Buell 2009 XB Series Service Manual

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2009 Buell XB Models Service Manual

99490-09Y

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Summary of Contents for Buell 2009 XB Series

Page 2: Important Notice
IMPORTANT NOTICE Buell motorcycles conform to all applicable U.S.A. Federal Motor Vehicle Safety Standards and U.S.A. Environmental Protection Agency regulations effective on the date of manufacture. To maintain the safety, dependability, and emission and noise control performance, it is essential that the procedures, specifications and service instructions in this manual are followed.
Page 4 Blank Text Here...
Page 5 READER COMMENTS Blank Text Here The Buell Motorcycle Company maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we need user feedback - your critical evaluation of this manual. Please comment on the completeness, accuracy, organization, usability, and readability of this manual.
Page 6 NOTES...
Page 7: About This Manual
First, it will acquaint the user with the construction of the To avoid unnecessary disassembly, carefully read all rel- Buell product and assist in the performance of basic mainten- ance and repair. Secondly, it will introduce to the professional ative service information before repair work is started.
Page 8 Accordingly, anyone who uses a service H-D MICHIGAN, INC. TRADEMARK procedure or tool which is not recommended by Buell Motor- INFORMATION cycle Company must first thoroughly satisfy himself that neither his nor the operator's safety will be jeopardized as a result.
Page 9: Table Of Contents
Ratchets and Handles..........1-6 Sockets................1-6 1.11 PRIMARY CHAIN Storage Units...............1-6 Inspection.................1-33 1.3 FUEL AND OIL Adjustment...............1-33 Fuel..................1-7 1.12 STEERING HEAD BEARINGS Gasoline Blends: Buell Models...........1-7 General................1-35 Engine Lubrication..............1-7 Inspection.................1-35 Winter Lubrication..............1-8 Determining Proper Resistance........1-35 1.4 MAINTENANCE SCHEDULE 1.13 SPARK PLUGS General................1-9 Inspection.................1-36...
Page 10 TABLE OF CONTENTS 1.16 INTERACTIVE EXHAUST CABLE CHASSIS Adjustment...............1-42 2.1 FASTENER TORQUE VALUES 1.17 HEADLAMP Fastener Torque Values in this Chapter......2-1 Headlamp Alignment............1-44 Headlamp Adjustment: Firebolt........1-44 2.2 SPECIFICATIONS Headlamp Adjustment: Lightning........1-45 Firebolt................2-11 Horizontal Alignment..........1-45 Lightning................2-12 Vertical Alignment.............1-45 Ulysses................2-13 Headlamp Adjustment: Ulysses........1-45 Suspension Settings............2-15 Horizontal Alignment..........1-45 Vertical Alignment.............1-46...
Page 11 TABLE OF CONTENTS Cleaning and Inspection..........2-41 2.15 FENDERS Assembly..............2-42 Front Fender: XB12R............2-71 Master Cylinder/Reservoir: Installation......2-43 Removal..............2-71 Front Brake Fluid Line............2-44 Installation..............2-71 Removal..............2-44 Rear Fender: XB12R............2-71 Installation..............2-45 Removal..............2-71 Caliper: Removal and Installation........2-45 Installation..............2-71 Removal..............2-45 Front Fender: XB9SX/XB12Scg/XB12XT......2-71 Installation..............2-46 Removal..............2-71 Caliper: Repair..............2-46 Installation..............2-71 Disassembly..............2-46 Rear Fender: XB9SX/XB12Scg........2-71...
Page 12 TABLE OF CONTENTS 2.21 FRAME PUCKS 2.30 FRONT MODULES: LIGHTNING/ULYSSES Removal................2-91 Installation................2-91 Removal.................2-116 Installation..............2-117 2.22 FRAME 2.31 HANDLEBARS: FIREBOLT Removal................2-92 Installation................2-92 General................2-118 Removal.................2-118 2.23 REAR SHOCK ABSORBER Right Clip-On............2-118 General................2-93 Left Clip-On.............2-118 Removal: Firebolt..............2-95 Installation..............2-118 Removal: Lightning............2-96 Right Clip-On............2-118 Removal: Ulysses.............2-96 Left Clip-On.............2-118 Installation: Firebolt............2-97 2.32 HANDLEBARS: LIGHTNING/ULYSSES...
Page 13 TABLE OF CONTENTS Assembly................2-133 Installation...............2-156 Engine Shroud Air Scoop..........2-156 2.40 LEFT TAIL SECTION AND BATTERY Removal..............2-156 PAN: LIGHTNING Installation...............2-156 Oil Cooler Air Scoop............2-156 Disassembly..............2-135 Removal..............2-156 Cleaning.................2-137 Installation...............2-156 Assembly................2-137 2.50 CHIN FAIRING 2.41 CENTER TAIL SECTION: LIGHTNING Removal.................2-158 Disassembly..............2-139 Installation..............2-158 Assembly................2-139 2.51 SEAT 2.42 RIGHT TAIL SECTION: LIGHTNING Firebolt................2-159...
Page 14 TABLE OF CONTENTS 3.2 SPECIFICATIONS Cleaning and Inspection...........3-64 Assembly/Installation............3-65 General................3-3 3.11 OIL RESERVOIR AND OIL HOSE 3.3 ENGINE ROUTING Adjustment/Testing.............3-7 General................3-67 General................3-7 Compression Test...............3-7 3.12 OIL LINE FITTINGS Cylinder Leakage Test............3-7 Removal................3-69 Diagnosing Smoking Engine or High Oil Consumption..3-8 Installation................3-69 3.4 ENGINE ROTATION FOR SERVICE 3.13 OIL COOLER General................3-9...
Page 15 TABLE OF CONTENTS 4.11 COOLING FAN FUEL SYSTEM General................4-19 4.1 FASTENER TORQUE VALUES Removal................4-19 Installation................4-19 Fastener Torque Values in this Chapter......4-1 4.12 FUEL TANK VENT VALVE 4.2 SPECIFICATIONS General................4-20 General................4-3 Removal................4-20 Installation................4-20 4.3 AIR CLEANER ASSEMBLY 4.13 FUEL CAP RETAINING RING Removal................4-4 Inspection................4-5 Removal................4-21...
Page 16 TABLE OF CONTENTS Removal: Firebolt..............4-42 5.10 TRANSMISSION DISASSEMBLY Vent Valve..............4-42 Transmission Removal From Left Crankcase....5-31 Canister..............4-42 Mainshaft/Countershaft............5-35 Removal: Lightning/Ulysses..........4-42 Mainshaft Disassembly.............5-35 Vent Valve..............4-42 Cleaning and Inspection..........5-36 Canister..............4-42 Countershaft Disassembly..........5-36 Installation: Firebolt............4-42 Cleaning and Inspection..........5-36 Vent Valve..............4-42 Canister..............4-42 5.11 TRANSMISSION ASSEMBLY Installation: Lightning/Ulysses..........4-43 Mainshaft Assembly............5-38 Vent Valve..............4-43...
Page 17 TABLE OF CONTENTS 6.2 SPECIFICATIONS Assembly..............6-28 Solenoid Contacts............6-28 General................6-4 Disassembly..............6-28 Assembly..............6-29 6.3 IGNITION SYSTEM 6.10 VOLTAGE REGULATOR General................6-6 Troubleshooting..............6-7 General................6-31 Removal................6-31 6.4 IGNITION/HEADLAMP KEY SWITCH Installation................6-31 General................6-8 6.11 ALTERNATOR FIREBOLT................6-8 Removal..............6-8 Removal and Disassembly..........6-33 Disassembly..............6-9 Rotor.................6-33 Assembly..............6-9 Stator.................6-33 Installation..............6-10 Cleaning and Inspection...........6-34 LIGHTNING..............6-10 Assembly and Installation..........6-34 Removal..............6-10...
Page 18 TABLE OF CONTENTS 6.17 INTERACTIVE EXHAUST SYSTEM 6.27 MAIN WIRE HARNESS General................6-50 General................6-74 Removal................6-52 Removal................6-74 Installation................6-53 Installation................6-81 6.18 HEADLIGHT 6.28 AUXILIARY HARNESS: XB12XP General................6-54 XB12XP Ulysses Police Model Auxiliary Harness....6-90 Headlight Bulbs: Firebolt..........6-54 Removal..............6-90 Removal..............6-54 Installation..............6-92 Installation..............6-54 6.29 INTERACTIVE EXHAUST HARNESS: Headlight Bulbs: Lightning and Ulysses......6-55 Removal..............6-55 XB12 MODELS...
Page 19 TABLE OF CONTENTS A.4 DEUTSCH ELECTRICAL CONNECTORS Crimping Terminals...........A-22 Deutsch Connector Repair..........A-8 A.11 PACKARD 480 METRI-PACK General...............A-8 CONNECTORS Separating Pin and Socket Housings......A-8 480 Metri-Pack Connector Repair........A-23 Mating Pin and Socket Housings........A-8 General..............A-23 Removing Socket Terminals........A-8 Separating Pin and Socket Housings.......A-23 Installing Socket Terminals..........A-8 Mating Pin and Socket Housings......A-23 Removing Pin Terminals...........A-10...
Page 20 TABLE OF CONTENTS Place and Color............B-1 Ulysses................D-26 Connector Number............B-1 APPENDIX E ACTIVE INTAKE Repair Instructions............B-1 (JAPANESE MODELS) B.2 WIRING DIAGRAMS Wiring Diagram Information..........B-3 E.1 ACTIVE INTAKE SYSTEM (JAPANESE Wire Color Codes............B-3 MODELS ONLY) Wiring Diagram Symbols..........B-3 2009 XB Wiring Diagrams..........B-4 General................E-1 Active Intake System..........E-1 APPENDIX C CONVERSIONS...
Page 21 TABLE OF CONTENTS SUBJECT..........................PAGE NO. 1.1 FASTENER TORQUE VALUES....................1-1 1.2 GENERAL..........................1-3 1.3 FUEL AND OIL..........................1-7 1.4 MAINTENANCE SCHEDULE ....................1-9 1.5 BATTERY MAINTENANCE.....................1-11 1.6 ENGINE OIL AND FILTER......................1-15 1.7 BRAKE SYSTEM MAINTENANCE..................1-18 1.8 TIRES AND WHEELS......................1-25 1.9 CLUTCH/TRANSMISSION/PRIMARY FLUID.................1-27 1.10 DRIVE BELT MAINTENANCE....................1-30 1.11 PRIMARY CHAIN........................1-33 1.12 STEERING HEAD BEARINGS....................1-35 1.13 SPARK PLUGS........................1-36...
Page 22 NOTES...
Page 23: Fastener Torque Values
HOME FASTENER TORQUE VALUES FASTENER TORQUE VALUES IN THIS CHAPTER The table below lists torque values for all fasteners presented in this chapter. FASTENER TORQUE VALUE NOTES Battery terminal fastener 72-96 in-lbs 8-11 Nm 1.5 BATTERY MAINTENANCE, Battery Installation and Connection Battery terminal fastener 72-96 in-lbs 8-11 Nm...
Page 24 HOME FASTENER TORQUE VALUE NOTES Primary drain plug 14-30 ft-lbs 19-41 Nm 1.9 CLUTCH/TRANSMISSION/PRIMARY FLUID, Transmission Fluid Pushrod adjustment locknut 130-173.5 in-lbs 14.7-19.6 Nm 1.7 BRAKE SYSTEM MAINTENANCE, Brake Pedal Adjustment Rear brake caliper mounting fasteners 24-26 ft-lbs 32.5-35 Nm 1.7 BRAKE SYSTEM MAINTENANCE, Brake Pad Replacement Rear brake line assembly fastener...
Page 25: General
HOME GENERAL SERVICING A NEW MOTORCYCLE 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 Perform the service and maintenance operations as proper tools.
Page 26: Disassembly And Assembly
HOME Disassembly and Assembly Wiring, Hoses and Lines Always assemble or disassemble one part at a time. Do not Hoses, clamps, electrical wiring, electrical switches or fuel lines work on two assemblies simultaneously. Be sure to make all if they do not meet specifications. necessary adjustments.
Page 27: O-Rings (Preformed Packings)
HOME Leaking oil or grease usually means that a seal is damaged. Bearings Replace leaking seals to prevent overheated bearings. Remove shields and seals from bearings before cleaning. Always discard seals after removal. Do not use the same seal Clean bearings with permanent shields and seals in solution. twice.
Page 28: Hammers
HOME Hammers Ratchets and Handles Never strike a hammer against a hardened object, such Periodically clean and lubricate ratchet mechanisms with as another hammer. a light grade oil. Do not replace parts individually; ratchets should be rebuilt with the entire contents of service kit. Always grasp a hammer handle firmly, close to the end.
Page 29: Fuel And Oil
Pump Octane (R+M)/2 91 (95 RON) some lubricants interact chemically when mixed. Use of GASOLINE BLENDS: BUELL MODELS inferior lubricants can damage the engine. (00184a) Engine oil is a major factor in the performance and service life Your motorcycle was designed to get the best performance of the engine.
Page 30: Winter Lubrication
HOME Water vapor is a normal by-product of combustion in any WINTER LUBRICATION engine. During cold weather operation, some of the water vapor In colder climates, the engine oil should be changed often. If condenses to liquid form on the cool metal surfaces inside the motorcycle is used frequently for short trips, less than 15 miles engine.
Page 31: Maintenance Schedule
Verify component and system func- tions NOTES: 1. Should be performed by an authorized Buell dealer, unless you have the proper tools, service data and are mechanically qualified. 2. Change brake fluid every two (2) years. Table 1-4. Quick Reference Maintenance Chart: XB Models...
Page 32 HOME Table 1-4. Quick Reference Maintenance Chart: XB Models ITEM SERVICED SPECIFICATION DATA Primary chain/transmission Lubricant level GENUINE HARLEY-DAVIDSON FORMULA+ TRANSMISSION lubricant AND PRIMARY CHAINCASE LUBRICANT (Part No. 99851-05) as required until fluid level is even with bottom of clutch dia- phragm spring Primary chaincase drain plug Apply LOCTITE 565 THREAD SEALANT and reinstall plug and...
Page 33: Battery Maintenance
HOME BATTERY MAINTENANCE GENERAL NOTE For charging information, see 1.5 BATTERY MAINTENANCE, Charging Battery. For testing information, see ELECTRICAL DIAGNOSTIC MANUAL. Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield, sm04816 rubberized gloves and protective clothing when working with batteries.
Page 34: Battery Disconnection And Removal
HOME CHARGING BATTERY Table 1-5. Antidotes for Battery Acid Safety Precautions CONTACT TREATMENT Never charge a battery without first reviewing the instructions External Flush with water. for the charger being used. In addition to the manufacturer's Internal Drink large quantities of milk or water, followed instructions, follow these general safety precautions: by milk of magnesia, vegetable oil or beaten Always wear eye, face and hand protection.
Page 35: Battery Installation And Connection
HOME Table 1-6. 12 Amp-Hour Battery Charging Rates and Times READING PERCENT 3 AMP 6 AMP 10 AMP 20 AMP (VOLTS) CHARGE CHARGER CHARGER CHARGER CHARGER 12.7 12.6 1 hour 10 minutes 34 minutes 20 minutes 10 minutes 12.3 2 hours 20 minutes 1 hour 10 minutes 40 minutes 20 minutes...
Page 36: Storage
HOME Insert fastener through battery positive cable (red) into Figure 1-3. Self-discharge is a normal condition and occurs threaded hole of battery positive (+) terminal and tighten continuously at a rate that depends on the ambient temperature fastener to 72-96 in-lbs (8-11 Nm). and the battery's state of charge.
Page 37: Engine Oil And Filter
HOME ENGINE OIL AND FILTER Figure 1-5. Unscrew and remove dipstick and read GENERAL oil level. The engine oil level can be checked with the oil and engine at If the level is below the lower registration mark, add only ambient temperatures (cold check).
Page 38: Change Filter
Change Filter 3. Oil line fittings Remove chin fairing. See 2.50 CHIN FAIRING. Figure 1-7. Oil Filter: Buell Models except Blast Figure 1-7. Remove oil filter using pliers or belt type oil filter wrench. Fill Engine With Oil Clean filter gasket contact surface on crankcase. Surface must be smooth and free of debris or old gasket material.
Page 39: Return To Service
HOME Blow out any debris from fins with compressed air from Start engine. Verify that oil pressure signal light on instru- the inside of the oil cooler outward. Inspect cooler fins for ment cluster turns off after a few seconds when engine debris or damage.
Page 40: Brake System Maintenance
HOME BRAKE SYSTEM MAINTENANCE Inspect front and rear brake lines and replace as required: GENERAL Every 4 years. Check brake fluid level and condition: Inspect caliper and master cylinder seals and replace as When storing or removing the motorcycle for the season. required: Replace D.O.T.
Page 41: Bleeding Front Brake
HOME braking ability and lead to brake failure which could result in sm00485 death or serious injury. 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 pres- surization.
Page 42: Bleeding Rear Brake
HOME Install seat, if removed. Bleeding Rear Brake NOTE sm00488 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 pres- surization. Figure 1-11.
Page 43: Brake Pad Thickness
HOME NOTES sm00490 Figure 1-13. On the very end of the threaded brake rod, are two flat sides (2). To verify proper thread engagement with the clevis (3), the flat sides must extend below the extruded nut (1) in the clevis by at least one full thread.
Page 44: Brake Rotor Thickness
HOME BRAKE ROTOR THICKNESS sm00493 Be sure that no lubricants or fluids get 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. (00047d) Figure 1-16 Figure 1-17.
Page 45: Rear Pad Removal
HOME Figure 1-18. Install pin hanger (2) making sure it Figure 1-20. Remove inner and outer pads, being engages hole on both pads and spring clip. careful not to dislodge pad spring. Rotate caliper clockwise to align mounting fastener hole. Rear Pad Installation Install lower caliper mounting fastener (4).
Page 46 HOME sm00495 sm00496 Figure 1-20. Rear Brake Pad Spring Installed 1. Rear caliper mounting fasteners 2. Brake pad retainer 3. Rear caliper pin plug 4. Rear caliper pin hanger Figure 1-19. Rear Brake Caliper 1-24 2009 XB Service: Maintenance...
Page 47: Tires And Wheels
TIRES AND WHEELS TIRE INFLATION om00962 Use only Buell approved tires. See a Buell dealer. Using non-approved tires can adversely affect stability, which could result in death or serious injury. (00133a) Do not inflate tire beyond maximum pressure as specified on sidewall.
Page 48: Wheel Bearings
HOME Table 1-9. Tires: 2009 XB Models MODEL TIRE TYPE SOLO RIDING LOADED TO GVWR XB12R Front Pirelli Diablo Corsa III 120/70 ZR 17 Same as solo riding values. Rear Pirelli Diablo Corsa III 180/55 ZR 17 XB9SX, Front Pirelli Scorpion SYNC 120/70 ZR 17 Same as solo XB12X, riding values.
Page 49: Clutch/Transmission/Primary Fluid
HOME CLUTCH/TRANSMISSION/PRIMARY FLUID INSPECTION sm01388 Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect negative battery cable from battery. Figure 1-23. Remove three TORX screws with washers (1) from clutch inspection cover (2).
Page 50: Adjustment
HOME sm05323 Do not overfill the primary chaincase with lubricant. Overfilling can cause rough clutch engagement, incom- plete disengagement, clutch drag and/or difficulty in finding neutral at engine idle. (00199b) Make certain primary chaincase is filled with proper amount of lubricant with motorcycle upright. If under filled, transmission can be damaged during vehicle operation.
Page 51 HOME hook. Once the measurement has been attained you will sm00091 need to route the cable through the hook. Spring installs on outboard side of hex lockplate. Squeeze clutch hand lever to maximum limit three times. This sets the ball and ramp mechanism. Adjust as follows: Figure 1-29.
Page 52: Drive Belt Maintenance
HOME DRIVE BELT MAINTENANCE 1.10 result in belt failure and indicates worn transmission GENERAL sprocket teeth. Replace belt and transmission sprocket. The drive belt tension on a new belt will loosen after approxim- Signs of puncture or cracking at the base of the belt teeth. ately 1000 miles (1600 km).
Page 53 HOME Table 1-10. Potential Limits to Belt Drive Service Life CONDITION ROOT CAUSE REQUIRED ACTION Excessive edge wear Misalignment or bent drive structure Check structure (bad bearing, bent members, etc.) (mistracking) Bent or rough flange Repair flange/replace sprocket Damage due to handling (pry on, etc.) Follow proper handling/installation procedure Debris damage to edge of belt Inspect/replace belt...
Page 54 HOME Table 1-10. Potential Limits to Belt Drive Service Life CONDITION ROOT CAUSE REQUIRED ACTION Belt breakage Excessive load/shock load Inspect/replace belt Riding practice/operator choice Damage due to handling (pry-on, etc.) Follow proper handling/installation procedure Debris in sprocket or belt Inspect/replace sprocket Clean and protect drive Inspect/replace belt...
Page 55: Primary Chain
HOME PRIMARY CHAIN 1.11 INSPECTION sm00097 Figure 1-31. Measure primary chain tension through the inspection cover opening. Adjust primary chains not meeting vertical free play specifications. Figure 1-31. Remove two fasteners with captive washers and primary chain inspection cover with gasket from primary cover.
Page 56 HOME Tighten locknut (1) to 20-25 ft-lbs (27-34 Nm). sm00096 1. Locknut 2. Adjusting fastener Figure 1-33. Chain Tension Adjusting Fastener (Typical) 1-34 2009 XB Service: Maintenance...
Page 57: Steering Head Bearings
Loosen steering stem capnut and back off several turns. Do not operate motorcycle with loose, worn or damaged steering or suspension systems. Contact a Buell dealer Remove lower triple clamp pinch fasteners, two per side. for repairs. Loose, worn or damaged steering or suspen- Tighten steering stem capnut to 38-42 ft-lbs (52-57 Nm).
Page 58: Spark Plugs
HOME SPARK PLUGS 1.13 INSPECTION sm00099 Check spark plugs: Replace every 10,000 mile (16,000 km) service interval. Use only Harley-Davidson 10R12X spark plugs. Remove left side air scoop to access front cylinder spark plug. See 2.49 AIR SCOOPS. Disconnect cable from front spark plug. Using a 5/8 in.
Page 59 HOME 12. Apply LOCTITE ANTI-SEIZE to threads of spark plugs. 16. Install seat. Install and tighten spark plugs to 12-18 ft-lbs (16-24 Nm). NOTE sm00100 An extension may be needed to push on rear spark plug boot to verify it is seated properly. 13.
Page 60: Air Cleaner And Exhaust System
HOME AIR CLEANER AND EXHAUST SYSTEM 1.14 REMOVAL sm00376 Install air filter before running engine. Failure to do so can draw debris into the engine and could result in engine damage. (00207a) Check air filter element: Inspect at the 1000 mile (1600 km) service interval and at every 5000 mile (8000 km) service interval thereafter.
Page 61: Cleaning And Inspection
HOME sm00501 sm00503 Figure 1-40. Air Cleaner Cover Latches 1. Breather hoses (2) 2. Intake air sensor 3. Velocity stack sm00502 Figure 1-42. Air Cleaner Baseplate Assembly INSTALLATION Figure 1-43. Place filter element (1) on baseplate (2). Position air cleaner cover over baseplate. Make sure air filter remains correctly positioned.
Page 62: Exhaust System Leak Check
HOME EXHAUST SYSTEM LEAK CHECK sm00502 Check the exhaust system for leaks at every scheduled service interval as follows: Check entire exhaust system for loose or missing fasteners, broken pipe clamps or brackets, and obvious signs of leakage (carbon tracks at pipe joints, etc.). Check for loose or broken heat shields.
Page 63: Throttle Cable
HOME THROTTLE CABLE 1.15 released. If this is not the case, turn adjuster on idle control THROTTLE CABLE ADJUSTMENT cable (shortening cable housing) until throttle control functions properly. Tighten cable adjuster lock on idle control cable. Recheck Be sure that steering is smooth and free without interfer- operation of throttle control.
Page 64: Interactive Exhaust Cable
HOME INTERACTIVE EXHAUST CABLE 1.16 is working properly. If you do not see the mark, verify ADJUSTMENT previous cable adjustment. Remove intake cover assembly. See 2.38 INTAKE DO NOT start vehicle in this mode. COVER. 10. Cycle the actuator to verify cable and valve operation: NOTES Hold the throttle wide open.
Page 65 HOME sm00506 sm00505 Figure 1-46. Checking For 1/8 in. (3.2 mm) Maximum Free Play In Either Direction For Proper Adjustment 1. Interactive exhaust cable 2. Frame lug Figure 1-47. Correct Cable Routing Behind Frame Lug (Typical) 2009 XB Service: Maintenance 1-43...
Page 66: Headlamp
HOME HEADLAMP 1.17 HEADLAMP ALIGNMENT om00029 The automatic-on headlamp feature provides increased visibility of the rider to other motorists. Be sure headlamp is on at all times. Poor visibility of rider to other motorists can result in death or serious injury. (00030b) NOTE Vehicles with multiple beam headlamps that are individually aimed should be adjusted so both lamps converge into one...
Page 67 HOME pd00196 pd00198 1. High beam adjuster (left) 2. Low beam adjuster (right) Figure 1-49. Headlamp Height Adjustment: Firebolt Figure 1-51. Horizontal Headlamp Adjustment Fastener: Lightning HEADLAMP ADJUSTMENT: LIGHTNING Horizontal Alignment pd00199 Figure 1-50 Figure 1-51. Loosen fasteners on right and left side of headlamp housing to adjust the horizontal alignment.
Page 68 HOME Vertical Alignment pd00202 Figure 1-55 Figure 1-56. Loosen fastener on the bottom of headlamp housing to adjust the vertical alignment. The ver- tical headlamp adjustment screw is located under the front upper fender. NOTE Only loosen headlamp alignment fastener enough to adjust headlamp.
Page 69: Windshield Maintenance
Failure to maintain polycarbonate properly can result in damage to the wind- screen/windshield. (00483d) Buell recommends using Harley Softcloths with the following products to clean your windscreen. To minimize swirl marks, cleaning should be done when motorcycle is cool and parked in the shade.
Page 70: Storage
HOME STORAGE 1.19 Wash and polish molded-in-color, painted and chrome- GENERAL plated surfaces. If motorcycle is to be covered, use a material that will breathe, such as light canvas. Plastic materials that do Do not store motorcycle with gasoline in tank within the not breathe promote the formation of condensation.
Page 71: Troubleshooting
HOME TROUBLESHOOTING 1.20 12. Fuel pump inoperative. GENERAL 13. Plugged fuel injectors. NOTE The troubleshooting section of this manual is a guide to dia- 14. Fuse blown. gnose problems. Read the appropriate sections of this manual Starts Hard before performing any work. Spark plugs in bad condition or have improper gap or are The following check list of possible operating troubles and their partially fouled.
Page 72: Lubrication System
HOME Incorrect spark plug for the kind of service. Check Engine Light Illuminates During Operation Piston rings badly worn or broken. Fault detected. See the Electrical Diagnostic Manual for Valve guides or seals badly worn or damaged. this motorcycle. Pre-Ignition or Detonation (Knocks or Pings) LUBRICATION SYSTEM Fuel octane rating too low.
Page 73: Electrical System
HOME Oil diluted with gas. Clutch Slips Open in oiling circuit. Clutch controls improperly adjusted. High Oil Pressure Insufficient clutch spring tension. Oil tank overfilled. Worn friction discs. Bypass valve stuck in closed position. Clutch Drags Or Does Not Release Restricted oil tank return hose.
Page 74 HOME Rims and tires out-of-round or eccentric with hub: tire 10. Heavy front end loading. Non-standard equipment on the runout should not be more than 0.060 in. (1.5 mm). front end (such as heavy radio receivers, extra lighting equipment or luggage) tends to cause unstable handling. Irregular or peaked front tire tread wear.
Page 75 HOME Table 1-14. Front Suspension Problems TROUBLESHOOTING CONDITION ADJUSTMENT SOLUTION Not absorbing bumps. A good suspension is a balance between damping and track condition. Finding this balance requires exploring all possible compression settings. Lack of tire feedback. Increase compression damping. Tire slides.
Page 76 NOTES 1-54 2009 XB Service: Maintenance...
Page 77 TABLE OF CONTENTS SUBJECT..........................PAGE NO. 2.1 FASTENER TORQUE VALUES....................2-1 2.2 SPECIFICATIONS........................2-11 2.3 VEHICLE IDENTIFICATION NUMBER (VIN)................2-19 2.4 WHEELS..........................2-21 2.5 FRONT WHEEL........................2-23 2.6 REAR WHEEL.........................2-31 2.7 TIRES............................2-35 2.8 CHECKING CAST RIM RUNOUT...................2-39 2.9 FRONT BRAKE: EIGHT PISTON CALIPER................2-40 2.10 FRONT BRAKE: SIX PISTON CALIPER................2-48 2.11 BRAKE PEDAL........................2-56 2.12 REAR BRAKE MASTER CYLINDER..................2-57 2.13 REAR BRAKE LINE......................2-63...
Page 78 NOTES...
Page 79: Fastener Torque Values
HOME FASTENER TORQUE VALUES FASTENER TORQUE VALUES IN THIS CHAPTER The table below lists torque values for all fasteners presented in this chapter. FASTENER TORQUE VALUE NOTES Axle (front) 39-41 ft-lbs 53-56 Nm 2.5 FRONT WHEEL, Installation/ANTI-SEIZE, left handed thread Axle (rear, final torque) 48-52 ft-lbs 65-70.5 Nm...
Page 80 HOME FASTENER TORQUE VALUE NOTES Brake caliper bleeder valve 36-60 in-lbs 4-7 Nm 2.9 FRONT BRAKE: EIGHT PISTON CAL- IPER, Front Brake Fluid Line Brake hand lever fastener, Firebolt 80-90 in-lbs 9-10 Nm 2.31 HANDLEBARS: FIREBOLT, Installation Brake hand lever housing fasteners 80-90 in-lbs 9-10 Nm 2.10 FRONT BRAKE: SIX PISTON CAL-...
Page 81 HOME FASTENER TORQUE VALUE NOTES Brake reservoir cover fasteners, front 9-18 in-lbs 1-2 Nm 2.9 FRONT BRAKE: EIGHT PISTON CAL- IPER, Master Cylinder/Reservoir: Installation Brake reservoir fastener, rear 48-72 in-lbs 5.4-8 Nm 2.12 REAR BRAKE MASTER CYLINDER, Installa- tion: Firebolt/Lightning Brake reservoir fastener, rear 48-72 in-lbs 5.4-8 Nm...
Page 82 HOME FASTENER TORQUE VALUE NOTES Clutch hand lever fasteners 60-84 in-lbs 7-9.5 Nm 2.32 HANDLEBARS: LIGHT- NING/ULYSSES, Installation Clutch inspection cover fasteners 84-108 in-lbs 9.5-12 Nm 2.25 CLUTCH CONTROL, Assembly and Installa- tion/Tighten in a crosswise pattern Damper rod jamnut 22-30 ft-lbs 30-41 Nm 2.16 FRONT FORKS: ALL MODELS, Assembly...
Page 83 HOME FASTENER TORQUE VALUE NOTES Fork clamp, upper 23-25 ft-lbs 31.2-33.8 Nm 2.18 STEERING HEAD BEARINGS, Installa- tion/LOCTITE 271 (red) Front fender fasteners 36-48 in-lbs 4-5.4 Nm 2.15 FENDERS, Front Fender: XB12R/LOCTITE 271 (red) Front fender fasteners 36-48 in-lbs 4-5.4 Nm 2.15 FENDERS, Front Fender: XB9SX/XB12Scg/XB12XT/LOCTITE 271 (red) Front fender fasteners...
Page 84 HOME FASTENER TORQUE VALUE NOTES Horn fastener, Firebolt 72-96 in-lbs 8-10 Nm 2.27 FAIRING SUPPORT BRACKET: FIRE- BOLT, Installation Horn fastener, Ulysses 36-60 in-lbs 4-7 Nm 2.26 HEADLAMP ASSEMBLY AND SUPPORT BRACKET, Installation: Lightning/Ulysses Ignition coil fasteners 120-144 in-lbs 13.6-16.3 Nm 2.24 THROTTLE CONTROL, Throttle Cable Replacement Instrument module fastener...
Page 85 HOME FASTENER TORQUE VALUE NOTES P clamp, front tie bar and clutch cable 25-27 ft-lbs 33.9-36.6 Nm 2.25 CLUTCH CONTROL, Assembly and Installa- tion Preload adjuster knob fastener 25-43 in-lbs 2.8-4.9 Nm 2.23 REAR SHOCK ABSORBER, Removal: Ulysses Preload adjuster mounting 48-72 in-lbs 5.4-8 Nm 2.23 REAR SHOCK ABSORBER, Installation:...
Page 86 HOME FASTENER TORQUE VALUE NOTES Rotor mounting fasteners, front 25-27 ft-lbs 34-37 Nm 2.5 FRONT WHEEL, Assembly/Metric, replace with Rotor mounting fasteners, rear 25-27 ft-lbs 34-37 Nm 2.6 REAR WHEEL, Assembly/Replace with new Seat latch fastener 60-96 in-lbs 7-11 Nm 2.45 RIGHT TAIL SECTION: ULYSSES MODELS, Assembly Seat lock bracket fasteners, Ulysses...
Page 87 HOME FASTENER TORQUE VALUE NOTES Stone guard fasteners 12-36 in-lbs 1.4-4 Nm 2.37 BELT GUARDS, Installation Swingarm brace mounting fasteners 25-27 ft-lbs 34-37 Nm 2.19 SWINGARM AND BRACE, Brace Swingarm pivot shaft 44-46 ft-lbs 59-62 Nm 2.19 SWINGARM AND BRACE, Installation: Swingarm/ANTI-SEIZE Swingarm pivot shaft pinch fastener 17-19 ft-lbs...
Page 88 HOME FASTENER TORQUE VALUE NOTES Wire cover screws, Ulysses 36-48 in-lbs 4-5.4 Nm 2.52 SEAT LOCKS, Installation: Ulysses Models Wire cover screws, Ulysses 36-48 in-lbs 4.0-5.4 Nm 2.53 TRIPLE TAIL: ULYSSES, Installation 2-10 2009 XB Service: Chassis...
Page 89: Specifications
HOME SPECIFICATIONS (GAWR) are given on an information decal located on the FIREBOLT steering head. NOTE Gross Vehicle Weight (GVWR) (maximum allowable loaded vehicle weight) and corresponding Gross Axle Weight Ratings Table 2-1. Weights: 2009 Firebolt and Lightning Models ITEM XB9SX XB12R XB12Scg...
Page 90 HOME LIGHTNING Table 2-4. Dimensions: 2009 Firebolt and Lightning Models ITEM XB9SX XB12R XB12Scg XB12Ss Overall length 76.2 1935 76.2 1935 75.7 1923 81.9 2080 Overall width (without 29.7 28.1 29.7 29.7 mirrors) Overall height (without 42.3 1075 43.3 1100 41.3 1050 43.3...
Page 91 HOME ULYSSES Table 2-7. Capacities: 2009 XB12Ss ITEM U.S. LITERS Fuel tank total 4.40 gallons 16.7 (including reserve) Reserve/low fuel lamp 0.83 gallons illuminates at Engine oil (with filter) 2.5 quarts Transmission 1.0 quart Table 2-8. Dimensions: 2009 Ulysses Models ITEM XB12X XB12XT*...
Page 92 HOME Table 2-10. Capacities: 2009 Ulysses Models ITEM U.S. LITERS Do not inflate tire beyond maximum pressure as specified on sidewall. Over inflated tires can blow out, which could Fuel tank total 4.40 gallons 16.7 result in death or serious injury. (00027a) (including reserve) Reserve/low fuel lamp 0.83 gallons...
Page 93: Suspension Settings
Be sure tires are properly inflated, balanced and have Exceeding these weight ratings can affect stability and adequate tread. Inspect your tires regularly and see a Buell handling, which could result in death or serious injury. dealer for replacements. Riding with excessively worn,...
Page 94 HOME Table 2-12. Recommended Suspension Settings: 2009 Lightning XB9SX LOAD*** FRONT FORK REAR SHOCK *PRELOAD: **COMPRES- **REBOUND: PRELOAD **COMPRES- **REBOUND: TURNS IN SION: TURNS TURNS OUT POSITION SION: TURNS TURNS OUT FROM MIN- OUT FROM FROM MAX- OUT FROM FROM MAX- IMUM MAXIMUM IMUM...
Page 95 HOME Table 2-14. Recommended Suspension Settings: 2009 Lightning XB12Ss LOAD** FRONT FORK REAR SHOCK PRELOAD: *COMPRES- *REBOUND: PRELOAD *COMPRES- *REBOUND: NO. OF LINES SION: TURNS TURNS OUT POSITION SION: TURNS TURNS OUT SHOWING OUT FROM FROM MAX- OUT FROM FROM MAX- MAXIMUM IMUM MAXIMUM...
Page 96 HOME Table 2-16. Recommended Suspension Settings: 2009 Ulysses XB12XT LOAD*** FRONT FORKS REAR SHOCK *PRELOAD: **COMPRES- **REBOUND: *PRELOAD: **COMPRES- **REBOUND: TURNS IN SION: TURNS TURNS OUT TURNS IN SION: TURNS TURNS OUT FROM MIN- OUT FROM FROM MAX- FROM MIN- OUT FROM FROM MAX- IMUM...
Page 97: Vehicle Identification Number (Vin)
Market designation (WMI code) 4MZ = Buell vehicles originally manufactured for sale within the United States 5MZ = Buell vehicles originally manufactured for sale outside the United States 95Z = Buell vehicles originally manufactured for sale in Brazil at Manaus CKD plant ®...
Page 98 HOME Table 2-17. Buell V.I.N. Breakdown: 2009 Models POSITION DESCRIPTION POSSIBLE VALUES Model 0=Blast 2=XB9SX 3=XB12R 5=XB12Scg 6=XB12Ss 7=XB12X 9=XB12XP A=XB12XT B=1125R C=1125CR D=1125R, 105 HP France E=1125CR, 105 HP France Sequential number (last five Varies digits) 2-20 2009 XB Service: Chassis...
Page 99: Wheels
HOME WHEELS GENERAL sm00110 Good handling and maximum tire mileage are directly related to the care of wheels and tires. Regularly inspect wheels and tires for damage and wear. If handling problems occur, see 1.20 TROUBLESHOOTING Table 2-18. 1.8 TIRES AND WHEELS for tire pressures.
Page 100 Tires and wheels are critical items. Since the servicing of Buell tires are equipped with wear bars that run horizont- these components requires special tools and skills, Buell ally across the tread. When wear bars become visible and recommends that you see your dealer for these services.
Page 101: Front Wheel
HOME FRONT WHEEL REMOVAL sm00511 Place a scissor jack under jacking point and raise front wheel off ground. For location of jacking point see 4.18 EXHAUST SYSTEM. NOTE Do not operate front brake lever with front wheel removed or caliper pistons may be forced out. Reseating pistons requires caliper disassembly.
Page 102 HOME 50A) and WHEEL BEARING REMOVER/INSTALLER (Part sm00513 No. HD-44060A). Sparingly apply EXTREME PRESSURE LUB- RICANT (Part No. J-23444-A) to the threads of the short forcing screw (1) to prolong service life and verify smooth operation. Assemble the short forcing screw (1), nut (2), Nice bearing (3), washer (4) and bridge (5).
Page 103 HOME sm00515 sm00517 1. Bridge 2. Nut 3. Forcing screw Figure 2-10. Remove the Spacer Figure 2-8. Remove the Bearing Front Rotor Removal Figure 2-16. Remove and discard rotor mounting fasteners (7). sm00516 Remove and inspect brake rotor (6) for wear and warping. 2.10 FRONT BRAKE: SIX PISTON CALIPER, Cleaning and Inspection.
Page 104: Bearing Installation
HOME ASSEMBLY sm00518 PART NUMBER TOOL NAME B-43993-10 FRONT WHEEL BEARING INSTALLER B-43993-11 FRONT BACKING PLATE WHEEL B-43993-50A WHEEL BEARING REMOVER/INSTALLER KIT B-43993-7 FRONT WHEEL BEARING REMOVER COLLET B-43993-9 FRONT BEARING INSTALLER B-43993-9, FROM FRONT BEARING INSTALLER KIT PART NO. B- 43993-50A HD-44060A WHEEL BEARING...
Page 105 HOME sm00519 sm00520 1. Forcing screw 2. Backing plate Figure 2-13. Insert Forcing Screw and Backing Plate Figure 2-13. Remove the backing plate (2) from the long forcing screw (1). Reinstall the Backing Plate onto 1. Long forcing screw the forcing screw, with the smaller diameter toward the 2.
Page 106 HOME NOTE sm00522 Figure 2-14. Center the spacer (2) while installing the wheel bearing. Failure to center the spacer could cause the bearing not to pull in straight. 11. See Figure 2-15. Insert a new wheel bearing (1) squarely into the hub, with the lettered side facing out (away from the wheel).
Page 107 HOME sm00523 Front axle Front brake springs (6) Rotor mount fastener (6) Wheel bearing Front wheel spacer Drive bushings (6) Front wheel Front brake rotor Washer (6) Figure 2-16. Front Wheel Assembly Front Rotor Installation Figure 2-16. Install new springs (4). Rotor mounting fasteners must be seated into drive Install new washers (9).
Page 108 HOME Figure 2-17. Install caliper. sm00511 Align wheel so that rotor mounting fasteners straddle caliper. Rotate right front fork counterclockwise to align caliper with rotor. Lower front wheel into caliper assembly. NOTE The front axle is left handed thread. Install front axle. Apply LOCTITE ANTI-SEIZE LUBRICANT to axle.
Page 109: Rear Wheel
HOME REAR WHEEL REMOVAL CLEANING AND INSPECTION Place a scissor jack under jacking point and raise rear wheel off ground. For location of jacking point see 4.18 EXHAUST SYSTEM. Using compressed air to "spin dry" bearings can cause NOTE bearing to fly apart, which could result in death or serious injury.
Page 110 HOME sm00525 Rotor mounting fastener (6) Wheel spacer Sprocket fastener Brake rotor Wheel Axle Wheel bearing Sprocket Figure 2-20. Rear Wheel Assembly 2-32 2009 XB Service: Chassis...
Page 111 HOME BACKING PLATES (Part No. B-43993-11 front wheel and ASSEMBLY B-43993-12 rear wheel). PART NUMBER TOOL NAME The procedure for the rear wheel bearing installation is B-43993-10 FRONT WHEEL BEARING INSTALLER the same as front wheel bearing installation. See 2.5 FRONT WHEEL, Assembly.
Page 112 HOME Slide axle through right side of swingarm and wheel hub sm00524 and thread partially into swingarm on left side. Install idler pulley. See 5.7 DRIVE BELT AND IDLER PULLEY, Idler Pulley Installation. NOTE Never tighten rear axle with swingarm brace removed. sm00302 Figure 2-24.
Page 113: Tires
TIRES GENERAL Tires should be inspected for punctures, cuts, breaks and wear Buell tires are equipped with wear bars that run horizont- before every ride. ally across the tread. When wear bars become visible and New tires should be stored in a horizontal tire rack. Avoid only 1/32 in.
Page 114 Figure 2-26. Loosening Beads from Rim Flange Buell front and rear tires are not the same. Interchanging front and rear tires can cause tire failure, which could result in death or serious injury. (00512b) Damaged or leaking valve stems must be replaced.
Page 115 HOME Start 180 degrees from valve stem hole and place second sm04915 bead on rim. Work bead onto rim with tire tools, working toward valve in both directions. Do not inflate tire beyond maximum pressure as specified on sidewall. Over inflated tires can blow out, which could result in death or serious injury.
Page 116: Wheel Balancing
HOME NOTE ADJUSTMENT If wheel assembly is out of specification (1 oz. front, 2 oz. rear) PART NUMBER TOOL NAME rotate tire on rim and rebalance until wheel is within specifica- tion. HD-99500-80 WHEEL TRUING AND BALANCING STAND Table 2-21. Maximum Weight Applied To Cast Wheels Wheel Balancing WHEEL MAXIMUM WEIGHT...
Page 117: Checking Cast Rim Runout
HOME CHECKING CAST RIM RUNOUT GENERAL sm00111 PART NUMBER TOOL NAME HD-99500-80 WHEEL TRUING AND BALANCING STAND Before installing a new tire, check wheels for lateral and radial runout. Rim Lateral Runout Figure 2-32. Install truing arbor in wheel hub and place wheel in the WHEEL TRUING AND BALANCING STAND (Part No.
Page 118: Front Brake: Eight Piston Caliper
HOME FRONT BRAKE: EIGHT PISTON CALIPER FRONT BRAKE HAND LEVER Figure 2-34. Remove pivot bolt nut (1) and pivot bolt D.O.T. 4 brake fluid will damage painted and body panel (2) to detach the brake hand lever (3). surfaces it comes in contact with. Always use caution and To install, lubricate pivot bolt with LOCTITE ANTI-SEIZE.
Page 119 HOME Figure 2-38. Depress piston assembly (1) and remove sm04577 internal circlip (2) and discard. Remove piston and spring from master cylinder and dis- card. sm00529 Figure 2-36. Master Cylinder/Reservoir Banjo Bolt 1. Piston assembly 2. Circlip sm04578 Figure 2-38. Piston Assembly in Master Cylinder Cleaning and Inspection Use denatured alcohol to clean brake system components.
Page 120 HOME Inspect the outlet port that mates with the fluid line banjo sm05440 fitting. Replace the housing if any scratches, dents or other damage is present. Clean the reservoir diaphragm, stiffener and cover. Clean the pressure relief channels (2) in the cover. sm05442 Figure 2-39.
Page 121 HOME Connect the brake fluid line (6) to the master cylinder/reser- sm05439 voir using two new copper washers (7) and banjo bolt (8) and tighten to 16-20 ft-lbs (22-27 Nm). NOTE Use only new copper crush banjo washers with D.O.T. 4 brake fluid.
Page 122 HOME Remove caliper banjo bolt (2) and two copper washers to sm04586 disconnect brake line from caliper. Discard copper washers. Remove master cylinder banjo bolt and two copper washers to disconnect brake line from master cyl- inder/reservoir. Discard copper washers. Figure 2-46.
Page 123 HOME sm04617 Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) 10. Test the brake lamp. sm05391 Figure 2-44. Front Brake Fluid Line P-Clamp Installation Figure 2-45.
Page 124 HOME sm05522 Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) Test the brake light. CALIPER: REPAIR PART NUMBER TOOL NAME B-42887 BRAKE CALIPER PISTON REMOVER Disassembly Figure 2-47.
Page 125 HOME Blow out drilled passages and bore with a clean air supply. sm05524 Wipe dry with a clean, lint free cloth. Carefully inspect all components. Replace any parts that appear damaged or worn. Do not hone caliper piston bore. Always replace brake pads in complete sets for correct and safe brake operation.
Page 126: Front Brake: Six Piston Caliper
HOME FRONT BRAKE: SIX PISTON CALIPER 2.10 MASTER CYLINDER RESERVOIR REMOVAL sm00528 On XB9SX, XB12X, XB12XT and XB12XP models, remove right deflector. 2.28 DEFLECTORS: XB9SX/XB12X/XB12XT/XB12XP. 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.
Page 127 HOME MASTER CYLINDER AND HAND LEVER CLEANING AND INSPECTION DISASSEMBLY Brake Hand Lever Use denatured alcohol to clean brake system components. Figure 2-50. On XB9SX, XB12XT, XB12XP and Do not use mineral-based solvents (such as gasoline or XB12X models, remove the pivot shaft riser and nut (9) paint thinner), which will deteriorate rubber parts even from the brake pivot shaft (18) to detach the brake hand after assembly.
Page 128 HOME Figure 2-54. Remove two master cylinder cover sm00530 screws, cover and cover gasket. D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is per- formed.
Page 129 HOME On Ulysses models, remove fasteners (4) on right lower sm00531 fender. NOTE Damaged banjo bolt seating surfaces will leak when reas- sembled. Prevent damage to seating surfaces by carefully removing brake line components. Figure 2-50. Remove master cylinder banjo bolt (metric) (14) and two copper washers (16) to disconnect brake line from master cylinder.
Page 130 HOME On Firebolt and Lightning models, use the following steps sm00533 to install the brake line to caliper. Figure 2-55. Install new copper washer (3), brake line, new copper washer (3) and wire form (4) onto banjo bolt (2). Finger tighten banjo bolt (2) onto front caliper, being careful not to pinch wire form (4) while tightening.
Page 131 HOME sm00535 Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) Only Ulysses models, remove fasteners on lower right fender. See 2.15 FENDERS. Figure 2-57. Disconnect brake line (1) at caliper (2). 2.10 FRONT BRAKE: SIX PISTON CALIPER, Brake Line Removal.
Page 132 HOME INSTALLATION Figure 2-60. Install pad spring (7) and brake pads Always replace brake pads in complete sets for correct (10). and safe brake operation. Improper brake operation could Install pin hanger set (1) and tighten to 11-14 ft-lbs (15-19 result in death or serious injury.
Page 133 HOME sm00537 Pin hanger set Piston Caliper mounting fasteners Brake bleeder Piston o-rings Bleeder cap Pad spring Brake pads Caliper Small o-ring Caliper fasteners (4) Figure 2-60. Front Caliper Assembly 2009 XB Service: Chassis 2-55...
Page 134: Brake Pedal
HOME BRAKE PEDAL 2.11 REMOVAL sm00119 Figure 2-61. Remove cotter pin (3) and discard. Remove clevis pin (2). Remove pedal fastener (4). Remove shift brake pedal sleeve (5). Remove pedal bushings (6). Remove brake pedal (7). INSTALLATION Figure 2-61. Install pedal bushings (6). Install shift brake pedal sleeve (5).
Page 135: Rear Brake Master Cylinder
HOME REAR BRAKE MASTER CYLINDER 2.12 REMOVAL: FIREBOLT/LIGHTNING sm00539 Figure 2-62. Drain brake fluid into a suitable container. Discard used fluid according to local laws. Install a length of plastic tubing over caliper bleeder valve. Place free end in a suitable container. Open bleeder valve (metric) about 1/2-turn.
Page 136 HOME 10. See Figure 2-66 Figure 2-67. Detach remote reservoir. sm00541 Remove top clamp (4) on hose connected to master cylinder. Disconnect hose. Remove fastener (2) to detach reservoir (1) from frame if necessary. sm00538 1. Reservoir 2. Fastener and washer 3.
Page 137 HOME Remove cotter pin from brake pedal. See 2.11 BRAKE Remove fasteners (11) to detach master cylinder (4) from PEDAL. rider footpeg mount. Remove seat. Figure 2-71. Detach remote reservoir. On Ulysses models, remove air flow guide. Figure 2-70. Disconnect brake light connector located under the seat.
Page 138 HOME Remove piston assembly (4) from master cylinder body sm00548 (1). Loosen adjuster locknut on the rod assembly (3). Remove the clevis from the rod assembly (3). NOTE Do not disassemble master cylinder unless problems are experienced. Discard all seals during the disassembly pro- cedure.
Page 139 HOME sm00542 Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury.
Page 140 HOME Be sure that all lights and switches operate properly before After installing seat, pull upward on seat to be sure it is operating motorcycle. Low visibility of rider can result in locked in position. While riding, a loose seat can shift death or serious injury.
Page 141: Rear Brake Line
HOME REAR BRAKE LINE 2.13 REMOVAL: FIREBOLT sm00550 Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect battery by unthreading fastener removing negative cable (black) from battery first. See 1.5 BATTERY MAINTENANCE.
Page 142: Removal: Lightning
HOME NOTE Tighten the right side banjo bolt with FLARE NUT SOCKET (Part No. SNAP-ON FRXM14) or a crowsfoot. To prevent accidental vehicle start-up, which could cause Install brake line, banjo bolt and new copper washers to death or serious injury, disconnect negative (-) battery rear caliper.
Page 143: Removal: Ulysses
HOME INSTALLATION: LIGHTNING REMOVAL: ULYSSES Remove seat. PART NUMBER TOOL NAME SNAP-ON FRXB14 FLARE NUT SOCKET Figure 2-76. Install brake light switch/banjo bolt with To prevent accidental vehicle start-up, which could cause new copper washers to the master cylinder. Tighten to death or serious injury, disconnect negative (-) battery 16-20 ft-lbs (22-27 Nm).
Page 144: Installation: Ulysses
HOME sm00546 sm00553 Figure 2-80. Rear Brake Light Switch/Banjo Bolt: Ulysses Figure 2-78. Brake Line Switch Connector (Ulysses) INSTALLATION: ULYSSES Route the brake line. See D.1 APPENDIX D: HOSE AND sm00552 WIRE ROUTING for brake line routing. Figure 2-80. Install brake light switch/banjo bolt with new copper washers to the master cylinder.
Page 145 HOME After servicing brakes and before moving motorcycle, After repairing the brake system, test brakes at low speed. pump brakes to build brake system pressure. Insufficient If brakes are not operating properly, testing at high speeds pressure can adversely affect brake performance, which can cause loss of control, which could result in death or could result in death or serious injury.
Page 146: Rear Brake Caliper
HOME REAR BRAKE CALIPER 2.14 REMOVAL DISASSEMBLY NOTE PART NUMBER TOOL NAME Steps 1 and 2 are not required for detaching caliper from rotor. B-42887 BRAKE CALIPER PISTON REMOVER Drain fluid only when disassembling caliper. Figure 2-81. Remove pin plug (5) and pad hanger (metric) to free brake pads.
Page 147 HOME sm00556 Table 2-24. Rear Rotor Runout RUNOUT Rotor radial 0.0177 0.45 Rotor lateral 0.0154 0.39 ASSEMBLY Figure 2-82. Place clip (1) inside caliper body as shown. NOTE To verify proper brake pad-to-brake rotor clearance when the caliper is installed, piston must be pressed all the way into the bore whenever new brake pads are used.
Page 148 HOME Figure 2-81. Install caliper assembly on caliper mount. Turn ignition key switch to ON. Apply brake pedal to test Brake pad surfaces must face rear brake rotor. brake lamp operation. Turn ignition key switch to LOCK. Install large caliper fastener (7) (metric) tightening to 18-21 ft-lbs (24-28 Nm).
Page 149: Fenders
HOME FENDERS 2.15 NOTE FRONT FENDER: XB12R It is necessary to align the rear brake line with the rear inner Removal fender. The rear fender captures the rear brake line to help maintain the proper alignment and location. Figure 2-86. Remove fasteners and washers (2) securing the front fender (1) to front forks.
Page 150 HOME right side of the upper front fender before installing and tight- Install the right lower front fender (9) with fasteners (6, 7). ening fastener. Tighten all fender fasteners to 36-48 in-lbs (4.0-5.4 Nm). Figure 2-87. Align front fender (2) to fender mounts on lower triple clamp, apply LOCTITE 271 (red) and Install sm00654 front fender fasteners and washers (1) and tighten to 12-36...
Page 151: Front Forks: All Models
HOME FRONT FORKS: ALL MODELS 2.16 REMOVAL sm00559 Remove front fender. See 2.15 FENDERS Remove front wheel. See 2.5 FRONT WHEEL. Remove caliper mounting fasteners. See 2.10 FRONT BRAKE: SIX PISTON CALIPER, Brake Caliper Removal. Figure 2-89. Loosen upper and lower fork clamp pinch fasteners (1, 5).
Page 152 FRONT FORK COMPRESSOR (Part No. HD-45966) assembly. comes with a cup and screw that are for FLT models only and not to be used with Buell. Figure 2-93. The bottom of the preload adjuster is round with two flat sides so a wrench (2) can be used to...
Page 153 HOME Loosen the damper rod assembly jamnut (3) and back it sm03822 off all the way to the bottom. Hold damper rod assembly jamnut (3) and remove fork cap (1). Figure 2-96. Inside the damper rod assembly (6) is a fork push rod (4) that is tapered on one end to control the movement of fluid in the front fork increasing and decreasing the damping properties.
Page 154 HOME sm03826 Fork cap Bolt, center Guide bushing Seat, rubber Spring collar Seal spacer Slider piston Spring joint Oil seal Push rod Spring Oil seal stopper ring Damper jamnut Stopper ring Dust seal Damper rod assembly Outer tube Slider fork Centering plate Reflector assembly Axle clamp bolt...
Page 155 NOTE Table 2-25. Fork Spring Service Wear Limit Figure 2-98. For Buell model motorcycles, there are three MODEL different tools that can be used to install the fork seal and dust boot depending on the size of your slider fork. You will either XB9R, XB12R 14.31...
Page 156 HOME 13. See Figure 2-99. Thread damper rod retrieval tool found sm00569 in the Race Tech Inc. FORK BLEED TOOL SET (Part No. TBFT 02S) onto end of damper rod assembly (6). See Figure 2-96. NOTE While pumping the outer tube up and down be sure not to exceed the travel of the fork assembly.
Page 157 HOME Table 2-26. Fork Oil Levels: XB12X/XB12XT MODEL Both forks should be adjusted equally. Forks that are not properly adjusted can lead to loss of control, which could XB12R 4.21 result in death or serious injury. (00124b) XB12Ss 4.65 Repeat previous steps on second front fork. XB9SX 4.21 Temporarily install front axle to the fork assemblies to...
Page 158: Fork Clamps: Upper And Lower
HOME FORK CLAMPS: UPPER AND LOWER 2.17 REMOVAL FIREBOLT: sm00573 Place a scissor jack under jacking point and raise front wheel off ground. For location of jacking point see 4.18 EXHAUST SYSTEM. Remove handlebars. See 2.31 HANDLEBARS: FIRE- BOLT. Remove cable straps securing wiring harnesses to the upper fork clamp.
Page 159 HOME NOTE Remove the upper fork clamp (4). Carefully install the fork into the upper fork clamp. Forcing the Remove the lower fork clamp with stem (6). fork into the upper fork clamp could move the stopper ring out of the groove which will not allow the correct clamp load. steering head bearings...
Page 160 HOME Install steering stem capnut (1). Tighten but do not torque. NOTE For additional information, see 2.16 FRONT FORKS: ALL Install one front fork assembly into lower fork clamp with MODELS. stem (6). Figure 2-101. Position both forks with same number Figure 2-96.
Page 161: Steering Head Bearings
HOME STEERING HEAD BEARINGS 2.18 REMOVAL INSTALLATION Place a scissor jack under jacking point and raise front PART NUMBER TOOL NAME wheel off ground. For location of jacking point see B-43993-12 BACKING PLATE 4.18 EXHAUST SYSTEM. B-45521 STEERING HEAD BEARING Remove brake lever housing.
Page 162 HOME sm00576 sm00578 1. Forcing screw 2. Steering Head Bearing Installation Tool 3. Lower bearing 4. Bearing 5. Washer 6. Nut Figure 2-107. Lower Bearing Figure 2-107. Sparingly apply EXTREME PRESSURE LUBRICANT (Part No. J-23444-A) to the threads of the forcing screw (1) from the steering head bearing race 1.
Page 163 HOME 12. Install steering stem pinch bolt applying LOCTITE 271 sm00579 (red) and tightening to 20-22 ft-lbs (27-30 Nm). 13. Apply LOCTITE 271 (red) to upper triple clamp fasteners and tighten to 23-25 ft-lbs (31.2-33.8 Nm). 14. On Lightning and Ulysses models, install front modules. 2.30 FRONT MODULES: LIGHTNING/ULYSSES.
Page 164: Swingarm And Brace
HOME SWINGARM AND BRACE 2.19 GENERAL sm00302 The swingarm also serves as the oil tank. For information on the swingarm function as the oil tank, see 3.11 OIL RESER- VOIR AND OIL HOSE ROUTING. The swingarm features a removable brace on the right side to allow drive belt replacement.
Page 165 HOME sm00581 Swingarm Oil drain plug Dipstick Pivot shaft Swingarm bushings Brace fastener (4) Swingarm spacer Swingarm brace Swingarm bearing (5) Rear axle pinch fastener Engine crankcase Jiffy Tite oil line fittings (3) 7. Pivot shaft pinch fastener with nut Figure 2-110.
Page 166 HOME Thoroughly clean all components in solvent. Blow dry with sm00585 compressed air. Carefully inspect all bearing components for wear and/or corrosion. Replace complete bearing assembly if any component is damaged. Check that swingarm is not bent or twisted. Replace if damaged.
Page 167 HOME Install rear fender. See 2.15 FENDERS. 14. Connect battery cables to battery: positive cable (red) first. Tighten to 72-96 in-lbs (8-11 Nm). See 1.5 BATTERY Install rear inner fender and tighten fasteners to 12-36 in- MAINTENANCE. lbs (1.4-4.0 Nm). Connect three oil lines to swingarm fittings and install and tighten p-clamps to 48-72 in-lbs (5.4-8 Nm).
Page 168: Front And Rear Isolators
HOME FRONT AND REAR ISOLATORS 2.20 FRONT ISOLATOR sm05389 Removal NOTE Avoid cross-threading front isolator bolt or insert. Keep weight of motorcycle off front isolator by alternately loosening front isolator bolt and raising scissor jack to support engine. Place a scissor jack under jacking point for supporting engine only.
Page 169: Frame Pucks
HOME FRAME PUCKS 2.21 From the tacked corners, pivot the puck onto the frame REMOVAL keeping the directional point aligned with the horizontal crease. The aluminum frame of this motorcycle is the fuel tank. is00878 Drilling, welding, cutting, grinding, sanding, polishing or other modifications to this frame can weaken it or cause a fire, which could result in death or serious injury.
Page 170: Frame
HOME FRAME 2.22 Install main wire harness. See 6.27 MAIN WIRE HAR- REMOVAL NESS. Remove fuel from frame. See 4.14 FUEL PUMP, Draining Install upper and lower fork clamps. See 2.17 FORK Fuel Tank. CLAMPS: UPPER AND LOWER. Rotate engine. See 3.4 ENGINE ROTATION FOR SER- Install rear shock.
Page 171: Rear Shock Absorber
HOME REAR SHOCK ABSORBER 2.23 GENERAL The rear suspension is controlled by the shock absorber. The shock allows adjustment of rear compression and rebound damping and spring preload. sm00588 Shock remote reservoir clamp fastener Lower shock mount Shock remote reservoir clamp Lower shock mount sleeve Shock remote reservoir Lower shock mount fastener...
Page 172 HOME sm00591 XB9SX XB12Ss XB12Scg Remote reservoir clamp fastener Lower shock mount fastener Remote reservoir clamp Shock reservoir body Remote reservoir Upper shock mount fastener Lower shock mount nut Lower shock mount Washers (2) Shock spring retainer kit Lower shock mount sleeve Rear shock spring Figure 2-119.
Page 173 HOME sm00594 Screw and washer, preload adjuster knob Lower shock mount nut Preload adjuster knob Lower shock mount washer, thick Preload adjust assembly Lower shock mount washer, thin Preload adjuster fasteners (2) Lower shock mount sleeve Rear shock body Lower shock mount fastener Remote reservoir clamp fastener Upper shock mount fastener Remote reservoir clamp...
Page 174 HOME Disconnect and remove battery. See 1.5 BATTERY Remove the nut (4) and washer (5) from the lower shock MAINTENANCE. bolt and raise scissor jack until the lower bolt can be removed by hand. Remove tail body work. See 2.39 SUBFRAME TAIL ASSEMBLY AND BODY WORK: FIREBOLT.
Page 175 HOME Remove ECM. See 4.4 ELECTRONIC CONTROL MODULE (ECM). NOTE Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, When removing the ECM, the fastener closest to the shock assembly has a nut that is captured in the plastic shield below the resulting sparks can cause a battery explosion, which the ECM.
Page 176 HOME Install the two fasteners holding the preload adjuster in place and tighten to 48-72 in-lbs (5.4-8 Nm). Connect positive (+) battery cable first. If positive (+) cable Install rear shock reservoir clamp (7) and fastener (6) and should contact ground with negative (-) cable connected, tighten clamp fastener to 80-88 in-lbs (9.0-9.9 Nm).
Page 177: Throttle Control
HOME THROTTLE CONTROL 2.24 REMOVAL AND DISASSEMBLY sm00597 Remove right handlebar deflector if required. See 2.28 DEFLECTORS: XB9SX/XB12X/XB12XT/XB12XP. NOTE On Ulysses models, it will be necessary to disconnect and remove the heated handgrips. See 6.12 HEATED HAND GRIPS: ULYSSES MODELS. Figure 2-126.
Page 178: Throttle Cable Replacement
HOME Position the lower idle control cable barrel in the throttle THROTTLE CABLE REPLACEMENT cam wheel of the throttle body and then slip the elbow into Removal the slotted hole in the throttle cable mounting bracket. Position the throttle control cable in the same manner so NOTE both elbows are inserted into the bracket.
Page 179 HOME sm03924 sm03923 Figure 2-128. Throttle Cable Retention Clip Figure 2-129. Throttle Cable Retention Clip, Inside View sm04534 Figure 2-130. Throttle cable elbow alignment 2009 XB Service: Chassis 2-101...
Page 180: Clutch Control
HOME CLUTCH CONTROL 2.25 GENERAL sm04195 For clutch adjustment, see 1.9 CLUTCH/TRANSMIS- SION/PRIMARY FLUID. For clutch replacement, see CLUTCH. REMOVAL AND DISASSEMBLY Clutch Cable Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding.
Page 181 HOME 13. See Figure 2-135. Remove the outer ramp and hook (1) 14. See Figure 2-136. Unscrew the cable fitting from the from the cable end (3) and coupling (2). Remove cable primary cover. Remove clutch cable and fitting. end from slot in coupling. See 5.4 CLUTCH RELEASE 15.
Page 182: Assembly And Installation
HOME Figure 2-134. Install (7) bearings and (8) sleeve into sm00268 the shift lever. After applying LOCTITE 271 (red), install flange bolt (6) and shift pedal (4) to primary cover, and tighten to 22-24 ft-lbs (30-32.5 Nm). After applying LOCTITE 271 (red), tighten engine shift lever pinch screw to 48-60 in-lbs (5.4-7 Nm).
Page 183 HOME NOTE 19. Connect negative battery cable to battery terminal.Tighten Always connect front tie bar to engine mount first. fastener to 72-96 in-lbs (8-11 Nm). 15. Install front tie bar, p-clamp and clutch cable to front engine mount and tighten fastener to 25-27 ft-lbs (33.9-36.6 Nm). 16.
Page 184: Headlamp Assembly And Support Bracket
HOME HEADLAMP ASSEMBLY AND SUPPORT BRACKET 2.26 REMOVAL: FIREBOLT sm00605 Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect battery cables from battery: negative cable (black) first. See 1.5 BATTERY MAINTENANCE.
Page 185: Installation: Firebolt
HOME sm00606 Headlight pivot fasteners Headlight fastener Headlight support bracket High beam headlight Electronic control module fasteners Headlight bulb Black rubber cover Bank angle sensor Low beam headlight Bank angle sensor fastener with washers Figure 2-140. Headlight Support Bracket Assembly: Firebolt INSTALLATION: FIREBOLT 11.
Page 186: Removal: Lightning/Ulysses
HOME Remove windscreen and windshield. See 2.48 WIND- sm00607 SHIELD WINDSCREEN: LIGHTNING ULYSSES. Disconnect horn connectors [122] (2). For Lightning Models: See Figure 2-142. For Ulysses: See Figure 2-143. NOTE Horn (1) can remain attached to support bracket. The horn can be removed and replaced as needed.
Page 187 HOME sm00608 Horn Fasteners (2), upper headlight mounting Horn connectors [122] Headlight assembly Horn bracket Fasteners (2), headlight support bracket Horn fastener Headlight support bracket Headlight connector [38] Left and right front modules Figure 2-142. Electrical Connectors Behind Windscreen: Lightning 2009 XB Service: Chassis 2-109...
Page 188: Disassembly: Lightning/Ulysses
HOME sm00621 Horn Screws (2), upper headlight mounting Horn connectors [122] Headlight assembly Horn bracket Screws (2), headlight support bracket Horn fastener Headlight support bracket Headlight connector [38] Left and right front modules Figure 2-143. Headlight and Support Bracket: Ulysses DISASSEMBLY: LIGHTNING/ULYSSES ASSEMBLY: LIGHTNING/ULYSSES Figure...
Page 189: Installation: Lightning/Ulysses
HOME sm00622 Boot (2) Wiring harness Bulb holder (2) Position bulb socket (used for HDI only) Bulb (2) Headlight connector 4. Headlight housing Figure 2-144. Headlight Assembly Connect horn connectors [122] (2). INSTALLATION: LIGHTNING/ULYSSES Adjust headlights. See 1.17 HEADLAMP. Install headlight support bracket (9). For Lightning Models: See Figure 2-142.
Page 190: Fairing Support Bracket: Firebolt
HOME FAIRING SUPPORT BRACKET: FIREBOLT 2.27 Connect instrument cluster connector and install instru- REMOVAL ment cluster. Tightening to 12-36 in-lbs (1.4-4 Nm). See Remove seat. 6.26 INSTRUMENT MODULE. Install horn and tighten fasteners to 72-96 in-lbs (8-10 Nm). See 6.13 HORN.
Page 191 HOME sm00625 Jam nut Fairing support bracket Washer Instrument cluster Rubber grommet P-clamp Fairing support bracket fasteners and washers P-clamp fastener and washers Figure 2-145. Fairing Support Bracket Assembly: Firebolt 2009 XB Service: Chassis 2-113...
Page 192: Deflectors: Xb9Sx/Xb12X/Xb12Xt/Xb12Xp
HOME DEFLECTORS: XB9SX/XB12X/XB12XT/XB12XP 2.28 REMOVAL AND DISASSEMBLY ASSEMBLY AND INSTALLATION Figure 2-146. Remove fasteners (2) from clutch and Install brake and clutch levers with pivot shafts (3, 6). See brake pivot shafts (3, 6) and pivot shaft risers (4). 2.25 CLUTCH CONTROL 2.10 FRONT BRAKE: SIX PISTON CALIPER.
Page 193: Grille: Xb9Sx/Xb12X/Xb12Xp
HOME GRILLE: XB9SX/XB12X/XB12XP 2.29 GENERAL sm00572 Figure 2-147. The headlamp grille is offered as a standard feature on the XB9SX, XB12X and XB12XP models to provide additional protection for the headlight assemblies. REMOVAL AND INSTALLATION Figure 2-147. Grab headlamp grille on either side and spread to remove from headlamp assemblies.
Page 194: Front Modules: Lightning/Ulysses
HOME FRONT MODULES: LIGHTNING/ULYSSES 2.30 REMOVAL sm03875 Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect battery cables from battery: negative cable (black) first. See 1.5 BATTERY MAINTENANCE.
Page 195: Installation
HOME Attach front brake line p-clamp to rear of right front module sm03877 and tighten fastener to 36-60 in-lbs (4-7 Nm). Install ignition switch. See 6.4 IGNITION/HEADLAMP KEY SWITCH. Install connect instrument module. 6.26 INSTRUMENT MODULE. Connect turn signals. See 6.15 FRONT TURN SIGNALS.
Page 196: Handlebars: Firebolt
HOME HANDLEBARS: FIREBOLT 2.31 Install left switch gear housing. GENERAL Figure 2-152. Install grip and end cap (1). Firebolt handlebars are a clip-on assembly and are not adjustable. Install left clip-on into upper fork clamp (3) and tighten fastener (4) to 24-26 ft-lbs (33-35 Nm). REMOVAL Position clutch hand lever to rider preferences and tighten Right Clip-On...
Page 197: Handlebars: Lightning/Ulysses
HOME HANDLEBARS: LIGHTNING/ULYSSES 2.32 Install clutch hand control. Tighten but do not torque. See REMOVAL 2.25 CLUTCH CONTROL. Remove seat. Install left switch housing. NOTE Check control wire routings. See D.1 APPENDIX D: HOSE On Ulysses Models, it will be necessary to disconnect and AND WIRE ROUTING.
Page 198 HOME sm03889a 1. End cap 2. Harness retainers 3. Clamp fasteners 4. Handlebar clamp 5. Left hand grip (XB12X models are OEM equipped with heated handgrips) 6. Handlebar (Ulysses models) 7. Handlebar (XB9SX) 8. Handlebar (XB12Scg, XB12Ss) 9. Clutch cable hook (Ulysses models) Figure 2-153.
Page 199: Mirrors
HOME MIRRORS 2.33 NOTES REMOVAL In a convex mirror, cars and other objects will look smaller Figure 2-154. Loosen adjuster nut (2) and remove and farther away than they actually are. Adjust mirrors to mirror (1) from mount (3). see a small portion of the riders shoulders in each mirror. This helps the rider establish the relative distance of Loosen mount (3) and remove from bracket (4).
Page 200: Footpeg, Heel Guard And Mount: Firebolt/Lightning
HOME FOOTPEG, HEEL GUARD AND MOUNT: FIREBOLT/LIGHTNING 2.34 RIDER sm03637 REMOVAL Figure 2-155. Remove wear peg (7) from end of footpeg assembly. Remove clip (5). Remove footpeg pin (9). Remove footpeg (8). Remove heel guard fasteners (4). Remove heel guard (3). Remove footpeg mount fasteners (2).
Page 201: Installation
HOME INSTALLATION sm03837 Figure 2-156. Position footpeg mount (3) onto sub- frame tail assembly. Install footpeg mount (3). Using LOCTITE 271 tighten, fasteners (10) to 25-28 ft-lbs (34-38 Nm). Position heel guard (2) onto footpeg mounts (3). Install heel guard (2). Tighten heel guard fasteners to 72-96 in-lbs (8-11 Nm).
Page 202: Heel Guard And Footpeg Mounts: Ulysses Models
HOME HEEL GUARD AND FOOTPEG MOUNTS: ULYSSES MODELS 2.35 RIDER FOOTPEGS sm03636 Footpeg Removal Figure 2-157. Remove clip (3). Remove footpeg pin (8). Remove footpeg (10) and spring (9). Footpeg Installation Figure 2-157. Fit spring ends to footpeg mount and footpeg.
Page 203: Heel Guard Replacement
HOME Install footpeg mount fasteners (2), and tighten to 132-144 HEEL GUARD REPLACEMENT in-lbs (15-16 Nm). Figure 2-160. If necessary, cut the rubber heel guard Install brake pedal fastener. See 2.11 BRAKE PEDAL. tabs on the inside of the footpeg mount to remove the heel guard.
Page 204: Sprocket Cover
HOME SPROCKET COVER 2.36 REMOVAL sm00123 Figure 2-161. Remove rear right chin fairing fasteners. Figure 2-162. Remove sprocket cover fasteners and washers (1, 3). INSTALLATION NOTE Apply LOCTITE 222 (purple) to long fastener (1) only. Figure 2-162. Install sprocket cover (2) using sprocket cover fasteners (1, 3) and tighten all fasteners and washers (1) to 12-36 in-lbs (1.4-4 Nm).
Page 205: Belt Guards
HOME BELT GUARDS 2.37 REMOVAL INSTALLATION Place a scissor jack under jacking point and raise rear Figure 2-163. Install upper belt guard (1) to swingarm wheel off ground. For location of jacking point see brace tightening fasteners (2) to 12-36 in-lbs (1.4-4 Nm). 4.18 EXHAUST SYSTEM.
Page 206: Intake Cover
HOME INTAKE COVER 2.38 REMOVAL INSTALLATION Figure 2-164. Position intake cover assembly (2) over NOTE top of air cleaner cover. Figure 2-164. The X-Guard (1) on the XB9SX model is a non-replaceable part. NOTE Front fasteners are installed at a slight angle. Remove seat.
Page 207 HOME sm00656 1. X-Guard (XB9SX only) 2. Intake cover assembly 3. Rear intake cover fasteners with nylon washers (2) 4. Front intake cover fasteners with nylon washers (2) (models without translucent covers) 5. Front intake cover fasteners with top hat bushings (2) and isolating washers (4) (translucent covers only) Figure 2-164.
Page 208: Subframe Tail Assembly And Body Work: Firebolt
HOME SUBFRAME TAIL ASSEMBLY AND BODY WORK: FIREBOLT 2.39 Figure 2-165. Remove upper body work (1) from DISASSEMBLY subframe tail assembly (7). Remove seat and pillion. Remove body work fasteners (2). Disconnect passenger seat lock cable (6) by removing cable from seat lock plate (4) and ferrule from keylock Disconnect negative (-) battery cable first.
Page 209 HOME sm00657 Upper tail body work Subframe tail assembly fasteners Upper tail body work fasteners Lower tail body work Passenger seat lock Lower tail body work fasteners Passenger seat lock plate Trunk Passenger seat lock retainer Fastener Passenger seat lock cable License plate bracket Subframe tail assembly Passenger seat latch and fastener...
Page 210 HOME 18. Disconnect fuel pump connection and remove connector sm00432 from subframe tail assembly. See 4.14 FUEL PUMP. 19. Remove shock reservoir fasteners and feed the reservoir out of subframe tail assembly. See 2.23 REAR SHOCK ABSORBER. 20. See Figure 2-165.
Page 211: Cleaning
HOME Figure 2-166. Feed fuel vent hose (1) through tail sm00660 section, keeping the hose on top of rear shock reservoir hose. See D.1 APPENDIX D: HOSE AND WIRE ROUTING for hose and wire routing. 10. Install cable strap (3) holding shock reservoir hose, wire harness and fuel vent hose to subframe tail assembly.
Page 212 HOME Connect positive (+) battery cable first. If positive (+) cable After installing seat, pull upward on seat to be sure it is should contact ground with negative (-) cable connected, locked in position. While riding, a loose seat can shift the resulting sparks can cause a battery explosion, which causing loss of control, which could result in death or could result in death or serious injury.
Page 213: Left Tail Section And Battery Pan: Lightning
HOME LEFT TAIL SECTION AND BATTERY PAN: LIGHTNING 2.40 DISASSEMBLY Figure 2-169. Remove fuse block and relay center from support bracket. Remove seat. Move rear main harness and shock absorber reservoir to right side of vehicle. Remove left side passenger footrest support assembly. Disconnect negative (-) battery cable first.
Page 214 HOME sm00661 Main harness Bank angle sensor (BAS) connector [134] Main harness ground (high voltage ground wire) Right turn signal connector [18] Battery negative cable Left turn signal connector [19] (under remote Battery positive cable License plate lamp connector [45] Rear brake light switch connector [121] Tail light connectors [93] Ground terminals [GRD1] and [GRD3]...
Page 215 HOME Move rear main harness and shock absorber reservoir CLEANING back to left side of vehicle. NOTE Do not use wheel care products or other compounds developed specifically for cleaning and polishing powdercoat. These Be sure that all lights and switches operate properly before cleaners could potentially damage the tail section finish.
Page 216 HOME is02466 1. Left and right tail section fastener to main frame/fuel tank assembly (4) 2. Right tail section 3. Center tail section 4. Center tail section fastener to rear tail section (4) 5. Left tail section 6. Ground terminal fastener (2) 7.
Page 217: Center Tail Section: Lightning
HOME CENTER TAIL SECTION: LIGHTNING 2.41 Install two fasteners (12) securing trunk pan to center tail DISASSEMBLY section but do not tighten. Remove seat. Apply LOCTITE 271 (red) to threads of left and right rear tail sections fasteners (4) and tighten to 102-114 in-lbs (11.5-12.8 Nm).
Page 218: Right Tail Section: Lightning
HOME RIGHT TAIL SECTION: LIGHTNING 2.42 DISASSEMBLY ASSEMBLY Remove seat. Figure 2-169. Install right tail section (16) onto vehicle. Install fastener (14) attaching right front trunk pan to right side tail section and tighten to 12-36 in-lbs (1.4- 4 Nm). Disconnect negative (-) battery cable first.
Page 219: Left Tail Section And Battery Pan: Ulysses Models
HOME LEFT TAIL SECTION AND BATTERY PAN: ULYSSES MODELS 2.43 the fastener to retain the nut in the correct location. The DISASSEMBLY rear fastener attaches directly to the battery pan. Remove seat. Disconnect rear brake light switch connector [121]. Disconnect and remove Bank Angle Sensor (2) [134]. Remove fuse block and relay center (5).
Page 220 HOME sm04798 Main harness Battery positive cable Electronic control module Left rear and right rear tail section fasteners (4) ECM connectors [10] and [11] Seat lock cable Fuse block and relay center Bank angle sensor (BAS) connector [134] Main harness ground wire [GRD2] Auxiliary power outlet Main harness with plastic grommet Trunk pan...
Page 221 HOME 10. Install seat. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) 2009 XB Service: Chassis 2-143...
Page 222 HOME sm00663 1. Fastener, washer and nut to main frame/fuel tank assembly (4) 2. Right tail section 3. Left tail section 4. Battery pan 5. Front trunk pan fastener to side tail section (2) 6. Ground terminal fastener (2) 7. Trunk pan assembly 8.
Page 223: Center Tail Loop: Ulysses Models
HOME CENTER TAIL LOOP: ULYSSES MODELS 2.44 Tighten nuts of left and right tail sections to 20-22 ft-lbs DISASSEMBLY (27-30 Nm). Repeat to verify torque. Remove seat. Connect: Right turn signal connector [18]. Left turn signal connector [19]. Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable con- License plate lamp connector [45].
Page 224 HOME sm00664 1. Tail loop 2. License plate bracket 3. Wire cover Figure 2-173. Wire Cover, Tail Loop and License Plate Bracket: Ulysses 2-146 2009 XB Service: Chassis...
Page 225: Right Tail Section: Ulysses Models
HOME RIGHT TAIL SECTION: ULYSSES MODELS 2.45 DISASSEMBLY sm00665 Remove seat. NOTES Before removing right tail section, it will be necessary to remove certain components of the luggage system. See LUGGAGE: XB12XT. The center tail loop must be removed before removing the left or right tail sections.
Page 226 HOME Install master cylinder remote reservoir. See 2.12 REAR sm00667 BRAKE MASTER CYLINDER. Install shock reservoir, retainer, and fastener. Tighten to 80-88 in-lbs (9.0-9.9 Nm). Connect rear brake light switch connector [121]. Be sure that all lights and switches operate properly before operating motorcycle.
Page 227: General
HOME SIDESTAND 2.46 GENERAL sm03932 This motorcycle does NOT have a locking sidestand. Park the motorcycle on a level, firm surface. An unbalanced motorcycle can fall, which could result in death or serious injury. (00122a) The sidestand is located on the left side of the motorcycle. The sidestand swings outward to support the motorcycle for parking.
Page 228: Installation
HOME Retract sidestand leg (9). sm05260 Install spring extension plate (2) and sidestand spring (1) using SNAP-ON SPRING TOOL (Part No. HE-52B). Extension plate should curve away from primary chain adjustment screw to allow for clearance around adjustment screw. INSTALLATION Figure 2-179.
Page 229: Removal
HOME FRONT FAIRING, WINDSHIELD, AND MIRRORS: FIREBOLT 2.47 REMOVAL INSTALLATION Figure 2-181. Remove two center (4) and four side Figure 2-181. Position fairing (5) onto fairing support windscreen fasteners (3) to remove windshield (1). bracket and install turn signals (6, 7). See 6.15 FRONT TURN SIGNALS.
Page 230: Windshield And Windscreen: Lightning And Ulysses
HOME WINDSHIELD AND WINDSCREEN: LIGHTNING AND ULYSSES 2.48 Remove windscreen (4). LIGHTNING Installation Removal Figure 2-182. Position windscreen (4) onto left and NOTE right front modules (2, 5). Figure 2-182.The windscreen fasteners (3) extend through Install four fasteners (3) and tighten to 10-12 in-lbs (1.1- the left and right front modules (2, 5) and thread into the 1.4 Nm).
Page 231 HOME Remove six windscreen fasteners (5). ULYSSES XB12X Remove windscreen (6). Removal Installation NOTES Figure 2-183. Position windscreen (6) onto left and The windshield releases from the windscreen by pulling right front modules (2, 8) and the center fairing support outward and away from vehicle.
Page 232 HOME After removing the lower windshield mounting hardware ULYSSES XB12XT/XB12XP it will be necessary to pull the windshield loose from the Removal windscreen by pulling up sharply at the upper mounting pins. NOTES Remove windshield mounting hardware (3) securing the Figure 2-184.
Page 233 HOME Installation pd00272 Figure 2-184. Install windshield onto windscreen by aligning the mounting pins (2) on the windshield with the mounting grommets (12) on the windscreen and pushing in place to install. Pull on windshield to verify attachment. Insert well nuts (6) into the windshield and windscreen holes.
Page 234: Air Scoops
HOME AIR SCOOPS 2.49 RAM AIR SCOOP ENGINE SHROUD AIR SCOOP Removal Removal Figure 2-186. On right side of motorcycle, locate NOTE engine shroud air scoop (6). When removing and installing the left air scoop, the alternator and voltage regulator harnesses and connections are secured Remove three engine shroud air scoop fasteners (5).
Page 235 HOME sm00124 Oil cooler air scoop fastener and washer (2) Ram air scoop Oil cooler air scoop Engine shroud scoop fastener and washer (3) Ram air scoop fastener and washer Engine shroud scoop Figure 2-186. Ram Air Scoop, Engine Shroud, and Oil Cooler 2009 XB Service: Chassis 2-157...
Page 236: Removal
HOME CHIN FAIRING 2.50 Align left section (3) and loosely install left side fasteners REMOVAL and washers (4). Turn wheel full right or left for easier access to center Tighten all fasteners to 36-48 in-lbs (4-5 Nm). fasteners. Figure 2-187. Remove center section fasteners and washers (2).
Page 237: Seat
HOME SEAT 2.51 FIREBOLT Pillion Rider Seat NOTE The trunk is located under the pillion. Figure 2-188. Peel up rear corners of seat and remove two fasteners. Figure 2-190. Insert ignition key into the pillion lock located on the left side of motorcycle. Turn key clockwise Pull seat back over tail section and remove.
Page 238 HOME pd00242 om00339 1. Seat hooks (2) Figure 2-191. Seat Lock Location: Lightning Models 2. Seat latch 3. Tab Figure 2-193. Seat Mounting Points: XB9SX/XB12Scg om00340 pd00230 Figure 2-192. Seat Removal: Lightning Models 1. Seat hooks (4) 2. Seat latch 3.
Page 239: Ulysses
HOME Figure 2-198. Grip rear of seat and pull toward rear pd00187 of motorcycle to remove. om00576 Figure 2-197. Seat Lock: Ulysses Models om00574 1. Seat hooks 2. Tab Figure 2-195. Fitting Seat Hooks to Frame Mounting Posts om00054 Figure 2-198. Seat Removal: Ulysses Models Installation Figure 2-199.
Page 240 HOME om00573 1. Seat hook 2. Seat lock latch 3. Front tab Figure 2-199. Seat Tab/Hooks: Ulysses Models 2-162 2009 XB Service: Chassis...
Page 241: Seat Locks
HOME SEAT LOCKS 2.52 NOTES LIGHTNING Once seat lock has been started through the hole in the Removal trunk pan and plate, now is the time to connect the cable end to the seat lock. Remove seat. Seat lock plate must be aligned to tab on seat lock for Cut cable strap loosely securing BAS wiring harness to proper installation.
Page 242 HOME sm00689 Seat lock Retainer Plate Cable end Retainer Latch Cable end Latch bracket Cable Trunk pan 6. Latch screw Figure 2-200. Seat Lock Assembly: Lightning REMOVAL: ULYSSES MODELS Remove seat lock: Remove wire cover from bottom side of license plate Remove seat.
Page 243 HOME Install the seat lock (1) into license plate bracket and plate sm03841 (2). NOTES Once seat lock has been started through the hole in the license plate bracket and plate (2), now is the time to connect the cable end to the seat lock. Seat lock plate must be aligned to tab on seat lock for proper installation.
Page 244 HOME Remove seat lock lever (4) by removing fastener (2) and washer (3) from seat lock (7). Remove spring (5). After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift Remove seat lock clip (1) by sliding from seat lock plate causing loss of control, which could result in death or (6).
Page 245: Removal
HOME TRIPLE TAIL: ULYSSES 2.53 the upright position, it is a passenger backrest (2) with subtle GENERAL flex for passenger comfort. When in the rearward position, you Figure 2-203. The Triple Tail when folded forward acts as can carry a passenger and have a luggage rack (3) for extra a luggage rack (1) with integrated tie-down hooks.
Page 246: Installation
HOME Using a Snap-on seal and bushing driver, tap in the Holding the rack, fit the RH grab handle (2) unto the front bearing. fastener and install the rear fastener. Do not tighten. Tighten front and rear fasteners to the following specifica- INSTALLATION tions: Figure...
Page 247: Luggage: Xb12Xt
HOME LUGGAGE: XB12XT 2.54 REMOVAL: SIDE CASE NOTES The side cases and brackets may be removed without removing the top case and bracket. This procedure is recommended for service only. The vehicle should never Do not exceed the motorcycle's Gross Vehicle Weight be operated with just the top case in place.
Page 248 HOME Figure 2-205. Place key in side case locking latch sm05145 (12), on front surface of side case, in open position. Open latch. Remove side case by pulling away from vehicle. Remove fastener (10) securing the side case bracket (11) to the back of the passenger footrest support bracket.
Page 249 HOME Tighten the two fasteners (6) attaching the top case sm05204 mounting bracket (2) to the grab handles (5) to 19-20 ft- lbs (26-27 Nm). Tighten all remaining fasteners to 96-120 in-lbs (11-13 Nm). LUGGAGE CASE LATCH MECHANISM Removal Open desired case in order to access the latch mechanism for replacement.
Page 250 HOME sary to lift the lid gasket above the middle of latch and out of Figure 2-210. Loosen large hex nut and remove lock the way. from latch mechanism. Figure 2-208. Remove and discard two Phillips head Installation screws from existing latch mechanism. Figure 2-210.
Page 251: Luggage: Xb12Xp
HOME LUGGAGE: XB12XP 2.55 top case in place. This would result in a high stress situ- SIDE CASE ation on the left and right tailsection castings. Removal This operation should be performed for one side case bracket at a time. It does not matter which side case bracket is removed first.
Page 252 HOME Installation sm06004 NOTE To make sure you have proper alignment of side case brackets, always loosen the passenger peg support bracket fasteners and leave loose until all side case bracket fasteners have been tightened and then tighten as a final step. Figure 2-211.
Page 253 TABLE OF CONTENTS SUBJECT..........................PAGE NO. 3.1 FASTENER TORQUE VALUES....................3-1 3.2 SPECIFICATIONS........................3-3 3.3 ENGINE.............................3-7 3.4 ENGINE ROTATION FOR SERVICE..................3-9 3.5 ENGINE REMOVAL.........................3-14 3.6 ENGINE INSTALLATION......................3-24 3.7 CYLINDER HEAD........................3-35 3.8 CYLINDER AND PISTON......................3-51 3.9 OILING SYSTEM........................3-60 3.10 OIL PUMP..........................3-61 3.11 OIL RESERVOIR AND OIL HOSE ROUTING...............3-67 3.12 OIL LINE FITTINGS......................3-69 3.13 OIL COOLER.........................3-71 3.14 OIL PRESSURE INDICATOR SWITCH.................3-72...
Page 254 NOTES...
Page 255: Fastener Torque Values
HOME FASTENER TORQUE VALUES FASTENER TORQUE VALUES IN THIS CHAPTER The table below lists torque values for all fasteners presented in this chapter. FASTENER TORQUE VALUE NOTES Air scoop fastener at oil cooler 48-72 in-lbs 5.4-8 Nm 3.13 OIL COOLER, Installation/LOCTITE 271 (red) Anti-rotation screws (lifter) 55-65 in-lbs 6-7 Nm...
Page 256 HOME FASTENER TORQUE VALUE NOTES Oil pump body and cover fasteners 100-120 in-lbs 11.3-13.6 Nm 3.10 OIL PUMP, Assembly/Installation Oil pump body and cover fasteners 108-156 in-lbs 12.2-17.6 Nm 3.10 OIL PUMP, Assembly/Installation Oil pump body and cover fasteners 96-120 in-lbs 11-13.8 Nm 3.10 OIL PUMP, Assembly/Installation Oil pump body and cover fasteners...
Page 257: Specifications
HOME SPECIFICATIONS not given under SERVICE WEAR LIMITS, see NEW COMPON- GENERAL ENTS. NOTE Service wear limits are given as a guideline for measuring components that are not new. For measurement specifications Table 3-1. General Engine Specifications ITEM SPECIFICATION Type 2 cylinder, air cooled, four-stroke 45 degree V-twin Compression ratio 10:1...
Page 258 HOME Table 3-4. Valve Spring Specifications VALVE SPRING NEW COMPONENTS SERVICE WEAR LIMITS Exhaust 1.850 in. (closed) 135 lbs 61.2 kg Exhaust 1.300 in. (open) 312 lbs 141.5 kg Table 3-5. Rocker Arm Specifications ROCKER ARM NEW COMPONENTS SERVICE WEAR LIMITS Shaft fit in bushing (loose) 0.0005-0.0020 in.
Page 259 HOME Table 3-9. Connecting Rod Specifications CONNECTING ROD NEW COMPONENTS SERVICE WEAR LIMITS Piston pin fit (loose) 0.00145-0.00155 in. 0.03683-0.03937 mm 0.00200 in. 0.0508 mm Side play between flywheels 0.005-0.031 in. 0.1-0.8 mm 0.036 in. 0.9 mm Fit on crankpin (loose) 0.0004-0.0017 in.
Page 260 HOME Table 3-14. Pinion Shaft (Right Main) Bearing Specifications PINION SHAFT BEARINGS NEW COMPONENTS SERVICE WEAR LIMITS Bearing running clearance 0.00012-0.00086 in. 0.003-0.022 mm Fit in oil pump body bore. 0.0023-0.0043 in. 0.058-0.109 mm 0.0050 in. 0.127 mm Table 3-15. Sprocket Shaft Bearing Specifications ITEM SPECIFICATION (INTERFERENCE FIT) Outer race fit in crankcase (tight)
Page 261: Engine
Use a CYLINDER LEAKDOWN TESTER (Part No. HD-35667A) COMPRESSION TEST and follow the instructions supplied with the tester. The following are some general instructions that apply to Buell PART NUMBER TOOL NAME motorcycle engines:...
Page 262: Diagnosing Smoking Engine Or High Oil Consumption
HOME Refer to Table 3-17. Listen for air leaks at induction intake, DIAGNOSING SMOKING ENGINE OR HIGH exhaust and head gasket. OIL CONSUMPTION NOTE Perform the Compression Test. See 3.3 ENGINE, Compression If air is escaping through valves, check push rod length. Test.
Page 263: Engine Rotation For Service
HOME ENGINE ROTATION FOR SERVICE GENERAL The following process allows you to rotate engine down, To prevent accidental vehicle start-up, which could cause pivoting on rear isolator mount, in order to service components death or serious injury, disconnect negative (-) battery in the top end.
Page 264 HOME sm03746 Coil Fuel line connection Coil connection [83] Throttle position sensor connection [88] Coil wire harness retaining clip IAT sensor [89] Throttle cables Engine temperature sensor connection [90] Fuel injector connections [84 & 85] Oxygen sensor connection [137] 6. IAC sensor connection [87] Figure 3-1.
Page 265 HOME sm00701 Frame assembly Washers for center tie bar mount (2) "V" bracket Center tie bar assembly Fasteners for "V" bracket (3) Fasteners for center tie bar assembly (2) Front isolator assembly Washers for center tie bar assembly (2) Fasteners (2) Ground strap Bolt Rear isolator assembly...
Page 266 HOME NOTE Figure 3-2. Insert front isolator bolt (6) through front Cut the two cable straps securing the crank position sensor isolator (4) and loosely thread into frame. Do not tighten (CKP) wire to the "V" bracket. at this point. 19.
Page 267 HOME 20. Install idler pulley. See 5.7 DRIVE BELT AND IDLER sm04534 PULLEY. 21. Install left and right side rider footpeg mount. See 2.34 FOOTPEG, HEEL GUARD AND MOUNT: FIRE- BOLT/LIGHTNING 2.35 HEEL GUARD AND FOOTPEG MOUNTS: ULYSSES MODELS. 22. Install sprocket cover. See 2.36 SPROCKET COVER.
Page 268: Engine Removal
HOME ENGINE REMOVAL Remove intake cover and air cleaner assembly. See DISASSEMBLY 2.49 AIR SCOOPS. NOTES NOTE Vehicle should be placed onto the lift with rear tire in the When removing the left air scoop, the alternator and voltage wheel vise in order to successfully perform this procedure. regulator harnesses and connections are secured to the bottom of the air scoop with three cable straps.
Page 269 HOME sm03746 Coil Fuel line connection Coil connection [83] Throttle position sensor connection [88] Coil wire harness retaining clip IAT sensor [89] Throttle cables Engine temperature sensor connection [90] Fuel injector connections [84 & 85] Oxygen sensor connection [137] 6. IAC sensor connection [87] Figure 3-5.
Page 270 HOME 20. Disconnect clutch cable. 21. See Figure 3-9. Remove front "V" bracket with oil cooler from main frame. Slide clutch cable adjuster boot (2) up to access clutch adjuster. Disconnect alternator connector [46] (1) and voltage regulator connector [77] (2) in order to remove the Loosen clutch adjuster to release tension from hand "V"...
Page 271 HOME 28. See Figure 3-8. Remove vent oil line (11). 30. Remove return oil line (7). Remove clamp (12) in front of starter securing vent Remove p-clamp (8) at swingarm/oil reservoir (10). oil line to return oil line. Disconnect oil return line (7) at swingarm/oil reservoir Disconnect vent oil line from oil pump.
Page 272 HOME sm03729 Oil pump P-clamp Oil cooler return line to crankcase Rear muffler bracket Oil cooler feed line from oil pump Swingarm/Oil reservoir Oil filter Vent oil line Front muffler mount Oil line clamp Feed oil line Cable, interactive exhaust Return oil line Drain plug Figure 3-8.
Page 273 HOME sm00701 Frame assembly Washers for center tie bar mount (2) "V" bracket Center tie bar assembly Fasteners for "V" bracket (3) Fasteners for center tie bar assembly (2) Front isolator assembly Washers for center tie bar assembly (2) Fasteners (2) Ground strap Bolt Rear isolator assembly...
Page 274 HOME sm03744 sm03933 1. Neutral switch connection [131] 2. Oil pressure indicator switch wire 3. Interactive exhaust cable Figure 3-10. Electrical Connectors and Interactive Exhaust Cable Under Sprocket Cover 31. Remove front and rear muffler brackets. 32. See Figure 3-11. Remove two fasteners (2) and remove sidestand assembly.
Page 275 HOME sm03741 sm00730 Figure 3-14. Transmission Vent Line: Firebolt Figure 3-12. Supporting Vehicle for Disassembly 34. See Figure 3-9. Remove front isolator bolt (6). Remove front isolator assembly fasteners (5). sm00737 35. See Figure 3-13. Remove: Rear isolator bolt (1). Swingarm pivot shaft (2).
Page 276 HOME sm03745 sm00739 1. Left side 2. Right side Figure 3-19. Front Exhaust Mount Bushings (2 piece) Figure 3-17. Center Tie Bar Mount 40. Once engine has been removed from vehicle, finish sm02996 removing the following items as required: Shifter assembly. See 5.3 PRIMARY COVER.
Page 277 HOME 41. See Figure 3-21. If the crankcases are being separated it sm03731 will be necessary to remove rear isolator assembly by removing the forward two fasteners first and then the two rear fasteners (re-install with new fasteners). 42. See Figure 3-22.
Page 278: Engine Installation
HOME ENGINE INSTALLATION NOTE ASSEMBLY Hand thread pivot shaft into crankcase prior to installing Engine Preparation for Re-installation the threaded insert. Remove pivot shaft after installing the threaded insert. NOTE Figure 3-26. Apply LOCTITE 242 (blue) to Install components that were removed from engine as were swingarm pivot shaft pinch bolt threaded insert and necessary for service prior to installing engine in frame.
Page 279 HOME Install transmission vent line. Installing Engine in Frame Figure 3-30. On Firebolt models, route transmis- NOTES sion vent line up through left side of frame exiting Vehicle should be placed onto the lift with rear tire in the under the rear master cylinder under the rider's seat. wheel vise in order to successfully perform this procedure.
Page 280 HOME sm02952b sm00736 Figure 3-32. Transmission Vent Line: Ulysses Figure 3-33. Rear Isolator Bolt Figure 3-33. Using the overhead hoist to align the frame to the rear isolator, install rear isolator bolt and leave loose at this time. 3-26 2009 XB Service: Engine...
Page 281 HOME sm00701 Frame assembly Washers for center tie bar mount (2) "V" bracket Center tie bar assembly Fasteners for "V" bracket (3) Fasteners for center tie bar assembly (2) Front isolator assembly Washers for center tie bar assembly (2) Fasteners (2) Ground strap Bolt Rear isolator assembly...
Page 282 HOME NOTES Figure 3-35. Insert front isolator bolt (3) through front Exhaust header must be tightened with the engine rotated isolator (1) and loosely thread into frame. Do not tighten in the down position. It is not possible to reach fasteners at this point.
Page 283 HOME sm00936 Clamp, Torca Front muffler mount Muffler (XB9 models) Rear muffler bracket Muffler (XB12 models) Rear muffler straps Front muffler strap Rear muffler strap fastener 5. Front muffler strap fastener Figure 3-36. Muffler Mounting System 18. See Figure 3-36. Apply LOCTITE 271 (red) to rear muffler NOTES bracket fasteners, install and tighten to 32-36 ft-lbs (43.4- DO NOT install muffler at this time.
Page 284 HOME sm03729 Oil pump P-clamp Oil cooler return line to crankcase Rear muffler bracket Oil cooler feed line from oil pump Swingarm/Oil reservoir Oil filter Vent oil line Front muffler mount Oil line clamp Feed oil line Cable, interactive exhaust Return oil line Drain plug Figure 3-37.
Page 285 HOME 23. Install p-clamp (8) on return oil line (7) at the swingarm/oil 26. Install oil cooler feed line (3) and oil cooler return line (2). reservoir and tighten fastener to 40-50 in-lbs (4.5-5.6 Nm). NOTE 24. Install the vent oil line (11) in the same manner as the Figure 3-38.
Page 286: Lightning
HOME 31. Install muffler. See 4.18 EXHAUST SYSTEM. sm05389 32. Install rear belt and idler pulley. See 5.7 DRIVE BELT AND IDLER PULLEY. 33. Install left and right side rider footrests and support plates. 2.34 FOOTPEG, HEEL GUARD AND MOUNT: FIREBOLT/LIGHTNING 2.35 HEEL GUARD AND FOOTPEG MOUNTS: ULYSSES...
Page 287 HOME sm03746 Coil Fuel line connection Coil connection [83] Throttle position sensor connection [88] Coil wire harness retaining clip IAT sensor [89] Throttle cables Engine temperature sensor connection [90] Fuel injector connections [84 & 85] Oxygen sensor connection [137] 6. IAC sensor connection [87] Figure 3-41.
Page 288 HOME 48. Install and connect battery. See 1.5 BATTERY MAINTEN- ANCE. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury.
Page 289: Removal
HOME CYLINDER HEAD REMOVAL sm00131 Before removing the cylinder head assembly, it is necessary to rotate engine down as described in 3.4 ENGINE ROTATION SERVICE. The rocker arm covers and internal compon- ents must be removed before removing cylinder heads. NOTE All washers and fasteners used in the engine are hardened.
Page 290 HOME sm00130 Crankcase breather Gasket (lower) Screw, tappet anti-rotation (2) Grommet Rocker arm shafts Gasket (push rod cover) Screw (4) Screw (2) Push rod cover Washer (4) Washer (2) Screw (4) Fiber seal (4) Rocker cover (lower) O-ring (push rod cover - 2) Rocker cover (top) Rocker arm (2) Push rod...
Page 291 HOME Cylinder Head Assemblies sm00133 NOTE Figure 3-45. Distortion to the head, cylinder and crankcase studs may result if head screws are not loosened (or tightened) gradually in the sequence shown. Loosen each head screw 1/8-turn following the sequence shown. Continue loosening in 1/8-turn increments until screws are loose.
Page 292 HOME sm00134 Figure 3-46. Valve Spring Compressor 3-38 2009 XB Service: Engine...
Page 293 HOME sm00135 Screw Valve guide intake and exhaust Cylinder base gasket Screw Cylinder base stud Valve collar retainer Cylinder head Exhaust valve Upper valve spring collar Exhaust port stud Exhaust valve seat Valve spring Cylinder head gasket Valve seal and lower valve Cylinder insert spring collar assembly 12.
Page 294 HOME Measure and record rocker arm shaft diameter. CLEANING AND INSPECTION Figure 3-49. Measure where shaft fits in lower PART NUMBER TOOL NAME rocker arm cover. B-45525 VALVE GUIDE HONE Figure 3-50. Measure where rocker arm bushings HD-34751 VALVE GUIDE CLEANING BRUSH ride.
Page 295: Valve Guides
HOME Inspect for burrs around the valve stem keeper groove. sm00140 Remove burrs with a fine tooth file if found. Valve Seats NOTE Valve seats are also subject to wear. Resurface valve seats whenever valves are refinished. Inspect seats for cracking, chipping or burning. Replace seats if any evidence of these conditions are found.
Page 296 HOME Valve Springs sm00144 Inspect valve springs for broken or discolored coils. NOTE A single valve spring is used for each valve. The inner and outer springs are combined into one tapered spring that is progressively wound. Figure 3-54. Check free length and compression force of each spring.
Page 297 HOME REPLACING VALVE GUIDES sm00145 PART NUMBER TOOL NAME B-45523 VALVE GUIDE REAMER B-45524-A VALVE GUIDE REMOVER/INSTALLER B-45525 VALVE GUIDE HONE HD-34751 VALVE GUIDE CLEANING BRUSH Valve guide replacement, if necessary, must be done before valve seat is ground. It is the valve stem hole in valve guide that determines seat grinding location.
Page 298 HOME to be used and subtract 0.080 in. (2.032 mm) from that PROCEDURE FOR USING THE NEWAY number. VALVE SEAT CUTTER Set your dial caliper to the lesser measurement and lock PART NUMBER TOOL NAME down for quick reference. This is the location of your valve seat.
Page 299 HOME 11. When you accomplish a complete clean-up of the 46° angle and the width is at least 0.062 in. (1.575 mm), pro- ceed to the next step. Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear 12.
Page 300 HOME sm00149 sm00134 Figure 3-60. Valve Guide Seal Protector Sleeve sm00150 Figure 3-63. Valve Spring Compressor PUSH ROD COVER INSTALLATION Figure 3-65. Install push rod covers. Install new o-rings (2) on top of each push rod cover (3). NOTE Before installing o-rings on the top of each pushrod cover be sure to apply a small amount of clean engine oil to each o-ring.
Page 301: Cylinder Head Installation
HOME NOTE sm00153 After head(s) have been installed do not turn engine over until both push rods can be turned with fingers. Otherwise, damage to push rods or rocker arms may result. Table 3-19. Push Rod Selection POSITION COLOR LENGTH CODES Exhaust 1 Band...
Page 302 HOME NOTE 12. See Figure 3-69. Install upper rocker covers (6). The procedure for tightening the head screws is critical to Place a new inner gasket (9) on lower rocker box proper distribution of pressure over gasket area. It prevents assemblies.
Page 303 HOME sm00154 sm00131 1. Screws and washers 2. Bolts and washers Figure 3-67. Tightening Head Screws 3. Rocker arm fasteners Figure 3-68. Lower Rocker Box Fasteners 2009 XB Service: Engine 3-49...
Page 304 HOME sm00130 Crankcase breather Gasket (lower) Screw, tappet anti-rotation (2) Grommet Rocker arm shafts Gasket (push rod cover) Screw (4) Screw (2) Push rod cover Washer (4) Washer (2) Screw (4) Fiber seal (4) Rocker cover (lower) O-ring (push rod cover - 2) Rocker cover (top) Rocker arm (2) Push rod...
Page 305: Cylinder And Piston
HOME CYLINDER AND PISTON REMOVAL/DISASSEMBLY sm00155 PART NUMBER TOOL NAME HD-34623C PISTON PIN RETAINING RING INSTALLER Strip motorcycle as described under 3.4 ENGINE ROTA- TION FOR SERVICE. Remove cylinder head. See 3.7 CYLINDER HEAD. Clean crankcase around cylinder base to prevent dirt and debris from entering crankcase while removing cylinder.
Page 306 HOME the piston could score the cylinder during engine operation and sm00157 cause engine damage. sm00156 Figure 3-72. Piston Pin and Piston Identification NOTE Figure 3-72. The arrows on the pistons must always point toward the front of the engine. sm00158 1.
Page 307 HOME Soak cylinder and piston in an aluminum-compatible Figure 3-74. Check cylinder head gasket surface for cleaner/solvent until deposits are soft, then clean with a flatness. brush. Blow off loosened carbon and dirt particles and Lay a straightedge across the surface. wash in solvent.
Page 308: Deglazing Cylinder
HOME NOTE Starting at the bottom of the cylinder, move the deglazing If cylinder clearance exceeds service wear limit, cylinders and tool up and down the entire length of the cylinder bore for pistons should be replaced with new components. See 10 to 12 complete strokes.
Page 309 HOME sion ring, then the top ring. Use TRANSMISSION SHAFT sm00162 RETAINING RING PLIERS (Part No. J-5586-A) to slip compression rings over piston into their respective grooves. Be extremely careful not to over expand, twist rings or damage piston surface when installing rings. NOTE Install second compression ring with dot towards top.
Page 310 HOME CONNECTING ROD BUSHING sm00163 PART NUMBER TOOL NAME HD-35102 WRIST PIN BUSHING HONE HD-94800-26A REAMER HD-95952-33C CONNECTING ROD CLAMPING TOOL HD-95970-32D PISTON PIN BUSHING TOOL When connecting rod bushing is worn to excessive pin clear- ance 0.002 in. (0.051 mm) or more, it must be replaced. Figure 3-81.
Page 311 HOME sm03828 sm00165 1. Remover side of driver 2. Receiver cup Figure 3-81. Connecting Rod Clamping Tool Figure 3-83. Removing Wrist Pin Bushing sm00166 sm03829 Figure 3-84. Installer Side of Driver 1. Hex cylinder 2. Threaded rod 3. Flat washer ASSEMBLY/INSTALLATION 4.
Page 312 HOME if it has been installed and then removed for any reason. A sm00157 loosely installed ring will come out of the piston groove and damage cylinder and piston beyond repair. Figure 3-87. Install new piston pin retaining rings (1) using PISTON PIN RETAINING RING INSTALLER (Part No.
Page 313 HOME sm00163 sm00171 1. Piston ring compressor Figure 3-89. Compressing Piston Rings 1. Front 2. Rear 3. Piston pin 4. Position ring end gaps at arrows (minimum of 90 degrees apart) Figure 3-88. Ring End Gap Position 2009 XB Service: Engine 3-59...
Page 314: Oiling System
HOME OILING SYSTEM 10. Oil flow then continues to the main feed galley at the top GENERAL of the oil pump body. Passages in the crankcase intersect The engine has a gravity/suction type oiling system, the main feed galley and carry oil to all hydraulic lifters incorporating oil feed and return pumps in the same body and piston jets.
Page 315: Oil Pump
HOME OIL PUMP 3.10 The oil pump seldom needs servicing. Before you disassemble GENERAL an oil pump suspected of not producing adequate oil pressure, Figure 3-90. The oil pump consists of two gerotor gear be sure that all possible related malfunctions have been elim- sets, feed and return, housed in one pump body.

Buell 2009 XB Series Service Manual

Maintenance 1.6 Engine Oil and Filter

Appendix A Connector Repair

Fastener Torque Values

General

Fuel and Oil

Maintenance Schedule

Battery Maintenance

Engine Oil and Filter

Brake System Maintenance

Tires and Wheels

Clutch/Transmission/Primary Fluid

Drive Belt Maintenance

Primary Chain

Steering Head Bearings

Spark Plugs

Air Cleaner and Exhaust System

Table of Contents

6.17 Interactive Exhaust System 6.27 Main Wire Harness

Table of Contents

Throttle Cable

6.18 Headlight

Table of Contents

6.20 License Plate Lamp Assembly

6.21 Main Fuse and Fuses

6.22 Neutral Indicator Switch

(Ckp)

6.23 Sidestand Switch (Hdi)

6.24 Crankshaft Position Sensor

Table of Contents

6.19 Tail Lamp

6.25 Vehicle Speed Sensor (Vss)

Quick Links

Chapters

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Summary of Contents for Buell 2009 XB Series