Page 1 2003 BUELL XB9R SERVICE MANUAL Part Number 99493-03Y Section 1: Maintenance Section 2: Chassis Section 3: Engine Section 4: Fuel System Section 5: Starter Section 6: Drive/Transmission Section 7: Electrical Appendices...
Page 2 Edit Me: Printed June 5, 2002 12:26 pm...
Page 3 Part No. B-42887 Brake Caliper Piston Remover Part No. 39302 Part No. B-43721 Front Fork Seal Driver Part No. B-59000A Pro Level Oil Gauge Part No. B-43993-7/-8 Wheel Bearing Collets Part No. HD-01289 Rim Protectors 2003 Buell XB9R: Appendix A...
Page 4 Part No. HD-44060 Part No. HD-33416 Universal Driver Handle Part No. HD-99500-80 Wheel Truing and Balancing Stand Part No. HD-33418 Universal Puller Forcing Screw Part No. HD-95637-46A Wedge Attachment for Claw Puller. Use with HD-95635-46. 2003 Buell XB9R: Appendix A...
Page 5 Part No. HD-35667A Cylinder Leakdown Tester Part No. HD-39964 Reamer Lubricant (Cool Tool) 2003 Buell XB9R: Appendix A...
Page 6 Part No. HD-39786 Cylinder Head Holding Fixture Part No. B-45525 Valve Guide Hone Part No. HD-34736B Valve Spring Compressor Part No. HD-34751 Nylon Valve Guide Brush Part No. B-45524 Valve Guide Installer Part No. HD-94804-57 Rocker Arm Bushing Reamer 2003 Buell XB9R: Appendix A...
Page 7 Part No. HD-34623C Piston Pin Retaining Ring Installer/Remover Part No. HD-94800-26A Connecting Rod Bushing Part No. HD-42322 Piston Support Plate Reamers and Pilots Part No. HD-96333-51C Piston Ring Compressor Part No. HD-35102 Wrist Pin Bushing Hone (20 mm) 2003 Buell XB9R: Appendix A...
Page 8 Part No. HD-41609 Amp Terminal Crimp Tool Part No. HD-97292-61 Two Claw Puller Part No. HD-95760-69A Bushing/Bearing Puller Tool Set. Set includes items 1-7. Items 8 (HD-95769-69), 9 (HD- 95770-69) and 10 (HD-95771-69) are optional. 2003 Buell XB9R: Appendix A...
Page 9: Amp Multilock Electrical Connectors
Pin terminal Secondary lock open Pin housing Socket housing Latch Latch Secondary lock open Button Latch Secondary lock open Socket terminal Figure B-1. 10-Place Amp Multilock Connector 2003 Buell XB9R: Appendix B...
Page 10 Figure B-3. Multilock Connector Cutaway View engage latches on both sides of connector. Insert the socket housing (plug) into the pin housing (receptacle) until it snaps in place. Install connector on retaining device, either attachment or rosebud clip. 2003 Buell XB9R: Appendix B...
Page 11 Pin terminal Socket housing Button Pin housing Secondary lock Pin terminal Secondary lock Socket terminal Latch Button Pin housing Latch Socket housing Secondary lock Socket terminal d0245x2x Figure B-4. 3-Place and 6-Place Amp Multilock Connectors 2003 Buell XB9R: Appendix B...
Page 12 Release contacts locking bar. locking bar GAUGE CRIMP TOOL WIRE NEST Front Middle Rear Close and squeeze crimp tool. Raise locking bar and remove contact. d0246x8x Figure B-5. Amp Multilock Crimping Procedure 2003 Buell XB9R: Appendix B...
Page 13: Deutsch Electrical Connectors
“clicks” in place. Verify that socket will not back out of rear wire seal. chamber; a slight tug on the wire will conﬁrm that it is prop- erly locked in place. 2003 Buell XB9R: Appendix B...
Page 14 (Part No. HD-41475-100). See Figure B-10. Figure B-9. Depress Terminal Latches/Back Out Pins Gently depress terminal latches inside pin housing and back out pins through holes in wire seal. 2003 Buell XB9R: Appendix B...
Page 15 The socket and pin halves of all other connectors are interchangeable, that is, the black may be mated with the gray, since the alignment tabs are absent and the orientation of the external latch is the same. 2003 Buell XB9R: Appendix B...
Page 16 When correctly positioned, the locking bar ﬁts snugly in the space between the contact band and the core crimp tails. 2003 Buell XB9R: Appendix B...
Page 17 SOCKET SIDE PIN SIDE Socket terminal Locking wedge Wire seal Latch cover Socket housing Pin housing External latch 10. Wire seal Internal seal 11. Pin terminal Locking wedge Figure B-13. 2-Pin, 3-pin and 4-pin Deutsch Connectors 2003 Buell XB9R: Appendix B...
Page 18 MAP sensor connector [80]. d0258x8x Locate tang on latch side of chamber. Push on wire end of lead to remove terminal. Pivot end of pin to depress tang. Raise tang and re-install terminal. Figure B-14. Packard Connectors B-10 2003 Buell XB9R: Appendix B...
Page 19 NOTE A series of Packard Electrical Terminal Crimp Tools are avail- able to install Packard pin and socket terminals on wires. If new terminals must be installed, see Crimping Instructions. 2003 Buell XB9R: Appendix B B-11...
Page 20 Repeat the step if the terminal is still locked in place. NOTE A series of Packard Electrical Terminal Crimp Tools are avail- able to install Packard pin and socket terminals on wires. If new terminals must be installed, see Crimping Instructions. B-12 2003 Buell XB9R: Appendix B...
Page 21 11. See Figure B-16. Inspect the quality of the core (3) and insulation/seal (2) crimps. Distortion should be minimal. Insulation Insulation crimp Core crimp Figure B-16. Inspect Core and Insulation/Seal Crimps 2003 Buell XB9R: Appendix B B-13...
Page 22: Electrical Connectors
2-place Amp in airbox base [90] engine temperature sensor 1-place bullet beneath airbox base [91A] data link 4-place Deutsch beneath left side fairing 2-place spade [93] tail light back of tail light 1-place spade (ground) B-14 2003 Buell XB9R: Appendix B...
Page 23 [131] neutral switch 1-place bullet under sprocket cover [133] sidestand switch 2-place Multilock top of sidestand [134] bank angle sensor 6-place Sumitomo in fairing [137] oxygen sensor 1-place Packard behind rear cylinder head 2003 Buell XB9R: Appendix B B-15...
Page 24: Table Of Contents
INDEX TO WIRING DIAGRAMS Table B-3. XB9R Wiring Diagrams DIAGRAM PAGE Main harness B-17 Engine management circuit B-18 Lighting circuit B-19 Horn and instruments circuit B-20 Starting circuit B-21 Starting and charging circuits B-22 Component Circuits B-23 B-16 2003 Buell XB9R: Appendix B...
Page 25: Main Harness
IGNITION START [38HA] [38HB] [93A] [93B] TO RH TURN SIGNAL KEY SWITCH [18A] [18A] RH TURN SIGNAL INSTRUMENT CLUSTER [29A] [29B] [18A] [18A] POSITION [31A] [31B] LAMPS TOP VIEW (HDI ONLY) 2003 XB9R Main Harness 2003 Buell XB9R: Electrical B-17...
Page 26: Engine Management Circuit
Unused TO DATA LINK [39A] [39B] LT.GN/R [38A] [38B] R/BK HEADLIGHT [91A] INSTRUMENT CLUSTER SUB-HARNESS IGNITION START [38LA] [38LB] KEY SWITCH H3-55W HI AND LO BEAMS TOP VIEW [38HA] [38HB] 2003 XB9R Engine Management Circuit 2003 Buell XB9R: Electrical B-18...
Page 27: Lighting Circuit
TO LH TURN SIGNAL Unused Unused Unused H3-55W Unused HI AND LO BEAMS [39A] [39B] [31A] [31B] [38HA] [38HB] INSTRUMENT CLUSTER TO RH TURN SIGNAL [29B] [29A] POSITION LAMPS [31B] [31A] (HDI ONLY) 2003 XB9R Lighting Circuit 2003 Buell XB9R: Electrical B-19...
Page 28: Horn And Instruments Circuit
Right Turn High Beam Check Engine Oil Pressure GN/Y Unused Unused Unused Ignition Ground Tach In Low Fuel Warning Vss In Unused Unused Unused Unused [39A] [39B] INSTRUMENT CLUSTER 2003 XB9R Horn & Instruments Circuit 2003 Buell XB9R: Electrical B-20...
Page 29: Starting Circuit
SIDESTAND TN/W SWITCH RELAY CENTER [62A] [62B] W/BK CLUTCH SWITCH W/BK TN/W [95B] [95A] TN/W GY/O TN/LTGN GY/O IGNITION START BK/R TN/LT.GN R/BK KEY SWITCH R/BK TOP VIEW TOP VIEW R/BK 2003 XB9R Starting Circuit 2003 Buell XB9R: Electrical B-21...
Page 30: Starting And Charging Circuits
HOME bd0006xx BATTERY CABLE STARTER SOLENOID BATTERY STARTER MOTOR GROUND [GRD2] 30A MAIN FUSE [5A] TO VOLTAGE REGULATOR [77A] [77B] VOLTAGE REGULATOR STATOR (HD 3-PHASE) [46A] [46B] 2003 XB9R Starting & Charging Circuit 2003 Buell XB9R: Electrical B-22...
Page 31: Component Circuits
[84A] FUEL SENSOR GN/Y OIL PRESSURE [84B] [85B] [120A] [120B] SWITCH ENGINE TEMP SENSOR [65A] [90B] [90A] GN/GY VEHICLE GN/Y MAIN HARNESS SPEED SENSOR PK/Y LT.GN/Y LT.GN/Y BK/W BK/W [89A] [89B] 2003 XB9R Component Circuits 2003 Buell XB9R: Electrical B-23...
Page 32 44.45 79.37 114.30 .8268 2.126 3.425 4.724 10.160 45.72 80.96 115.89 .8661 2.165 3.464 4.764 11.112 46.04 81.28 116.84 .9055 2.205 3.504 4.803 12.700 47.62 82.55 117.47 .9449 2.244 3.543 4.842 14.288 48.26 83.82 119.06 2003 Buell XB9R: Appendix C...
Page 33 WARNING meters, use the formulas given under the metric chart. For all The quality fasteners used on Buell motorcycles have other steel fasteners, use the values listed in one of the tables speciﬁc strength, ﬁnish and type requirements to perform below.
Page 34 HOME HOSE AND WIRE ROUTING b1114xax Figure D-1. Front and Rear Brake Systems, Right Side View...
Page 35 HOME b1115xbx Figure D-2. Rear Brake Systems, Top View...
Page 36 HOME b1116xcx Figure D-3. Rear Brake Systems, Left Side View...
Page 37 HOME b1117xax Carbon canister Figure D-4. Evaporative Emissions Control, California Models, Top View...
Page 38 HOME b1118xbx To induction module From fuel tank (California) From induction module (California) From fuel tank to atmosphere (49 state) Figure D-5. Evaporative Emissions Control, California and 49 State Models, Left Side View...
Page 39 HOME b1119xax Intake air temperature sensor (IAT) Fuel pump Sidestand switch Figure D-6. Wiring Harness, Left Side View...
Page 40 HOME b1120xbx Fuel injector (2) Intake air temperature (IAT) sensor Throttle position sensor (TPS) Oxygen (O2) sensor Figure D-7. Wiring Harness, Top View...
Page 41 HOME b1121xcx Speedometer sensor Cable, starter to battery positive Solenoid Transmission vent line Voltage regulator Switch, oil pressure Cam position sensor Figure D-8. Wiring Harness, Right Side View...
Page 42 HOME b1122xax Vent line Feed oil line from the oil pump to the oil cooler Feed oil line Return oil line from the oil cooler to the oil ﬁlter housing Return oil line Figure D-9. Oil Lines, Right Side View...
Page 43 HOME b1123xbx Vent line Feed oil line Return oil line Figure D-10. Oil Lines, Bottom View...
Page 44 HOME b1124xax Figure D-11. Clutch and Throttle Cables, Right Side View...
Page 45 HOME b1125xbx Cable, seat lock Figure D-12. Clutch, Throttle and Seat Release Cables, Left Side View...
Page 46 HOME b1126xcx TPS adjuster Cable, seat lock Figure D-13. Clutch, Throttle and Seat Release Cables, Top View...
Page 48: Table Of Contents
MAINTENANCE Table Of Contents SUBJECT PAGE NO. 1.1 General ............1.2 Fluid Requirements .
Page 50: General
HOME GENERAL SERVICING A NEW XB9R TOOL SET MOTORCYCLE The Buell XB9R comes with a standard tool set (stored in the trunk) that consists of the following: Shock Spanner Wrench WARNING WARNING T27 TORX Wrench Always follow the listed service and maintenance recom- 7/8”...
Page 51: Fluid Requirements
20W-50, 15W-40 and 10W-40. At the the metric system equivalents. In the metric system, 1 liter (L) ﬁrst opportunity, see a Buell dealer to change back to 100 = 1,000 milliliters (mL). Should you need to convert from U.S.
Page 52 Road test. Chart Codes: I - Inspect, & if necessary correct, clean or replace. R- Replace or change. A- Adjust. D- Disassemble (lube & inspect). L- Lubricate with specified lubricant. T- Tighten to proper torque. X- Perform. 2003 Buell XB9R: Maintenance...
Page 53: Care Of Molded-In-Color Body Panels
Untreated molded-in-color body panels sometimes have a Special care and maintenance are required for the molded-in- static charge that attracts dust. Applying Harley Gloss or Har- color body panels that are standard on your Buell XB9R ley Glaze Polish and Sealant to molded-in-color surfaces will motorcycle.
Page 54: Battery Maintenance
HOME BATTERY MAINTENANCE GENERAL BATTERY TESTING Voltmeter Test Buell motorcycle batteries are permanently sealed, mainte- nance-free, valve-regulated, lead/calcium and sulfuric acid Table 1-4. The voltmeter test provides a general indicator batteries. The batteries are shipped pre-charged and ready to of battery condition. Check the voltage of the battery to verify be put into service.
Page 55 Inspect the battery case for cracks or leaks. at 77 ° F 75 % at 105 ° F 50 % M O N T H S O F S T A N D Figure 1-2. Battery Self-Discharge Rate 2003 Buell XB9R: Maintenance...
Page 56 If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install seat. See 2.38 SEAT. 2003 Buell XB9R: Maintenance...
Page 57: Engine Lubrication System
Do not allow hot oil level to fall below lower mark on dip- stick. To do so may result in equipment damage and/or malfunction. CAUTION Do not overﬁll oil tank. Overﬁlling oil tank may result in oil carryover to the air cleaner, equipment damage and/or equipment malfunction. 2003 Buell XB9R: Maintenance...
Page 58 Rotate ﬁlter another 1/2-3/4 turn by hand. LEVEL. WARNING WARNING Be sure no oil gets on tires when changing oil and ﬁlter. Traction will be adversely affected which may lead to loss of control which could result in death or serious injury. 2003 Buell XB9R: Maintenance...
Page 59 HD 360 Poor Heavy (16°C) H.D. Extra Heavy Above ° HD 360 Poor (27°C) Figure 1-3. Oil Tank Drain Plug 8352 8374 Operating Range Figure 1-4. Dipstick Location/Engine Oil Level 8418 Figure 1-5. Oil Filter 1-10 2003 Buell XB9R: Maintenance...
Page 60: Brake System Maintenance
At every 2500 miles (4000 km) service interval thereaf- ing or bleeding system. To prevent death or serious ter. injury, Buell recommends that all brake repairs be per- formed by a Buell dealer or other qualiﬁed technician. Every 2 years.
Page 61 Replace pads. brake pads. Brake pads drag on rotor – Cup in master cylinder not uncovering Inspect master cylinder. will not retract. relief port. Rear brake pedal linkage out of Adjust linkage. adjustment. 1-12 2003 Buell XB9R: Maintenance...
Page 62: Bleeding Front Brake
Verify master cylinder ﬂuid level as described in step 4. 10. Attach cover to front master cylinder reservoir and tighten fastener to 9-13 in-lbs (1.0-1.5 Nm). 11. Remove cover from molded-in-color surfaces, right han- dlebar switches and instrument panel. 2003 Buell XB9R: Maintenance 1-13...
Page 63: Bleeding Rear Brake
If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. 11. Install seat. See 2.38 SEAT. 1-14 2003 Buell XB9R: Maintenance...
Page 64 (2). Move locknut away from top surface of turn buckle (4). Turn rod adjuster to set pedal height. Return locknut (3) to ﬁt ﬂush against top surface of clevis. NOTE Brake pedal has no free play adjustment. 2003 Buell XB9R: Maintenance 1-15...
Page 65 0.18 in. (4.5 mm). Replace drive bush- ings, fasteners, washers and springs whenever rotor is replaced. Check rotor surface. Replace if warped or badly scored. 2.5 FRONT WHEEL 2.6 REAR WHEEL for proce- dure. 1-16 2003 Buell XB9R: Maintenance...
Page 66: Brake Pad Replacement
(48-50 Nm). Tighten pin (1) to 11-15 ft-lbs (15-20 Nm). NOTE Avoid making hard stops for the ﬁrst 100 miles (160 km) to allow new brake pads to “wear in” properly with the rotor. 2003 Buell XB9R: Maintenance 1-17...
Page 67 Install pin plug (2). Tighten plug to 18-25 in-lbs (2- 3 Nm). NOTE Avoid making hard stops for the ﬁrst 100 miles (160 km) to allow new brake pads to “wear in” properly with the rotor. Figure 1-15. Rear Brake Pad Spring 1-18 2003 Buell XB9R: Maintenance...
Page 68: Tires And Wheels
Puncture, cut or other damage to the tire that cannot be Check rear wheel bearing: repaired. At every 10000 mile (16000 km) service interval. Check wheel bearings for wear and corrosion. Excessive play or roughness indicates worn bearings. Replace bearings in sets only. 2003 Buell XB9R: Maintenance 1-19...
Page 69: Clutch
ﬂuid level (3) is even with bottom of clutch diaphragm spring (2). Figure 1-17. Install clutch inspection cover tighten- ing three fasteners and washers to 7-9 ft-lbs (10-12 Nm). Clean up any ﬂuid that may have spilled on mufﬂer. Figure 1-19. Fluid Level 1-20 2003 Buell XB9R: Maintenance...
Page 70 Figure 1-20. Clutch Cable Adjuster Mechanism does not align with recess in outer ramp, rotate adjusting screw clockwise until it aligns. NOTE 8405 Spring installs on outboard side of hex lockplate. Diaphragm spring Lockplate Adjusting screw Figure 1-21. Clutch Adjustment 2003 Buell XB9R: Maintenance 1-21...
Page 71 Install clutch inspection cover and gas- ket using three fasteners and washers and tighten to 7- 9 ft-lbs (10-12 Nm). Figure 1-22. Adjusting Clutch Free Play Check clutch cable free play. See Step 6 above. 1-22 2003 Buell XB9R: Maintenance...
Page 72: Drive Belt System
If scribe or knife point digs in and leaves a visible mark, it is cutting the bare aluminum. A knife point will not penetrate the chrome plating. Replace rear sprocket if major tooth damage or loss of chrome exists. 2003 Buell XB9R: Maintenance 1-23...
Page 73: Drive Belt Installation
Slide belt onto sprocket. Axle Figure 1-24. Install upper belt guard (10) to swing- Pinch bolt fastener arm brace tightening fasteners (9) to 12-36 in-lbs (1- 4 Nm). Figure 1-23. Rear Wheel Mounting, Right Side 1-24 2003 Buell XB9R: Maintenance...
Page 74 Spacer collar Lower belt guard Front belt guard Sprocket cover Sprocket cover fasteners Lower belt guard fasteners Upper belt guard fasteners, short Upper belt guard fasteners, long 10. Upper belt guard Figure 1-24. Belt Guard Assembly 2003 Buell XB9R: Maintenance 1-25...
Page 75 The pulley wheel bearings can not be replaced separately. b1106x6x 8420 Axle Pinch bolt fastener Wheel Figure 1-25. Rear Wheel Mounting, Right Side Wheel nut Stud Idler pulley bracket Idler pulley bracket nut and washer Wheel fastener Figure 1-26. Idler Pulley Assembly 1-26 2003 Buell XB9R: Maintenance...
Page 76 OK to run, but monitor condition Fuzzy edge cord OK to run, but monitor condition Hook wear Replace belt Stone damage Replace belt if damage is on the edge Bevel wear (outboard edge only) OK to run, but monitor condition 2003 Buell XB9R: Maintenance 1-27...
Page 77 HOME NOTES 1-28 2003 Buell XB9R: Maintenance...
Page 78: Primary Chain
9.5-12.7 mm Figure 1-28. Install primary chain inspection cover Hot (normal running and gasket to primary cover using two fasteners with 1/4-3/8 in. 6.4-9.5 mm temperature) captive washers. Tighten fasteners to 40-60 in-lbs (5- 7 Nm). 2003 Buell XB9R: Maintenance 1-29...
Page 79 Loosen locknut (1). Turn adjusting fastener (2): Clockwise (inward) to reduce free play. Counterclockwise (outward) to increase free play. Locknut Tighten locknut (1) to 20-25 ft-lbs (27-34 Nm). Adjusting screw Figure 1-30. Chain Tension Adjusting Fastener 1-30 2003 Buell XB9R: Maintenance...
Page 80: Suspension Damping Adjustments
(2) with a wrench. WARNING WARNING Always adjust each fork leg to the same settings. Uneven adjustment between left and right forks may lead to a loss of control which could result in death or serious injury. 2003 Buell XB9R: Maintenance 1-31...
Page 81 Figure 1-31. Rear Shock Preload Adjuster GVWR Up to 410 lbs (186 kg) 8360 of rider+passenger+cargo Rebound Adjuster Screw Preload Adjuster Nut Four Lines Visible (factory setting) Figure 1-32. Front Fork Preload And Rebound Adjuster 1-32 2003 Buell XB9R: Maintenance...
Page 82 This is the maximum compression damping setting. Then turn the dial counterclockwise the recommended amount specified in Table 1-11. Figure 1-35. Rear Shock Compression Adjustment 8415 Figure 1-36. Accessing Rear Shock Compression Adjuster 2003 Buell XB9R: Maintenance 1-33...
Page 83 1-1/4 Average Roads, sport riding (Note: this is the factory setting) 1-1/4 1-1/4 1-5/8 1-1/2 Moderately rough roads, more comfort, less sport 3-1/2 1-3/4 Rough roads, long rides, “max comfort setting” 2-5/8 4-3/4 2-3/8 2-1/4 1-34 2003 Buell XB9R: Maintenance...
Page 84: Front Fork Oil Change
Rebound adjuster screw Snap ring Preload adjuster Fork cap Fork cap Preload pins Preload pins Damper rod assembly Preload washer Preload washer Slider piston Slider piston Figure 1-38. Fork Cap Assembly Figure 1-40. Holding Damper Rod Assembly 2003 Buell XB9R: Maintenance 1-35...
Page 85 Outer tube Adjuster Damper assembly Fork oil level Figure 1-41. Measuring Fork Oil Level Figure 2-42. Install spring (16), and spring collar (15). Move fork assembly from holding tool to the FORK SPRING COMPRESSION TOOL. 1-36 2003 Buell XB9R: Maintenance...
Page 86 24. Oil seal Inner slider piston o-ring 16. Spring 25. Oil seal stopper ring Snap ring 17. Spring joint 26. Dust seal Rebound adjuster assembly 18. Outer tube 27. Slide pipe Figure 2-42. Front Fork Assembly 2003 Buell XB9R: Maintenance 1-37...
Page 87: Steering Head Bearings
13-15 ft-lbs (18-20 Nm). within speciﬁcation, see ADJUSTMENT. 11. When adjustment is complete, attach clutch cable and When adjustment is complete, attach clutch cable and adjust. See 1.8 CLUTCH. adjust. See 1.8 CLUTCH. 12. Remove scissor jack. 1-38 2003 Buell XB9R: Maintenance...
Page 88: Spark Plugs
A plug with eroded electrodes, heavy deposits or a cracked insulator must be replaced. A plug with a white, yellow, tan or rusty brown pow- dery deposit indicates balanced combustion. Clean off spark plug deposits at regular intervals. 2003 Buell XB9R: Maintenance 1-39...
Page 89 If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. 16. Install seat. See 2.38 SEAT. 1-40 2003 Buell XB9R: Maintenance...
Page 90: Air Cleaner Filter
Thoroughly clean baseplate and inside of air box. Figure 1-48. Make sure two crankcase breather hoses (1) and intake air sensor (3) are captured in base- plate behind velocity stack (2). 2003 Buell XB9R: Maintenance 1-41...
Page 91 If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install seat. See 2.38 SEAT. 1-42 2003 Buell XB9R: Maintenance...
Page 92: Throttle Cable And Idle Speed Adjustment
Tighten cable adjuster lock on idle control cable. Recheck operation of throttle control. Recheck engine slow idle speed; adjust if required. 10. Install airbox, baseplate and intake cover assembly. See 4.43 AIRBOX. 2003 Buell XB9R: Maintenance 1-43...
Page 93: Ignition Timing
HIGH - 5 volts as timing mark is just coming into view at left edge of window and will switch to LOW - 0 volts at same point as the timing mark continues through the window. (If this is observed, turn ﬂywheel forward one 1-44 2003 Buell XB9R: Maintenance...
Page 94 If timing is retarded (mark appears on right side of window) rotate timing plate clockwise. Recheck timing. Figure 1-53. Timer Cover 8391 Figure 1-54. Cam Position Sensor b0964x1x Figure 1-55. Advanced Timing b0963x1x Figure 1-56. Retard Timing 2003 Buell XB9R: Maintenance 1-45...
Page 95: Headlights
Low beam Check that the correct pattern of light is a circular Figure 1-58. Headlamp Switch pattern and is centered on the horizontal line as shown in Figure 1-57. Adjust headlamp alignment. See ADJUSTMENT section. 1-46 2003 Buell XB9R: Maintenance...
Page 96 If headlamp requires adjustment, perform the following: NOTE To lower beam, turn adjuster clockwise. To raise beam, turn adjuster counterclockwise. High beam adjuster (left) Low beam adjuster (right) Figure 1-59. Headlamp Height Adjustment 2003 Buell XB9R: Maintenance 1-47...
Page 97: Throttle Position Sensor (Tps)
NOTE This is to ensure that the throttle plate is completely closed before beginning recalibration. Select calibrations screen. Select the Buell calibrations tab. Select Zero TPS function. NOTE When calibration is complete, dialogue box will appear on Digital Tech screen with message display "Command Sent Successfully".
Page 98: Storage
Apply a light ﬁlm of oil to exposed uncoated metal sur- faces. If motorcycle is to be covered, use a material that will breathe, such as light canvas. Plastic materials that do not breathe promote the formation of condensation. 2003 Buell XB9R: Maintenance 1-49...
Page 99: Troubleshooting
18. TP Sensor/fast idle screw not set properly. See dealer. 20. Inoperative fuel injector. See dealer. 19. No output from CMP sensor. See dealer. 21. Obstructed fuel tank vent valve or pinched vent tube. 20. Inoperative fuel pump. See dealer. See dealer. 1-50 2003 Buell XB9R: Maintenance...
Page 100: Electrical System
Dirt or other foreign matter between valve and its seat. Wheels not aligned and/or tires worn. Poor Fuel Economy Internal engine problem. O2 sensor damaged or malfunctioning (bike running Wheels not balanced correctly. rich). See dealer. 2003 Buell XB9R: Maintenance 1-51...
Page 101 LOWER. Shock absorber or front forks not functioning normally. 10. Heavy front end loading. Non-standard equipment on the front end (such as heavy radio receivers, extra lighting equipment or luggage) tends to cause unstable handling. 1-52 2003 Buell XB9R: Maintenance...
Page 102 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. Decrease compression damping. 2003 Buell XB9R: Maintenance 1-53...
Page 103 HOME NOTES 1-54 2003 Buell XB9R: Maintenance...
Page 104 Table Of Contents CHASSIS SUBJECT PAGE NO. 2.1 Specifications ..........2.2 Tire Specifications .
Page 106 0.45 Lateral 0.0154 0.39 WARNING WARNING Do not inﬂate any tire beyond its maximum inﬂation pressure as speciﬁed on tire sidewall. Overinﬂation may cause tire to suddenly deﬂate which could result in death or serious injury. 2003 Buell XB9R: Chassis...
Page 107 Footpeg mount fasteners, rider 108-132 in-lbs 12-15 Nm page 2-68 Footpeg mount, passenger 25-28 ft-lbs 34-38 Nm LOCTITE 272, page 2-69 Fork cap 22-30 ft-lbs 30-40 Nm page 2-42 Fork center bolt 22-30 ft-lbs 30-40 Nm page 2-42 2003 Buell XB9R: Chassis...
Page 108 Rotor mounting fasteners, front 25-27 ft-lbs 34-37 Nm metric, Replace with new, page 2-13 Rotor mounting fasteners, rear 25-27 ft-lbs 34-37 Nm metric, Replace with new, page 2-16 Safety interlock fastener 7-10 in-lbs 0.8-1.1 Nm page 2-58 2003 Buell XB9R: Chassis...
Page 109 Tail frame to frame 21-23 ft-lbs 28-31 Nm LOCTITE 272, page 2-78 Torca clamp 40-45 ft-lbs 54-61 Nm page 2-67 Turn signals and reﬂectors 25-28 in-lbs 2-3 Nm page 2-78 Valve stem nut 40-44 in-lbs 4-5 Nm page 2-20 2003 Buell XB9R: Chassis...
Page 110: Tire Specifications
& POSITION RIM SIZE HOLE DIAMETER TIRE SIZE 17 in. – Front MT 3.5 x 17.0 DOT 0.33 in. 120/70 ZR17 D207FY 17 in. – Rear MT 5.5 x 17.0 DOT 0.33 in. 180/55 ZR17 D207U 2003 Buell XB9R: Chassis...
Page 111: Vehicle Identification Number
An abbreviated V.I.N. is stamped on the front left side of the crankcase. NOTE Figure 2-3. Always give the V.I.N. or abbreviated V.I.N. when ordering parts or making inquiries about your Buell motorcycle. Figure 2-2. Abbreviated V.I.N. Location Manufacturer: Buell Motorcycle Company Type Designation-Firebolt XB9R...
Page 112 Figure 2-4. Checking Tire Inﬂation Pressure Figure 2-4. Check tire inﬂation pressure at least once each week. At the same time, inspect tire tread for punctures, cuts, breaks and other damage. Repeat the inspection before long trips. 2003 Buell XB9R: Chassis...
Page 113 Always locate and eliminate the cause of the original your Buell dealer. Speed should not exceed 50 mph (80 tire failure. km/h) for the ﬁrst 24 hours after repair and the repaired Do not patch or vulcanize a tire casing.
Page 114: Front Wheel
Figure 2-5. Front Wheel Mounting Figure 2-6. Raise the wheel up until the rotor clears the caliper and rotate the fork leg counterclockwise allowing wheel clearance for removal. 8441 Remove wheel. Figure 2-6. Front Wheel Removal and Installation 2003 Buell XB9R: Chassis...
Page 115 Forcing screw Figure 2-9. Expand the Collet Figure 2-10. Place the bridge (1) against the wheel hub. Hold the forcing screw (2), and turn the nut (3) clockwise until the bearing is free of the hub. 2-10 2003 Buell XB9R: Chassis...
Page 116 Always replace brake pads in complete sets for correct brake operation. Never replace just one brake pad. Fail- ure to install brake pads as a set could result in death or serious injury. Inspect brake rotor and pads. See 1.6 BRAKE SYSTEM MAINTENANCE. 2003 Buell XB9R: Chassis 2-11...
Page 117: Bearing Installation
Figure 2-13. Install the Backing Plate (B-43993-11) and Forcing Screw Figure 2-14. Sparingly apply Extreme Pressure Lubricant (J-23444-A) to the threads of the long forcing screw (1) to prolong service life and ensure smooth operation. 2-12 2003 Buell XB9R: Chassis...
Page 118 Failure to comply may affect braking ability and 14. While holding the forcing screw (3), tighten the nut (6) lead to brake failure which could result in death or seri- until the bearing is ﬂush with the hub. ous injury. 2003 Buell XB9R: Chassis 2-13...
Page 119 Apply LOCTITE ANTI-SEIZE LUBRICANT to axle. b0935x2x Front axle Front brake rotor Wheel bearing Rotor mount fastener (6) Front wheel Drive bushings (6) Front brake springs (6) Washers (6) Front wheel spacer Figure 2-18. Front Wheel Assembly 2-14 2003 Buell XB9R: Chassis...
Page 120: Rear Wheel
See Bearing Removal 2.5 FRONT WHEEL. Remove rear wheel spacer (4). Axle Pinch bolt fastener Figure 2-20. Rear Wheel Mounting, Right Side Figure 2-20. Remove rear axle (1). Remove rear wheel. 2003 Buell XB9R: Chassis 2-15...
Page 121 Remove rear wheel bearing. ing or bleeding system. To prevent death or serious The procedure for the rear wheel bearing installation is injury, Buell recommends that all brakes repairs be per- the same as front wheel bearing installation. See Bear- formed by a Buell dealer or other qualiﬁed mechanic.
Page 122 HOME b0936x2x Rotor mounting fastener (6) Wheel Brake rotor Sprocket Wheel bearing Sprocket fastener Wheel spacer Axle Figure 2-23. Rear Wheel Assembly 2003 Buell XB9R: Chassis 2-17...
Page 123: Checking Cast Rim Runout
Figure 2-24. Checking Cast Rim Lateral Runout Table 2-8. Wheel Runout b0758x2x CAST WHEEL Wheel Truing and Balancing Maximum Lateral 0.040 1.02 Stand (Part No. HD-99500-80) Runout Maximum Radial 0.030 0.76 Runout Gauge rod Figure 2-25. Checking Cast Rim Radial Runout 2-18 2003 Buell XB9R: Chassis...
Page 124 Installing a tire with the wrong rotation could result in death or serious injury. Dunlop front and rear tires for Buell motorcycles are not the same. They are not interchangeable. Use Figure 2-26. Loosening Beads from Rim Flange front tire ONLY for a front tire.
Page 125 40 psi (275 kPa). Apply air to stem to seat beads on rim. It may be neces- sary to use a TIRE BEAD EXPANDER (Part No. HD- 28700) on the tire until beads seal on rim. 2-20 2003 Buell XB9R: Chassis...
Page 126 BONDER 420 to adhesive side of weight. Locate a ﬂat surface on the right side of the wheel rim and press weight ﬁrmly in place, holding for ten seconds. Allow eight hours for adhesive to cure completely before using wheel. 2003 Buell XB9R: Chassis 2-21...
Page 127: Brake Pedal
(5) to 22-24 ft-lbs (30-33 Nm). Install clevis pin (2). Install new cotter pin (7). Rear master cylinder body Clevis pin Pedal bushings (2) Shift brake pedal sleeve Brake pedal fastener Brake pedal Cotter pin Figure 2-32. Brake Pedal Assembly 2-22 2003 Buell XB9R: Chassis...
Page 128: Front Brake Master Cylinder And Hand Lever
Figure 2-34. Remove rubber boot (1) and discard. Figure 2-33. Depress piston assembly (1) and remove internal snap ring (2) and discard. Figure 2-35. Remove piston assembly (6) from front master cylinder reservoir (4) and discard. 2003 Buell XB9R: Chassis 2-23...
Page 129 Brake hand lever Pivot bolt nut (metric) Brake switch fastener 10. Brake switch 11. Brake switch terminal 12. Banjo bolt (metric) 13. Brake line 14. Copper washers 15. Pivot bolt Figure 2-35. Front Brake Hand Lever Assembly 2-24 2003 Buell XB9R: Chassis...
Page 130 Always test motorcycle brakes at low speed after servic- ing or bleeding system. To prevent death or serious injury, Buell recommends that all brake repairs be per- formed by a Buell dealer or other qualiﬁed technician. 2003 Buell XB9R: Chassis...
Page 131: Front Brake Line
D.O.T. 4 ﬂuid and will Banjo bolt not seal properly over time. Failure to comply may adversely affect braking ability and lead to brake failure which could result in death or serious injury. Figure 2-38. Front Brake Line 2-26 2003 Buell XB9R: Chassis...
Page 132 Always test motorcycle brakes at low speed after servic- ing or bleeding system. To prevent death or serious injury, Buell recommends that all brake repairs be per- formed by a Buell dealer or other qualiﬁed mechanic. Install bleeder valve if removed. Reﬁll master cylinder and bleed brakes.
Page 133: Front Brake Caliper
Figure 2-39. Remove pistons using a BRAKE PIS- Caliper pad spring TON REMOVER (Part No. B-42887). Caliper fasteners Figure 2-41. Pad Spring (Typical) 6495 Figure 2-39. Removing Pistons (B-42887) Remove and discard top and bottom seal. 2-28 2003 Buell XB9R: Chassis...
Page 134 Install two new o-rings (6) in grooves of each piston bore. Install pistons (5) in each piston bore. Install new o-rings (8) between caliper halves. Clamp caliper together with caliper fasteners (11) and tighten to 15-19 ft-lbs (20-26 Nm). 2003 Buell XB9R: Chassis 2-29...
Page 135 HOME b0976x2x Pin hanger set Bleeder set cover Bleeder set screw Caliper Piston Piston o-rings Clip Small o-ring Caliper mounting fasteners 10. Brake pads 11. Caliper fasteners Figure 2-42. Front Caliper Assembly 2-30 2003 Buell XB9R: Chassis...
Page 136: Rear Brake Master Cylinder
(3) to detach brake switch (1) from Fastener and washer master cylinder (4). Discard copper crush washers. Remote reservoir hose Clamp Figure 2-44. Remove fasteners (3) (metric) to detach master cylinder (4) from rider footpeg mount. Figure 2-45. Remote Reservoir 2003 Buell XB9R: Chassis 2-31...
Page 137 Snap ring must be snapped into the groove of the master cylinder body. If the snap ring is not properly installed, improper brake operation could result in death or seri- ous injury. Tuck rubber boot on rod assembly (3) into master cylin- der body (1). 2-32 2003 Buell XB9R: Chassis...
Page 138 Always test motorcycle brakes at low speed after servic- ing or bleeding system. To prevent death or serious injury, Buell recommends that all brake repairs be per- formed by a Buell dealer or other qualiﬁed mechanic. 10. Add brake ﬂuid and bleed brake system. See 1.6 BRAKE...
Page 139: Rear Brake Line
Remove banjo bolt (4) from rear caliper. Discard copper Figure 2-49. Rear Brake Line washers. Figure 2-50. Remove brake line switch/banjo bolt from rear master cylinder. Discard copper washer. 8439 Remove brake line from motorcycle. Figure 2-50. Rear Brake Line Switch/Banjo Bolt 2-34 2003 Buell XB9R: Chassis...
Page 140 Install battery by threading positive cable (red) into threaded hole ﬁrst tightening to 72-96 in-lbs (8-11 Nm). 1.4 BATTERY MAINTENANCE. Install seat. See 2.38 SEAT. 2003 Buell XB9R: Chassis 2-35...
Page 141: Rear Brake Caliper
Remove piston (3) using BRAKE CALI- PER PISTON REMOVER (1) (Part No. B-42887) with adaptor (2). Remove two o-rings from groove in caliper bore and dis- card. Clip Rear caliper mount Figure 2-52. Caliper Mount Clip 2-36 2003 Buell XB9R: Chassis...
Page 142 Install pad hanger pin (metric). Tighten to 11-14 ft- lbs (15-19 Nm). Install pin plug. Tighten to 22-26 in-lbs (2-3 Nm). Install a new bleeder valve (metric) if necessary and tighten to 36-60 in-lbs (4-7 Nm). 2003 Buell XB9R: Chassis 2-37...
Page 143 Always test motorcycle brakes at low speed after servic- ing or bleeding system. To prevent death or serious injury, Buell recommends that all brake repairs be per- formed by a Buell dealer or other qualiﬁed mechanic. Turn ignition key switch to ON. Apply brake pedal to test brake lamp operation.
Page 144: Front Fork
Remove fork from upper fork clamp and slide the stopper ring up and over the top of the fork. Figure 2-69. Remove fork from lower fork clamp (8). Repeat 4 through 6 on opposite side. 2003 Buell XB9R: Chassis 2-39...
Page 145 Careful not to damage preload pins (2) while holding damper rod assembly (3). 19. Remove guide bushing (22), seal spacer (23), oil seal Remove preload washer (4) and slider piston (5). (24), stopper ring (19) and dust seal (26). 2-40 2003 Buell XB9R: Chassis...
Page 146: Fork Assembly
NOTE 43721). See Figure 2-64. Set both forks to the exact same suspension settings. Install the oil seal stopper ring (25) and a new dust seal Adjust rebound assembly for proper range of motion. (26). 2003 Buell XB9R: Chassis 2-41...
Page 147 4.6 in. (118 mm) from the top of the fork tube. while holding damper rod assembly (3), 22. Apply fork oil or light grease to o-rings on preload adjuster and install preload adjuster (3). 23. Install snap ring (2). 2-42 2003 Buell XB9R: Chassis...
Page 148 11. Install front wheel. See 2.5 FRONT WHEEL. 12. Install front fender. See 2.31 FENDERS. 13. Check headlamp alignment. See 1.18 HEADLIGHTS. 14. Adjust front forks suspension to rider preferences. See 1.11 SUSPENSION DAMPING ADJUSTMENTS. 2003 Buell XB9R: Chassis 2-43...
Page 149 24. Oil seal Inner slider piston o-ring 16. Spring 25. Oil seal stopper ring Snap ring 17. Spring joint 26. Dust seal Rebound adjuster assembly 18. Outer tube 27. Slide pipe Figure 2-67. Front Fork Assembly 2-44 2003 Buell XB9R: Chassis...
Page 150 Install cable strap to the right of ignition switch securing right hand switch and brake line wires to upper fork clamp. Install cable strap to the left of ignition switch secur- ing left hand switch and clutch cable wires to upper fork clamp. 2003 Buell XB9R: Chassis 2-45...
Page 151 HOME b0937x2x Stem capnut Stem pinch fastener Upper fork clamp pinch fastener Upper fork clamp Head bearing Stem Lower fork clamp pinch fastener Lower fork clamp Figure 2-69. Steering Stem Assembly 2-46 2003 Buell XB9R: Chassis...
Page 152 Figure 2-71. Install new upper and lower steering head bearings into the steering stem using STEERING HEAD BEARING RACE INSTALLER (Part No. HD- 39302). STEERING HEAD BEARING INSTALLER (Part No. B-45521). 2003 Buell XB9R: Chassis 2-47...
Page 153 Con- tinue tightening until both bearings are fully seated. Visually check to make sure the bearings are completely seated against the shoulders in the steering head. 2-48 2003 Buell XB9R: Chassis...
Page 154: Swingarm And Brace
The upper belt guard is attached to the swingarm brace and can not be removed from vehicle at this time. The swingarm also serves as the oil tank on the Buell XB9R. For information on the swingarm function as the oil tank, see Figure 2-78.
Page 155 Remove rear fender. See 2.31 FENDERS. NOTE Figure 2-78. Remove swingarm bearings (5, 9) only if replacement is required. The complete bearing assembly must be replaced as a unit when replacement is necessary. Do not intermix bearing components. 2-50 2003 Buell XB9R: Chassis...
Page 156 Check oil level after starting motorcycle and allowing it to to swingarm and tighten to 36-60 in-lbs (4-7 Nm). reach operating temperature. Install three oil lines from swingarm ﬁttings. See 3.9 OIL HOSE ROUTING AND OIL RESERVOIR. Check rear brake operation. 2003 Buell XB9R: Chassis 2-51...
Page 157 Pivot shaft pinch fastener 14. Rear axle pinch fastener Figure 2-78. Swingarm Assembly Table 2-12. Oil line Fittings FITTINGS HEX SIZE HEX SIZE (FUNCTION) (SWINGARM) (HOSE) Right/Small (Vent) 5/8” 7/16” Center/Large (Supply) 13/16” 5/8” Left/Medium (Return) 3/4” 1/2” 2-52 2003 Buell XB9R: Chassis...
Page 158: Front And Rear Isolators
Tighten front isolator bolt (6) to 49-51 ft-lbs (66-69 Nm). Figure 2-79. Install clutch cable p-clamp. Tighten 3.4 STRIPPING MOTORCYCLE FOR ENGINE SER- fastener to 12-36 in-lbs (1-4 Nm). VICE to access the rear isolator. 2003 Buell XB9R: Chassis 2-53...
Page 159 LOWER. Install rear shock. See 2.22 REAR SHOCK ABSORBER. Install tail frame. See 2.36 TAIL FRAME AND BODY WORK. Install exhaust header. See 2.28 EXHAUST SYSTEM. Rotate engine. See 3.3 ENGINE ROTATION FOR SER- VICE. 2-54 2003 Buell XB9R: Chassis...
Page 160: Rear Shock Absorber
Feed rear shock reservoir through tail section. D.1 HOSE AND WIRE ROUTING for correct routing. Loosely install reservoir in clamp. See Figure 2-83. Temporarily place upper body work onto tail section and adjust reservoir placement so dial aligns with bodywork. 2003 Buell XB9R: Chassis 2-55...
Page 161 Shock remote reservoir Lower shock mount fastener and washer Shock reservoir body 10. Shock spring retainer kit Upper shock mount fastener 11. Rear shock spring Lower shock mount nut and washer Figure 2-85. Rear Shock Absorber Assembly 2-56 2003 Buell XB9R: Chassis...
Page 162: Throttle Control
Attach housings with two fasteners, installing longer fastener on bottom. Tighten to 25-33 in-lbs (3-4 Nm). Adjust cables. See 1.16 THROTTLE CABLE AND IDLE SPEED ADJUSTMENT. Install airbox assembly. See 4.43 AIRBOX. 2003 Buell XB9R: Chassis 2-57...
Page 163: Clutch Hand Lever
If not yet performed, route clutch cable to primary cover. Figure 2-90. Cable Straps On Upper Fork Clamp D.1 HOSE AND WIRE ROUTING for clutch cable routing. 10. With clutch cable lower section connected to primary cover, adjust clutch. See CLUTCH. 2-58 2003 Buell XB9R: Chassis...
Page 164 Loosen headlamp pivot fasteners (1). Rotate headlight bracket (2) down. Figure 2-92. Disconnect headlight connection. Disconnect and remove electronic control module. See 4.29 ELECTRONIC CONTROL MODULE. Figure 2-93. Remove headlight support bracket (2). Figure 2-92. Headlight Connector 2003 Buell XB9R: Chassis 2-59...
Page 165 Headlight pivot fasteners Headlight support bracket Electronic control module fasteners Black rubber cover Low beam headlight High beam headlight Headlight fastener Headlight bulb Bank angle sensor 10. Bank angle sensor fastener Figure 2-93. Headlight Support Bracket Assembly 2-60 2003 Buell XB9R: Chassis...
Page 166 Tighten electronic control module fasteners (3) to 72-96 in-lbs (8-11 Nm). Figure 2-91. Connect ﬂasher (1) and bank angle sensor (2). Install front fairing. See 2.37 FRONT FAIRING, WIND- SHIELD, AND MIRRORS. 2003 Buell XB9R: Chassis 2-61...
Page 167: Fairing Support Bracket
Install battery by threading positive cable (red) into threaded hole ﬁrst tightening to 72-96 in-lbs (8-11 Nm). 1.4 BATTERY MAINTENANCE. 10. Install seat. See 2.38 SEAT. 2-62 2003 Buell XB9R: Chassis...
Page 168 HOME b0958x2x Jam nut Washer Rubber grommet Fairing support bracket fasteners and washers Fairing support bracket Instrument cluster P-clamp P-clamp fastener and washers Figure 2-95. Fairing Support Bracket Assembly 2003 Buell XB9R: Chassis 2-63...
Page 169 Figure 2-88. Position clutch hand lever to rider pref- erences and tighten fastener (1) to 36-60 in-lbs (4- 7 Nm). See 2.24 CLUTCH HAND LEVER. 8355 Figure 2-96. Handlebar Clip-on Mounting Fasteners (right clip-on shown) 2-64 2003 Buell XB9R: Chassis...
Page 170 HOME b0945x2x Endcap Hand grip Clip-on Upper fork clamp Clip-on fastener Figure 2-97. Handlebar Clip-on Assembly (left clip-on shown) 2003 Buell XB9R: Chassis 2-65...
Page 171: Exhaust System
Rear mufﬂer strap Front mufﬂer strap mount fastener Mufﬂer Front mufﬂer strap mount bushings Front mufﬂer strap Rear mufﬂer strap mount block Front mufﬂer strap fastener 10. Rear mufﬂer strap mount fasteners Figure 2-98. Mufﬂer Assembly 2-66 2003 Buell XB9R: Chassis...
Page 172 Exhaust retaining ring graphite tape during assembly. To ensure sealing integrity of Exhaust port gasket mufﬂer clamps and prevent the possibility of leakage, Buell recommends that mufﬂer clamp assemblies be discarded and Figure 2-99. Exhaust Header replaced each time they are removed.
Page 173 Install heel guard (3) with fasteners (4). Tighten to 72- 96 in-lbs (8-11 Nm). Install Mount Figure 2-100. Position footpeg mount (1). Install footpeg mount with fasteners (2). Tighten to 108- 132 in-lbs (12-15 Nm). 2-68 2003 Buell XB9R: Chassis...
Page 174 10. Footpeg mount fastener Figure 2-101. Position footpeg mount (3) onto tail Figure 2-101. Passenger Footpeg, Mount and Heel Guard frame. Assembly Install footpeg mount (3). Using LOCTITE 272 tighten, fasteners (10) to 25-28 ft-lbs (34-38 Nm). 2003 Buell XB9R: Chassis 2-69...
Page 175: Sprocket Cover
(1) and tighten all fasteners and washers (1) to 12-36 in-lbs (1-4 Nm). Install chin fairing. See 2.33 CHIN FAIRING. Sprocket cover fastener and washers Sprocket cover Front belt guard Figure 2-103. Sprocket Cover 2-70 2003 Buell XB9R: Chassis...
Page 176: Front Fender
Align rear fender (3) to frame. Install rear fender (3) with fasteners and washers (4), Tighten to 12-15 in-lbs (1-1.7 Nm). Front fender Front fender fastener Rear fender Rear fender fastener Figure 2-104. Front and Rear Fender 2003 Buell XB9R: Chassis 2-71...
Page 177: Belt Guards
16. Install right passenger footrest mount. use LOCTITE 272 NOTE and tighten fasteners to 25-28 ft-lbs (34-38 Nm). The rear wheel does not have to be removed to remove inner belt guard. 17. Remove scissor jack from motorcycle. 2-72 2003 Buell XB9R: Chassis...
Page 178 Spacer collar Lower belt guard Front belt guard Sprocket cover Sprocket cover fasteners Lower belt guard fasteners Upper belt guard fasteners, short Upper belt guard fasteners, long 10. Upper belt guard Figure 2-105. Belt Guard Assembly 2003 Buell XB9R: Chassis 2-73...
Page 179: Chin Fairing
(2). Use LOCTITE 272 on all fas- Left section teners tightening to 36-48 in-lbs (4-5 Nm). Left section fastener and washer Install sprocket cover. See 2.30 SPROCKET COVER. Right section Right section fastener and washer Figure 2-106. Chin Fairing Assembly 2-74 2003 Buell XB9R: Chassis...
Page 180: Intake Cover Assembly
(2). Tighten to 12-36 in-lbs (1-4 Nm). NOTE Front screws go in at a slight angle. Intake cover assembly Intake cover fasteners Install seat. See 2.38 SEAT. Figure 2-107. Intake Cover Assembly 2003 Buell XB9R: Chassis 2-75...
Page 181: Air Scoops
Oil cooler air scoop fastener and washer Ram air scoop Oil cooler air scoop Engine shroud scoop fastener and washer Ram air scoop fastener and washer Engine shroud scoop Figure 2-108. RAM Air Scoop, Engine Shroud, Oil Cooler 2-76 2003 Buell XB9R: Chassis...
Page 182 16. See Figure 2-109. Cut cable strap (3) from tail frame from lower tail body work (9) and remove license plate holding vent hose (1), main wire harness (2) and shock (13). reservoir hose (4). 2003 Buell XB9R: Chassis 2-77...
Page 183 Install rear shock reservoir into shock reservoir clamp and install clamp on to tail frame. Do not tighten. See 20. Install passenger seat latch (14) from rear of tail frame 2.22 REAR SHOCK ABSORBER. and tighten to 60-96 in-lbs (7-11 Nm). 2-78 2003 Buell XB9R: Chassis...
Page 184 Passenger seat lock plate 11. Trunk Passenger seat lock retainer 12. License plate fastener Passenger seat lock cable 13. License plate bracket Tail frame fasteners 14. Passenger seat latch Figure 2-112. Tail Frame and Body Work Assembly 2003 Buell XB9R: Chassis 2-79...
Page 185 Install two center (4) and four side windscreen and remove front fairing (5). fasteners (3). b0967x2x Windshield Mirrors Side windshield fastener Center windshield fastener Front fairing Turn signal Turn signal fastener Well nut Figure 2-113. Front Fairing and Windscreen 2-80 2003 Buell XB9R: Chassis...
Page 186 Align rear tab with latch slot at rear of motorcycle. Press down firmly on rear of pillion seat to engage seat latch. Pull up on rear of pillion seat to make sure latch is engaged. Turn ignition key counterclockwise and remove from seat lock. 2003 Buell XB9R: Chassis 2-81...
Page 187: Passenger Seat Lock
11. Install the seat lock cable (9) into the seat lock plate (6). 12. Install upper body work on tail section. See 2.36 TAIL FRAME AND BODY WORK. 13. Install rider and pillion seat. See 2.38 SEAT. 2-82 2003 Buell XB9R: Chassis...
Page 188: Sidestand Removal
Remove mufﬂer. See Mufﬂer and Straps 2.28 EXHAUST SYSTEM. Figure 2-120. Remove sidestand switch (6). See SIDESTAND SWITCH REMOVAL in this section. Remove fasteners (2) securing sidestand bracket (3) to frame. Figure 2-119. Sidestand Switch 2003 Buell XB9R: Chassis 2-83...
Page 189: Sidestand Installation
Install sidestand switch to sidestand assembly. Install sidestand to frame tightening the sidestand bracket fasteners to 25-27 ft-lbs (34-37 Nm). Install mufﬂer. See Mufﬂer and Straps 2.28 EXHAUST SYSTEM. Inspect sidestand. See INSPECTION in this section. 2-84 2003 Buell XB9R: Chassis...
Page 190 ENGINE Table Of Contents SUBJECT PAGE NO. 3.1 Specifications ..........3.2 Engine .
Page 192 59.1 mm 2.2.325. (min) 59.1 mm (min) Intake 1.850 in. (closed) 135 lbs 61.2 kg 1.300 in. (open) 312 lbs 141.5 kg Exhaust 1.850 in. (closed) 135 lbs 61.2 kg 1.300 in. (open) 312 lbs 141.5 kg 2003 Buell XB9R: Engine...
Page 193 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. 0.0102-0.0432 mm 0.0027 in. 0.0686 mm Connecting rod race ID 1.6245-1.6250 in. 41.2623-41.2750 mm 1.6270 in. 41.3258 mm 2003 Buell XB9R: Engine...
Page 194 Table 3-14. Sprocket Shaft Bearing Speciﬁcations SPROCKET SHAFT BEARING NEW COMPONENTS SERVICE WEAR LIMITS Bearing outer race ﬁt in crankcase 0.006 in. 0.2 mm (tight) Interference fit Bearing inner race ﬁt on shaft 0.006 in. 0.2 mm (tight) Interference fit 2003 Buell XB9R: Engine...
Page 195 19-21 ft-lbs 26-29 Nm page 3-88 Piston jet TORX screws 25-35 in-lbs 2.8-4 Nm Loctite 222, page 3-91 Pushrod cover screw 30-40 in-lbs 3-5 Nm page 3-84 Rear isolator assembly fasteners 25-27 ft-lbs 33.9-36.6 Nm page 3-29 2003 Buell XB9R: Engine...
Page 196 Alternator stator [46] Located under sprocket cover. Starter solenoid wire [128B] Disconnect at bottom of starter. Positive battery at starter [128A] Disconnect at rear of starter Side stand switch [60] Tie wrapped to rear brake line under vehicle. 2003 Buell XB9R: Engine...
Page 197 General Gasoline/alcohol Blends When an engine needs repair, it is not always possible to The Buell XB9R motorcycle has been designed to obtain the determine deﬁnitely beforehand whether repair is possible best performance and efﬁciency using a good quality with only cylinder head, cylinder and piston disassembled or unleaded gasoline.
Page 198: Diagnosing Smoking Engine Or High Oil Consumption
Valve guide seals. 35667A) and follow the speciﬁc instructions supplied with the tester. Valve guide-to-valve stem clearance. The following are some general instructions that apply to Buell motorcycle engines: Gasket surface of both head and cylinder. 2003 Buell XB9R: Engine...
Page 199: Engine Rotation For Service
8707 Fuel line connection Connections for fuel injectors [84 & 85] Connection for throttle position sensor [88] Figure 3-1. Fuel Line and DDFI Electrical Connections 2003 Buell XB9R: Engine...
Page 200 Throttle cables Cylinder head temperature sensor connection [90] Figure 3-2. Electrical Connections and Throttle Cables Figure 3-2. Disconnect the ignition coil [83] and Figure 3-2. Disconnect the following sensors: remove. Temperature sensor [90]. Oxygen sensor [137]. 2003 Buell XB9R: Engine...
Page 201 Remove front mufﬂer strap. 12. Remove transmission sprocket side cover. Remove rear mufﬂer straps. 13. Remove rear belt and idler pulley. See 1.9 DRIVE BELT Loosen Torca clamp and remove mufﬂer. SYSTEM 2.13 REAR BRAKE MASTER CYLINDER. 3-10 2003 Buell XB9R: Engine...
Page 202 Disconnect oil lines at oil cooler only. 16. Remove left side rider footrest and support plate. 8720 Figure 3-5. Clutch Cable Retaining Clamps 17. See Figure 3-5. Disconnect clutch cable. Remove retaining clamps. Pull clutch cable down. 2003 Buell XB9R: Engine 3-11...
Page 203 20. Bolt, rear isolator 10. Mount, center tie bar 21. Tie bar assembly, rear 11. Fasteners for center tie bar mount (2) 22. Fasteners for rear tie bar assembly (2) Figure 3-6. Engine Mounting System 3-12 2003 Buell XB9R: Engine...
Page 204 Figure 3-7. Rear Isolator Bolt and Rear Tie Bar 24. Remove front isolator mount from engine. 21. See Figure 3-7. Remove rear tie bar from frame. 25. Rotate engine down. 22. Loosen rear isolator bolt. DO NOT REMOVE. 2003 Buell XB9R: Engine 3-13...
Page 205 120-144 in-lbs (13.6-16.3 Nm). Figure 3-10. Install front tie-bar to engine and tighten to 25-27 ft-lbs (33.9-36.6 Nm). Attach regulator wiring harness to bracket nylon cable straps. Remove scissors jack. 3-14 2003 Buell XB9R: Engine...
Page 206 Verify that the clutch cable and feed line have a clearance of 1/8 to 1/4 in. (3.175-6.35 mm) between them. Verify that oil lines have a minimum clearance of 1/8 in. (3.175 mm) between them. Figure 3-12. Oil Cooler Feed and Return Oil Line Orientation and Clearances 2003 Buell XB9R: Engine 3-15...
Page 207 Install front mufﬂer strap fastener (7) and tighten to It is important that the front mufﬂer mount is tightened 108-120 in-lbs (12.2-13.6 Nm). last in order to ensure proper alignment of the exhaust Tighten torca clamp to 40-45 ft-lbs (54.2-61 Nm). system. 3-16 2003 Buell XB9R: Engine...
Page 208 Connect throttle cables from induction module/throttle body. 16. Disconnect the following sensors: Temperature sensor [90]. Oxygen sensor [137]. 17. See Figure 3-14. Install the ignition coil and connect [83] and tighten fasteners to 120-144 in-lbs (13.6-16.3 Nm). 2003 Buell XB9R: Engine 3-17...
Page 209 26. Install chin fairing. See 2.33 CHIN FAIRING. control resulting in death or serious injury. 27. Install air scoops, right and left sides. See 2.35 AIR SCOOPS. 3-18 2003 Buell XB9R: Engine...
Page 210: Stripping Motorcycle For Engine Service
Disconnect fuel injector leads [84 & 85]. Drain oil tank. 8707 Fuel line connection Connections for fuel injectors [84 & 85] Connection for throttle position sensor [88] Figure 3-16. Fuel Line and DDFI Electrical Connections 2003 Buell XB9R: Engine 3-19...
Page 211 Figure 3-17. Electrical Connections and Throttle Cables Figure 3-17. Disconnect the ignition coil (2) and remove. 10. Disconnect the following sensors: Temperature sensor [90]. Oxygen sensor [137]. 11. Disconnect throttle cables from induction module/throttle body. 3-20 2003 Buell XB9R: Engine...
Page 212 14. Remove transmission sprocket side cover. Alternately loosen rear strap fasteners (12) and 15. Remove rear belt and idler pulley. See 1.9 DRIVE BELT remove rear mufﬂer straps. SYSTEM 2.13 REAR BRAKE MASTER CYLINDER. Loosen Torca clamp and remove mufﬂer. 2003 Buell XB9R: Engine 3-21...
Page 213 Feed oil line from oil cooler to crankcase Figure 3-19. Oil Lines and Connections 17. See Figure 3-19. Remove oil ﬁlter. 19. Remove front and rear mufﬂer brackets. 18. Remove all oil lines (including lines to oil cooler). 3-22 2003 Buell XB9R: Engine...
Page 214 Figure 3-20. Clutch Cable Retaining Clamps 24. Remove sidestand assembly. 21. See Figure 3-20. Disconnect clutch cable from handle- bars. Remove retaining clamps. Pull clutch cable down. 2003 Buell XB9R: Engine 3-23...
Page 215 20. Bolt, rear isolator 10. Mount, center tie bar 21. Tie bar assembly, rear 11. Fasteners for center tie bar mount (2) 22. Fasteners for rear tie bar assembly (2) Figure 3-23. Engine Mounting System 3-24 2003 Buell XB9R: Engine...
Page 216 Unbolt “V” bracket from main frame and remove from left side. 8717 Neutral switch [131] Alternator connection [46] Speedometer sensor connection [65] Voltage regulator connection [77] Cam position sensor connection [14] Figure 3-24. Electrical Connections 2003 Buell XB9R: Engine 3-25...
Page 217 37. Lower engine with scissors lift all the way down. 38. Move the engine assembly from under the main frame to the right side of the lift. 39. Remove engine. Figure 3-26. Rear Isolator Bolt and Swingarm Pivot Shaft 3-26 2003 Buell XB9R: Engine...
Page 218 Right Side Figure 3-30. Swingarm pivot shaft pinch bolt threaded insert. Figure 3-31. Aluminum bushings from front exhaust mount. Figure 3-31. Front Exhaust Mount Bushings (2 piece) Timer cover. 8724 8729 Figure 3-30. Removing Threaded Insert 2003 Buell XB9R: Engine 3-27...
Page 219 43. Route a ratcheting tie down through the swingarm bear- ings, up over the main frame, through the top stabilizer area, back down to the ratchet mechanism and secure swingarm to main frame. 3-28 2003 Buell XB9R: Engine...
Page 220: Engine Installation
Figure 3-36. Center tie bar mount 25-27 ft-lbs Figure 3-38. Front Exhaust Mount Bushings (2 piece) (33.9-36.6 Nm). Figure 3-37. Swingarm pivot shaft pinch bolt threaded insert. Figure 3-38. Aluminum bushings from front exhaust mount. 2003 Buell XB9R: Engine 3-29...
Page 221 Using the overhead hoist to align the secure transmission vent line in place. Inspect vent line frame to the rear isolator, install rear isolator bolt and to verify space between vent line and rear exhaust. leave loose at this time. 3-30 2003 Buell XB9R: Engine...
Page 222 20. Bolt, rear isolator 10. Mount, center tie bar 21. Tie bar assembly, rear 11. Fasteners for center tie bar mount (2) 22. Fasteners for rear tie bar assembly (2) Figure 3-44. Engine Mounting System 2003 Buell XB9R: Engine 3-31...
Page 223 120-144 in-lbs (13.6-16.3 Nm). Install front tie-bar to engine and tighten to 25-27 ft- lbs (33.9-36.6 Nm). Attach regulator wiring harness to bracket nylon cable straps. 17. Remove scissors jack. 3-32 2003 Buell XB9R: Engine...
Page 224 32-36 ft-lbs (43.4-48.8 Nm). DO NOT install mufﬂer at this time. It is necessary to install mufﬂer mounts ﬁrst in order to properly install oil lines. 19. Install front mufﬂer mount and leave loose at this time. 2003 Buell XB9R: Engine 3-33...
Page 225 Front mufﬂer mount Return oil line 10. Rear mufﬂer bracket Feed oil line from oil pump to oil cooler 11. Oil cooler Feed oil line from oil cooler to crankcase Figure 3-48. Oil Lines and Connections 3-34 2003 Buell XB9R: Engine...
Page 226 ﬁrst. 21. See Figure 3-49. Torque the return oil line ﬁrst making sure to maintain the proper clearance between the oil line and the rear mufﬂer bracket. 19-21 ft-lbs (25.8-28.5 Nm.) 2003 Buell XB9R: Engine 3-35...
Page 227 25. Also torque the return oil line at the top front oil pump ﬁt- with the feed and return lines after torquing. ting to 18-20 ft-lbs (24.4-27.1 Nm). When the oil line has been properly torqued, the orientation of the line should also be approximately 7 o’clock. 3-36 2003 Buell XB9R: Engine...
Page 228 NOTE the vehicle. The 5/16 in. clearance is between the crankcase and the steel oil line as shown. Not between the crankcase and the clamp. 2003 Buell XB9R: Engine 3-37...
Page 229 Also be aware of the 1/8- properly torque certain oil line ﬁttings. 1/4 (3.175-6.35 mm) clearance speciﬁed between the feed oil line and the clutch cable at the front of the crankcase. 3-38 2003 Buell XB9R: Engine...
Page 230 Oil cooler feed line should be centered after line is torqued. Orientation of return line should be approximately 4 o’clock Figure 3-54. Oil Cooler Feed and Return Oil Lines Location and Orientation 2003 Buell XB9R: Engine 3-39...
Page 231 Neutral switch [131]. Speedometer sensor [65] (install tie wrap). Cam position sensor [14]. Alternator [46]. Voltage regulator [77]. Positive battery cable at starter. Starter solenoid [128]. Oil pressure switch [120]. Figure 3-56. Correct Routing of Wiring Harnesses 3-40 2003 Buell XB9R: Engine...
Page 232 37. Install sidestand switch to sidestand assembly and install cable strap. Figure 3-58. Clutch Cable Retaining Clamps 38. See Figure 3-58. Pull clutch cable back up into the proper position. Connect clutch cable to handlebars and adjust to speciﬁcations. Install retaining clamps. 2003 Buell XB9R: Engine 3-41...
Page 233 (5.4-6.8 Nm). system. Install front mufﬂer strap fastener (7) and torque to 108-120 in-lbs (12.2-13.6 Nm). Tighten Torca clamp to 40-45 ft-lbs (54.2-61 Nm). Tighten front mufﬂer mount to 22-25 ft-lbs (29.8-33.9 Nm). 3-42 2003 Buell XB9R: Engine...
Page 234 Temperature sensor [90]. Oxygen sensor [137] (Install wire tire on harness). 42. See Figure 3-60. Install the ignition coil and spark plug wires and connect [83]. Tighten ignition coil fasteners to 120-144 in-lbs (13.6-16.3 Nm). 2003 Buell XB9R: Engine 3-43...
Page 235 A loose seat may shift during vehicle operation and startle the rider, possibly causing loss of vehicle 52. Install sprocket cover and tighten fasteners and washers to 12-36 in-lbs (1-4 Nm). control resulting in death or serious injury. 3-44 2003 Buell XB9R: Engine...
Page 236: Cylinder Head
20. Gasket (push rod cover) 21. Pushrod cover 22. Screw (4) 23. O-ring (push rod cover - 2) 24. Push rod 25. Washer (4) 26. Bolt (4) b0960x3x Figure 3-62. Rocker Arm and Pushrod Cover Assemblies 2003 Buell XB9R: Engine 3-45...
Page 237 Remove rocker arms; mark them for reassembly in their original locations. 10. Mark the location and orientation (top/bottom) of each push rod. Remove push rods. Figure 3-64. Removing Rocker Arm Shafts 3-46 2003 Buell XB9R: Engine...
Page 238 Repeat the above procedure for the other valves. Head Screw Loosening/Tightening Sequence Figure 3-65. Head Screw Loosening/Tightening Sequence 8684 Figure 3-66. Valve Spring Compressor (Part No. HD-34736B) 2003 Buell XB9R: Engine 3-47...
Page 239 11. Cylinder O-ring (4) 12. Cylinder insert 13. Cylinder w/piston & rings 14. Cylinder base gasket 15. Cylinder base stud 16. Exhaust valve 17. Exhaust valve seat Figure 3-67. Cylinder Head, Cylinder and Piston Assembly 3-48 2003 Buell XB9R: Engine...
Page 240 Never use a ﬁle or SERVICE WEAR LIMIT of 0.006 in. (0.152 mm). other hardened tool which could scratch or nick valve. Polish valve stem with very ﬁne emery cloth or steel wool. 2003 Buell XB9R: Engine 3-49...
Page 241 Figure 3-70. Measure where rocker arm bush- Check end play of rocker arm with feeler gauge. ings ride. Replace rocker arm or lower cover or both if end play exceeds 0.025 in. (0.635 mm). 3-50 2003 Buell XB9R: Engine...
Page 242: Valve Guides
If the seat is loose or is not fully seated in the head, then seat movement will prevent the proper transfer of heat from the valve. The seat surface must be ﬂush with (or below) the head surface. See 3.1 SPECIFICATIONS for valve seat-to-cylinder head ﬁt. 2003 Buell XB9R: Engine 3-51...
Page 243 Using remaining old bushing as a pilot, line ream new bushing with ROCKER ARM BUSHING REAMER (Part No. HD-94804-57). Repeat for other end of rocker arm. 8733 8734 Figure 3-75. Replacing Rocker Arm Bushings 3-52 2003 Buell XB9R: Engine...
Page 244 Valve guide brush (Part No. HD-34751) Cylinder head holding ﬁxture (Part No. HD-39786) Figure 3-77. Cleaning Valve Guides Figure 3-77. Thoroughly clean valve guide bores using VALVE GUIDE BRUSH (Part No. HD-34751) and hot soapy water. 2003 Buell XB9R: Engine 3-53...
Page 245 Clamp tool in vise and further tighten cylinder head onto the ﬁxture to prevent any movement during operation. Place cylinder head at a 45° angle or one that offers a comfortable working position. 3-54 2003 Buell XB9R: Engine...
Page 246 (1.575 mm), pro- ceed to the next step. b0972x3x Intake & Exhaust Valve and Seat 60˚ Min. 0.040 in. (1.016 mm) Max. 0.062 in. (1.575 mm) Margin 31˚ 46˚ Figure 3-79. Valve and Seat Dimensions 2003 Buell XB9R: Engine 3-55...
Page 247 11. Cylinder O-ring (4) 12. Cylinder insert 13. Cylinder w/piston & rings 14. Cylinder base gasket 15. Cylinder base stud 16. Exhaust valve 17. Exhaust valve seat Figure 3-80. Cylinder Head, Cylinder and Piston Assembly 3-56 2003 Buell XB9R: Engine...
Page 248 Figure 3-82. Valve Seal and Lower Collar Assembly leakage around the valve stem, excessive oil consump- (seal and lower collar replaced as assembly only) tion and valve sticking. 2003 Buell XB9R: Engine 3-57...
Page 249 10. Insert valve keepers into upper collar, making sure they engage grooves in valve stem. The keeper gaps should be equal. 11. Release and remove from VALVE SPRING COMPRES- SOR. 12. Repeat Steps 4-11 for the remaining valve. 3-58 2003 Buell XB9R: Engine...
Page 250 17909-02 Orange/Brown (272.948 mm) CAUTION After head(s) have been installed do not turn engine over until both push rods can be turned with ﬁngers. Other- wise, damage to push rods or rocker arms may result. 2003 Buell XB9R: Engine 3-59...
Page 251: Cylinder Head Installation
Tighten each screw to 13-15 ft-lbs (18-20 Nm). Figure 3-88. Tightening Head Screws Figure 3-88. Mark cylinder head and head screw shoulder with a line as shown (View A). ° ° Turn all bolts an additional 85 -95 . 3-60 2003 Buell XB9R: Engine...
Page 252 20. Gasket (push rod cover) 21. Push Rod cover 22. Screw (4) 23. O-ring (push rod cover - 2) 24. Push Rod 25. Washer (4) 26. Bolt (4) b0960x3x Figure 3-89. Rocker Arm and Pushrod Cover Assemblies 2003 Buell XB9R: Engine 3-61...
Page 253 Place a new inner gaskets on lower rocker box assemblies. Place a new lower gaskets on lower rocker cover. Install upper rocker cover using screws with washers and new ﬁber seals. Tighten screws to 10-14 ft-lbs (13.6-19 Nm). 3-62 2003 Buell XB9R: Engine...
Page 254: Cylinder And Piston
Piston reinstalled resulting in engine damage. Piston pin Retaining ring (2) Dowel and o-ring Cylinder Base gasket Cylinder stud (4) Connecting rod 10. Piston pin bushing Figure 3-91. Cylinder and Piston 2003 Buell XB9R: Engine 3-63...
Page 255 In the event that the circlip should ﬂy out, hold a shop towel over the bore during removal. Figure 3-94. To remove piston rings spread outward Remove circlip from claw and discard. until they clear grooves in piston and lift off. 3-64 2003 Buell XB9R: Engine...
Page 256 Lay a straightedge across the surface. Try to insert a feeler gauge between the straight- edge and the gasket surface. If cylinder base gasket surface is not ﬂat within 0.008 in. (0.203 mm), replace cylinder and piston. 2003 Buell XB9R: Engine 3-65...
Page 257: Deglazing Cylinder
With the cylinder at room temperature, check the piston NOTE clearance in the cylinder in which the piston will run. See If piston clearance exceeds service wear limit, cylinders and SPECIFICATIONS. pistons should be replaced with new components. See SPECIFICATIONS. 3-66 2003 Buell XB9R: Engine...
Page 258 ﬁt standard and oversize pistons. Ring Type Ring End Gap inches Top compression ring 0.010 - 0.020 0.25 - 0.51 2nd compression ring 0.014 - 0.024 0.36 - 0.61 Oil control ring rails 0.010 - 0.050 0.25 - 1.27 2003 Buell XB9R: Engine 3-67...
Page 259 Figure 3-100. Ring End Gap Position Figure 3-100. Install rings so end gaps of adjacent rings are a minimum of 90° apart. Ring gaps are not to be within 10° of the thrust face centerline. 3-68 2003 Buell XB9R: Engine...
Page 260 Hone bushing to ﬁnal size using WRIST PIN BUSHING HONE (Part No. HD-35102). Use a liberal amount of honing oil to prevent damage to hone or bushing. Use care to prevent foreign material from falling into the crankcase. 2003 Buell XB9R: Engine 3-69...
Page 261 NOTE Install piston pin. Make sure the ring groove is clean. Ring must be fully seated in the groove with the gap away from the slot at the bottom. 3-70 2003 Buell XB9R: Engine...
Page 262 PISTON SUPPORT PLATE (Part No. HD-42322). Lubricate cylinder wall, piston, pin and rod bushing with engine oil. Remove protective sleeves from cylinder studs. Install a new cylinder base gasket. Make sure the piston does not bump the studs or crankcase. 2003 Buell XB9R: Engine 3-71...
Page 263 HOME NOTES 3-72 2003 Buell XB9R: Engine...
Page 264: Lubrication System
The colder the weather, the shorter the recommended oil tion on checking oil level and changing oil and ﬁlter. change interval. A vehicle used only for short runs in cold weather must have the engine oil drained frequently. 2003 Buell XB9R: Engine 3-73...
Page 265: Oil Hose Routing And Oil Reservoir
Front mufﬂer mount Return oil line 10. Rear mufﬂer bracket Feed oil line from oil pump to oil cooler 11. Oil cooler Return oil line from oil cooler to crankcase Figure 3-112. Oil Lines and Connections 3-74 2003 Buell XB9R: Engine...
Page 266: Oil Pressure Indicator Switch
Dead battery (see NOTE). ating engine). temperature. At 2500 RPM, oil pressure will vary from 10- 12 psi (69-83 KPa). At idle speed (950-1050 RPM), oil pres- sure will vary from 6-8 psi (42-55 KPa). 2003 Buell XB9R: Engine 3-75...
Page 267: Crankcase Breathing System
Breather hose, rear Breather hose, front The oil mist collects and eventually returns to the crankcase PCV Valves (2) through oil passageways in the cylinder head. Grommet Rocker cover, top (2) Figure 3-115. Crankcase Breathing System, 3-76 2003 Buell XB9R: Engine...
Page 268 3.11 CRANKCASE BREATHING SYSTEM. When replacing the reed valve it is not necessary to Fasteners should be tightened to 30-40 in-lbs (3.4-4.5 Nm). replace the reed block. See Figure 3-116. 2003 Buell XB9R: Engine 3-77...
Page 269: Oiling System
The return gears pump oil back to the oil reservoir. travels to the right ﬂywheel where it is routed through the ﬂywheel to the crankpin. Oil is forced through the crank- pin to properly lubricate the rod bearing assembly. 3-78 2003 Buell XB9R: Engine...
Page 270: Oil Pump
Thrust washer Retaining ring Gerotor return set Separator plate 10. Gerotor feed set 11. Cover º 12. 45 Fitting 13. Sems screw (2) 14. TORX screw (2) 15. Rear connector ﬁtting Figure 3-118. Oil Pump 2003 Buell XB9R: Engine 3-79...
Page 271 6) on both sides of the oil pump. Remove and discard retaining ring. Remove thrust Detach return line connection (3). washer and gear shaft. Carefully remove mounting screws (5) and washers only. Pump will drop with screws removed. Discard mounting gasket. 3-80 2003 Buell XB9R: Engine...
Page 272 10. See Figure 3-119. Attach return line connection. 11. Attach feed line connections to both sides of the oil pump. 12. Install new oil ﬁlter and ﬁll oil reservoir with proper oil. 1.5 ENGINE LUBRICATION SYSTEM. 2003 Buell XB9R: Engine 3-81...
Page 273: Oil Filter Mount
TITE) against check ball to compress spring. Screw adapter into threaded hole. Tighten to 8-12 ft- lbs (11-16 Nm). Install a new ﬁlter and ﬁll oil reservoir with proper oil. See 1.5 ENGINE LUBRICATION SYSTEM. 3-82 2003 Buell XB9R: Engine...
Page 274: Hydraulic Lifters
End clearance should be within 0.008-0.022 in. (0.203-0.559 mm). Replace lifters if clearance exceeds SERVICE WEAR LIMIT of 0.026 in. (0.660 mm). Soak lifters in clean engine oil. Keep covered until assembly. 2003 Buell XB9R: Engine 3-83...
Page 275 Tighten screws evenly to 30-40 in-lbs (3-5 Nm). Place new o-rings on top of push rod cover. Install push rods, cylinder head, lower and upper rocker covers. See 3.6 CYLINDER HEAD. Repeat process for remaining cylinder head. 3-84 2003 Buell XB9R: Engine...
Page 276: Gearcase Cover And Cam Gears
Gear cover gasket 13. Oil pump drive gear Bushing, outer, intake camshaft gear 14. Pinion gear “E” Cam gear set 15. Nut Right crankcase half 16. bushing, gear shaft- pinion Figure 3-126. Gearcase Cover & Cam Assembly 2003 Buell XB9R: Engine 3-85...
Page 277 Check for minimum cam gear end play. Record readings. 8662a Front exhaust cam gear Rear exhaust cam gear Front intake cam gear Pinion gear Rear intake cam gear Pinion nut Figure 3-127. Cam and Pinion Gear Location and Timing Mark Indexing 3-86 2003 Buell XB9R: Engine...
Page 278 (“E”) indicates model year application: Table 3-26. Stamp Location/Function Front Exhaust Front Intake Rear Intake Rear Exhaust NOTE Prior to changing any cam gears, check gear shaft ﬁt within corresponding bushings. Worn bushings can cause exces- sive backlash. 2003 Buell XB9R: Engine 3-87...
Page 279 Figure 3-126. Install a new seal and new dry gear- cover gasket on crankcase. Figure 3-130. Crankshaft Locking Tool (Part No. HD-43984) 3-88 2003 Buell XB9R: Engine...
Page 280 Install cam position sensor and rotor in gearcase cover. See CAM POSITION SENSOR AND ROTOR section. Install any components removed to gain access to gear- case (i.e. exhaust system components, air cleaner, etc.). Figure 3-132. Checking Cam Gear End Play 2003 Buell XB9R: Engine 3-89...
Page 281 Remove oil pump. See 3.13 OIL PUMP. Remove gearcase components. See 3.16 GEARCASE COVER AND CAM GEARS. Remove primary cover and primary drive/clutch compo- nents. See 6.2 PRIMARY CHAIN. Remove starter motor. See 5.7 STARTER. 3-90 2003 Buell XB9R: Engine...
Page 282 (2.8-4.0 Nm). Figure 3-135. Piston Oil Jet Assemblies Figure 3-135. Remove two TORX screws from each piston jet assembly to free piston jets from right crank- case. Remove piston jet gaskets from right crankcase. 2003 Buell XB9R: Engine 3-91...
Page 283 Thrust washer 10. Inner race Crankcase half 11. Gear shaft bearing Bearing 12. Retaining ring Retaining ring 13. Outer bearing race Inner race, left main bearing 14. Crankshaft case Figure 3-137. Crankcase and Flywheel Assembly 3-92 2003 Buell XB9R: Engine...
Page 284 42720-2) press left main bearing out of the left crank- case half. NOTE The bearing presses to the inside. There is a shoulder incor- porated into the left crankcase half which allows the bearing to be removed in one direction only. 2003 Buell XB9R: Engine 3-93...
Page 285 (OD) of the inner race and the smallest measured inside diameter (ID) of the outer race (crankcase bushing). A running clearance of 0.0002-0.0008 in. (0.0051-0.0203 mm) is established during crankcase set or ﬂywheel assembly replacement and engine rebuild. 3-94 2003 Buell XB9R: Engine...
Page 286 ROLLER OD (*A) IDENTIFICATION* 1.5650-1.5652 in. Largest (39.7510-39.7561 mm) Blue White (Grey) 13. See Table 3-29. Outer races are identiﬁed at the factory Smallest Green as shown. 14. See Figure 3-144. Pinion bearings are identiﬁed as shown. 2003 Buell XB9R: Engine 3-95...
Page 287 1.2502 1.2504 1.2508 1.2510 1.2512 1.2514 1.2516 1.2518 31.740 31.745 31.750 31.755 31.760- 31.765 31.770 31.775 31.780 31.786 3.791- 31.745 31.750 31.765 31.796 31.755 31.760 31.770 31.755 31.780 31.786 31.791 FACTORY COLOR CODE Green White 3-96 2003 Buell XB9R: Engine...
Page 288 0.0002 in. (0.0051 mm) NOTE Taper within 0.0002 in. (0.0051 mm) Figure 3-145. Dimensions are shown for fabrication of tools used in pressing the outer race into or out of crankcase. Surface ﬁnish 16 RMS 2003 Buell XB9R: Engine 3-97...
Page 289 Table 3-31. The ﬁnished inner race must meet the speciﬁcations in Table 3-34. Table 3-34. Pinion Inner Race Fitment Speciﬁcations Roundness within 0.0002 in. (0.0051 mm) Taper within 0.0002 in. (0.0051 mm) Surface ﬁnish 16 RMS 3-98 2003 Buell XB9R: Engine...
Page 290 Check connecting rod side play with a thickness gauge as shown. If side play measurement is greater than service wear limit listed below, replace ﬂywheel/connecting rod assembly. Service wear limit, 0.036 in. (0.8 mm) Figure 3-148. Checking Connecting Rod Side Play 2003 Buell XB9R: Engine 3-99...
Page 291 ASSEMBLY Crankcase Halves NOTE Lubricate all parts with Harley-Davidson 20W50 engine oil, and proceed as follows: b1046x3x Spacer, sprocket shaft Crankcase half Oil seal Bearing Thrust washer Retaining ring Figure 3-149. Left Main Bearing Assembly 3-100 2003 Buell XB9R: Engine...
Page 292 NOTE Make sure that the bearing assembly bottoms against the machined shoulder in the left crankcase half. Install bearing retaining ring in left crankcase half. Install transmission. See 6.12 TRANSMISSION INSTAL- LATION. 2003 Buell XB9R: Engine 3-101...
Page 293 #732 CLEAR sealant to crankcase joint faces. Slide outer race in right crankcase over pinion shaft and bearing assembly. Tighten fasteners to 15-19 ft-lbs (20-26 Nm). NOTE According to manufacturing, there is no torque sequence to follow when tightening crankcase fasteners. 3-102 2003 Buell XB9R: Engine...
Page 294 Slide sleeve over pilot until sleeve contacts the oil seal. Install handle on top of sleeve. Rotate handle clockwise until tool bottoms on crank- case lip. Remove tool from sprocket shaft. Figure 3-154. Sprocket Shaft Seal/Spacer Installer (Part No. HD-42579 and B-45676) 2003 Buell XB9R: Engine 3-103...
Page 295 Install the stud in the crankcase with the shoulder end down. Use an air gun to drive the stud until the shoulder reaches the crankcase. Remove air gun. Use a torque wrench to tighten stud to 10-20 ft-lbs (14-27 Nm). 3-104 2003 Buell XB9R: Engine...
Page 296 Table Of Contents FUEL SYSTEM SUBJECT PAGE NO. 4.1 Specifications ..........4.2 Dynamic Digital Fuel Injection .
Page 297 4.38 Fuel Pump ........... 4-104 4.39 Fuel Tank Vent Valve .
Page 298 4-122 clamp rear Throttle position sensor LOCTITE THREADLOCKER 222 (purple), page 4- 16-20 in-lbs 1.8-2.3 Nm Timer plate studs 15-30 in-lbs 2-3 Nm page 4-94 Upper tie bar 25-27 ft-lbs 33.9-36.6 Nm page 4-99 2003 Buell XB9R: Fuel System...
Page 299 HOME NOTES 2003 Buell XB9R: Fuel System...
Page 300 INTRODUCTION GENERAL The Buell Dynamic Digital Fuel Injection (DDFI) System pro- The Buell DDFI operates both as an open and closed loop vides microprocessor-based electronic engine management system which allows it to adjust for all possible operating con- for the 984cc high performance engine. The DDFI system has ditions.
Page 301 Bank Angle Sensor BK/W Y/BE Front GN/W Sensor Rear BE/O BK/W IGN Coil Throttle Cooling Position To cooling BK/O Sensor fan fuse BK/W BK/W Sensor LT GN/Y Ground Figure 4-112. Buell Dynamic Digital Fuel Injection 2003 Buell XB9R: Fuel System...
Page 302: Diagnostic Introduction
Correct problems through the replacement and/or repair of the affected components. After repairs are performed, the work must be validated. This involves clearing the trouble codes and conﬁrming proper vehicle operation as indicated by the behavior of the check engine lamp. 2003 Buell XB9R: Fuel System...
Page 303: Checking For Trouble Codes
Key ON Lamp ON 8 seconds: functional error** 4 Sec. 8 Sec. Lamp OFF 4 Sec. Key ON Lamp remains ON: current trouble code 4 Sec. 4 Sec. Key ON Figure 4-116. Check Engine Lamp Operation 2003 Buell XB9R: Fuel System...
Page 304 The fuel injection system provides two levels of diagnostics. The most sophisticated mode employs using a computer based diagnostic package called DIGITAL TECHNICIAN (Part No. HD-44750). The other mode requires using the check engine lamp. 4.5 CHECK ENGINE LAMP DIAGNOSTICS more information. 2003 Buell XB9R: Fuel System...
Page 305: Check Engine Lamp Diagnostics
Once all codes have been sent, the data string is repeated. When you have recorded the same trouble code twice, it is an indication that the transmission has been restarted and that all trouble codes have been retrieved. 2003 Buell XB9R: Fuel System...
Page 306 50 start and run cycles. To execute one run cycle: Remove diagnostic test wire and install protective cover Start the vehicle. over data link connector. Return data link to original posi- Let it run for at least 30 seconds. tion. Turn the engine off. 2003 Buell XB9R: Fuel System...
Page 307: Breakout Box
[10] (black) and [11] (gray). Detach Breakout Box connectors from ECM connectors. Detach Breakout Box connectors from wiring harness. Breakout Box Install ECM. See 4.29 ELECTRONIC CONTROL MOD- ULE. Figure 4-121. Installed Breakout Box 4-10 2003 Buell XB9R: Fuel System...
Page 308: Wiggle Test
BOX. Set DVOM to read voltage changes. Start motorcycle engine and run at idle. Shake or wiggle harness to detect intermittents. If inter- mittents are present, radical voltage changes will register on the DVOM. 2003 Buell XB9R: Fuel System 4-11...
Page 309: General Information
AND IDLE SPEED Compare engine behavior to tables. ADJUSTMENT. Starts hard. See Table 4-28. EVAP hose disconnected Connect. Hesitates, stumbles, surges, misﬁres and/or slug- from induction module (CA) gish performance. See Table 4-29. 4-12 2003 Buell XB9R: Fuel System...
Page 310 Cooling fan 4.25 TROUBLE CODE 36 Bank angle sensor 4.26 TROUBLE CODE 44 52, 53, 54, 55 ECM failure 4.27 TROUBLE CODES 52, 53, 54 AND 55 Cam sync failure 4.28 TROUBLE CODE 56 2003 Buell XB9R: Fuel System 4-13...
Page 311 Table 4-32. Wire Harness Connectors in Figure 4-123. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing [11] ECM (gray) 12-place Deutsch in fairing [91A] data link 4-place Deutsch beneath left side fairing 4-14 2003 Buell XB9R: Fuel System...
Page 312 Refer to applicable trouble code flow chart. Start with lowest trouble code. All diagnostic Refer to diagnostic codes are listed on page 7-13 Table 4-31. tips in related trouble code chart (even if no code is set). 2003 Buell XB9R: Fuel System 4-15...
Page 313 ECM TERMINAL Wire Color Connector Lt. GN/R [11B] [10B] [11B] [10B] Continuity present in all four circumstances? Inspect terminals for damage or repair Replace ECM. See opens as necessary. 4.29 ELECTRONIC CONTROL MODULE. 7120 4-16 2003 Buell XB9R: Fuel System...
Page 314: Check Engine Lamp Not Illuminated At Key On
If connection is good, replace ECM. See 4.29 ELECTRONIC CONTROL MODULE. Check continuity between instrument connector [39] Pin 7 and ECM connector [10] (black), Pin 4. Headlights Figure 4-125. Electronic Control Module 2003 Buell XB9R: Fuel System 4-17...
Page 315 Electronic Control Module (ECM) Figure 4-126. Check Engine Lamp Circuit Table 4-33. Wire Harness Connectors in Figure 4-126. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing [39] instrument module 20-place Multilock in fairing 4-18 2003 Buell XB9R: Fuel System...
Page 316 Repair open or Repair open on O short to voltage on wire that feeds bulb BK/Y wire between or open on wire connector [39] and from bulb to con- connector [10B]. nector [39]. 7145 7140 2003 Buell XB9R: Fuel System 4-19...
Page 317: Check Engine Lamp On Continuously
Test 4.10 ﬂow chart. Figure 4-128. If the lamp goes off when the black ECM connector [10] is unplugged, the BK/Y wire is not 8428 shorted to ground. Headlights Figure 4-128. Electronic Control Module 4-20 2003 Buell XB9R: Fuel System...
Page 318 Electronic Control Module (ECM) Figure 4-129. Check Engine Lamp Circuit Table 4-34. Wire Harness Connectors in Figure 4-129. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing [39] instrument module 20-place Multilock in fairing 2003 Buell XB9R: Fuel System 4-21...
Page 319 OK. Check for 4.29 ELECTRONIC on BK/Y wire between on BK/Y wire between trouble codes. See CONTROL MODULE. connector [39] and connector [39] and CHECKING FOR lamp in tachometer. connector [10]. 7150 TROUBLE CODES. 7165 7160 4-22 2003 Buell XB9R: Fuel System...
Page 320 DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing [11] ECM (gray) 12-place Deutsch in fairing [14] cam position sensor 3-place Deutsch under sprocket cover [83] ignition coil 3-place Amp beneath airbox base 2003 Buell XB9R: Fuel System 4-23...
Page 321 Cylinder Ignition Coil [83] Cam Position Sensor [14] Front Rear Injector Injector [84] [85] To Ignition Relay A B C Dyno Loop Connector [11] Connector [10] Electronic Control Module (ECM) Figure 4-132. Ignition Circuit 4-24 2003 Buell XB9R: Fuel System...
Page 322 49-51 PSI (338-352 kPa). Adequate pressure? Go to Test 4.11 STOP Incorrect pressure. See 4.13 (Part 2 of 3). FUEL PRESSURE TEST. 7195 2003 Buell XB9R: Fuel System 4-25...
Page 323 (Part 3 of 3). Check for continuity between Ter- minal A connector [14B] and ground. Continuity present? Repair open circuit. 7240 Repair short Replace ECM. See to ground. 4.29 ELECTRONIC CONTROL MODULE. 7241 7250 4-26 2003 Buell XB9R: Fuel System...
Page 324 Replace cam position Mechanical failure. position sensor. See 4.30 7260 sensor. See 4.30 Inspect for loose CAM POSITION SENSOR CAM POSITION SEN- rotor cup and ROTOR. SOR AND ROTOR. sheared pinion 7265 gear key. 7265 7255 2003 Buell XB9R: Fuel System 4-27...
Page 325 Test 4.12 ﬂow chart. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. 8748a Figure 4-135. Clutch Switch (viewed from underneath fair- ing) Transmission sprocket Neutral switch Figure 4-133. Neutral Switch 4-28 2003 Buell XB9R: Fuel System...
Page 326 Table 4-36. Wire Harness Connectors in Figure 4-136. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing [22] right hand controls 4-place Multilock beneath right side of fairing [95] clutch switch 2-place Multilock beneath fairing 2003 Buell XB9R: Fuel System 4-29...
Page 327 [22] and ignition relay. nector [22A] W/BK wire. Voltage present? 7277 Repair open on W/BK Replace handlebar wire between connector switch assembly. [22] and ignition relay. 7278 7277 4-30 2003 Buell XB9R: Fuel System...
Page 328: Fuel Pressure Test
Connect the fuel line (3) to fuel pressure gauge adapter. NOTE Figure 4-140. Verify that fuel valve (2) and air bleed pet- cock (5) on the gauge are closed. Attach FUEL PRESSURE GAUGE (Part No. HD-41182) (4) to fuel pressure gauge adapter (1). 2003 Buell XB9R: Fuel System 4-31...
Page 329 Air bleed tube 41404), gray socket probe and patch cord. Fuel pressure gauge (HD-41182) Air bleed petcock Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Figure 4-140. Fuel Pressure Gauge (Part No. HD-41182) 4-32 2003 Buell XB9R: Fuel System...
Page 330 Table 4-37. Wire Harness Connectors in Figure 4-141. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing [39] instrument module 20-place Multilock in fairing [86] fuel pump 4-place Multilock left side of rear shock absorber 2003 Buell XB9R: Fuel System 4-33...
Page 331 7457 key ON. Is voltage greater than 1 VDC? Locate and repair poor Replace ignition relay. See Ignition Relay connection between bat- under 7.5 STARTER INTERLOCK. tery and ignition relay. 7458 7456 4-34 2003 Buell XB9R: Fuel System...
Page 332 3. Is continuity present? Replace fuel pump Repair fuel pump assembly. See 4.38 wiring. FUEL PUMP. 7463 7462 Replace ECM. See 4.29 Locate and repair open ELECTRONIC CONTROL on BN/Y wire. MODULE. 7466 7464 2003 Buell XB9R: Fuel System 4-35...
Page 333: Idle Speed Control
An idle speed too low can cause poor throttle response. An idle speed too high can cause a slow return to idle. 1.16 THROTTLE CABLE AND IDLE SPEED ADJUST- MENT for more information on idle speed adjustment. 4-36 2003 Buell XB9R: Fuel System...
Page 334 7.4 SPARK PLUG CABLES. Using an ohmmeter, touch probes to terminals on each end plug wire. Compare resistance values to Table 4-39. Replace cables not meeting speciﬁcations. Reinstall and repeat procedure on other spark plug cable. 2003 Buell XB9R: Fuel System 4-37...
Page 335 Table 4-40. Wire Harness Connectors in Figure 4-144. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing [22] right hand controls 4-place Multilock beneath right side of fairing [83] ignition coil 3-place Packard beneath airbox base 4-38 2003 Buell XB9R: Fuel System...
Page 336 Replace known to be good. ignition coil. Perform spark test. 7535 Did spark jump gap during engine cranking? Original ignition coil Go to Test 4.15 is faulty. Replace. STOP (Part 2 of 2). 7535 2003 Buell XB9R: Fuel System 4-39...
Page 337 4.30 CAM POSITION Replace cam position Mechanical failure. 7260 SENSOR AND ROTOR. sensor. See 4.30 Inspect for loose CAM POSITION SEN- rotor cup and 7265 SOR AND ROTOR. sheared pinion gear key. 7265 7255 4-40 2003 Buell XB9R: Fuel System...
Page 338 TP sensor voltage (when throttle is closed) to greater than 4.0 volts (when throttle is held wide open). As the throttle is slowly moved, the voltage should change gradually without spikes or low voltages being observed. 2003 Buell XB9R: Fuel System 4-41...
Page 339 ECM (gray) 12-place Deutsch in fairing [14] cam position sensor 3-place Deutsch under sprocket cover [88] throttle position sensor 3-place Packard right side of engine between cylinders [134] bank angle sensor 6-place Sumitomo in fairing 4-42 2003 Buell XB9R: Fuel System...
Page 340 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2003 Buell XB9R: Fuel System 4-43...
Page 341 Replace BAS. between connector [88] Terminal A and Terminal C. Is resistance greater 7591 than 1 megaohm? Locate and repair short between R/W and BK/W Replace cam position wires. Reconnect [14]. sensor. 7589 7592 4-44 2003 Buell XB9R: Fuel System...
Page 342 If fresh air enters exhaust system, the O2 sen- sor will read a lean condition, causing the system to go rich. Diagnostic Notes Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. 2003 Buell XB9R: Fuel System 4-45...
Page 343 Electronic Control Module (ECM) Figure 4-150. Oxygen Sensor Circuit Table 4-42. Wire Harness Connectors in Figure 4-150. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch in fairing [137] oxygen sensor 1-place Packard behind rear cylinder head 4-46 2003 Buell XB9R: Fuel System...
Page 344 V/GY wire. CONTROL MODULE. CONTROL MODULE. 7657 7658 7659 7656 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2003 Buell XB9R: Fuel System 4-47...
Page 345 Fuel injectors may be dirty. See Fuel Injectors 7663 under 4.41 THROTTLE BODY. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-48 2003 Buell XB9R: Fuel System...
Page 346 (4.29 now OK. ELECTRONIC CONTROL 7672 MODULE). Road test again to verify. 7671 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2003 Buell XB9R: Fuel System 4-49...
Page 347 Shifted sensor. The temperature-to-resistance values table may be used to test the ET sensor at various tem- perature levels in order to evaluate the possibility of a shifted (out-of-calibration) sensor which may result in driveability problems. 4-50 2003 Buell XB9R: Fuel System...
Page 348 (ECM) Figure 4-151. Engine Temperature Sensor Circuit Table 4-44. Wire Harness Connectors in Figure 4-151. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch in fairing [90] engine temperature sensor 1-place bullet beneath airbox base 2003 Buell XB9R: Fuel System 4-51...
Page 349 Dis- DIGITAL TECHNICIAN (Part No. HD-44750). regard the asterisk (but not the instruction box) if your normal progression through the chart brings you to this location. 4-52 2003 Buell XB9R: Fuel System...
Page 350 7690 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2003 Buell XB9R: Fuel System 4-53...
Page 351 Shifted sensor. The temperature-to-resistance values table may be used to test the IAT sensor at various tem- perature levels in order to evaluate the possibility of a shifted (out-of-calibration) sensor which may result in driveability problems. 4-54 2003 Buell XB9R: Fuel System...
Page 352 Figure 4-152. Intake Air Temperature Sensor Circuit Table 4-46. Wire Harness Connectors in Figure 4-152. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch in fairing [89] intake air temperature sensor 2-place Amp in airbox base 2003 Buell XB9R: Fuel System 4-55...
Page 353 7745 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-56 2003 Buell XB9R: Fuel System...
Page 354 7755 through the chart brings you to this location. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2003 Buell XB9R: Fuel System 4-57...
Page 355: Battery Voltage
Figure 4-154. Fuse Block b1003x4x Spare Diode 1 Spare Diode 2 Brake/Horn Empty Cooling Fan Ignition Lights Accessory Key Switch Figure 4-155. Fuses and Diodes 4-58 2003 Buell XB9R: Fuel System...
Page 356 Connector [11] Connector [10] Electronic Control Module (ECM) Figure 4-156. Battery Voltage Circuit Table 4-47. Wire Harness Connectors in Figure 4-156. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing 2003 Buell XB9R: Fuel System 4-59...
Page 357 Replace ignition relay. STOP 7767 Go to Code 16 Test (Part 2 of 2). Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-60 2003 Buell XB9R: Fuel System...
Page 358 Replace R/Y wire between main fuse and Replace main fuse. battery. 7779 7784 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2003 Buell XB9R: Fuel System 4-61...
Page 359: Trouble Codes 23 And
Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), purple pin probes and patch cord to BREAKOUT BOX (Part No. HD-42682) and gray socket probes and patch cord to FUEL INJECTOR TEST LAMP (Part No. HD-34730-2C). 4-62 2003 Buell XB9R: Fuel System...
Page 360 [10] ECM (black) 12-place Deutsch in fairing [14] cam position sensor 3-place Deutsch under sprocket cover [84] front fuel injector 2-place Packard underneath airbox base [85] rear fuel injector 2-place Packard underneath airbox base 2003 Buell XB9R: Fuel System 4-63...
Page 361 4.29 Perform 4.7 WIGGLE TEST. ELECTRONIC CONTROL Repair as necessary. MODULE. 7815 7810 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-64 2003 Buell XB9R: Fuel System...
Page 362 WIGGLE TEST to locate open wire. intermittents. Repair 7825 as necessary. 7820 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2003 Buell XB9R: Fuel System 4-65...
Page 363: Trouble Codes 24 And
Use HARNESS CONNECTOR TEST KIT (Part No. HD- b0638x4x 41404), purple pin probes and patch cord. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Battery Figure 4-161. Testing Ignition Coil Connectors 4-66 2003 Buell XB9R: Fuel System...
Page 364 Electronic Control Module (ECM) Figure 4-162. Ignition Coil Circuit Table 4-49. Wire Harness Connectors in Figure 4-162. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under fairing [83] ignition coil 3-place Packard beneath airbox base 2003 Buell XB9R: Fuel System 4-67...
Page 365 7860 Repair as Replace ECM. See necessary. 4.29 ELECTRONIC CONTROL MODULE. 7865 7870 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-68 2003 Buell XB9R: Fuel System...
Page 366 Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), red pin probe and patch cord. Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), gray socket probe and patch cord. 2003 Buell XB9R: Fuel System 4-69...
Page 367 Table 4-50. Wire Harness Connectors in Figure 4-164. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing [39] instrument module 20-place Multilock in fairing [86] fuel pump 4-place Multilock left side of rear shock absorber 4-70 2003 Buell XB9R: Fuel System...
Page 368 Terminal 87 to Pin D of [86]. Continuity present? 7896 Repair open. 7898 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2003 Buell XB9R: Fuel System 4-71...
Page 369 Code 35 ﬂow chart. Breakout box Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Figure 4-165. Installed Breakout Box Replace instrument module. See 7.17 INSTRUMENT MODULE. 8426 Figure 4-166. Instrument Module Connector [39] 4-72 2003 Buell XB9R: Fuel System...
Page 370 Connector [11] Electronic Control Module (ECM) Figure 4-167. Tachometer Circuit Table 4-51. Wire Harness Connectors in Figure 4-167. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing [39] instrument module 20-place Multilock in fairing 2003 Buell XB9R: Fuel System 4-73...
Page 371 MODULE. tents found? 7882 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). Repair. Replace instrument module. 7.17 INSTRUMENT 7881 MODULE 7883 4-74 2003 Buell XB9R: Fuel System...
Page 372 The reference numbers below correlate with the circled num- bers on the Code 36 ﬂow charts. Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), gray pin probes and patch cord. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. 2003 Buell XB9R: Fuel System 4-75...
Page 373 Electronic Control Module (ECM) Figure 4-169. Cooling Fan Circuit Table 4-53. Wire Harness Connectors in Figure 4-169. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch in fairing [97] cooling fan 2-place Multilock behind rear cylinder 4-76 2003 Buell XB9R: Fuel System...
Page 374 Disregard the asterisk (but not the instruction box) if your normal pro- gression through the chart brings you to this location. Defective ECM or System ok. ECM connection. 7902 2003 Buell XB9R: Fuel System 4-77...
Page 375 Place a jumper wire between fan Y/BN wire and 7879 battery positive. Place a System ok. jumper between fan BK Replace fan. wire and ground. Does fan run at full speed? 7879 Replace fan. System ok. 7879 4-78 2003 Buell XB9R: Fuel System...
Page 376 Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Run Mode 0.25-2.7 volts b1085x4x Figure 4-171. Bank Angle Sensor Operation Table 4-54. Bank Angle Sensor Voltage MODE VOLTS Run mode 0.25-2.7 volts Disable mode 2.8-4.8 volts 2003 Buell XB9R: Fuel System 4-79...
Page 377 ECM (gray) 12-place Deutsch in fairing [14] cam position sensor 3-place Deutsch under sprocket cover [88] throttle position sensor 3-place Packard right side of engine between cylinders [134] bank angle sensor 6-place Sumitomo in fairing 4-80 2003 Buell XB9R: Fuel System...
Page 378 Install properly. See 4.34 BANK 0.25 in. (6.4 mm) of sides, face or ANGLE SENSOR. top of bank angle sensor? 7976 Replace bank angle sensor. See 4.34 Return to original BANK ANGLE SENSOR. configuration. 2003 Buell XB9R: Fuel System 4-81...
Page 379 Replace ECM. See on Lt GN/GY wire. 4.29 ELECTRONIC CONTROL MODULE. 7973 7974 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-82 2003 Buell XB9R: Fuel System...
Page 380 Code 54 - EE PROM failure. Code 55 - Microprocessor failure. NOTE Dealership technicians ﬁling warranty claims should use job/ time code 7913 for all Code 52, 53, 54 and 55 ECM replace- ments. 2003 Buell XB9R: Fuel System 4-83...
Page 381 Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), black pin probes and patch cord. Timer plate stud (2) 4.30 CAM POSITION SENSOR AND ROTOR. Sensor wiring Cam position sensor b0313a7x Figure 4-173. Cam Position Sensor 4-84 2003 Buell XB9R: Fuel System...
Page 382 ECM (gray) 12-place Deutsch in fairing [14] cam position sensor 3-place Deutsch under sprocket cover [88] throttle position sensor 3-place Packard right side of engine between cylinders [134] bank angle sensor 6-place Sumitomo in fairing 2003 Buell XB9R: Fuel System 4-85...
Page 383 TRONIC CON- [14]. [14]. TROL MODULE. 7970 7955 7965 7945 7945 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-86 2003 Buell XB9R: Fuel System...
Page 384 Install original cam System position sensor. Replace ECM. See 4.29 ELECTRONIC 7952 CONTROL MODULE. 7960 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2003 Buell XB9R: Fuel System 4-87...
Page 385 HOME NOTES 4-88 2003 Buell XB9R: Fuel System...
Page 386: Electronic Control Module
2.25 HEADLIGHT SUP- PORT BRACKET. Install front fairing. See 2.37 FRONT FAIRING, WIND- SHIELD, AND MIRRORS. Recalibrate Throttle position sensor. Throttle position sensor can only be calibrated using DIGITAL TECHNI- CIAN (Part No. HD-44750). 2003 Buell XB9R: Fuel System 4-89...
Page 387 Fan control Rear coil primary Sensor ground 1 Injector rear Vehicle speed sensor Unused Engine temperature Bank angle sensor input Intake air temperature System ground B (coil) Serial data receive Tachometer Serial data transmit 4-90 2003 Buell XB9R: Fuel System...
Page 388: Cam Position Sensor And Rotor
Remove timer plate studs (4). Care- fully remove cam position sensor. Remove bolt (18) and trigger rotor (17). 10. Carefully remove camshaft oil seal (16) if damaged or if there is any evidence of oil leakage past the seal. 2003 Buell XB9R: Fuel System 4-91...
Page 389 12. Ignition coil 13. Front spark plug cable 14. Engine mount 15. Gearcase cover 16. Seal 17. Trigger rotor 18. Trigger rotor bolt 19. Cam position sensor 20. Inner cover b0990x4x Figure 4-179. Ignition Components 4-92 2003 Buell XB9R: Fuel System...
Page 390 HOME bd0002xx Figure 4-180. Ignition System Circuit 2003 Buell XB9R: Fuel System 4-93...
Page 391 Use of regular rivets can damage ignition system components and may allow water to enter the timing compartment. 10. Secure timer cover (2) to inner cover using new rivets (1). 11. Connect negative battery cable. 4-94 2003 Buell XB9R: Fuel System...
Page 392: Ignition Coil
An inﬁnite ohms (∞ or no continuity) resistance value indicates an open circuit (a break in the coil winding). Replace coil. 2003 Buell XB9R: Fuel System 4-95...
Page 393 Install intake cover assembly. See 2.34 INTAKE COVER Rear Cylinder Post ASSEMBLY. Coil Pin A (rear cylinder) Coil Pin B (12 VDC) Connect negative battery cable. Coil Pin C (front cylinder) Front Cylinder Post Figure 4-184. Ignition Coil 4-96 2003 Buell XB9R: Fuel System...
Page 394 ABSORBER. Figure 4-186. Connect 1-place connector [137] (1) to wiring harness. Install cable straps (2). Install airbox assembly. See 4.43 AIRBOX. Install intake cover assembly. See 2.34 INTAKE COVER ASSEMBLY. Connect negative battery cable. 2003 Buell XB9R: Fuel System 4-97...
Page 395 Slide rubber boot up ET sensor wire. Remove sensor from rear cylinder head using Snap-on socket M3503B. Engine temperature sensor connector [90] (approximate location) Upper tie bar fastener (right side) Figure 4-188. Engine Temperature Sensor Connector Approximate Location [90] 4-98 2003 Buell XB9R: Fuel System...
Page 396 [90] to wiring harness. Install right upper tie bar fastener (2). Tighten fastener to 25-27 ft-lbs (33.9-36.6 Nm). Install airbox. See 4.43 AIRBOX. Install intake cover assembly. See 2.34 INTAKE COVER ASSEMBLY. Connect negative battery cable. 2003 Buell XB9R: Fuel System 4-99...
Page 397 Tighten fastener to 12-36 in-lbs (1.4- 4.1 Nm). Figure 4-189. Install bank angle sensor connector [134]. Install front fairing. See 2.37 FRONT FAIRING, WIND- SHIELD, AND MIRRORS. Connect negative battery cable. 4-100 2003 Buell XB9R: Fuel System...
Page 398 Inspect sensor grommet for damage and replace as required. INSTALLATION Connect IAT sensor connector [89] to wiring harness. Install IAT sensor into grommet on air cleaner base from underneath. Install airbox. See 4.43 AIRBOX. Install negative battery cable. 2003 Buell XB9R: Fuel System 4-101...
Page 399 [88A]. NOTE b0995x4x Throttle position sensor can only be calibrated using DIGITAL TECHNICIAN (Part No. HD-44750). Calibrate throttle position sensor. Figure 4-192. Throttle Position Sensor b0651x4x Figure 4-193. Tabs on TP Sensor Connector [88A] 4-102 2003 Buell XB9R: Fuel System...
Page 400: Cooling Fan
Install fan and rotate counter-clockwise into position. Install cooling fan fasteners. Tighten to 12-36 in-lbs (1.4- 4.1 Nm). Install shock absorber. See 2.22 REAR SHOCK ABSORBER. Connect negative battery cable. 2003 Buell XB9R: Fuel System 4-103...
Page 401 Remove drain plug (5) and drain fuel into appropriate container. Discard plug. When fuel tank is empty, replace with new drain plug. Tighten to 84-108 in-lbs (9.5-12.2 Nm). 4-104 2003 Buell XB9R: Fuel System...
Page 402 10. Place wrench onto nut and another wrench onto the bolt. Figure 4-198. Fuel Pump Removal Hold the bolt stationary and turn nut clockwise until fuel pump is pulled free from frame. 2003 Buell XB9R: Fuel System 4-105...
Page 403 Figure 4-200. Fuel Pump Assembly (right side) 11. See Figure 4-200. Tighten fuel ﬁlter clamps (3, 7). 12. See Figure 4-201. Install clips (1) into center grooves. 13. Install fuel pump assembly. See INSTALLATION in this section. 4-106 2003 Buell XB9R: Fuel System...
Page 404 Table 4-60. Fuel Pump Speciﬁcations SPECIFICATION DATA Pressure Setting 49 PSI Operating Voltage 13.2 volts Fuel Delivery 60 LPH @ 45 PSI [310 kPa] Clip grooves Current Draw 6.0 amps O-rings Figure 4-202. Regulator Housing O-rings 2003 Buell XB9R: Fuel System 4-107...
Page 405 Install clips (1) into middle grooves. 16. See Figure 4-199. Connect low fuel level sensor connec- tor (11).. 17. Connect fuel pump connectors (10). Connectors are two different sizes. 18. Install fuel pump assembly. See INSTALLATION in this section. 4-108 2003 Buell XB9R: Fuel System...
Page 406 Connect fuel pump connector [86] (2) and push cable strap tab into hole in frame. Fuel pump fastener Fuel pump connector [86] Fuel supply line Fuel supply stud Drain plug 90-110 in lbs (10.2-12.4 Nm) Figure 4-205. Fuel Pump Installation 2003 Buell XB9R: Fuel System 4-109...
Page 407: Fuel Tank Vent Valve
Bracket during vehicle operation and startle the rider, causing Fastener (2) loss of control which could result in death or serious injury. Figure 4-207. Fuel Tank Vent Valve 10. Install seat. See 2.38 SEAT. 4-110 2003 Buell XB9R: Fuel System...
Page 408: Fuel Cap Retaining Ring
Insert fuel cap retaining ring into fuel ﬁller neck. Install fasteners (4). Tighten to 17-70 in-lbs (1.9-7.9 Nm). Install fuel ﬁller cap. Fuel ﬁller neck O-ring Fuel cap retaining ring Fastener (5) Figure 4-209. 2003 Buell XB9R: Fuel System 4-111...
Page 409: Throttle Body
Reconnect fuel pump connector. Label and detach throttle cables. See 2.23 THROTTLE CONTROL. Figure 4-212. On California models, pull EVAP hose from ﬁtting (1). Rotate engine for service. See 3.3 ENGINE ROTATION FOR SERVICE. 4-112 2003 Buell XB9R: Fuel System...
Page 410 10. Velocity stack fastener (2) 11. Ring seal 12. Intake manifold 13. Intake ﬂange fastener (2) 14. Intake ﬂange (2) 15. Intake seal (2) 16. Intake ﬂange fastener (2, socket) Figure 4-211. Throttle Body/Intake Manifold Assembly 2003 Buell XB9R: Fuel System 4-113...
Page 411: Fuel Injectors
Separate fuel rail from injectors (2, 5) by gently rock- ing the fuel rail and pulling it away from the injectors. Remove fuel injectors (2, 5) from manifold by gently rock- ing and pulling it away from the manifold. 4-114 2003 Buell XB9R: Fuel System...
Page 412 Front fuel injector evidence of raw fuel in throttle body manifold. Lower fuel rail fastener Install airbox cover. See 4.43 AIRBOX. Figure 4-215. Fuel Injectors Install intake cover assembly. See 2.34 INTAKE COVER ASSEMBLY. 2003 Buell XB9R: Fuel System 4-115...
Page 413 Connect EVAP hose to port at bottom of throttle body (California models only). Calibrate throttle position sensor if removed or replaced. 4.36 THROTTLE POSITION SENSOR. Install airbox. See 4.43 AIRBOX. 10. Check throttle cable adjustment. See 2.23 THROTTLE CONTROL. 4-116 2003 Buell XB9R: Fuel System...
Page 414: Intake Leak Test
Figure 4-217. Flatten one end of copper tube to form a nozzle. Insert round side of copper tube into end of tubing. Nozzle Copper Tube Hose Valve Knob Propane bottle Figure 4-218. Leak Tester 2003 Buell XB9R: Fuel System 4-117...
Page 415 Aim nozzle toward possible sources of leak such as fuel injectors and intake tract. Push valve (4) to release propane. Tone of engine will change when propane enters source of leak. 4-118 2003 Buell XB9R: Fuel System...
Page 416 Inspect breather hoses, intake air temperature sensor grommet and baseplate gasket (3). Replace as neces- Fasteners sary. Intake air temperature sensor (IAT) Gasket Baseplate Intake snorkel Breather hoses Velocity stack Velocity stack sealing ring Figure 4-220. baseplate 2003 Buell XB9R: Fuel System 4-119...
Page 417 Carefully lower baseplate into mounting position. Ensure rubber sealing ring on velocity stack completely engages b1030x4x Airbox cover Intake snorkel Rear cylinder breather hose Air ﬁlter Fasteners Front cylinder breather hose Airbox seal Baseplate Figure 4-221. Airbox 4-120 2003 Buell XB9R: Fuel System...
Page 418 4.44 GENERAL 8817a Buell motorcycles sold in the state of California are equipped with an evaporative (EVAP) emissions control system. The EVAP system prevents fuel hydrocarbon vapors from escap- ing into the atmosphere and is designed to meet the Califor- nia Air Resource Board (CARB) regulations in effect at the time of manufacture.
Page 419 Make sure to push hoses all the way on to carbon canis- ter ﬁttings. 8354 Install upper tail body work. See 2.36 TAIL FRAME AND BODY WORK. Adjuster screw Adjuster screw alignment hole Figure 4-225. Adjuster Screw Alignment 4-122 2003 Buell XB9R: Fuel System...
Page 420 ﬁtting and not on the ﬁtting barb. Failure to comply may result in fuel leakage which could result in death or seri- ous injury. Figure 4-226. Emissions Hose Attachment, California Modesl Only 2003 Buell XB9R: Fuel System 4-123...
Page 421 HOME NOTES 4-124 2003 Buell XB9R: Fuel System...
Page 422 ELECTRIC STARTER Table Of Contents SUBJECT PAGE NO. 5.1 Specifications ..........5.2 Electric Starter System .
Page 424 400 amp (max.) @ 2.4 V (minimum) Stall Torque 8 ft-lbs (11 Nm) (min.) @ 2.4 V TORQUE VALUES ITEM TORQUE NOTES Starter battery positive cable 60-85 in-lbs 7-10 Nm page 5-19 Starter mounting bolts 13-20 ft-lbs 18-27 Nm page 5-19 2003 Buell XB9R: Starter...
Page 425: Electric Starter System
The solenoid plunger (7) is returned to its original 7.5 STARTER INTERLOCK for operation and trouble- position by the return spring, which causes the pinion gear shooting information. (1) to disengage from the clutch ring gear (13). 2003 Buell XB9R: Starter...
Page 426 Pinion gear Idler gear Field winding Armature Brush Ball bearing Solenoid plunger Main solenoid contacts Battery 10. Pull-in winding Starting circuit-see 11. Hold-in winding wiring diagram 12. Overrunning clutch 13. Clutch ring gear Figure 5-1. Starter Operation 2003 Buell XB9R: Starter...
Page 427: Starting System Diagnosis
Is 12V present on starter relay Replace Starter Test 3: Relay Clicks. Terminal 86 with starter button solenoid. not pressed? 5845 Nothing clicks. See Starter Replace Replace Test 4: Nothing Clicks. starter relay. right handlebar switchgear. 5832 5818 2003 Buell XB9R: Starter...
Page 428 Terminal 30 Replace grounds. Replace or Terminal 87 when starter on starter relay. solenoid. repair starter motor. button is pressed? 5827 5860 5817 Repair open on Replace GN wire between relay starter relay. and solenoid. 5832 5827 2003 Buell XB9R: Starter...
Page 429 (W/BK wire at connector [22]). Interlock Circuit relay. button to relay. Battery voltage present? or Correct 5832 Relay Ground. 5831 5828 Replace right han- Repair wiring to dlebar switchgear. starter button. 5816 5831 2003 Buell XB9R: Starter...
Page 430 Are test results within range? Remove spark plugs while in Test starter motor for 5th gear. Rotate rear wheel. opens, shorts or grounds. Check for engine, primary Replace or repair starter and/or crankshaft bind. motor. 5817 Use appropriate code 2003 Buell XB9R: Starter...
Page 431: Starter Activation Circuits
10. Start relay Main fuse (30 A) purposes only) 11. Solenoid Key switch fuse Ignition fuse 12. Starter Key switch Key switch relay Run/Stop switch Start switch Figure 5-3. Typical Circuity. Refer to wiring diagrams for more information. 2003 Buell XB9R: Starter...
Page 432 However, when sufﬁ- entire difference in potential displayed on the meter. cient current is passed through, the resistance caused by the powdered paint will cause a voltage drop or potential difference in the ground circuit. 2003 Buell XB9R: Starter...
Page 433 5-10 2003 Buell XB9R: Starter...
Page 434: Starter System Testing
Typical starter current draw will range between 140- 180 amperes. If starter current draw exceeds 180 amperes, then the problem may be in the starter or starter drive. Battery Remove starter for further tests. See STARTER. Figure 5-7. Starter Draw Test 2003 Buell XB9R: Starter 5-11...
Page 435 Remove positive battery cable ring terminal (2). Detach solenoid wire (3). 8742 Remove starter and gasket from the gearcase cover side. Fastener with washer (metric) Positive battery cable ring terminal Solenoid wire Figure 5-9. Starter Wires (Protective Boot Not Shown) 5-12 2003 Buell XB9R: Starter...
Page 436: Testing Assembled Starter
Solenoid motor terminal to negative battery post. Solenoid relay terminal to positive battery post. Observe starter pinion. If starter pinion pulls in strongly, solenoid is working properly. If starter pinion does not pull in, replace the sole- noid. 2003 Buell XB9R: Starter 5-13...
Page 437 If starter pinion returns to its original position, sole- Motor terminal noid is working properly. Relay terminal If starter pinion does not return to its original posi- tion, replace the solenoid. Battery Figure 5-13. Return Test 5-14 2003 Buell XB9R: Starter...
Page 438 1/32 in. (0.794 mm) deep. The slots should then be cleaned to remove any dirt or cop- per dust. Field frame Brush holder Brush spring (4) Armature Solenoid housing Figure 5-16. Starter Components 2003 Buell XB9R: Starter 5-15...
Page 439 Mica must not be left with a thin edge next to segments Mica Segments WRONG Mica must be cut away clean between segments Mica Undercutting mica with Segments piece of hacksaw blade RIGHT WAY Figure 5-17. Undercutting Mica Separators 5-16 2003 Buell XB9R: Starter...
Page 440 There should be continuity (0 ohms) at all test points. No continuity at any test point indicates armature is open and must be replaced. Figure 5-19. Grounded Armature Test 6012a Figure 5-20. Open Armature Test 2003 Buell XB9R: Starter 5-17...
Page 441 16. Remove drive (1), idler gear (2), idler gear bearing (3), and O-ring (4) from drive housing (O-ring is located in Figure 5-22. Open Field Test drive housing groove). s0164x5x Figure 5-23. Brush Holder Insulation Test 5-18 2003 Buell XB9R: Starter...
Page 442 If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install seat. See 2.38 SEAT. Mounting bolts and washers Starter Figure 5-26. Starter Mounting 2003 Buell XB9R: Starter 5-19...
Page 443 10. Drive housing 11. Solenoid housing 12. Drive assembly/ Overrunning clutch 13. Idler gear 14. Idler gear roller (5) 15. Idler gear Bearing cage 16. O-ring 17. Return spring 18. Ball 19. Gasket Figure 5-27. Starter Assembly 5-20 2003 Buell XB9R: Starter...
Page 444 Figure 5-28. Replace wire connection hardware as necessary. Install plunger (5) in solenoid housing (6). Install new gasket (4) onto cover (3). Position cover with gasket onto solenoid housing. Install clip (2) and screws (1). 2003 Buell XB9R: Starter 5-21...
Page 445 HOME NOTES 5-22 2003 Buell XB9R: Starter...
Page 446 Table Of Contents DRIVE/TRANSMISSION 6 SUBJECT PAGE NO. 6.1 Specifications ..........6.2 Primary Chain .
Page 448 Fifth gear (high) 4.74 * Internal gear ratios indicate number of mainshaft revolutions required to drive output sprocket one revolution. ** Overall gear ratios indicate number of engine revolutions required to drive rear wheel one revolution. 2003 Buell XB9R: Drive/Transmission...
Page 449 12-14 ft-lbs 16.3-19.0 Nm Page 6-6 LOCTITE 262, left hand threads, special Transmission sprocket nut See NOTES See NOTES torque turn method, page 6-48 Transmission sprocket screws 90-110 in-lbs 10.2-12.4 Nm Replace after 3 removals, page 6-49 2003 Buell XB9R: Drive/Transmission...
Page 450 14. Bolt, ﬂange head 22. Nut, chain adjustment Gasket, inspection cover 15. Sleeve, shift/brake lever 23. O-ring Cover, inspection 16. Bearing, pedal (2) 24. Drain plug Figure 6-1. Primary Cover, Primary Chain Adjuster and Shifter Assembly 2003 Buell XB9R: Drive/Transmission...
Page 451 1.8 CLUTCH. Figure 6-2. Loosen locknut (6). Turn chain adjuster screw (5) counterclockwise to remove tension on primary chain. Remove three TORX screws with washers and clutch inspection cover. Figure 6-2. Remove clutch inspection cover (3). 2003 Buell XB9R: Drive/Transmission...
Page 452 Figure 6-4. Remove chain adjusting nut from the MARY CHAIN. chain limiting screw. Turn the chain limiting screw clockwise until it can be removed from the inside of the primary cover along with the chain adjuster shoe. 2003 Buell XB9R: Drive/Transmission...
Page 453 ﬁts in slot of primary cover. Thread nut on adjustment screw until slot of screw is accessible with a screwdriver. Fit nut hex into recess of outer ramp and turn adjustment screw counterclockwise. Adjust clutch. See ADJUSTMENT under 1.8 CLUTCH. 2003 Buell XB9R: Drive/Transmission...
Page 454: Clutch Release Mechanism
ﬂats of adjusting screw. b1057x6x TORX screw with washers (3) Ramp assembly Clutch inspection cover Adjusting screw assembly Clutch cover gasket Primary cover Spring 10. Coupling Lockplate 11. Drain plug and o-ring Figure 6-9. Clutch Release Mechanism 2003 Buell XB9R: Drive/Transmission...
Page 455 Connect negative battery cable to battery terminal. Tighten fastener to 60-96 in-lbs (6.8-10.9 Nm). Install seat. See 2.38 SEAT. Outer ramp Adjusting screw Coupling Cable end Lockplate Slot in primary cover Figure 6-11. Nut and Outer Ramp 2003 Buell XB9R: Drive/Transmission...
Page 456 Worn clutch release ramps or balls. Replace release ramps and/or balls. Warped clutch steel plates. Replace clutch steel plates. Blade worn or damaged clutch gear splines. Replace clutch gear or hub as required. Overﬁlled primary. Drain lubricant to correct level. 2003 Buell XB9R: Drive/Transmission...
Page 457 12. Retaining ring 23. Mainshaft nut 28. Needle bearing 13. Release plate 24. Washer 29. Clutch shell and sprocket 14. Retaining ring 25. Clutch hub 30. Thrust washer, outer 15. Bearing Figure 6-12. Clutch Assembly 6-10 2003 Buell XB9R: Drive/Transmission...
Page 458 ﬁber plate, one damper screw. spring and one damper spring seat. Place the bridge of SPRING COMPRESSING TOOL (Part No. HD-38515-A) against diaphragm spring. Install bearing and washer. Thread the tool handle onto end of forcing screw. 2003 Buell XB9R: Drive/Transmission 6-11...
Page 459 Replace damaged parts as necessary. 6251 Retaining ring Bearing and release plate Retaining ring Adjusting screw Figure 6-16. Adjusting Screw Assembly Figure 6-16. Remove adjusting screw assembly. Remove large retaining ring. Remove adjusting screw assembly from pressure plate. 6-12 2003 Buell XB9R: Drive/Transmission...
Page 460 Once the pressure plate assem- bly has been removed the clutch hub will slide out of the clutch shell. Remove clutch pack components. See Steps 3-4 of CLUTCH PACK under 6.4 PRIMARY DRIVE/CLUTCH. 2003 Buell XB9R: Drive/Transmission 6-13...
Page 461 If necessary, disassemble adjusting screw assem- bly. Remove and discard small retaining ring (6) and then separate the adjusting screw (8) from the bear- ing (7) and release plate (5). Remove bearing (7) from release plate (5). 6-14 2003 Buell XB9R: Drive/Transmission...
Page 462 The mini- mum thickness must be 0.661 in. (16.789 mm). If the thickness is less than speciﬁed, discard the ﬁber plates and steel plates. Install a new set of both friction and steel plates. 2003 Buell XB9R: Drive/Transmission 6-15...
Page 463 Inspect clutch shell bearing inner race replaced. See Replacing Clutch Shell Bearing. on the back side of the clutch hub for pitting and wear. If the inner race shows any of these signs the complete hub assembly must be replaced. 6-16 2003 Buell XB9R: Drive/Transmission...
Page 464 (Part No. B-45926) is clearly marked for removal and installa- shell. This will be the correct installed height. tion purposes. Figure 6-27. Insert removal end of tool into bearing assembly and remove bearing from clutch shell. Continue with CLEANING AND INSPECTION. 2003 Buell XB9R: Drive/Transmission 6-17...
Page 465 Narrow Plate Regular Plate Figure 6-31. Friction Plates Figure 6-31. Install the narrow friction plate on the clutch hub engaging tabs on plate with slots in clutch shell. 6-18 2003 Buell XB9R: Drive/Transmission...
Page 466 The spring seat provides an operating sur- face for the diaphragm spring at the same time preventing the retaining ring from coming out during operation. 2003 Buell XB9R: Drive/Transmission 6-19...
Page 467 Prior to installing engine sprocket nut and the clutch hub nut, the threads on the sprocket shaft, sprocket nut, mainshaft and clutch hub nut must be thoroughly cleaned to remove any oil that might contaminate and interfere with the locking agent. 6-20 2003 Buell XB9R: Drive/Transmission...
Page 468 Pull up on seat to verify that it is properly secured, front and rear. A loose seat may shift during vehicle operation and startle the rider, possibly causing loss of vehicle control resulting in death or serious injury. 10. Install seat. See 2.38 SEAT. 2003 Buell XB9R: Drive/Transmission 6-21...
Page 469 HOME NOTES 6-22 2003 Buell XB9R: Drive/Transmission...
Page 470 Neutral 1st Gear Mainshaft Mainshaft Countershaft Countershaft 2nd Gear 3rd Gear Mainshaft Mainshaft Countershaft Countershaft 4th Gear 5th Gear Mainshaft Mainshaft Countershaft Countershaft – Sliding member – Power ﬂow Figure 6-39. Transmission Power Flow 2003 Buell XB9R: Drive/Transmission 6-23...
Page 471: Case Disassembly For Transmission Removal
Remove clutch assembly, primary chain and engine sprocket. See 6.4 PRIMARY DRIVE/CLUTCH. 8615 TORX screw Retention collar Shifter lever assembly Figure 6-40. Countershaft Retainer Figure 6-40. Place transmission in 1st gear. Remove countershaft TORX screw (1) and retention collar (2). 6-24 2003 Buell XB9R: Drive/Transmission...
Page 472 Figure 6-44. Rear Isolator Assembly 13. See Figure 6-44. Remove rear isolator assembly by removing the forward two fasteners ﬁrst and then the two rear fasteners (re-install with new fasteners). 2003 Buell XB9R: Drive/Transmission 6-25...
Page 473 No tools are required for this operation. 8621 8636 Figure 6-48. Separating Crankcase Halves Figure 6-49. Removing Flywheels from Left Case Half 17. See Figure 6-48. Separate crankcase halves. 18. See Figure 6-49. Remove the ﬂywheel assembly from left crankcase half. 6-26 2003 Buell XB9R: Drive/Transmission...
Page 474: Transmission Disassembly
Carefully tap on alternate sides of the shaft using the pro- Countershaft vided slots. Figure 6-52. Shifter Forks, Drum and Shafts 8628a Figure 6-51. Transmission Assembly Figure 6-51. Remove shifter drum and shifter forks. Remove mainshaft 2nd gear from mainshaft. 2003 Buell XB9R: Drive/Transmission 6-27...
Page 475 Fork assembly, shifter (3rd-5th) Fork assembly, shifter (4th) 21. Pad, rubber, shift lever 10. Pin, shifter stop 22. Linkage assembly, shifter 11. Spring, shifter return 23. Bolt, linkage assembly 12. Spring, extension Figure 6-53. Shifter Mechanism 6-28 2003 Buell XB9R: Drive/Transmission...
Page 476 (4) on arbor press (1) and support transmission assembly on parallel supports (5). Press transmission assembly using TRANSMIS- SION REMOVER (2) (Part No. B-43895-1) to remove transmission assembly from crankcase half. Remove crankcase from press. 2003 Buell XB9R: Drive/Transmission 6-29...
Page 477 Fifth gear mainshaft Quad seal Bearing (Outer) Spacer Oil seal 10. Oil seal Right crankcase half 11. Bearing (closed end) shifter drum Ball bearing 12. Bearing (closed end) countershaft Figure 6-56. Transmission Assembly-Right Crankcase Half 6-30 2003 Buell XB9R: Drive/Transmission...
Page 478 14. Fourth gear countershaft 15. First gear countershaft 16. Countershaft 17. Third gear countershaft 18. Second gear countershaft 19. Fifth gear countershaft 20. Bearing 21. Retaining ring 22. Countershaft retainer 23. Screw Figure 6-57. Transmission Assembly-Left Crankcase Half 2003 Buell XB9R: Drive/Transmission 6-31...
Page 479 (6), and slide off end of shaft. dimpled. Remove mainshaft 1st gear (6). Expand retaining ring (5) and remove. Discard all retaining rings that were removed. 6-32 2003 Buell XB9R: Drive/Transmission...
Page 480 Slide countershaft 1st gear (13) off end of shaft. dimpled. Remove split bearing (12). Discard all retaining rings that were removed. Remove thrust washer (14). Expand remaining retaining ring (15) and slide off countershaft. 2003 Buell XB9R: Drive/Transmission 6-33...
Page 481: Transmission Assembly
Left Crankcase Retaining ring Mainshaft 3rd 11. Mainshaft 4th Mainshaft 1st Thrust washer 12. Spacer Retaining ring Retaining ring 13. Mainshaft Thrust washer Thrust washer Split bearing 10. Split bearing Figure 6-61. Transmission Mainshaft Assembly/Reassembly 6-34 2003 Buell XB9R: Drive/Transmission...
Page 482 Thrust washer Retaining ring 14. Countershaft 4th Countershaft 1st Thrust washer 15. Beveled spacer Split bearing 10. Split bearing 16. Countershaft Thrust washer 11. Countershaft 2nd Retaining ring 12. Countershaft 5th Figure 6-62. Transmission Countershaft Assembly/Reassembly 2003 Buell XB9R: Drive/Transmission 6-35...
Page 483: Main Drive Gear
(2). Install and tighten nut (6) until 5th gear (3) is free. 8681 Figure 6-64. Bearing Remover Cross Plate Mounting (Part No. B-45847) Figure 6-64. Place cross plate on crankcase as shown. 6-36 2003 Buell XB9R: Drive/Transmission...
Page 484 Place main drive gear on a press. Press in the outer bearing to a depth of 0.315-0.285 in. (8.001-7.239 mm). Press in the inner bearing to a depth of 0.080 in. (2.032 mm). 2003 Buell XB9R: Drive/Transmission 6-37...
Page 485 Retaining ring Fifth gear mainshaft Quad seal Bearing (outer) Spacer Oil seal 10. Oil seal Right crankcase half 11. Bushing, shifter drum Ball bearing 12. Bearing (closed end), countershaft Figure 6-69. Transmission Assembly Right Crankcase Half 6-38 2003 Buell XB9R: Drive/Transmission...
Page 486: Transmission Right Case Bearings
ﬁt and wear. If bushing is to be replaced, use a BUSHING AND BEARING PULLER (Part No. HD-95760-69A) with a 1/2 in. collet (Part No. HD-95765-69A) to remove bushing from right crankcase half. 2003 Buell XB9R: Drive/Transmission 6-39...
Page 487 15. First gear countershaft 16. Countershaft 17. Third gear countershaft 18. Second gear countershaft 19. Fifth gear countershaft 20. Bearing 21. Retaining ring 22. Countershaft retainer 23. Screw Figure 6-72. Transmission Assembly Left Crankcase Half 6-40 2003 Buell XB9R: Drive/Transmission...
Page 488: Transmission Left Case Bearings
If using a pressing tool larger than diam- eter of bushing, the pressing tool will bottom against crankcase when bushing is ﬂush with top surface. 2003 Buell XB9R: Drive/Transmission 6-41...
Page 489: Transmission Installation
(Part No. B-43985-2) on arbor press. Install mainshaft 2nd gear with shifter fork groove Install COUNTERSHAFT GUIDE ADAPTER towards mainshaft 3rd gear. (Part No. B-43985-4). Install shifter forks, shafts and shifter drum. 6.8 TRANSMISSION ASSEMBLY. 6-42 2003 Buell XB9R: Drive/Transmission...
Page 490 Figure 6-78. Installing Shift Fork Shafts NOTE Figure 6-78. Install shifter fork shafts in the left case half by lightly tapping on the end with a brass hammer until seated in bore. Countershaft Figure 6-77. Shifter Forks, Drum and Shafts 2003 Buell XB9R: Drive/Transmission 6-43...
Page 491 HOME b1016x3x One Behind Shifter Mechanism Indicates Bolt Pattern Location Figure 6-79. Crankcase Fasteners 6-44 2003 Buell XB9R: Drive/Transmission...
Page 492 Figure 6-79. Tighten 5/16-in. fasteners to 15-19 ft-lbs (20.3-25 Nm). Figure 6-81. Retract detent assembly in right case half and install GEAR DETENT ASSEMBLY AID (Part No. B-45520) until it has bottomed in right case half. 2003 Buell XB9R: Drive/Transmission 6-45...
Page 493: Shifter Shaft Installation
Insert screw (1) through retention collar (2) and thread into end of shaft. b0951x6x Place transmission in gear and tighten TORX screw (1) to 13-17 ft-lbs (18-23 Nm). Figure 6-85. Shifter Shaft Return Spring (Incorrectly Installed) 6-46 2003 Buell XB9R: Drive/Transmission...
Page 494: Transmission Sprocket
If pulley wheel needs replacement, remove fastener (6) and nut (3) from idler pulley bracket (2) and discard. Replace with new pulley wheel (1). NOTE The pulley wheel bearings can not be replaced separately. A new pulley wheel must be installed. 2003 Buell XB9R: Drive/Transmission 6-47...
Page 495 Figure 6-90. Transmission Sprocket Tightening Figure 6-90. Install SPROCKET HOLDING TOOL (Part No. B-45659) as shown. Using MAINSHAFT LOCKNUT WRENCH (Part No. HD- 94660-37B) and a torque wrench, tighten sprocket nut to 50 ft-lbs (67.8 Nm) INITIAL TORQUE ONLY. 6-48 2003 Buell XB9R: Drive/Transmission...
Page 496 19. Remove engine from ENGINE SUPPORT STAND (Part No. HD-42310/HD-43646 or HD-43682). 20. Install engine in chassis. See 3.4 STRIPPING MOTOR- CYCLE FOR ENGINE SERVICE. 21. Fill transmission and engine to proper level with fresh lubricant. See 1.2 FLUID REQUIREMENTS. 2003 Buell XB9R: Drive/Transmission 6-49...
Page 497 HOME NOTES 6-50 2003 Buell XB9R: Drive/Transmission...
Page 498 Table Of Contents SUBJECT PAGE NO. 7.1 Specifications ..........7.2 Ignition System .
Page 500 Turn Signal Lamp (front and rear 10.0 0.84 Y0042.K (1 bulb each) Indicator Lamps, Speedometer and Indicator, Speedometer and Tachometer LED’s are part of the instrument module and are not replaceable. Tachometer Entire assembly must be replaced if LED fails. Illumination 2003 Buell XB9R: Electrical...
Page 501 2.8-3.2 Nm page 7-42 Turn signal fasteners (front) 25-28 in-lbs 2.8-3.2 Nm page 7-42 Turn signal ﬂasher fastener 30-40 in-lbs 3.4-4.5 Nm page 7-43 Voltage regulator mounting 36-60 in-lbs 4.0-6.8 Nm use new fasteners, page 7-28 fasteners 2003 Buell XB9R: Electrical...
Page 502: Ignition System
As See Section 4 Fuel System for troubleshooting information. the vehicle warms up to operating temperature the fuel mix- ture will lean and the spark advance will decrease. 2003 Buell XB9R: Electrical...
Page 503 12. Ignition coil 13. Front spark plug cable 14. Engine mount 15. Gearcase cover 16. Seal 17. Trigger rotor 18. Trigger rotor bolt 19. Cam position sensor 20. Inner cover b0990x4x Figure 7-1. Ignition System Components 2003 Buell XB9R: Electrical...
Page 504 Front and rear turn signals can be activated cannot be Horn can be 8345 activated activated Run switch must be on. ON position OFF position PUSH DETENT LOCK position PARKING LIGHT position Upper triple clamp Figure 7-2. Ignition/Headlight Key Switch 2003 Buell XB9R: Electrical...
Page 505 (3) securing ignition switch (4) to upper fork clamp. Slide ignition switch out of upper fork clamp. Upper fork clamp pinch fastener (2) Stem pinch fastener Stem cap fastener Upper fork clamp Figure 7-4. Upper Fork Clamp 2003 Buell XB9R: Electrical...
Page 506 Install ignition switch body fasteners (1). Tighten to 12-36 Ignition switch in-lbs (1.4-4.0 Nm). Ignition switch housing Ignition switch connector [33] Figure 7-5. Ignition Switch Assembly b1023b8x Headlights (2) Cable strap Ignition switch connector [33] Figure 7-6. Ignition Switch Connector (viewed from underneath fairing) 2003 Buell XB9R: Electrical...
Page 507 If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. 10. Install seat. See 2.38 SEAT. 2003 Buell XB9R: Electrical...
Page 508: Spark Plug Cables
Pulling on the cable will damage the cable’s carbon core. Remove airbox assembly. See 4.43 AIRBOX. Figure 7-8. Disconnect spark plug cables from igni- tion coil and spark plug terminals. Inspect cables for damage. 2003 Buell XB9R: Electrical...
Page 509 Connect spark plug cables to ignition coil and spark plugs. Fasten boots/caps securely. Tight connections provide the necessary moisture-proof environment for the ignition coil and spark plug terminals. Install airbox assembly. See 4.43 AIRBOX. 7-10 2003 Buell XB9R: Electrical...
Page 510 Listen for relay “click”. If click is not heard, perform stand retracted or clutch disengaged. ignition system tests. Motorcycle will not start after starter No spark at spark plug. Check for 12 VDC at coil W/BK wire. relay tests. Follow ignition system troubleshooting. 2003 Buell XB9R: Electrical 7-11...
Page 511 Top View Spare Diode 1 Key Switch Ignition Diode 2 Spare Neutral Switch [131] Brake/Horn Empty TN/W Cooling Fan Ignition Lights Key Switch Accessory Sidestand Switch [60] Start TN/W Ignition TN/W Relay Figure 7-12. Diode Wiring 7-12 2003 Buell XB9R: Electrical...
Page 512 Diode OK? Check for ground at neutral switch terminal. Ground present? Repair open on TN/Y Diode installed backwards. Replace Replace neutral wire between neutral Reverse polarity. diode. switch. switch and Diode 2. 5064 5061 5062 5063 2003 Buell XB9R: Electrical 7-13...
Page 513 [95]. GN wire between Reverse polarity. Ground present? connector [95] and 5072 Diode 1. 5071 5073 Replace clutch Repair open on switch. BK wire between connector [95] and 5074 ground. 5075 7-14 2003 Buell XB9R: Electrical...
Page 514 To Starter Solenoid R/BK Key Switch Relay R/BK *ECM [10] Pin 1 also provides power to fuel pump, both fuel injec- Connector [11] Connector [10] tors and coil. Electronic Control Module (ECM) Figure 7-13. Interlock Circuit 2003 Buell XB9R: Electrical 7-15...
Page 515: Sidestand Switch
0 ohms or little resistance. Replace the assembly with a new switch if necessary. Clutch engaged (switch open) 2.24 CLUTCH HAND LEVER. Clutch disengaged (switch closed) Connector [95] Figure 7-15. Clutch Switch 7-16 2003 Buell XB9R: Electrical...
Page 516 A 30 Amp main fuse links the ignition key switch and the bat- tery. The 30A main fuse is located under the rider’s seat. See 7.22 MAIN FUSE AND FUSES for more information. Figure 7-17. Starter Relay Test 2003 Buell XB9R: Electrical 7-17...
Page 517 Figure 7-18. Fuse Block (contains diodes) b1003x4x Diode 1 Spare Spare Diode 2 Brake/Horn Empty Cooling Fan Ignition Lights Key Switch Accessory Figure 7-19. Fuses and Diodes 7-18 2003 Buell XB9R: Electrical...
Page 518: Charging System
Wiring Check for corroded or loose connections in the charging cir- cuit. See Figure 7-22. Voltage Regulator Inspection Figure 7-21. The plug connector to stator must be clean and tight. 2003 Buell XB9R: Electrical 7-19...
Page 519 STOP 5310 Go to Test 7.6 (Part 2 of 2). NOTE Whenever a charging system component fails a test and is replaced, re-test the system to be sure the problem has been corrected. 7-20 2003 Buell XB9R: Electrical...
Page 520 System Damaged or Replace Replace slipping rotor. stator. rotor. 5319 5314 5319 NOTE Whenever a charging system component fails a test and is replaced, re-test the system to be sure the problem has been corrected. 2003 Buell XB9R: Electrical 7-21...
Page 521 HOME b1091x7x Starter Battery Main Fuse [77] Voltage Regulator [46] Stator Figure 7-22. Charging System Circuit 7-22 2003 Buell XB9R: Electrical...
Page 522 [46] under front sprocket cover See 7.24 SPROCKET COVER WIRING. Start the motorcycle and run the engine at 2000 RPM. With ignition and all continuously running lights and accessories turned on (headlight on high beam), read the total current draw. 2003 Buell XB9R: Electrical 7-23...
Page 523 If the resistance is lower, the stator is damaged and must be replaced. NOTE Verify that meter reads 0 ohms when probes are shorted together. If not, subtract lowest value to resistance value of stator. 7-24 2003 Buell XB9R: Electrical...
Page 524 If output is good, charging problem might be faulty regulator/rectiﬁer. Replace as required. Check the output again as described under CURRENT AND VOLTAGE OUTPUT TEST page 7-24. b0997x7x Figure 7-27. Check for Stator Resistance b0998x7x Figure 7-28. Check Stator AC Voltage Output 2003 Buell XB9R: Electrical 7-25...
Page 525 Remove stator wiring grommet (3) from left crankcase half. Withdraw stator wiring (4) from grommet hole in left crankcase half. Remove stator. Stator fastener (4) Stator Grommet Stator wiring Connector [46] Figure 7-31. Stator Assembly 7-26 2003 Buell XB9R: Electrical...
Page 526 Test charging system. See 7.6 CHARGING SYSTEM. to 30-40 in-lbs (3-4 Nm). Route stator wiring (4) behind rear cylinder and in front of transmission breather hose. See 7.24 SPROCKET COVER WIRING for remaining wire routing information. 2003 Buell XB9R: Electrical 7-27...
Page 527: Voltage Regulator
Voltage regulator loss of control which could result in death or serious Fastener (3) injury. Install seat. See 2.38 SEAT. Figure 7-34. Voltage Regulator Test charging system. See 7.6 CHARGING SYSTEM. 7-28 2003 Buell XB9R: Electrical...
Page 528: Battery Cables
Connect positive cable to positive (+) battery termi- nal using fastener. Figure 7-36. Negative Battery Cable Connect negative cable to negative (-) battery termi- nal using fastener. Tighten terminal fasteners to 72-96 in-lbs (8-11 Nm). 2003 Buell XB9R: Electrical 7-29...
Page 529 Attach negative cable to frame. Tighten to 48-72 in-lbs (5.4-8.1 Nm). Apply light coat of petroleum jelly or corrosion-retardant material to both battery terminals. Fastener with washer Positive battery cable Figure 7-37. Positive Battery Cable (Protective Boot Not Shown) 7-30 2003 Buell XB9R: Electrical...
Page 530 7.10 GENERAL f1730x8x Warning Label All Buell batteries are permanently sealed, maintenance-free, valve-regulated, lead/calcium and sulfuric acid batteries. The batteries are shipped pre-charged and ready to be put into service. Do not attempt to open these batteries for any reason.
Page 531: Battery Testing
(black) cable. See Figure 7-41. could result in death or serious injury. Install the battery on the motorcycle. See BATTERY INSTALLATION AND CONNECTION. 7-32 2003 Buell XB9R: Electrical...
Page 532: Disconnection And Removal
Unthread fastener and remove battery negative cable Inspect the battery case for cracks or leaks. (black) from battery negative (-) terminal. Unthread fastener and remove battery positive cable (red) from battery positive (+) terminal. Unhook battery strap from frame. Remove battery. 2003 Buell XB9R: Electrical 7-33...
Page 533: Battery Charging
Overheating may result in plate distortion, internal shorting, dryout or other damage. Perform a voltmeter test to determine the state of charge. See BATTERY TESTING. If battery needs to be charged, proceed to step 2. 7-34 2003 Buell XB9R: Electrical...
Page 534 (+) terminal. Tighten fastener to 72-96 in-lbs (8-11 Nm). Insert fastener through battery negative cable (black) into threaded hole of battery negative (-) terminal. Tighten fastener to 72-96 in-lbs (8-11 Nm). 2003 Buell XB9R: Electrical 7-35...
Page 535 (not freezing), dry place. See Fig- ure 7-42. Charge the battery every month if stored at temperatures below 60˚ F. (16˚ C). Charge the battery more frequently if stored in a warm area above 60˚ F. (16˚ C). 7-36 2003 Buell XB9R: Electrical...
Page 536 Always wrap the bulb in paper or a clean, dry cloth during handling. Figure 7-43. Disconnect headlight connection (1). Release wire retaining latch (5) from headlight housing clips. Pull bulb housing from headlight housing. 2003 Buell XB9R: Electrical 7-37...
Page 537 HIGH beam (2) settings. Set headlight to LOW beam. Press passing lamp switch (1). Headlight should ﬂash HIGH beam for as long as the switch is pressed. Turn ignition key switch to OFF. Align headlight. See 1.18 HEADLIGHTS. 7-38 2003 Buell XB9R: Electrical...
Page 538: Tail Lamp
If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install pillion seat. See 2.38 SEAT. 2003 Buell XB9R: Electrical 7-39...
Page 539: Turn Signals
In next step, reﬂector bracket (3) will be removed with turn signal (1). Remove turn signal from tail section (7) and license plate bracket (4). Turn signal (2) Lockwasher (2) Fastener (2) Fairing support bracket Fairing Bulb Figure 7-47. Front Turn Signals 7-40 2003 Buell XB9R: Electrical...
Page 540 HOME b1008a7x Turn signal Turn signal bulb Reﬂector bracket License plate bracket Washer (2) Fastener (2) Tail section Figure 7-48. Rear Turn Signals 2003 Buell XB9R: Electrical 7-41...
Page 541 Attach bullet connectors on turn signal wires as shown in loss of control which could result in death or serious Figure 7-49. injury. Install seat. See 2.38 SEAT. 7-42 2003 Buell XB9R: Electrical...
Page 542: Turn Signal Flasher
Front and rear left turn sig- nals must ﬂash. Activate right turn signals using switch on left han- dlebar. Front and rear right turn signals must ﬂash. Turn ignition key switch to OFF. 2003 Buell XB9R: Electrical 7-43...
Page 543: Handlebar Switches
Remove cable straps. Detach connector [24] from To Ign. relay wiring harness. GY/O From Ign. relay W/BK W/BK From Ign. relay W/BK W/BK To starter relay BK/R BK/R Accessory power To stoplight Brake Switch [121] Figure 7-52. Right Handlebar Switch Connection 7-44 2003 Buell XB9R: Electrical...
Page 544 Set headlight to LOW beam. Press passing lamp switch. Headlight should ﬂash HIGH beam for as long as the switch is pressed. Check left and right turn signals. Activate horn by pressing horn switch. Turn ignition key switch to OFF. 2003 Buell XB9R: Electrical 7-45...
Page 545 Accessory R/GY Fuse R/GY Key Switch Fuse Top View Vehicle Speed Sensor Connector [65] BK/W Instrument Module Vehicle Speed [39] Sensor Connector [10] Connector [11] Electronic Control Module (ECM) Figure 7-55. Vehicle Speed Sensor Wiring 7-46 2003 Buell XB9R: Electrical...
Page 546 Connect instrument module connector [39]. Install headlight support bracket. See 2.25 HEADLIGHT SUPPORT BRACKET. Install negative battery cable. Headlight support bracket Instrument module Grommet (3) Washer (3) Fastener (3) Instrument module connector [39] Figure 7-58. Instrument Module 2003 Buell XB9R: Electrical 7-47...
Page 547: Speedometer Performance Check
This allows for testing the smoothness of operation and checking for hesitancy or a Place speedometer tester power switch in the ON posi- stuck needle. tion. Place signal switch in the OUT position. 7-48 2003 Buell XB9R: Electrical...
Page 548 Rotate the motorcycle’s rear wheel. If reading on speedometer tester changes as wheel is rotated, speedometer sensor is OK. If reading does not change, vehicle speed sensor is suspect. Install a known, good vehicle speed sensor and test again. 2003 Buell XB9R: Electrical 7-49...
Page 549 Are correct 6020 numbers displayed? Replace instrument module. Press reset for 5 sec- onds. Does trip odome- 6020 ter reset to zero? STOP Replace instrument module. Go to 6020 Speedometer Test: Chart 7-50 2003 Buell XB9R: Electrical...
Page 550 Go to If necessary, remove vehicle speed sensor Speedometer Test: and check for accumulation of debris. If Chart debris is not present, replace sensor. If debris is present, clean sensor and repeat test. Replace if necessary. 2003 Buell XB9R: Electrical 7-51...
Page 551 Does damage exist? Check speedometer speed Repair as necessary. sensor. Clean or replace sen- sor as required. Retest. 6016 Problem solved? System OK. Replace instrument module. 6029 6024 7-52 2003 Buell XB9R: Electrical...
Page 552: Tachometer Performance Check
Enter the result (33.3 for 2000 RPM) into the speedome- ter tester. The tachometer should respond by moving its nee- dle to the desired RPM. Test the tachometer at several different RPM read- ings to verify proper operation. 2003 Buell XB9R: Electrical 7-53...
Page 553 Wires continue to If testing LO range, press 1 or 3. Electronic Control If testing CEN range, press 4 or 6. b0592x7x Module If testing HI range, press 7 or 9. Figure 7-63. Testing Tachometer 7-54 2003 Buell XB9R: Electrical...
Page 554 If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install seat. See 2.38 SEAT. 2003 Buell XB9R: Electrical 7-55...
Page 555 If horn is faulty, replace unit as an assem- bly. The horn is not repairable. If battery voltage is not present, either horn switch or wiring to horn is faulty. If horn switch is faulty, replace left handlebar switch. See 7.15 HANDLE- SWITCHES. 7-56 2003 Buell XB9R: Electrical...
Page 556: Neutral Indicator Switch
243 (blue) to new neutral indicator switch (1) threads. Install washer (3) over neutral indicator switch (2) threads. Install switch in crankcase. Tighten switch to 36-60 in-lbs (4-6.8 Nm). Connect wire lead (1) to switch. Install sprocket cover. See 2.30 SPROCKET COVER. 2003 Buell XB9R: Electrical 7-57...
Page 557: Main Fuse And Fuses
HOME MAIN FUSE AND FUSES 7.22 GENERAL 8378 Buell motorcycles feature two components which protect the electrical system. Fuses Figure 7-69.The covered fuse block is behind the fairing on the right hand side of the motorcycle. Figure 7-70. The lights, key switch, brake/horn and igni- tion fuses are rated at 15 amps.
Page 558: Main Wire Harness
Remove main fuse case (3). 10. Disconnect foot brake light switch connector [121] (5). Main battery ground Wire harness ground Main fuse case Cable strap Foot brake light switch connector [121] Figure 7-73. Battery Tray Wiring 2003 Buell XB9R: Electrical 7-59...
Page 559 22. Remove fuse and relay bundle clamps. 23. Remove fuse block and relay block from their brackets. 24. Remove any remaining cable straps and clamps secur- ing wire harness and remove harness from front of vehi- cle. 7-60 2003 Buell XB9R: Electrical...
Page 560 72-96 in-lbs (8.1-10.8 Nm). 15. Repeat previous steps for relay block. 16. Install steering head clamp around wire harness and secure clamp to fairing support bracket with loop facing vehicle. Tighten fastener to 16-18 ft-lbs (21.7-24.4 Nm). 2003 Buell XB9R: Electrical 7-61...
Page 561 If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. 30. Install seat. See 2.38 SEAT. 7-62 2003 Buell XB9R: Electrical...
Page 562 Left switch housing connector [24] Cable strap Headlight connector [38] Right turn signal connectors Cable strap Right switch housing connector [22] 10. Ignition switch connector [33] 11. Cable strap Figure 7-79. Fairing Wiring (viewed from underneath fairing) 2003 Buell XB9R: Electrical 7-63...
Page 563: Sprocket Cover Wiring
Form a loop (6) as shown using neutral switch wiring. Cam position sensor [14] Loop in voltage regulator wiring Neutral switch location Cam cover breather hose Stator connector [46] Oil pressure switch wiring Figure 7-81. Cam Position Sensor Wiring 7-64 2003 Buell XB9R: Electrical...
Page 564 8747 Cable strap Figure 7-85. Assembled Wiring Cam position sensor connector [14] Neutral switch location Cam position sensor wiring Neutral switch connector [131] Cable strap Loop in neutral switch wiring Figure 7-83. Neutral Switch Wiring 2003 Buell XB9R: Electrical 7-65...
Page 565 HOME NOTES 7-66 2003 Buell XB9R: Electrical...
Page 566 Table Of Contents SUBJECT PAGE NO. Appendix A-Tools ..........Appendix B-Wiring .

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