1996-1998 Buell S1 Lightning Service Manual

This service manual supplement provides detailed repair information for the 1996-1998 Buell S1 Lightning motorcycle. Includes procedures for maintenance, component removal, and installation. Part No. 99490-96Y.

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Document Details

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Document Number / Seller:
26886 / Laura Boyd
File Size:
18.51 MB
File Type:
ZIP
Language:
English
Printable:
Yes
Category:
Motorcycle
Last updated / verified
Jun 7, 2025

Models Covered & Key Technical Specifications

1996-1998 Buell S1 Lightning Service Manual (99490-96Y) Supplemental Service Manual | Buell Collection.

  • Specifications: 1203 cc engine displacement signifies the base motor configuration.
  • Fluid Requirements: For steering head bearing grease, 99855-89 specifies the required lubricant.
  • Weight: S1 shipping weight totals 446 lbs. (202 kg) for standard operation.
  • Capacities: The transmission requires 1.0 quart (0.95 liters) of fluid for optimal performance.
  • Engine Specs: 4-Cycle, 45 Degree V-Type engine delivers 91 hp @ 5800 RPM.
  • Ignition Gap: 0.038-0.045 in. (0.97-1.14 mm) establishes the spark plug gap range.

Professional Workshop Service Manual & Technical Specifications

Advanced Quality Wiring Manual: Motorcycle Buell S1 Lightning manual, 1996-98 edition Specification-Set

Reference-Category: Motorcycle / Buell // Subsystem-Focus: Engine / Chassis Logic // Reference-Category: Service Manual.

Metric Technical-Path Calibration-Data
Engine Displacement 1203 cc 73.4 cu. in.
Horsepower @ RPM 91 @ 5800 N/A
Torque ft-lb @ RPM 87 @ 5200 N/A
Fuel Tank Capacity 4.0 gallons 15.14 Liters
Transmission Capacity 1.0 quart 0.95 Liters
Shipping Weight 446 lbs. 202 Kg

Coverage is segmented into: Specifications, Fluid Requirements, Engine Specs, Ignition System, Transmission, Clutch, Rear Suspension Adjustment, Front Suspension Adjustment, and Troubleshooting. The manual details systems, procedures, and provides a comprehensive overview of the motorcycle's components. Torque specifications are documented for critical fasteners to ensure proper assembly and dynamic load distribution. Parts identification is covered for key components, assisting in efficient disassembly and reassembly.

Engine Specifications

This section documents the specifications for the Buell S1 Lightning's engine, including bore, stroke, and horsepower. It also covers fluid capacities and recommendations for optimal performance.

Chassis and Suspension

Details on the chassis, including suspension adjustments for both front and rear shocks, are provided. Learn how to properly adjust preload, rebound, and compression damping for a comfortable and stable ride.

Troubleshooting

This manual includes a detailed troubleshooting guide to help diagnose and resolve common issues. It covers engine performance, electrical systems, and component-specific problems.

FAQ

Calculate the **precise** pressure specifications for the Buell S1 Lightning tires. keyboard_arrow_down

32 PSI (2.2 bar) is specified for the front tire when ridden solo, and 36 PSI (2.5 bar) for the rear tire when ridden solo.

What values define the **proper** assembly sequence for the front wheel bearings? keyboard_arrow_down

New wheel bearings (6, 11) are installed into the hub using a suitable driver and must be pressed on the outer race only, with the spacer sleeve correctly seated.

Assess the **standard** service interval parameters for the rear brake fluid. keyboard_arrow_down

The rear brake fluid should be checked at every 5000 mile (8000 km) service interval thereafter, in addition to the initial 500 mile (800 km) interval.

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