand all precautions
contained in warning, could result in death or serious
injury. (00064a)
1WARNING1WARNING
Battery posts, terminals and related accessories contain
lead and lead components, chemicals known to the State
of California to cause cancer and birth defects or other
reproductive harm.Wash hands after handling. (00019a)
BATTERY TESTING
Voltmeter Test
See Table 1-4. The voltmeter test provides a general indicator
of battery condition. Check the voltage of the battery to verify
that it is in a 100% fully charged condition. If the open circuit
(disconnected) voltage reading is below 12.6V, charge the
battery and then recheck the voltage after the battery has set
for one to two hours. If the voltage reading is 12.8V or above,
perform the load test described under 7.11 BATTERY.
Table 1-3. Battery Electrolyte Antidotes
CONTACT SOLUTION
External Flush with water.
Internal
Drink large quantities of milk or water,
followed by milk of magnesia, vegeta-
ble oil or beaten eggs. Call doctor
immediately.
Eyes Flush with water, get immediate med-
ical attention.
Figure 1-1. Battery Warning Label
Table 1-4. Voltmeter Test For Battery Charge
VOLTAGE (OCV) STATE OF CHARGE
12.7 100%
12.6 75%
12.3 50%
12.0 25%
11.8 0%
b1142x7x

1-10 2007 Buell Lightning: Maintenance
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BATTERY DISCONNECTION AND
REMOVAL
1. Remove seat. See 2.44 SEAT.
1WARNING1WARNING
Disconnect negative (-) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explo-
sion, which could result in death or serious injury.
(00049a)
2. Unthread fastener and remove battery negative cable
(black) from battery negative (-) terminal.
3. Pull back terminal cover boot.
4. Unthread fastener and remove battery positive cable
(red) from battery positive (+) terminal.
5. Unhook strap and remove battery.
CLEANING AND INSPECTION
1. Battery top must be clean and dry. Dirt and electrolyte on
top of the battery can cause battery to self-discharge.
Clean battery top with a solution of baking soda (sodium
bicarbonate) and water (5 teaspoons baking soda per
quart or liter of water). When the solution stops bubbling,
rinse off the battery with clean water.
2. Clean cable connectors and battery terminals using a
wire brush or sandpaper. Remove any oxidation.
3. Inspect the battery screws, clamps and cables for break-
age, loose connections and corrosion. Clean clamps.
4. Check the battery posts for melting or damage caused
by overtightening.
5. Inspect the battery for discoloration, raised top or a
warped or distorted case, which might indicate that the
battery has been frozen, overheated or overcharged.
6. Inspect the battery case for cracks or leaks.
STORAGE
1WARNING1WARNING
Batteries contain sulfuric acid, which could cause severe
burns to eyes and skin. Wear a protective face shield,
rubberized gloves and protective clothing when working
with batteries. KEEP BATTERIES AWAY FROM CHIL-
DREN. (00063a)
CAUTION
Do not allow battery to completely discharge. The elec-
trolyte in a discharged battery will freeze. The more dis-
charged a battery is, the more easily it can freeze and
crack the battery case. (00218a)
If the motorcycle will not be operated for several months,
such as during the winter season, remove the battery from
the motorcycle and fully charge. See 7.11 BATTERY.
See Figure 1-2. Self-discharge is a normal condition and occurs
continuously at a rate that depends on the ambient temperature
and the battery’s state of charge. Batteries discharge at a faster
rate at higher ambient temperatures. To reduce the self-dis-
charge rate, store battery in a cool (not freezing), dry place.
Charge the battery every month if stored at temperatures
below 60˚ F. (16˚ C). Charge the battery more frequently if
stored in a warm area above 60˚ F. (16˚ C).
NOTE
The H-D Battery Tender Automatic Battery Charger (Part No.
99863-93TA) may be used to maintain battery charge for
extended periods of time without risk of overcharging or boil-
ing.
When returning a battery to service after storage, fully charge
the battery. See 7.11 BATTERY.
Figure 1-2. Battery Self-Discharge Rate
3 6 9 12 15
50%
75%
100%
MONTHS OF STAND
C
A
P
A
C
I
T
Y
0
at 105 ° F
at 77
° F
Effect of Temperature on
Battery Self-Discharge Rate
f1732x8x

2007 Buell Lightning: Maintenance 1-11
HOME
BATTERY INSTALLATION AND
CONNECTION
1. Place the fully charged battery in the mounting position,
terminal side to the rear of motorcycle.
2. Hook rubber strap around body of battery.
CAUTION
Connect the cables to the correct battery terminals. Fail-
ure to do so could result in damage to the motorcycle
electrical system. (00215a)
1WARNING1WARNING
Connect positive (+) battery cable first. If positive (+)
cable should contact ground with negative (-) cable con-
nected, the resulting sparks can cause a battery explo-
sion, which could result in death or serious injury.
(00068a)
CAUTION
Do not over-tighten bolts on battery terminals. Use rec-
ommended torque values. Over-tightening battery termi-
nal bolts could result in damage to battery terminals.
(00216a)
3. Insert fastener through battery positive cable (red) into
threaded hole of battery positive (+) terminal and tighten
fastener to 72-96 in-lbs (8-11 Nm).
4. Install terminal cover boot.
5. Insert fastener through battery negative cable (black) into
threaded hole of battery negative (-) terminal and tighten
fastener to 72-96 in-lbs (8-11 Nm).
6. Apply a light coat of petroleum jelly or corrosion retardant
material to both battery terminals.
1WARNING1WARNING
After installing seat, pull upward on front of seat to be
sure it is in locked position.While riding, a loose seat can
shift causing loss of control, which could result in death
or serious injury. (00070a)
7. Install seat. See 2.44 SEAT.

1-12 2007 Buell Lightning: Maintenance
HOME
ENGINE LUBRICATION SYSTEM 1.5
GENERAL
The engine oil level can be checked with the oil and engine at
ambient temperatures (cold check).
However, an accurate reading of the engine oil level can only
be taken with the engine at normal operating temperature
(hot check). Ride motorcycle for approximately 10 minutes to
warm the oil and the engine to normal operating temperature.
NOTE
The engine will require a longer warm up period in colder
temperatures.
Whether a cold or a hot check, the procedure is the same.
During the pre-ride inspection:
●Check for oil leaks from the oil filter and oil lines.
●Check the engine oil level (cold check).
●Check engine oil level (hot check).
At every fueling stop:
●At scheduled maintenance intervals.
●When storing the motorcycle.
NOTE
●Engine oil and filter should be changed when fluids are
hot.
●The colder the weather, the shorter the recommended oil
change interval. A vehicle used only for short runs in cold
weather must have the engine oil drained more fre-
quently.
ENGINE OIL LEVEL CHECK
CAUTION
Do NOT operate the engine when the oil level is below
the add mark on the dipstick at operating temperature.
Engine damage will result. (00187a)
CAUTION
Do not overfill oil tank. Doing so can result in oil carry-
over to the air cleaner leading to equipment damage and
or equipment malfunction. (00190a)
CAUTION
Do not switch lubricant brands indiscriminately because
some lubricants interact chemically when mixed. Use of
inferior lubricants can damage the engine. (00184a)
1. The motorcycle must be on level ground, on the side-
stand, with the engine off.
2. See Figure 1-3. Unscrew and remove dipstick from oil
tank/swingarm filler hole. Wipe dipstick clean.
3. Insert dipstick into oil tank filler hole, screwing dipstick in
completely. DO NOT OVER TIGHTEN.
NOTE
The area between the upper and lower registration marks is
the operating range.
4. See Figure 1-3. Unscrew and remove dipstick and read
oil level.
If the level is below the lower registration mark, add only
enough oil to bring oil level between lower and upper registra-
tion marks.
Figure 1-3. Dipstick Location/Engine Oil Level
11500a
Operating Range
11140

2007 Buell Lightning: Maintenance 1-13
HOME
CHANGING ENGINE OIL
AND FILTER
Ride motorcycle for approximately 10 minutes to ensure the
oil is hot and the engine is at normal operating temperature.
Turn engine off.
Draining Oil
1. See Figure 1-4. Place a suitable container under the
drain plug.
2. Using a 5/8 in. wrench, remove drain plug from under oil
tank/swingarm. Wipe any accumulated debris from mag-
netic tip on drain plug.
3. See Figure 1-5. Unscrew and remove dipstick from oil fill
hole on top of oil tank/swingarm.
Changing Filter
1. Remove chin fairing See 2.37 CHIN FAIRING.
2. See Figure 1-6. Remove oil filter using pliers or belt type
OIL FILTER WRENCH.
3. Clean filter gasket contact surface on crankcase. Surface
should be smooth and free of any debris or old gasket
material.
4. Apply a thin film of clean engine oil to filter gasket.
5. Pour 4.0 ounces (0.12 liter) of clean engine oil into new fil-
ter when changing oil (until filter is approximately 1/2 full).
6. Screw filter onto adapter until filter gasket touches crank-
case surface. Rotate filter another 1/2-3/4 turn by hand.
1WARNING1WARNING
Check that no lubricant gets on tires, wheels or brakes
when changing fluid. Traction can be adversely affected,
which could result in loss of control of the motorcycle
and death or serious injury. (00047b)
Figure 1-4. Oil Tank Drain Plug
Figure 1-5. Dipstick Location
12141
11140
Figure 1-6. Oil Filter
8418

1-14 2007 Buell Lightning: Maintenance
HOME
Replacing Oil
1. Inspect drain plug o-ring for tears or damage. Replace if
required. Wipe any foreign material from drain plug.
2. Apply Loctite 565 Thread Sealant, reinstall plug and
tighten to 26-29 ft-lbs (35-39 Nm).
3. Fill oil tank through filler (dipstick) hole with recom-
mended oil from Table 1-5. Oil tank capacity with filter
change is approximately 2.5 quarts (2.4 liters) and
includes the 4.0 ounces (0.12 liter) poured into the filter.
Always verify proper hot oil level on dipstick. Do not over-
fill.
4. Inspect o-ring on dipstick for rips or tears. Replace as
required.
NOTE
For ease of installation, apply a light film of clean engine oil to
the dipstick o-ring.
5. Install dipstick into oil tank/swingarm fill hole. Make sure
dipstick is installed completely. DO NOT OVER
TIGHTEN.
6. Remove left side oil cooler scoop. See 2.39 AIR
SCOOPS.
7. Inspect oil cooler fins for debris or damage. Blow out any
debris from fins with compressed air from the inside of
the cooler outward.
8. Wipe up any spilled oil on muffler.
9. Start engine.Verify that oil pressure signal light on instru-
ment support turns off after a few seconds when engine
speed is 1000 RPM or above.
10. Check for oil leaks at oil filter, drain plug, hoses and oil
cooler.
11. Install chin spoiler. See 2.37 CHIN FAIRING.
12. Install air scoop 2.39 AIR SCOOPS.
13. Check (hot) oil level. See ENGINE OIL LEVEL CHECK.
Table 1-5. Recommended Oil Grades
HARLEY-DAVIDSON TYPE VISCOSITY HARLEY-DAVIDSON
RATING LOWEST AMBIENTTEMP °F
COLD WEATHER
STARTS BELOW
50° F
H.D. Multi-Grade SAE 10W40 HD 360 Below 40°(4°C) Excellent
H.D. Multi-Grade SAE 20W50 HD 360 Above 40° (4°C) Good
H.D. Regular Heavy SAE 50 HD 360 Above 60° (16°C) Poor
H.D. Extra Heavy SAE 60 HD 360 Above 80° (27°C) Poor

2007 Buell Lightning: Maintenance 1-15
HOME
BRAKE SYSTEM MAINTENANCE 1.6
GENERAL
Check brake fluid level and condition:
●When storing or removing the motorcycle for the season:
Replace D.O.T. 4 BRAKE FLUID.
●Every 2 years.
Front brake hand lever and rear brake foot pedal must have a
firm feel when brakes are applied. If not, bleed system as
described.
Inspect front and rear brake lines and replace as required.
●Every 4 years.
Inspect caliper and master cylinder seals and replace as
required.
●Every 2 years.
If determining probable causes of poor brake operation, refer
to Table 1-6.
BLEEDING BRAKES
1WARNING1WARNING
Direct contact of D.O.T. 4 brake fluid with eyes can cause
irritation. Avoid eye contact. In case of eye contact flush
with large amounts of water and get medical attention.
Swallowing large amounts of D.O.T. 4 brake fluid can
cause digestive discomfort. If swallowed, obtain medical
attention. Use in well ventilated area. KEEP OUT OF
REACH OF CHILDREN. (00240a)
1WARNING1WARNING
Never mix D.O.T. 4 with other brake fluids (such as D.O.T.
5). Use only D.O.T. 4 brake fluid in motorcycles that spec-
ify D.O.T. 4 fluid on the reservoir cap. Mixing different
types of fluid may adversely affect braking ability and
lead to brake failure which could result in death or seri-
ous injury.
1WARNING1WARNING
Use only fresh, uncontaminated D.O.T. 4 fluid. Cans of
fluid that have been opened may have been contami-
nated by moisture in the air or dirt. Use of contaminated
brake fluid may adversely affect braking ability and lead
to brake failure which could result in death or serious
injury
1WARNING1WARNING
Use only new copper crush banjo washers (See Parts
Catalog for Part No.) with D.O.T. 4 brake fluid. Earlier sil-
ver banjo washers are not compatible with D.O.T. 4 fluid
and will not seal properly over time. Failure to comply
may adversely affect braking ability and lead to brake
failure which could result in death or serious injury.
1WARNING1WARNING
Use denatured alcohol to clean brake system compo-
nents. Do not use mineral-based solvents (such as gaso-
line or paint thinner), which will deteriorate rubber parts
even after assembly. Deterioration of these components
can cause brake failure, which could result in death or
serious injury. (00291a)
1WARNING1WARNING
After repairing the brake system, test brakes at low
speed. If brakes are not operating properly, testing at
high speeds can cause loss of control, which could
result in death or serious injury. (00289a)
CAUTION
D.O.T. 4 brake fluid will damage painted and molded-in
color surfaces it comes in contact with. Always use cau-
tion and protect surfaces from spills whenever brake
work is performed. Failure to comply can result in cos-
metic damage. (00239a)

1-16 2007 Buell Lightning: Maintenance
HOME
Table 1-6. Brake Troubleshooting
CONDITION CHECK FOR REMEDY
Excessive lever/pedal travel or spongy
feel.
Air in system.
Master cylinder low on fluid.
Bleed brake(s).
Fill master cylinder with approved
brake fluid.
Brake fade. Moisture in system. Bleed brake(s).
Replace fluid in master cylinder with
approved brake fluid.
Chattering sound when brake is
applied.
Worn pads.
Worn D shape bushings.
Loose mounting bolts.
Warped rotor.
Replace brake pads.
Replace rotor and bushings as set.
Tighten bolts.
Replace rotor and bushings as set.
Ineffective brake –
lever/pedal travels to limit.
Low fluid level.
Piston cup not functioning.
Fill master cylinder with approved
brake fluid, and bleed system.
Rebuild cylinder.
Ineffective brake –
lever/pedal travel normal.
Distorted or glazed rotor.
Distorted, glazed or contaminated
brake pads.
Replace rotor and bushings as set.
Replace pads.
Brake pads drag on rotor –
will not retract.
Cup in master cylinder not uncovering
relief port.
Rear brake pedal linkage out of
adjustment.
Inspect master cylinder.
Adjust linkage.

2007 Buell Lightning: Maintenance 1-17
HOME
Bleeding Front Brake
NOTE
Hydraulic brake fluid bladder-type pressure equipment can be
used to fill the brake master cylinder through the bleeder
valve if master cylinder reservoir cover is removed to prevent
pressurization.
1. See Figure 1-7. With motorcycle in upright position,
install end of plastic tubing over front caliper bleeder
valve; place other end in a clean container.
CAUTION
D.O.T. 4 brake fluid will damage painted and molded in
colored surfaces it comes in contact with. Always use
caution and protect surfaces from spills whenever brake
work is performed. Failure to comply can result in cos-
metic damage. (00239a)
2. Cover body surfaces, right handlebar switches and
instrument panel to protect from spillage.
3. See Figure 1-8. Remove two fasteners from front master
cylinder cover.
4. Add D.O.T. 4 BRAKE FLUID to master cylinder reser-
voir. Bring fluid level to within 1/8 in. (3.2 mm) of molded
boss inside front master cylinder.
NOTE
Do not reuse brake fluid.
5. Slowly depress and release hand lever several times to
build up hydraulic pressure, then hold brake hand lever in
the depressed position.
6. While holding brake hand lever in the depressed posi-
tion, open bleeder valve about 1/2-turn counterclockwise.
Brake fluid will flow from bleeder valve and through tub-
ing into clean container. When brake lever has moved 1/2
to 3/4 of its full range of travel, close bleeder valve (clock-
wise). Allow brake lever to return slowly to its released
position.
7. Repeat steps 5-6 until all air bubbles are purged.
8. Tighten front caliper bleeder valve (metric) to 36-60 in-
lbs (4-7 Nm).
9. Verify master cylinder fluid level as described in step 4.
10. Attach cover to front master cylinder reservoir and
tighten fasteners to 9-13 in-lbs (1.0-1.5 Nm).
11. Remove cover from molded-in-color surfaces, right han-
dlebar switches and instrument panel.
Figure 1-7. Front Caliper Bleeder Valve
Figure 1-8. Front Master Cylinder Reservoir
8346
12141