Buell 2005 FIREBOLT Service Manual

Table of Contents

Quick Links

Download this manual

2005 BUELL FIREBOLT MODELS

SERVICE MANUAL

Part Number 99493-05Y

Section 1: Maintenance

Section 2: Chassis

Section 3: Engine

Section 4: Fuel System

Section 5: Starter

Section 6: Drive/Transmission

Section 7: Electrical

Appendices

Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Buell 2005 FIREBOLT

Page 1 2005 BUELL FIREBOLT MODELS SERVICE MANUAL Part Number 99493-05Y 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: Table Of Contents
MAINTENANCE Table Of Contents SUBJECT PAGE NO. 1.1 General ............1.2 Fuel and Oil .
Page 4: General
Engine oil and transmission ﬂuid levels. Always clean around lines or covers before they are removed. Headlamp, passing lamp, tail lamp, brake lamp and turn Plug, tape or cap holes and openings to keep out dirt, dust signal operation. and debris. 2005 Buell Firebolt: Maintenance...
Page 5: Repair And Replacement Procedures
Always use the proper tools and ﬁxtures for removing and installing bearings. Part Replacement Bearings do not usually need to be removed. Only remove bearings if necessary. Always replace worn or damaged parts with new parts. 2005 Buell Firebolt: Maintenance...
Page 6: Part Protection
When breaking loose a fastener, apply a small amount of Always cut at right angles. pressure as a test to be sure the ratchet’s gear wheel is Don’t use any prybar as a chisel, punch or hammer. engaged with the pawl. 2005 Buell Firebolt: Maintenance...
Page 7: Storage Units
Close lids and lock drawers and doors before moving storage units. Don’t pull on a tool cabinet; push it in front of you. Set the brakes on the locking casters after the cabinet has been rolled to your work. 2005 Buell Firebolt: Maintenance...
Page 8: Fuel And Oil
You may ﬁnd that some gasoline blends adversely affect the starting, driveability or fuel efﬁciency of your bike. If you expe- rience one or more of these problems, we recommend you try a different brand of gasoline or gasoline with a higher octane rating. 2005 Buell Firebolt: Maintenance...
Page 9: Maintenance Schedule
Engine mounts and stabilizer links Inspect Road test Verify component and system functions NOTES: Should be performed by an authorized Harley-Davidson/Buell dealer, unless you have the proper tools, service data and are mechanically qualiﬁed. Or every two years. 2005 Buell Firebolt: Maintenance...
Page 10 Minimum brake disc thickness 0.18 in. (4.5 mm) or less Drive belt Replace drive belt and idler pulley At every 25,000 mi (40,000 km) service interval. assembly: Intake cover assembly Intake cover screw torque 12-36 in-lbs (4-4 Nm) 2005 Buell Firebolt: Maintenance...
Page 11 HYDRAULIC FORK OIL (TYPE E) Part No. 99884-80 4.6 in. (118 mm) from the top of the fork tube Battery Lubricant ELECTRICAL CONTACT LUBRICANT Part No. 99861-02 (1 oz.) Battery terminal torque 72-96 in-lbs (8-11 Nm) 2005 Buell Firebolt: Maintenance...
Page 12: Care Of Molded-In-Color Body Panels
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 motorcycle. ley Glaze Polish and Sealant to molded-in-color surfaces will eliminate this condition.
Page 13: Battery Maintenance
HOME BATTERY MAINTENANCE GENERAL BATTERY TESTING Buell motorcycle batteries are permanently sealed, mainte- Voltmeter Test 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 14: Cleaning And Inspection
Inspect the battery case for cracks or leaks. 100 % 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 2005 Buell Firebolt: Maintenance 1-11...
Page 15 (00068a) CAUTION Do not over-tighten bolts on battery terminals. Use rec- ommended torque values. Over-tightening battery termi- nal bolts could result in damage to battery terminals. (00216a) 1-12 2005 Buell Firebolt: Maintenance...
Page 16: Engine Lubrication System
Ride motorcycle for approximately 10 minutes to ensure the oil is hot and the engine is at normal operating temperature. The motorcycle must be on level ground, on the side- stand, with the engine off. 2005 Buell Firebolt: Maintenance 1-13...
Page 17 Using a 5/8 in. wrench, remove drain plug from under oil tank/swingarm. Wipe any accumulated debris from mag- netic tip on drain plug. 8352 Figure 1-5. Dipstick Location Figure 1-5. Unscrew and remove dipstick from oil ﬁll hole on top of oil tank/swingarm. 1-14 2005 Buell Firebolt: Maintenance...
Page 18 ° H.D. Multi-Grade SAE 20W50 HD 360 Above 40 (4°C) Good ° H.D. Regular Heavy SAE 50 HD 360 Above 60 (16°C) Poor ° H.D. Extra Heavy SAE 60 HD 360 Above 80 (27°C) Poor 2005 Buell Firebolt: Maintenance 1-15...
Page 19: Brake System Maintenance
D.O.T. 4 ﬂuid on the reservoir cap. Mixing different types of ﬂuid may adversely affect braking ability and lead to brake failure which could result in death or seri- ous injury. 1-16 2005 Buell Firebolt: Maintenance...
Page 20 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. 2005 Buell Firebolt: Maintenance 1-17...
Page 21: Bleeding Front Brake
Verify master cylinder ﬂuid level as described in step 4. 10. Attach cover to front master cylinder reservoir and tighten fasteners to 9-13 in-lbs (1.0-1.5 Nm). 11. Remove cover from molded-in-color surfaces, right han- dlebar switches and instrument panel. 1-18 2005 Buell Firebolt: Maintenance...
Page 22: Bleeding Rear Brake
After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 11. Install seat. See 2.38 SEAT. 2005 Buell Firebolt: Maintenance 1-19...
Page 23 Figure 1-11. Critical Measurements with Typical clevis and tighten to 130-173.5 in-lbs (14.7-19.6 Brake Pedal Nm). NOTE Brake pedal has no free play adjustment. 8349 Bottom of master cylinder Rod adjuster Locknut Clevis Clevis pin Figure 1-12. Pushrod Adjustment 1-20 2005 Buell Firebolt: Maintenance...
Page 24 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. Figure 1-14. Front Brake Rotor 2005 Buell Firebolt: Maintenance 1-21...
Page 25: Brake Pad Replacement
(48-50 Nm). Tighten pin (2) to 11-14 ft-lbs (15-19 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. 1-22 2005 Buell Firebolt: Maintenance...
Page 26 “wear in” properly with the rotor. Rear caliper mounting fasteners Brake pad retainer Rear caliper pin plug Rear caliper hanger pin Figure 1-16. Rear Brake Caliper 6487 Figure 1-17. Rear Brake Pad Spring 2005 Buell Firebolt: Maintenance 1-23...
Page 27: Tires And Wheels
A bump, bulge or split in the tire. Check wheel bearings for wear and corrosion. Excessive play Puncture, cut or other damage to the tire that cannot be or roughness indicates worn bearings. Replace bearings in repaired. sets only. 1-24 2005 Buell Firebolt: Maintenance...
Page 28: Clutch
Install clutch inspection cover tighten- ing three fasteners and washers to 84-108 in-lbs (10- Primary cover Correct chaincase lubricant level 12 Nm). Clean up any ﬂuid that may have spilled on mufﬂer. Figure 1-21. Fluid Level 2005 Buell Firebolt: Maintenance 1-25...
Page 29 Cable end adjusting screw clockwise until it aligns. Jam nut Adjuster NOTE Spring installs on outboard side of hex lockplate. Figure 1-22. Clutch Cable Adjuster Mechanism 8405 Diaphragm spring Lockplate Adjusting screw Figure 1-23. Clutch Adjustment 1-26 2005 Buell Firebolt: Maintenance...
Page 30 Figure 1-19. Install clutch inspection cover and new gasket using three fasteners and washers and tighten to 84-108 in-lbs (10-12 Nm). Check clutch cable free play. See Step 6 above. Figure 1-24. Adjusting Clutch Free Play 2005 Buell Firebolt: Maintenance 1-27...
Page 31: Drive Belt System
Keep dirt, grease, oil, and debris off the belt, idler pulley and sprockets. Clean the drive belt with a mild soap and water spray solution as required. Dry thoroughly. Do not immerse belt in solution. Do not direct pressurized water on belt. 1-28 2005 Buell Firebolt: Maintenance...
Page 32 Clean and protect drive Cracks in back of belt Inspect/replace sprocket Cut by sharp debris (not at belt edge) Continue to run but monitor condition frequently Inspect/replace sprocket Cut by sharp debris at belt edge Inspect/replace belt 2005 Buell Firebolt: Maintenance 1-29...
Page 33 Inspect/replace belt Excessive drive noise Inspect/replace sprocket Clean and protect drive Debris stuck in belt Inspect/replace belt Missing/damaged belt guards Inspect/replace sprocket Follow proper handling/installation procedure Debris stuck in sprocket Inspect/replace belt Missing/damaged belt guards 1-30 2005 Buell Firebolt: Maintenance...
Page 34: Primary Chain
Tighten fasteners to 40-60 in-lbs (5-7 Nm). Table 1-9. Primary Chain Tension ENGINE FREE PLAY TEMPERATURE Cold 3/8-1/2 in. 9.5-12.7 mm Hot (normal running 1/4-3/8 in. 6.4-9.5 mm temperature) 2005 Buell Firebolt: Maintenance 1-31...
Page 35 Loosen locknut (1). Turn adjusting fastener (2): Clockwise (inward) to reduce free play. Counterclockwise (outward) to increase free play. Tighten locknut (1) to 20-25 ft-lbs (27-34 Nm). Locknut Adjusting screw Figure 1-28. Chain Tension Adjusting Fastener 1-32 2005 Buell Firebolt: Maintenance...
Page 36: Suspension Damping Adjustments
Inspect your GVWR is the sum of the weight of the motorcycle, acces- tires regularly and see a Buell dealer for replacements. sories, and the maximum weight of the rider, passenger Riding with excessively worn, unbalanced or under- and cargo that can be safely carried.
Page 37 1.50 1.25 180-200 82-91 1.50 1.50 1.25 1.25 200-220 91-100 1.25 1.25 1.25 220-240 100-109 1.25 1.25 0.75 240-GVWR 109-GVWR 0.75 * Note all compression and rebound settings are # of turns out from maximum. 1-34 2005 Buell Firebolt: Maintenance...
Page 38 Using a screwdriver, turn the slotted dial Figure 1-30. Front Fork Compression Damping Adjuster clockwise until it stops. This is the maximum compression damping setting. Then turn the dial counterclockwise the recommended amount specified in Table 1-10. 2005 Buell Firebolt: Maintenance 1-35...
Page 39 This is the maximum rebound Figure 1-31. Rear Shock Preload Adjuster damping setting. Then turn the dial counterclockwise the recommended amount speciﬁed in Table 1-10. 8416 Figure 1-32. Rear Shock Rebound Adjustment 1-36 2005 Buell Firebolt: Maintenance...
Page 40 This is the maximum com- pression damping setting. Then turn the dial counterclockwise the recommended amount specified in Table 1-10. Install seat. See 2.38 SEAT. Figure 1-33. Accessing Rear Shock Compression Adjuster 8976 Figure 1-34. Rear Shock Compression Adjustment 2005 Buell Firebolt: Maintenance 1-37...
Page 41: Steering Head Bearings
Do not operate motorcycle with loose, worn or damaged steering or suspension systems. Contact a Turn front wheel all the way to the right. Buell dealer for repairs. Loose, worn or damaged steer- ing or suspension components can adversely affect sta- Figure 1-35.
Page 42: 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. 2005 Buell Firebolt: Maintenance 1-39...
Page 43 After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 16. Install seat. See 2.38 SEAT. 1-40 2005 Buell Firebolt: Maintenance...
Page 44: Air Cleaner Filter
Thoroughly clean base plate and inside of air cleaner Vapor Valve (XB9) cover. Figure 1-41. Make sure two crankcase breather hoses (1) and intake air sensor (2) are captured in base plate behind velocity stack (3). 2005 Buell Firebolt: Maintenance 1-41...
Page 45 After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) Install seat. See 2.38 SEAT. 1-42 2005 Buell Firebolt: Maintenance...
Page 46: 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, base plate and intake cover assembly. See 4.45 AIRBOX. 2005 Buell Firebolt: Maintenance 1-43...
Page 47 This ensures the system is working prop- For the next step in the procedure it will be necessary to erly. If you do not see the mark, verify previous cable adjust- obtain a permanent marker. ment. 1-44 2005 Buell Firebolt: Maintenance...
Page 48: Interactive Exhaust Cable (Xb12R)
(1) is routed behind the frame lug (2) before installing air intake cover. CAUTION If cable is routed in front of the frame lug it will cause the mufﬂer valve to stay open not allowing it to work prop- erly. 12. Install air intake cover. 2005 Buell Firebolt: Maintenance 1-45...
Page 49: Ignition Timing
10. See Figure 1-48. If the static timing is correct, the screen will switch to HIGH - 5 volts at the precise moment the timing mark exactly centers in the inspection window. Figure 1-48. Correct Timing 1-46 2005 Buell Firebolt: Maintenance...
Page 50 If timing is retarded (mark appears on right side of window) rotate timing plate clockwise. Recheck timing. Figure 1-49. Timer Cover 8391 Figure 1-50. Cam Position Sensor b0964x1x Figure 1-51. Advanced Timing b0963x1x Figure 1-52. Retard Timing 2005 Buell Firebolt: Maintenance 1-47...
Page 51: Headlights
Check that the correct pattern of light is a circular Low beam pattern and is centered on the horizontal line as shown in Figure 1-53. Figure 1-54. Headlamp Switch Adjust headlamp alignment. See ADJUSTMENT section. 1-48 2005 Buell Firebolt: Maintenance...
Page 52 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 1-55. Headlamp Height Adjustment 2005 Buell Firebolt: Maintenance 1-49...
Page 53: Throttle Position Sensor (Tps)
ADJUSTMENT 8390 Connect vehicle to Digital Technician. Select calibrations screen/TPS Function. Select Buell TPS zero tab. Select TP volts on screen. Figure 1-56. Back off idle adjustment until TP volts stop decreasing and then continue to back out one full turn.
Page 54: 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. 2005 Buell Firebolt: Maintenance 1-51...
Page 55: 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. 1-52 2005 Buell Firebolt: Maintenance...
Page 56: Electrical System
Primary chain badly worn or links tight as a result of insufﬁcient lubrication. Wheels not aligned and/or tires worn. Poor Fuel Economy Internal engine problem. Oxygen sensor damaged or malfunctioning (bike running Wheels not balanced correctly. rich). See dealer. 2005 Buell Firebolt: Maintenance 1-53...
Page 57 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. 1-54 2005 Buell Firebolt: Maintenance...
Page 58 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. 2005 Buell Firebolt: Maintenance 1-55...
Page 59 HOME NOTES 1-56 2005 Buell Firebolt: Maintenance...
Page 60 2.2 Tire Specifications ..........2.3 Buell Vehicle Identification Number (V.I.N.) ......
Page 62: Specifications
Do not inﬂate tire beyond maximum pressure as speci- Ratings (GAWR) are given on an information decal located ﬁed on sidewall. Over inﬂated tires can blow out, which on the steering head. could result in death or serious injury. (00027a) 2005 Buell Firebolt: Chassis...
Page 63: Torque Values
Tighten in a crosswise pattern, page 2-70 teners Electronic control module fas- 72-96 in-lbs 8-11 Nm page 2-73 teners Engine shroud air scoop 12-36 in-lbs 1-4 Nm page 2-89 Exhaust header mounting nut 72-96 in-lbs 8-11 Nm page 2-80 2005 Buell Firebolt: Chassis...
Page 64 8-11 Nm page 2-94 Mufﬂer mounting block fas- 32-36 ft-lbs 43-49 Nm page 2-80 tener, rear Mufﬂer strap fastener, front 108-120 in-lbs 12-14 Nm page 2-80 Mufﬂer strap fastener, rear 48-60 in-lbs 5-7 Nm page 2-80 2005 Buell Firebolt: Chassis...
Page 65 Tail frame to frame 21-23 ft-lbs 28-31 Nm LOCTITE 272, page 2-92 Torca clamp 28-30 ft-lbs 38-40.6 Nm page 2-80 Valve stem nut 40-44 in-lbs 4.5-4.9 Nm page 2-22 Wear peg, rider 36-48 in-lbs 4.1-5.4 m page 2-81 2005 Buell Firebolt: Chassis...
Page 66: Tire Specifications
8423 WARNING WARNING Tires must be correctly matched to wheel rims. Use only Buell approved tires. See a Buell dealer. Using non- approved tires can adversely affect stability, which could result in death or serious injury. (00133a) Figure 2-1. Tire sizes are molded on the sidewall. Rim size and contour are marked on the rim’s exterior surface.
Page 67: Buell Vehicle Identification Number (V.i.n.)
An abbreviated V.I.N. is stamped on the left side crankcase at about your motorcycle. the base between the cylinders. 400001 Figure 2-2. Buell Vehicle Identiﬁcation Number (V.I.N.) Typical Table 2-8. Buell 2005 XB Models V.I.N. Description ITEM DESCRIPTION POSSIBLE VALUES...
Page 68: Wheels
Figure 2-3. Checking Tire Inﬂation Pressure Figure 2-3. 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. 2005 Buell Firebolt: Chassis...
Page 69 WARNING WARNING To prevent death or serious injury, use the following Buell tires are equipped with wear bars that run horizon- guidelines when installing a new tire or repairing a ﬂat: tally across the tread. When wear bars become visible and only 1/32 in.
Page 70: Front Wheel
To prevent cosmetic damage to the wheel, center caliper 8441 between spokes before removal. Figure 2-5. Raise the wheel up until the rotor clears the caliper and rotate the fork leg counterclockwise allowing wheel clearance for removal. Remove wheel. Figure 2-5. Front Wheel Removal 2005 Buell Firebolt: Chassis...
Page 71 Forcing screw Figure 2-8. Expand the Collet Figure 2-9. 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 2005 Buell Firebolt: Chassis...
Page 72 WARNING Always replace brake pads in complete sets for correct and safe brake operation. Improper brake operation could result in death or serious injury. (00111a) Inspect brake rotor and pads. See 1.7 BRAKE SYSTEM MAINTENANCE. 2005 Buell Firebolt: Chassis 2-11...
Page 73: Bearing Installation
Bearing Installer/Remover (Part No. HD-44060), with the Remove the nut, bearing, washer, FRONT BEARING smaller diameter toward the wheel hub. Insert the forcing INSTALLER (Part No. B-43993-9) and forcing screw. screw and backing plate into the wheel hub. 2-12 2005 Buell Firebolt: Chassis...
Page 74 15. Remove the nut, bearing, washer, FRONT BEARING INSTALLER (Part No. B-43993-10) and forcing screw. 16. Install the wheel. See INSTALLATION under 2.5 FRONT Forcing screw WHEEL. Spacer Figure 2-15. Install the Spacer 10. See Figure 2-15. Install the spacer. 2005 Buell Firebolt: Chassis 2-13...
Page 75 ﬁtted into rotor properly. Failure to comply may affect braking ability and Align reference dot on front rotor with the valve stem. lead to brake failure which could result in death or seri- ous injury. 2-14 2005 Buell Firebolt: Chassis...
Page 76 Tighten the front axle pinch fasteners (2) to 20-22 ft-lbs (27-30 Nm). 8419 Install right side fender fasteners. See 2.31 FENDERS. Axle (left handed thread) Front axle pinch fasteners (2) (metric) Figure 2-19. Front Wheel Mounting 2005 Buell Firebolt: Chassis 2-15...
Page 77: Rear Wheel
See IDLER PULLEY REMOVAL 6.6 DRIVE For wheel bearing removal follow identical procedure as used BELT SYSTEM. for front wheel. Remove rear axle. Slide drive belt out of the way and remove rear wheel. 2-16 2005 Buell Firebolt: Chassis...
Page 78 HOME b0936x2x Rotor mounting fastener (6) Brake rotor Wheel bearing Wheel spacer Wheel Sprocket Sprocket fastener Axle Figure 2-22. Rear Wheel Assembly 2005 Buell Firebolt: Chassis 2-17...
Page 79 48-52 ft-lbs (65.1-70.5 Nm). Install brake rotor (2) with new rotor mounting fas- Tighten pinch fastener (2) on right side of swingarm to teners (1) and tighten to 25-27 ft-lbs (34-37 Nm). 40-45 ft-lbs (54-61 Nm). 2-18 2005 Buell Firebolt: Chassis...
Page 80 WARNING After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) 2005 Buell Firebolt: Chassis 2-19...
Page 81: Checking Cast Rim Runout
Wheel Truing and Balancing Stand (HD-99500-80) Table 2-10. Wheel Rim Runout b0758x2x RUNOUT Maximum lateral 0.040 1.02 Maximum radial 0.030 0.76 Gauge rod Figure 2-28. Checking Cast Rim Radial Runout Using Wheel Truing and Balancing Stand (HD-99500-80) 2-20 2005 Buell Firebolt: Chassis...
Page 82: Tires
Inadequate tread depth can cause an accident which could result in death or serious injury. Buell front and rear tires are not the same. Inter- changing front and rear tires can cause tire failure, which could result in death or serious injury.
Page 83 Start 180° from valve stem hole and place second bead Buell front and rear tires are not the same. Inter- on rim. Work bead onto rim with tire tools, working changing front and rear tires can cause tire failure, toward valve in both directions.
Page 84 Figure 2-33. Checking Tire Lateral Runout RUNOUT. Replace rims not meeting speciﬁcations. Install tire and check tire tread radial runout again. b0088x2x Gauge Figure 2-34. Checking Tire Radial Runout Table 2-11. Tire Runout RUNOUT Radial 0.060 1.52 Lateral 0.080 2.03 2005 Buell Firebolt: Chassis 2-23...
Page 85: Wheel Balancing
Allow eight hours for adhesive to cure completely before using wheel. NOTE If wheel assembly is out of speciﬁcation (1 oz. front, 2 oz. rear) rotate tire on rim and rebalance until wheel is within speciﬁcation. 2-24 2005 Buell Firebolt: Chassis...
Page 86: Brake Pedal
(5) to 22-24 ft-lbs (30-33 Nm). Install clevis pin (2). Rear master cylinder body Install new cotter pin (7). Clevis pin Pedal bushings (2) Shift brake pedal sleeve Brake pedal fastener Brake pedal Cotter pin Figure 2-36. Brake Pedal Assembly 2005 Buell Firebolt: Chassis 2-25...
Page 87 Pivot bolt nut (metric) 10. Brake switch fastener 11. Brake switch 12. Brake switch terminal 13. Banjo bolt (metric) 14. Brake line 15. Copper washers 16. Pivot bolt Figure 2-37. Front Brake Hand Lever Assembly 2-26 2005 Buell Firebolt: Chassis...
Page 88: Front Brake Master Cylinder
Circlip Figure 2-38. Piston Assembly in Master Cylinder Figure 2-38. Depress piston assembly (1) and remove internal circlip (2) and discard. Figure 2-37. Remove piston assembly (6) from front master cylinder reservoir (4) and discard. 2005 Buell Firebolt: Chassis 2-27...
Page 89: Front Master Cylinder
Figure 2-39. Front Master Cylinder Piston Assembly Figure 2-39. Assemble new piston components placing small end of spring (5) behind primary seal of piston (4). Lubricate master cylinder body and piston seals with special lubricant found in the service parts kit. 2-28 2005 Buell Firebolt: Chassis...
Page 90 1.7 BRAKE SYSTEM MAINTE- NANCE. 10. See Figure 2-37. Attach master cylinder cover (2) and cover gasket (3). Tighten two cover fasteners (1) to 9- 13 in-lbs (1.0-1.5 Nm). 11. Pump lever to raise pressure to operating level. 2005 Buell Firebolt: Chassis 2-29...
Page 91: Front Brake Line
Carefully inspect the brake line for dents, cuts, chafﬁng or other defects. Replace the brake line if any damage is noted. P-clamp Brake line Wire form Bleeder valve Banjo bolt Figure 2-42. Front Brake Line 2-30 2005 Buell Firebolt: Chassis...
Page 92 WARNING After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) 2005 Buell Firebolt: Chassis 2-31...
Page 93: Front Brake Caliper
Figure 2-44. Disconnect brake line at caliper. See 2.11 FRONT BRAKE LINE. Remove caliper mounting fasteners (5). Slide caliper down the rotor to clear fork lower and then remove off rotor. Figure 2-46. Removing Pistons (B-42887) 2-32 2005 Buell Firebolt: Chassis...
Page 94 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). 2005 Buell Firebolt: Chassis 2-33...
Page 95 HOME b0976x2x Pin hanger set Brake bleeder Bleeder cap Caliper Piston Piston o-rings Pad spring Small o-ring Caliper mounting fasteners 10. Brake pads 11. Caliper fasteners Figure 2-47. Front Caliper Assembly 2-34 2005 Buell Firebolt: Chassis...
Page 96: Rear Brake Master Cylinder
Remote reservoir hose bled. Prevent damage to seating surfaces by carefully removing brake line components. Figure 2-49. Rear Master Cylinder On Vehicle Figure 2-49. Remove brake reservoir hose at master cylinder. Remove seat. See 2.38 SEAT. 2005 Buell Firebolt: Chassis 2-35...
Page 97 Rear brake light switch assembly Brake line Copper washer Rear master cylinder body Clevis pin Pedal bearing Sleeve Brake pedal fastener Brake pedal 10. Cotter pin 11. Rear master cylinder mount screw Figure 2-51. Rear Master Cylinder Assembly 2-36 2005 Buell Firebolt: Chassis...
Page 98 Circlip must be snapped into the groove of the master cylinder body. If the circlip is not properly installed, improper brake operation could result in death or serious injury. Tuck rubber boot on rod assembly (3) into master cylin- der body (1). 2005 Buell Firebolt: Chassis 2-37...
Page 99 11. Install seat. See 2.38 SEAT. (5.4-8.1 Nm). Attach hose (3) to rear brake reservoir using clamp. Figure 2-50. Connect brake line switch connector under seat. Install heel guard. See 2.29 FOOTPEG, HEEL GUARD AND MOUNT. 2-38 2005 Buell Firebolt: Chassis...
Page 100: Rear Brake Line
Pump brake foot pedal to drain brake ﬂuid. Tighten bleeder valve to 36-60 in-lbs (4-7 Nm). Figure 2-56. Rear Brake Line Switch/Banjo Bolt Figure 2-56. Remove brake line switch/banjo bolt from rear master cylinder. Discard copper washer. Remove brake line from motorcycle. 2005 Buell Firebolt: Chassis 2-39...
Page 101 If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) 10. Test ride motorcycle and check for proper brake opera- tion. 2-40 2005 Buell Firebolt: Chassis...
Page 102: Rear Brake Caliper
Figure 2-59. Removing Rear Brake Caliper Piston Figure 2-59. 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. 2005 Buell Firebolt: Chassis 2-41...
Page 103 Install a new bleeder valve (metric) if necessary and Replace both pads as a set if the friction material of tighten to 36-60 in-lbs (4-7 Nm). either pad is worn to 0.04 in. (1.0 mm) or less. 2-42 2005 Buell Firebolt: Chassis...
Page 104 Low visibility of rider can result in death or serious injury. (00316a) NOTE Avoid making hard stops for the ﬁrst 100 miles (160 km) to allow new brake pads to “wear in” properly with the brake rotor. 2005 Buell Firebolt: Chassis 2-43...
Page 105: Front Fork
Remove fork from lower fork clamp (4). Repeat 4 through 6 on opposite side. Upper pinch fasteners Upper fork clamp Lower pinch fasteners Lower fork clamp Figure 2-62. Upper and Lower Fork Clamp Pinch Fasteners 2-44 2005 Buell Firebolt: Chassis...
Page 106 TOOL (1) (Part No. B-41177) in a vise and install the upper part of the front fork in the holding tool. Remove snap ring (2). Figure 2-66. Removing Fork Cap From Outer Tube Figure 2-66. Remove fork cap from outer tube. 2005 Buell Firebolt: Chassis 2-45...
Page 107 Careful not to damage preload pins while holding with a cup and screw that are for FLT models only and not to damper rod assembly. be used with Buell. Remove preload washer (4) and slider piston (5). CAUTION Figure 2-67.
Page 108 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. Slider fork Figure 2-69. Front Fork Assembly 2005 Buell Firebolt: Chassis 2-47...
Page 109 (9) counter clockwise till it stops. Holding the damper locknut (10), unscrew the rebound adjuster assembly (9) and remove from damper rod assembly (11). Remove damper locknut (10) from damper rod assembly (11). 2-48 2005 Buell Firebolt: Chassis...
Page 110: Fork Assembly
Tighten the damper locknut (10) to 22- 30 ft-lbs (30-40 Nm). 11. Replace the sealing washer (13) and center bolt (14) (metric). Tighten the center bolt to 22-30 ft-lbs (30- Repeat for other fork assembly. 40 Nm). 2005 Buell Firebolt: Chassis 2-49...
Page 111 Thread fork cap (3) into fork tube (18) and tighten to 25 ft-lbs (33.89 Nm). 24. Apply fork oil or light grease to o-rings on preload adjuster and install preload adjuster (3). 25. Install snap ring (2). 2-50 2005 Buell Firebolt: Chassis...
Page 112 11. Install front wheel. See 2.5 FRONT WHEEL. 12. Install front fender. See 2.31 FENDERS. 13. Check headlamp alignment. See 1.19 HEADLIGHTS. 14. Adjust front forks suspension to rider preferences. See 1.12 SUSPENSION DAMPING ADJUSTMENTS\. 2005 Buell Firebolt: Chassis 2-51...
Page 113 HOME NOTES 2-52 2005 Buell Firebolt: Chassis...
Page 114: Fork Clamps, Upper And Lower
See 7.3 IGNITION/HEADLIGHT KEY SWITCH. 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 2-75. Steering Stem Assembly 2005 Buell Firebolt: Chassis 2-53...
Page 115 Tighten steering stem cap to 38-42 ft-lbs (52-57 Nm). fork clamp. Install steering stem pinch bolt applying LOCTITE 272 and tightening to 17-19 ft-lbs (23-26 Nm). 2-54 2005 Buell Firebolt: Chassis...
Page 116: Steering Head Bearings
(upper bearing removed for clarity) NOTE Wheel Bearing Backing Plate (Part No. B-43993-12) Discard steering head bearings and replace with new. Steer- ing head bearings are not reusable. Figure 2-77. Steering Head Bearings Installation Tools 2005 Buell Firebolt: Chassis 2-55...
Page 117 Install the bearing (4), washer (5) and nut (6) from the STEERING HEAD BEARING RACE INSTALLER (Part No. HD-39302) onto the forcing screw (1). Tighten the nut (6) by hand, until the bearing is started into the bore in the steering head. 2-56 2005 Buell Firebolt: Chassis...
Page 118 11. Tighten steering stem capnut to 38-42 ft-lbs (52-57 Nm). 12. Use LOCTITE 272 on steering stem pinch fastener and tighten to 17-19 ft-lbs (23-26 Nm). 13. Install headlight assembly and support bracket. See 2.25 HEADLIGHT ASSEMBLY AND SUPPORT BRACKET. Figure 2-80. Install Bearings 2005 Buell Firebolt: Chassis 2-57...
Page 119: Swingarm And Brace
Loosen rear axle (1) approximately 15 rotations to allow partial tension to be removed from rear drive system. b1087a2x Upper belt guard Upper belt guard fasteners (3) Lower belt guard Lower belt guard fasteners (3) Figure 2-82. Belt Guard Assembly 2-58 2005 Buell Firebolt: Chassis...
Page 120 Loosen pivot shaft pinch fastener (7). Disconnect battery by unthreading fasteners removing negative cable (black) from battery ﬁrst. See 1.5 BAT- Remove pivot shaft (10) with a special 7/8 in. hex tool TERY MAINTENANCE. located in tool kit. 2005 Buell Firebolt: Chassis 2-59...
Page 121 Remove rear fender. See 2.31 FENDERS. NOTE Figure 2-83. 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. 2-60 2005 Buell Firebolt: Chassis...
Page 122 Install right side rider footpeg mount. Tighten fasteners to 108-132 in-lbs (12-15 Nm). See 2.29 FOOTPEG, HEEL GUARD AND MOUNT. Install heel guard. See 2.29 FOOTPEG, HEEL GUARD MOUNT. 10. Remove rear wheel support stand. 2005 Buell Firebolt: Chassis 2-61...
Page 123: Front And Rear Isolator
Tighten front isolator bolt (6) to 49-51 ft-lbs (66-69 Nm). Figure 2-85. Install clutch cable wire form. Tighten 3.4 STRIPPING MOTORCYCLE FOR ENGINE SER- fastener to 12-36 in-lbs (1-4 Nm). VICE to access the rear isolator. 2-62 2005 Buell Firebolt: Chassis...
Page 124: Frame
Install rear shock. See 2.22 REAR SHOCK ABSORBER. Install subframe tail assembly. See 2.36 SUBFRAME TAIL ASSEMBLY AND BODY WORK. Install exhaust header. See 2.28 EXHAUST SYSTEM. Rotate engine. See 3.3 ENGINE ROTATION FOR SER- VICE. 2005 Buell Firebolt: Chassis 2-63...
Page 125: Rear Shock Absorber
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 2-89. Rear Shock Absorber Assembly 2-64 2005 Buell Firebolt: Chassis...
Page 126 Tighten clamp on reservoir to 96-120 in-lbs Install seat. See 2.38 SEAT. (11-14 Nm). Figure 2-90. Install cable strap. NOTE Figure 2-89. Verify compression dial is facing up. Install upper body work. See 2.36 SUBFRAME TAIL ASSEMBLY AND BODY WORK. 2005 Buell Firebolt: Chassis 2-65...
Page 127: 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 4.45 AIRBOX. 2-66 2005 Buell Firebolt: Chassis...
Page 128: Clutch Control
Hand lever pinch fastener and nut engine. Clutch hand lever Clutch adjuster Remove cable strap securing clutch cable to voltage reg- Clutch cable adjuster boot ulator wire. Clutch cable ferrule Figure 2-96. Clutch Hand Control Assembly 2005 Buell Firebolt: Chassis 2-67...
Page 129 Figure 2-98. Clutch Release Mechanism 15. See Figure 2-98. Remove the outer ramp and hook (1) from the cable end (3) and coupling (2). Remove cable end from slot in coupling. See 6.3 CLUTCH RELEASE MECHANISM. 2-68 2005 Buell Firebolt: Chassis...
Page 130: Clutch Cable
Chain adjuster screw lever pinch screw to 48-60 in-lbs (5.4-6.8 Nm). Locknut Shift linkage assembly NOTE Figure 2-100. Installing Shift Linkage D.1 HOSE AND WIRE ROUTING in Appendix D. Route clutch cable through upper triple clamp. 2005 Buell Firebolt: Chassis 2-69...
Page 131 11. Install new clutch cover gasket. 12. See Figure 2-97. Install clutch inspection cover (4) with three TORX screws with washers. Tighten screws in a crosswise pattern to 84-108 in-lbs (9.5-12.2 Nm). 2-70 2005 Buell Firebolt: Chassis...
Page 132: Headlight Assembly And Support Bracket
Loosen headlamp pivot fasteners (1). Rotate headlight bracket (2) down. 8470 Figure 2-103. Disconnect headlight connection. Disconnect and remove electronic control module. See 4.30 ELECTRONIC CONTROL MODULE. Figure 2-104. Remove headlight support bracket (2). Figure 2-103. Headlight Connector 2005 Buell Firebolt: Chassis 2-71...
Page 133 Headlight pivot fasteners Headlight support bracket Electronic control module fasteners Black rubber cover Low beam headlight Headlight fastener High beam headlight Headlight bulb Bank angle sensor 10. Bank angle sensor fastener Figure 2-104. Headlight Support Bracket Assembly 2-72 2005 Buell Firebolt: Chassis...
Page 134 (2) and tighten pivot fasteners (1) to 72-96 in-lbs (8- 11 Nm). Figure 2-102. Install electric control module. Figure 2-104. Align electronic control module and headlight support bracket with fairing support bracket. Tighten electronic control module fasteners (3) to 72-96 in-lbs (8-11 Nm). 2005 Buell Firebolt: Chassis 2-73...
Page 135: Fairing Support Bracket
After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 10. Install seat. See 2.38 SEAT. 2-74 2005 Buell Firebolt: Chassis...
Page 136 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 2-106. Fairing Support Bracket Assembly 2005 Buell Firebolt: Chassis 2-75...
Page 137: Handlebars
Remove clip-on endcap (1). Figure 2-95. Position clutch hand lever to rider pref- erences and tighten fastener (1) to 36-60 in-lbs (4- 7 Nm). See 2.24 CLUTCH CONTROL. 8355 Figure 2-107. Handlebar Clip-on Mounting Fasteners (right clip-on shown) 2-76 2005 Buell Firebolt: Chassis...
Page 138 HOME b0945x2x Endcap Clip-on Upper fork clamp Clip-on fastener Figure 2-108. Handlebar Clip-on Assembly (left clip-on shown) 2005 Buell Firebolt: Chassis 2-77...
Page 139: Exhaust System
Remove exhaust header (2) by NOTE removing mounting fasteners (3). The mufﬂer may be removed for replacement without remov- Remove exhaust ring (4), retaining ring (5) and port gas- ing the exhaust header. ket (6). 2-78 2005 Buell Firebolt: Chassis...
Page 140 Front mufﬂer strap Front mufﬂer strap fastener Front mufﬂer mount Front mufﬂer mount fastener Front mufﬂer mount bushings Interactive exhaust cable 10. Rear mufﬂer bracket 11. Rear mufﬂer bracket fasteners (2) Figure 2-109. Mufﬂer Assembly 2005 Buell Firebolt: Chassis 2-79...
Page 141 Torca mufﬂer clamps have eliminated the need for silicone or graphite tape during assembly. To ensure sealing integrity of mufﬂer clamps and prevent the possibility of leakage, Buell recommends that mufﬂer clamp assemblies be discarded and replaced each time they are removed.
Page 142: Footpeg, Heel Guard And Mount
36-48 in-lbs (4-5 Nm). Figure 2-111. Position footpeg mount (1). b0934a2x Footpeg mount Spring Footpeg mount fasteners Wear peg Heel guard Footpeg Heel guard fasteners Clip, footpeg Figure 2-111. Rider Footpeg, Mount and Heel Guard Assembly 2005 Buell Firebolt: Chassis 2-81...
Page 143 Position footpeg mount (3) onto sub- frame tail assembly. Heel guard fasteners b0933x2x Heel guard Footpeg mount Spring Ball Detent plate Clip Footpeg 10. Footpeg mount fastener Figure 2-112. Passenger Footpeg, Mount and Heel Guard Assembly 2-82 2005 Buell Firebolt: Chassis...
Page 144: Sprocket Cover
36 in-lbs (1-4 Nm). Figure 2-113. Chin Fairing Assembly, Right Rear Fasteners Install chin fairing. See 2.33 CHIN FAIRING. b0943a2x Long fastener and washer Sprocket cover Short fastener and washer (2) Figure 2-114. Sprocket Cover 2005 Buell Firebolt: Chassis 2-83...
Page 145: Fenders
Install rear fender (3) with fasteners and washers (4), Tighten to 12-15 in-lbs (1-1.7 Nm). Front fender Install rear wheel. See 2.6 REAR WHEEL. Front fender fastener Rear fender Rear fender fastener Figure 2-115. Front and Rear Fender 2-84 2005 Buell Firebolt: Chassis...
Page 146: Belt Guards
ﬁrst. Removing swingarm brace without releasing Remove scissor jack from motorcycle. tension will cause swingarm brace damage. Remove swingarm brace by removing fasteners. See 2.19 SWINGARM AND BRACE. Remove upper belt guard (1) by removing fasteners from swingarm brace. 2005 Buell Firebolt: Chassis 2-85...
Page 147 HOME b1064a2x Upper belt guard Upper belt guard fasteners (3) Lower belt guard fasteners (3) Lower belt guard Sprocket cover Sprocket cover fasteners (2 short, 1 long) Figure 2-116. Belt Guard Assembly 2-86 2005 Buell Firebolt: Chassis...
Page 148: Chin Fairing
Turn wheel full right or left for easier access to center fas- Figure 2-117. Chin Fairing Assembly teners. Align center section (1) and install with center section fasteners and washers (2). Use LOCTITE 272 on all fas- teners tightening to 36-48 in-lbs (4-5 Nm). 2005 Buell Firebolt: Chassis 2-87...
Page 149: Intake Cover Assembly
After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) Install seat. See 2.38 SEAT. 2-88 2005 Buell Firebolt: Chassis...
Page 150: Air Scoops
Oil cooler air scoop fastener and washer (2) Ram air scoop Oil cooler air scoop Engine shroud scoop fastener and washer (3) Ram air scoop fastener and washer Engine shroud scoop Figure 2-119. Ram Air Scoop, Engine Shroud, Oil Cooler 2005 Buell Firebolt: Chassis 2-89...
Page 151: Subframe Tail Assembly And Body Work
Passenger seat lock plate 11. Trunk Passenger seat lock retainer 12. Fastener Passenger seat lock cable 13. License plate bracket Subframe tail assembly 14. Passenger seat latch and fastener Figure 2-120. Subframe Tail Assembly and Body Work Assembly 2-90 2005 Buell Firebolt: Chassis...
Page 152 15. See Figure 2-122. Cut cable strap (4) holding rear brake reservoir hose (5) and rear brake light wire (6). 16. Disconnect rear brake light connection (6). 2005 Buell Firebolt: Chassis 2-91...
Page 153 Because the surface is not bare polished aluminum, it must be cleaned using only mild soap and warm water. After wash- ing, always dry the surface using a clean, soft cloth. 2-92 2005 Buell Firebolt: Chassis...
Page 154 See 7.14 TURN SIGNALS 7.13 TAIL 23. Install seat and pillion. See 2.38 SEAT. LAMP. 20. Install passenger seat latch (14) from rear of subframe tail assembly and tighten to 60-96 in-lbs (7-11 Nm). 2005 Buell Firebolt: Chassis 2-93...
Page 155: Front Fairing, Windshield, And Mirrors
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 2-124. Front Fairing and Windscreen 2-94 2005 Buell Firebolt: Chassis...
Page 156: Seat
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. 2005 Buell Firebolt: Chassis 2-95...
Page 157: 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 SUB- FRAME TAIL ASSEMBLY AND BODY WORK. 13. Install rider and pillion seat. See 2.38 SEAT. 2-96 2005 Buell Firebolt: Chassis...
Page 158: Sidestand
Remove two fasteners from the left side of chin fairing. Remove sidestand leg (1). Retract sidestand leg. Remove sidestand spring (8) and spring extension plate (4) using SNAP-ON SPRING TOOL (Part No. HE-52B). Remove sidestand pivot bolt (5). Extend sidestand leg and remove. 2005 Buell Firebolt: Chassis 2-97...
Page 159 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. Figure 2-132. Lubricating Points (Shaded Areas) b1127x2x Figure 2-133. Threaded Area for Loctite Application 2-98 2005 Buell Firebolt: Chassis...
Page 160 ENGINE Table Of Contents SUBJECT PAGE NO. 3.1 Specifications ..........3.2 Engine .
Page 162: Specifications
59.1 mm 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 2005 Buell Firebolt: Engine...
Page 163 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 2005 Buell Firebolt: Engine...
Page 164 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 Flywheel endplay in crankcase .003-.010 in. 0.08-0.25 mm .010 in. 0.25 mm 2005 Buell Firebolt: Engine...
Page 165 50-70 in-lbs 6-8 Nm page 3-84 Oil pump cover screws 70-80 in-lbs 8-9 Nm TORX, page 3-83 Oil pump mounting screws 125-150 in-lbs 14-17 Nm Page 3-83 Pinion shaft nut 19-21 ft-lbs 26-29 Nm page 3-90 2005 Buell Firebolt: Engine...
Page 166 3-14 V bracket to main frame 120-144 in-lbs 13.6-16.3 Nm page 3-32 Vent oil line at gearcase cover 12-13 ft-lbs 16.3-17.6 Nm page 3-36 Vent oil line at oil reservoir 17-19 ft-lbs 23-25.8 Nm page 3-35 2005 Buell Firebolt: Engine...
Page 167: Engine
Gasoline/alcohol Blends When an engine needs repair, it is not always possible to The Buell Firebolt has been designed to obtain the best per- determine deﬁnitely beforehand whether repair is possible formance and efﬁciency using a good quality unleaded gaso- with only cylinder head, cylinder and piston disassembled or line.
Page 168: 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. 2005 Buell Firebolt: Engine...
Page 169: Engine Rotation For Service
10646 Fuel line connection Connection for throttle position sensor [88] Connections for fuel injectors [84 & 85] Figure 3-1. Fuel Line and DDFI Electrical Connections (Typical) 2005 Buell Firebolt: Engine...
Page 170 Oxygen sensor connection [137] Throttle cables Figure 3-2. Electrical Connections and Throttle Cables (Typical) 11. See Figure 3-2. Disconnect the ignition coil [83] (2) and remove. 12. Disconnect the following sensors: Temperature sensor (3) [90] Oxygen sensor (4) [137]. 2005 Buell Firebolt: Engine...
Page 171 16. Remove rear belt and idler pulley. See 1.10 DRIVE BELT 17. See Figure 3-3. Remove mufﬂer: 2.13 REAR BRAKE MASTER CYLINDER. Remove front mufﬂer strap. Remove rear mufﬂer straps. Loosen Torca clamp and remove mufﬂer. 3-10 2005 Buell Firebolt: Engine...
Page 172 Slide clutch cable adjuster boot (2) up to access Figure 3-5. Clutch Cable Wire Form Retainer and clutch adjuster. Adjuster Boot Loosen clutch adjuster to release tension from hand lever. Remove clutch cable ferrule from hand lever. 2005 Buell Firebolt: Engine 3-11...
Page 173 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 2005 Buell Firebolt: Engine...
Page 174 28. Rotate engine down. Rear isolator bolt Rear tie bar Figure 3-7. Rear Isolator Bolt and Rear Tie Bar 24. See Figure 3-7. Remove rear tie bar from frame only. 25. Loosen rear isolator bolt. DO NOT REMOVE. 2005 Buell Firebolt: Engine 3-13...
Page 175 120-144 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 2005 Buell Firebolt: Engine...
Page 176 H-D 20W50 engine oil. Wipe off any excess oil. Tighten return oil line to 19-21 ft-lbs (25.8-28.5 Nm) at oil cooler. 10501a Figure 3-12. Oil Cooler Feed and Return Oil Line 1/8-1/4 in. (3.175-6.35 mm) Clearance 2005 Buell Firebolt: Engine 3-15...
Page 177 Tighten torca clamp to 28-30 ft-lbs (38-40.6 Nm). 17. Tighten front mufﬂer mount to 22-25 ft-lbs (29.8-33.9 CAUTION Nm). When rear mufﬂer straps have been installed, it is impor- tant that strap fasteners do not contact idler pulley bracket. 3-16 2005 Buell Firebolt: Engine...
Page 178 Connect throttle cables from induction module/throttle body. 19. Connect the following sensors: Temperature sensor [90]. Oxygen sensor [137]. 20. See Figure 3-14. Install the ignition coil and connect [83] and tighten fasteners to 120-144 in-lbs (13.6-16.3 Nm). 2005 Buell Firebolt: Engine 3-17...
Page 179 While riding, a loose seat can 28. Install left side rider footrest and support plate and shift causing loss of control, which could result in death tighten fasteners to 120-144 in-lbs (13.56-16.27 Nm). or serious injury. (00070a) 3-18 2005 Buell Firebolt: Engine...
Page 180: Stripping Motorcycle For Engine Service
Disconnect fuel injector leads [84 & 85]. Drain oil tank. 10646 Fuel line connection Connection for throttle position sensor [88] Connections for fuel injectors [84 & 85] Figure 3-16. Fuel Line and DDFI Electrical Connections (Typical) 2005 Buell Firebolt: Engine 3-19...
Page 181 Figure 3-17. Electrical Connections and Throttle Cables (Typical) Figure 3-17. Disconnect the ignition coil (2) and remove. Disconnect the following sensors: Temperature sensor [90] (3). Oxygen sensor [137] (4). 10. Disconnect throttle cables from induction module/throttle body. 3-20 2005 Buell Firebolt: Engine...
Page 182 NOTE Loosen Torca clamp and remove mufﬂer. For details on removal of components on XB12R models with interactive exhaust system, see REMOVAL under INTERACTIVE EXHAUST SYSTEM(XB12 MODELS ONLY). Loosen front mufﬂer mount. 2005 Buell Firebolt: Engine 3-21...
Page 183 19. Remove left and right side rider footrests and support plates. See 2.29 FOOTPEG, HEEL GUARD AND MOUNT. NOTE When removing the right side rider footrest and support plate, also remove rear brake pedal assembly and remote reservoir and secure towards rear of vehicle. 3-22 2005 Buell Firebolt: Engine...
Page 184 Remove wire form retainer and lower retaining clamp. Pull clutch cable down. 21. See Figure 3-21. Remove sidestand assembly. b0946c2x Pivot bolt Spring extension plate Spring post Bracket Bracket fasteners (2) Figure 3-21. Sidestand Assembly (Extended) 2005 Buell Firebolt: Engine 3-23...
Page 185 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 3-22. Engine Mounting System 3-24 2005 Buell Firebolt: Engine...
Page 186 24. See Figure 3-22. Remove center tie-bar from engine. 8717a Neutral switch [131] Interactive exhaust cable Speedometer sensor connector [65] Voltage regulator connector [77] Alternator connector [46] Cam position sensor connector [14] Figure 3-23. Electrical Connectors 2005 Buell Firebolt: Engine 3-25...
Page 187 34. Lower engine with scissors lift all the way down. 8722 35. Move the engine assembly from under the main frame to the right side of the lift. 36. Remove engine. Figure 3-25. Rear Isolator Bolt and Swingarm Pivot Shaft 3-26 2005 Buell Firebolt: Engine...
Page 188 Figure 3-29. Swingarm pivot shaft pinch bolt Right Side threaded insert. Figure 3-30. Aluminum bushings from front exhaust mount. Figure 3-30. Front Exhaust Mount Bushings (2 piece) Timer cover. 8724 8729 Figure 3-29. Removing Threaded Insert 2005 Buell Firebolt: Engine 3-27...
Page 189 40. 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 2005 Buell Firebolt: Engine...
Page 190: Engine Installation
Figure 3-35. Center tie bar mount 25-27 ft-lbs Figure 3-37. Front Exhaust Mount Bushings (2 piece) (33.9-36.6 Nm). Figure 3-36. Swingarm pivot shaft pinch bolt threaded insert. Figure 3-37. Aluminum bushings from front exhaust mount. 2005 Buell Firebolt: Engine 3-29...
Page 191 Inspect vent line Figure 3-42. Using the overhead hoist to align the to verify space between vent line and rear exhaust. frame to the rear isolator, install rear isolator bolt and leave loose at this time. 3-30 2005 Buell Firebolt: Engine...
Page 192 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 3-43. Engine Mounting System 2005 Buell Firebolt: Engine 3-31...
Page 193 120-144 in-lbs (13.6-16.3 Nm). Install front tie-bar to “V” bracket and tighten to 25- 27 ft-lbs (33.9-36.6 Nm). Attach regulator wiring harness to bracket nylon cable straps. 18. Remove scissors jack. 3-32 2005 Buell Firebolt: Engine...
Page 194 At this point it will be necessary to install the oil lines. It is important to follow this procedure to ensure correct orientation of oil lines in order to establish the proper clearances needed between the oil lines and varied com- ponents on the vehicle. 2005 Buell Firebolt: Engine 3-33...
Page 195 Feed oil line from oil pump to oil cooler Feed oil line from oil cooler to crankcase Oil tank drain plug Oil Filter Front mufﬂer mount 10. Rear mufﬂer bracket 11. Oil cooler 12. Cable, interactive exhaust Figure 3-47. Oil Lines and Connections 3-34 2005 Buell Firebolt: Engine...
Page 196 ﬁrst. 24. Arrange the vent line and the feed line so that the dis- tance between is within speciﬁcations (3).Torque the vent oil line to 17-19 ft-lbs (23-25.8 Nm). 2005 Buell Firebolt: Engine 3-35...
Page 197 22-24 ft-lbs (29.8-32.5 Nm). When the oil line has been with the feed and return lines after torquing. properly torqued, the orientation of the line should also be approximately 7 o’clock. 3-36 2005 Buell Firebolt: Engine...
Page 198 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. 2005 Buell Firebolt: Engine 3-37...
Page 199 1/4 (3.175-6.35 mm) clearance speciﬁed between the feed oil line and the clutch cable at the front of the crankcase. 30. Verify that the clutch cable and feed line have 1/8-1/4 in. (3.175-6.35 mm) clearance. 3-38 2005 Buell Firebolt: Engine...
Page 200 Figure 3-52. Oil Cooler Oil Lines b1031x3x Oil cooler feed line should be centered after line is torqued. Orientation of return line should be approximately 6 o’clock Figure 3-53. Oil Cooler Feed and Return Oil Lines Location and Orientation 2005 Buell Firebolt: Engine 3-39...
Page 201 Connect the following electrical compo- nents: Neutral switch [131]. Speedometer sensor [65] (install cable strap). Cam position sensor [14]. Alternator [46]. Voltage regulator [77]. Positive battery cable at starter. Starter solenoid [128]. Oil pressure switch [120]. 3-40 2005 Buell Firebolt: Engine...
Page 202 Pull clutch cable back up into the proper position. Connect clutch cable to handlebars and adjust to speciﬁcations. Install retaining clamps. Figure 3-55. Correct Routing of Wiring Harnesses 10502 Figure 3-56. Clutch Cable Wire Form Retainer 2005 Buell Firebolt: Engine 3-41...
Page 203 Tighten Torca clamp to 28-30 ft-lbs (38-40.6 Nm). When rear mufﬂer straps have been installed, it is impor- tant that strap fasteners do not contact idler pulley Tighten front mufﬂer mount to 22-25 ft-lbs (29.8-33.9 bracket. Nm). 3-42 2005 Buell Firebolt: Engine...
Page 204 Temperature sensor [90] (3). Oxygen sensor [137] (Install cable strap on harness) (4). 38. Install the ignition coil (1) and spark plug wires and con- nect [83] (2). Tighten ignition coil fasteners to 120-144 in-lbs (13.6-16.3 Nm). 2005 Buell Firebolt: Engine 3-43...
Page 205 While riding, a loose seat can 47. Install left and right side rider footrests and support shift causing loss of control, which could result in death plates and torque to 108-132 in-lbs (12.20-14.91 Nm). or serious injury. (00070a) 3-44 2005 Buell Firebolt: Engine...
Page 206: 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 3-60. Rocker Arm and Pushrod Cover Assemblies 2005 Buell Firebolt: Engine 3-45...
Page 207 Remove rocker arms and mark them for reassembly in their original locations. 10. Mark the location and orientation (top/bottom) of each push rod. Remove push rods. Figure 3-62. Removing Rocker Arm Shafts 3-46 2005 Buell Firebolt: Engine...
Page 208 No special tools are required to remove valve stem seal and lower collar assembly. Repeat the above procedure for the other valves. Figure 3-63. Head Screw Loosening/Tightening Sequence 8684 Figure 3-64. Valve Spring Compressor (Part No. HD-34736B) 2005 Buell Firebolt: Engine 3-47...
Page 209 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 3-65. Cylinder Head, Cylinder and Piston Assembly 3-48 2005 Buell Firebolt: Engine...
Page 210 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. 2005 Buell Firebolt: Engine 3-49...
Page 211 Figure 3-68. 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 2005 Buell Firebolt: Engine...
Page 212: 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. 2005 Buell Firebolt: Engine 3-51...
Page 213 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 3-73. Replacing Rocker Arm Bushings 3-52 2005 Buell Firebolt: Engine...
Page 214 60°. Figure 3-75. Cleaning Valve Guides Figure 3-75. Thoroughly clean valve guide bores using VALVE GUIDE BRUSH (Part No. HD-34751) and hot soapy water. 2005 Buell Firebolt: Engine 3-53...
Page 215 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 2005 Buell Firebolt: Engine...
Page 216 0.062 in. (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 3-77. Valve and Seat Dimensions 2005 Buell Firebolt: Engine 3-55...
Page 217 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 3-78. Cylinder Head, Cylinder and Piston Assembly 3-56 2005 Buell Firebolt: Engine...
Page 218 (seal and lower collar replaced as assembly only) collar assembly will result in damage to the seal causing leakage around the valve stem, excessive oil consump- tion and valve sticking. 2005 Buell Firebolt: Engine 3-57...
Page 219 10. Insert valve keepers into upper collar, making sure they engage grooves in valve stem. 11. Release and remove from VALVE SPRING COMPRES- SOR. 12. Repeat steps 4-11 for the remaining valve. 3-58 2005 Buell Firebolt: Engine...
Page 220 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. 2005 Buell Firebolt: Engine 3-59...
Page 221 Tighten each screw to 96-120 in-lbs (11-14 Nm). Tighten each screw to 13-15 ft-lbs (18-20 Nm). Figure 3-86. Mark cylinder head and head screw shoulder with a line as shown (View A). ° ° Turn all bolts an additional 85 -95 . 3-60 2005 Buell Firebolt: Engine...
Page 222 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 3-87. Rocker Arm and Pushrod Cover Assemblies 2005 Buell Firebolt: Engine 3-61...
Page 223 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 120-168 in- lbs (13.6-19.0 Nm). 3-62 2005 Buell Firebolt: Engine...
Page 224: Cylinder And Piston
Ring set reinstalled resulting in engine damage. Piston Piston pin Retaining ring (2) Dowel and o-ring Cylinder Base gasket Cylinder stud (4) Connecting rod 10. Piston pin bushing Figure 3-89. Cylinder and Piston 2005 Buell Firebolt: Engine 3-63...
Page 225 In the event that the circlip should ﬂy out, hold a shop towel over the bore during removal. Figure 3-92. To remove piston rings spread outward Remove circlip from claw and discard. until they clear grooves in piston and lift off. 3-64 2005 Buell Firebolt: Engine...
Page 226 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. 2005 Buell Firebolt: Engine 3-65...
Page 227: Deglazing Cylinder
If piston clearance exceeds service wear limit, cylinders and pistons should be replaced with new components. See With the cylinder at room temperature, check the piston SPECIFICATIONS. clearance in the cylinder in which the piston will run. See SPECIFICATIONS. 3-66 2005 Buell Firebolt: Engine...
Page 228 No. 240 grit ﬂexible hone to facilitate ring seating. Piston ring sets must be properly ﬁtted to piston and cyl- inder: Ring sets are available to ﬁt standard and oversize pistons. 2005 Buell Firebolt: Engine 3-67...
Page 229 Figure 3-98. Ring End Gap Position Figure 3-98. 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 2005 Buell Firebolt: Engine...
Page 230 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. 2005 Buell Firebolt: Engine 3-69...
Page 231 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 2005 Buell Firebolt: Engine...
Page 232 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. 2005 Buell Firebolt: Engine 3-71...
Page 233 HOME NOTES 3-72 2005 Buell Firebolt: Engine...
Page 234: Lubrication System
A vehicle used only for short runs in cold 1.6 ENGINE LUBRICATION SYSTEM for more informa- weather must have the engine oil drained frequently. tion on checking oil level and changing oil and ﬁlter. 2005 Buell Firebolt: Engine 3-73...
Page 235: Oil Hose Routing And Oil Reservoir
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 12. Interactive exhaust cable Figure 3-110. Oil Lines and Connections 3-74 2005 Buell Firebolt: Engine...
Page 236: Oil Cooler
Loosen oil cooler return line (2) at oil cooler. Do not dis- connect. Loosen oil cooler feed line (1) at oil cooler. Do not dis- connect. Remove two fasteners (10) securing the oil cooler scoop (9) and remove scoop. 2005 Buell Firebolt: Engine 3-75...
Page 237 ﬁtting on the oil cooler Clutch cable Return oil line 1/8-1/4 in. (3.175-6.35 mm) clearance Oil line clamp Feed oil line Figure 3-112. Oil Cooler Oil Lines and Clamp 3-76 2005 Buell Firebolt: Engine...
Page 238: Oil Pressure Indicator Switch
50 MPH (80 KM/H) until engine oil reaches normal operating 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). 2005 Buell Firebolt: Engine 3-77...
Page 239: Crankcase Breathing System
8661 Base plate, air box Breather hose, rear Breather hose, front PCV Valves (2) Figure 3-114. Reed Valve Assembly in Gearcase Grommet Rocker cover (2) Figure 3-115. Crankcase Breathing System, 3-78 2005 Buell Firebolt: Engine...
Page 240 Fasteners should be tightened to 30-40 in-lbs (3.4-4.5 Nm). b1033x3x Reed valve stop Reed valve Reed block Figure 3-116. Reed Valve Assembly 8759 8794 Reed valve stop Reed valve Stop screw Figure 3-117. Reed Valve Stop and Reed Valve 2005 Buell Firebolt: Engine 3-79...
Page 241: 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. 3-80 2005 Buell Firebolt: Engine...
Page 242: 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 2005 Buell Firebolt: Engine 3-81...
Page 243 Feed line connection Cover TORX screw (2) Return line Oil pump Mounting screw and washer (2) Steel line connection to oil cooler Connection from oil cooler to oil ﬁlter housing Figure 3-119. Oil Pump Hardware 3-82 2005 Buell Firebolt: Engine...
Page 244 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. 1.6 ENGINE LUBRICATION SYSTEM. 2005 Buell Firebolt: Engine 3-83...
Page 245: Oil Filter Mount
Apply several drops of LOCTITE thread locker 243 (blue) to last few threads on that end of the ﬁlter adapter which is installed into ﬁlter mount. Do not apply LOCTITE to adapter threads on ﬁlter element side. 3-84 2005 Buell Firebolt: Engine...
Page 246: Hydraulic Lifters
Figure 3-123. Lifter Assembly (Typical) 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. 2005 Buell Firebolt: Engine 3-85...
Page 247 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. 3-86 2005 Buell Firebolt: Engine...
Page 248: 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 2005 Buell Firebolt: Engine 3-87...
Page 249 8662a Front exhaust cam gear Front intake cam gear Rear intake cam gear Rear exhaust cam gear Pinion gear Pinion nut Timing V marks Figure 3-127. Cam and Pinion Gear Location and Timing Mark Indexing 3-88 2005 Buell Firebolt: Engine...
Page 250 Prior to changing any cam gears, check gear shaft ﬁt within corresponding bushings. Worn bushings can cause excessive backlash. b0952x1x Figure 3-128. Cam Identiﬁcation Stamp Table 3-25. Cam Location Numbers STAMP LOCATION Front exhaust Front intake Rear intake Rear exhaust 2005 Buell Firebolt: Engine 3-89...
Page 251 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) 3-90 2005 Buell Firebolt: Engine...
Page 252 Install cam position sensor and rotor in gearcase cover. 8654 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 2005 Buell Firebolt: Engine 3-91...
Page 253: Crankcase
Remove oil pump. See 3.14 OIL PUMP. Remove gearcase components. See 3.17 GEARCASE COVER AND CAM GEARS. Remove primary cover and primary drive/clutch compo- nents. See 6.2 PRIMARY COVER. Remove starter motor. See 5.7 STARTER. 3-92 2005 Buell Firebolt: Engine...
Page 254 (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. 2005 Buell Firebolt: Engine 3-93...
Page 255 11. Inner race Thrust washer 12. Gear shaft bearing Crankcase half 13. Retaining ring Bearing 14. Outer bearing race Bearing retaining ring 15. Crankshaft case Inner race, sprocket shaft bearing Figure 3-137. Crankcase and Flywheel Assembly 3-94 2005 Buell Firebolt: Engine...
Page 256 Remove sprocket shaft oil seal retain- ing ring. Figure 3-137. Remove sprocket shaft oil seal 3) from crankcase using Snap-On Tool (Part No. CJ 114, Body Dent Puller) Remove outer thrust washer (4) next to sprocket shaft bearing (6). 2005 Buell Firebolt: Engine 3-95...
Page 257 1.2496-1.2498 in. Green (31.7398-31.7449 mm) (ID) of the outer race (crankcase bushing). A running clear- ance of 0.0002-0.0008 in. (0.0051-0.0203 mm) is established during crankcase set or ﬂywheel assembly replacement and engine rebuild. 3-96 2005 Buell Firebolt: Engine...
Page 258 That is, a replacement crankcase set may have a class 1, 2 or 3 pinion bearing outer race. Replacement ﬂywheel assemblies will have either a class A or B inner race. 2005 Buell Firebolt: Engine 3-97...
Page 259 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 3-98 2005 Buell Firebolt: Engine...
Page 260 The new outer race must be lapped slightly to true and align with left case bearing and to meet the following speciﬁcations in Table 3-33. LAPPING PINION SHAFT BEARING OUTER RACE. 2005 Buell Firebolt: Engine 3-99...
Page 261 Table 3-34. Pinion Inner Race 1.2499 in. (31.747 mm) OD inner race, a blue bear- Speciﬁcations ing is required. Roundness within 0.0002 in. (0.0051 mm) Taper within 0.0002 in. (0.0051 mm) Surface ﬁnish 16 RMS 3-100 2005 Buell Firebolt: Engine...
Page 262 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 3-149. Checking Connecting Rod Side Play 2005 Buell Firebolt: Engine 3-101...
Page 263 LATION. Figure 3-151. Using CRANKCASE BEARING REMOVER/INSTALLER (Part No. B-45655, HD-42720-2 b1046a3x Spacer, sprocket shaft Retaining ring, oil seal Oil seal Thrust washer Crankcase half Bearing Bearing retaining ring Figure 3-150. Sprocket Shaft Bearing Assembly 3-102 2005 Buell Firebolt: Engine...
Page 264 Figure 3-152. Installing Flywheel Assembly with CRANKSHAFT GUIDE (Part No. HD-42326) 8789 a0120x3x Figure 3-153. Pinion Shaft Bearing 8762 Shoulder Crankcase bearing remover/installer tool (Part No. B-45655, HD-42720-2 and HD-46663) Retaining ring Figure 3-151. Sprocket Shaft Bearing Installation 2005 Buell Firebolt: Engine 3-103...
Page 265 #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. 3-104 2005 Buell Firebolt: Engine...
Page 266 Be sure to reﬁll transmission to proper level with fresh lubri- cant. See 1.11 PRIMARY CHAIN. 20. See 3.6 CYLINDER HEAD and perform the applicable steps. 21. To reinstall engine in frame see 3.5 ENGINE INSTALLA- TION. 2005 Buell Firebolt: Engine 3-105...
Page 267 HOME NOTES 3-106 2005 Buell Firebolt: Engine...
Page 268 Table Of Contents FUEL SYSTEM SUBJECT PAGE NO. 4.1 Specifications ..........4.2 Dynamic Digital Fuel Injection .
Page 269 4.38 Cooling Fan ..........4-106 4.39 Fuel Pump/Early Model Year .
Page 270: Fuel System
9.5-12.2 Nm page 4-112 Fuel supply line banjo ﬁtting 84-108 in-lbs 9.5-12.2 Nm page 4-120 Fuel tank vent valve fasten- 39-41 in-lbs 4.4-4.6 Nm page 4-121 Ignition coil mounting 120-144 in-lbs 13.6-16.3 Nm page 4-100 screws 2005 Buell Firebolt: Fuel System...
Page 271 4-135 voir clamp rear Throttle position sensor 13-23 in-lbs 1.5-2.6 Nm LOCTITE THREADLOCKER 222 (purple), page 4-105 Timer plate studs 15-30 in-lbs 2-3 Nm page 4-98 Upper tie bar 25-27 ft-lbs 33.9-36.6 Nm page 4-102 2005 Buell Firebolt: Fuel System...
Page 272: Dynamic Digital Fuel Injection
DYNAMIC DIGITAL FUEL INJECTION (DDFI) INTRODUCTION GENERAL The Buell DDFI operates both as an open and closed loop The Buell Dynamic Digital Fuel Injection (DDFI) System pro- system which allows it to adjust for all possible operating con- vides microprocessor-based electronic engine management ditions.
Page 273 BE/O IGN Coil Throttle To cooling Position Cooling BK/O fan fuse Sensor BK/W BE/O TN/V BK/W LT GN/Y Sensor [165] Ground Interactive mufﬂer control To Brake/horn/ mufﬂer fuse Figure 4-1. Buell Dynamic Digital Fuel Injection 2005 Buell Firebolt: Fuel System...
Page 274: 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. 2005 Buell Firebolt: Fuel System...
Page 275: 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 4-5. Check Engine Lamp Operation 2005 Buell Firebolt: Fuel System...
Page 276 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. 2005 Buell Firebolt: Fuel System...
Page 277: 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. 2005 Buell Firebolt: Fuel System...
Page 278 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- tion. Let it run for at least 30 seconds. Turn the engine off. 2005 Buell Firebolt: Fuel System...
Page 279: 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 4.30 ELECTRONIC CONTROL MOD- ULE. Figure 4-10. Installed Breakout Box 4-10 2005 Buell Firebolt: Fuel System...
Page 280: 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. 2005 Buell Firebolt: Fuel System 4-11...
Page 281: General Information
Starts hard. See Table 4-4. ADJUSTMENT. Hesitates, stumbles, surges, misﬁres and/or slug- EVAP hose disconnected Connect. gish performance. See Table 4-5. from induction module Engine exhaust emits black smoke or fouls plugs. (CA) Table 4-6. 4-12 2005 Buell Firebolt: Fuel System...
Page 282 Cooling fan 4.26 TROUBLE CODE 36 Bank angle sensor 4.27 TROUBLE CODE 44 52, 53, 54, 55 ECM failure 4.28 TROUBLE CODES 52, 53, 54 AND 55 Cam sync failure 4.29 TROUBLE CODE 56 2005 Buell Firebolt: Fuel System 4-13...
Page 283 Table 4-8. Wire Harness Connectors in Figure 4-12. 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 2005 Buell Firebolt: Fuel System...
Page 284 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 4-7. tips in related trouble code chart (even if no code is set). 2005 Buell Firebolt: Fuel System 4-15...
Page 285 DATA LINK TERMINAL 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. 4.30 ELECTRONIC CONTROL MODULE. 4-16 2005 Buell Firebolt: Fuel System...
Page 286: Check Engine Lamp Not Illuminated At Key On 4.9
If connection is good, replace ECM. See 4.30 ELECTRONIC CONTROL MODULE. Check continuity between instrument connector [39] Pin 7 and ECM connector [10] (black), Pin 4. Headlights Figure 4-14. Electronic Control Module 2005 Buell Firebolt: Fuel System 4-17...
Page 287 Electronic Control Module (ECM) Figure 4-15. Check Engine Lamp Circuit Table 4-9. Wire Harness Connectors in Figure 4-15. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing [39] instrument module 20-place Multilock in fairing 4-18 2005 Buell Firebolt: Fuel System...
Page 288 Check engine lamp ON? 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]. 2005 Buell Firebolt: Fuel System 4-19...
Page 289: Check Engine Lamp On Continuously
Test 4.10 ﬂow chart. Figure 4-17. 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 4-17. Electronic Control Module 4-20 2005 Buell Firebolt: Fuel System...
Page 290 Electronic Control Module (ECM) Figure 4-18. Check Engine Lamp Circuit Table 4-10. Wire Harness Connectors in Figure 4-18 DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing [39] instrument module 20-place Multilock in fairing 2005 Buell Firebolt: Fuel System 4-21...
Page 291 OK. Check for 4.30 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]. TROUBLE CODES. 4-22 2005 Buell Firebolt: Fuel System...
Page 292: Engine Cranks But Will Not Start
Gasoline is extremely ﬂammable and highly explosive, which could result in death or serious injury. (00275a) Purge fuel line of high pressure gasoline. See 4.39 FUEL PUMP/EARLY MODEL YEAR. 2005 Buell Firebolt: Fuel System 4-23...
Page 293 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 4-24 2005 Buell Firebolt: Fuel System...
Page 294 [85] [84] [85A] [14A] [84A] To Ignition Relay A B C [84B] [85B] [14B] Dyno Loop To Interactive muffler control XB12 Models Connector [11] Connector [10] Electronic Control Module (ECM) Figure 4-21. Ignition Circuit 2005 Buell Firebolt: Fuel System 4-25...
Page 295 49-51 PSI (338-352 kPa). Adequate pressure? STOP Go to Test 4.11 Incorrect pressure. See 4.13 (Part 2 of 3). FUEL PRESSURE TEST. 4-26 2005 Buell Firebolt: Fuel System...
Page 296 Go to Test 4.11 (Part 3 of 3). Check for continuity between Ter- minal A connector [14B] and ground. Continuity present? Repair open circuit. Repair short Replace ECM. See to ground. 4.30 ELECTRONIC CONTROL MODULE. 2005 Buell Firebolt: Fuel System 4-27...
Page 297 Replace cam Replace cam position Mechanical failure. position sensor. See 4.31 sensor. See 4.31 Inspect for loose CAM POSITION SENSOR CAM POSITION SEN- rotor cup and ROTOR. SOR AND ROTOR. sheared pinion gear key. 4-28 2005 Buell Firebolt: Fuel System...
Page 298: No Ecm Power
ECM does not appear to be receiving power, check the bers on the Test 4.12 ﬂow chart. ground sources. A blown ignition fuse can also disable the Connect BREAKOUT BOX (Part No. HD-42682) to ECM. ECM. 4.6 BREAKOUT BOX. 2005 Buell Firebolt: Fuel System 4-29...
Page 299 Table 4-12. Wire Harness Connectors in Figure 4-22. 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 4-30 2005 Buell Firebolt: Fuel System...
Page 300 Check for 12 volts wire between connector on right handlebar con- [22] and ignition relay. nector [22A] W/BK wire. Voltage present? Repair open on W/BK Replace handlebar wire between connector switch assembly. [22] and ignition relay. 2005 Buell Firebolt: Fuel System 4-31...
Page 301: Fuel Pressure Test
Connect the fuel line (3) to fuel pressure gauge adapter. NOTE Figure 4-26. 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). 4-32 2005 Buell Firebolt: Fuel System...
Page 302 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 4-26. Fuel Pressure Gauge (Part No. HD-41182) 2005 Buell Firebolt: Fuel System 4-33...
Page 303 Table 4-13. Wire Harness Connectors in Figure 4-27. 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 4-34 2005 Buell Firebolt: Fuel System...
Page 304 Measure voltage relay and fuel pump. during first two seconds after key ON. Is voltage greater than 1 VDC? Locate and repair poor Replace ignition relay. connection between bat- tery and ignition relay. 2005 Buell Firebolt: Fuel System 4-35...
Page 305 [10] (black) Termi- nal 3. Is continuity present? Replace fuel pump Repair fuel pump assembly. See 4.39 wiring. FUEL PUMP/EARLY MODEL YEAR. Replace ECM. See 4.30 Locate and repair open ELECTRONIC CONTROL on BN/Y wire. MODULE. 4-36 2005 Buell Firebolt: Fuel System...
Page 306: 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. 2005 Buell Firebolt: Fuel System 4-37...
Page 307: Misfire
7.4 SPARK PLUG CABLES. Using an ohmmeter, touch probes to terminals on each end plug wire. Compare resistance values to Table 4-15. Replace cables not meeting speciﬁcations. Reinstall and repeat procedure on other spark plug cable. 4-38 2005 Buell Firebolt: Fuel System...
Page 308 Table 4-16. Wire Harness Connectors in Figure 4-30. 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 2005 Buell Firebolt: Fuel System 4-39...
Page 309 Switch coil with unit Replace known to be good. ignition coil. Perform spark test. Did spark jump gap during engine cranking? Original ignition coil Go to Test 4.15 is faulty. Replace. STOP (Part 2 of 2). 4-40 2005 Buell Firebolt: Fuel System...
Page 310 Replace cam position sensor. 4.31 CAM POSITION Replace cam position Mechanical failure. SENSOR AND ROTOR. sensor. See 4.31 Inspect for loose CAM POSITION SEN- rotor cup and SOR AND ROTOR. sheared pinion gear key. 2005 Buell Firebolt: Fuel System 4-41...
Page 311 HOME NOTES 4-42 2005 Buell Firebolt: Fuel System...
Page 312: Trouble Code 11
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. 2005 Buell Firebolt: Fuel System 4-43...
Page 313 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 4-44 2005 Buell Firebolt: Fuel System...
Page 314 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2005 Buell Firebolt: Fuel System 4-45...
Page 315 [14]. Measure resistance Replace BAS. between connector [88] Terminal A and Terminal C. Is resistance greater than 1 megaohm? Locate and repair short between R/W and BK/W Replace cam position wires. Reconnect [14]. sensor. 4-46 2005 Buell Firebolt: Fuel System...
Page 316: Trouble Code 13
If fresh air enters exhaust system, the oxygen sensor 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. 2005 Buell Firebolt: Fuel System 4-47...
Page 317 Electronic Control Module (ECM) Figure 4-36. Oxygen Sensor Circuit Table 4-18. Wire Harness Connectors in Figure 4-36. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch in fairing [137] oxygen sensor 1-place Packard behind rear cylinder head 4-48 2005 Buell Firebolt: Fuel System...
Page 318 4.30 ELECTRONIC 4.30 ELECTRONIC voltage and repair. V/GY wire. CONTROL MODULE. CONTROL MODULE. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2005 Buell Firebolt: Fuel System 4-49...
Page 319 Repair. Fuel injectors may be dirty. See Fuel Injectors under 4.43 THROTTLE BODY. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-50 2005 Buell Firebolt: Fuel System...
Page 320 ECM (4.30 now OK. ELECTRONIC CONTROL MODULE). Road test again to verify. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2005 Buell Firebolt: Fuel System 4-51...
Page 321: Trouble Code 14
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. 4-52 2005 Buell Firebolt: Fuel System...
Page 322 (ECM) Figure 4-37. Engine Temperature Sensor Circuit Table 4-20. Wire Harness Connectors in Figure 4-37. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch in fairing [90] engine temperature sensor 1-place bullet beneath airbox base 2005 Buell Firebolt: Fuel System 4-53...
Page 323 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. 4-54 2005 Buell Firebolt: Fuel System...
Page 324 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2005 Buell Firebolt: Fuel System 4-55...
Page 325: Trouble Code 15
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. 4-56 2005 Buell Firebolt: Fuel System...
Page 326 Figure 4-38. Intake Air Temperature Sensor Circuit Table 4-22. Wire Harness Connectors in Figure 4-38. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch in fairing [89] intake air temperature sensor 2-place Amp in airbox base 2005 Buell Firebolt: Fuel System 4-57...
Page 327 12 volts normal progression through the chart brings you to and repair. this location. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-58 2005 Buell Firebolt: Fuel System...
Page 328 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2005 Buell Firebolt: Fuel System 4-59...
Page 329: Trouble Code 16
Figure 4-40. Fuse Block bd0016ax Empty Spare Spare Diode Empty Bk/Hn/Mflr Lights Key Sw Acces. Figure 4-41. Fuses and Diode 4-60 2005 Buell Firebolt: Fuel System...
Page 330 Connector [10] Connector [11] Electronic Control Module (ECM) Figure 4-42. Battery Voltage Circuit Table 4-23. Wire Harness Connectors in Figure 4-42. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing 2005 Buell Firebolt: Fuel System 4-61...
Page 331 Replace ignition relay. STOP 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). 4-62 2005 Buell Firebolt: Fuel System...
Page 332 Is voltage drop greater than 0.5 volt? Replace R/Y wire between main fuse and Replace main fuse. battery. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2005 Buell Firebolt: Fuel System 4-63...
Page 333: Trouble Code 21
Using TEST CONNECTOR KIT (Part No. HD-41404), Figure 4-43. Fuses and Diode attach red probe and patch cord to [164B] (1, 2). Using TEST CONNECTOR KIT (Part No. HD-41404), use gray male pin probe and patch cord. 4-64 2005 Buell Firebolt: Fuel System...
Page 334 Table 4-24. Wire Harness Connectors in Figure 4-44. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [161] Interactive mufﬂer actuator 4-place Deutsch under air cleaner [164] 1-place Amp under seat [165] sub-harness 3-place Packard beneath airbox base 2005 Buell Firebolt: Fuel System 4-65...
Page 335 [161B] pin 4. binding? Replace inter- active muffler 4-6 v actuator. Replace ECM Replace inter- Locate and repair Replace inter- Replace muffler active motor. short to voltage on active muffler assembly TN/Y wire. cable. 4-66 2005 Buell Firebolt: Fuel System...
Page 336: Trouble Codes 23 And 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23 Trouble Codes 24 And
Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), purple pin probes and patch cord. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Use FUEL INJECTOR TEST LAMP (Part No. HD-34730- 2C). 2005 Buell Firebolt: Fuel System 4-67...
Page 337 [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 4-68 2005 Buell Firebolt: Fuel System...
Page 338 Replace ECM. See 4.30 Perform 4.7 WIGGLE TEST. ELECTRONIC CONTROL Repair as necessary. MODULE. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2005 Buell Firebolt: Fuel System 4-69...
Page 339 WIGGLE TEST to locate open wire. intermittents. Repair as necessary. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-70 2005 Buell Firebolt: Fuel System...
Page 340 24 or 25. This condition is normal and does not by itself indicate a malfunction. Codes must be cleared if his condition occurs. Figure 4-49. Testing Ignition Coil Connectors 2005 Buell Firebolt: Fuel System 4-71...
Page 341 (ECM) [10A] [11A] Figure 4-50. Ignition Coil Circuit Table 4-26. Wire Harness Connectors in Figure 4-50. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under fairing [83] ignition coil 3-place Packard beneath airbox base 4-72 2005 Buell Firebolt: Fuel System...
Page 342 Repair as Replace ECM. See necessary. 4.30 ELECTRONIC CONTROL MODULE. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2005 Buell Firebolt: Fuel System 4-73...
Page 343: Trouble Code 33
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. 4-74 2005 Buell Firebolt: Fuel System...
Page 344 Table 4-27. Wire Harness Connectors in Figure 4-52. 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 2005 Buell Firebolt: Fuel System 4-75...
Page 345 Terminal 87 to Pin D of [86]. Continuity present? Repair open. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-76 2005 Buell Firebolt: Fuel System...
Page 346: Trouble Code 35
Code 35 ﬂow chart. Breakout box Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Figure 4-53. Installed Breakout Box Replace instrument module. See 7.18 INSTRUMENT MODULE. 8426 Figure 4-54. Instrument Module Connector [39] 2005 Buell Firebolt: Fuel System 4-77...
Page 347 Connector [11] Electronic Control Module (ECM) Figure 4-55. Tachometer Circuit Table 4-28. Wire Harness Connectors in Figure 4-55. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing [39] instrument module 20-place Multilock in fairing 4-78 2005 Buell Firebolt: Fuel System...
Page 348 TEST. Intermit- TROL MODULE. tents found? 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. 7.18 INSTRUMENT MODULE 2005 Buell Firebolt: Fuel System 4-79...
Page 349: Trouble Code 36
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. 4-80 2005 Buell Firebolt: Fuel System...
Page 350 Electronic Control Module (ECM) Figure 4-57. Cooling Fan Circuit Table 4-30. Wire Harness Connectors in Figure 4-57. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch in fairing [97] cooling fan 2-place Multilock behind rear cylinder 2005 Buell Firebolt: Fuel System 4-81...
Page 351 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. 4-82 2005 Buell Firebolt: Fuel System...
Page 352 Place a jumper wire between fan Y/BN wire and battery positive. Place a System ok. jumper between fan BK Replace fan. wire and ground. Does fan run at full speed? System ok. Replace fan. 2005 Buell Firebolt: Fuel System 4-83...
Page 353: Trouble Code 44
41404), gray pin probes and patch cord. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Bank angle sensor Headlights Figure 4-59. Bank Angle Sensor Table 4-31. Bank Angle Sensor Voltage MODE VOLTS 0.25-2.7 Disable 2.8-4.8 4-84 2005 Buell Firebolt: Fuel System...
Page 354 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 2005 Buell Firebolt: Fuel System 4-85...
Page 355 Are ferrous metals located within Install properly. See 4.35 BANK 0.25 in. (6.4 mm) of sides, face or ANGLE SENSOR. top of bank angle sensor? Replace bank angle sensor. See 4.35 Return to original BANK ANGLE SENSOR. configuration. 4-86 2005 Buell Firebolt: Fuel System...
Page 356 Repair short to ground Replace ECM. See on Lt GN/GY wire. 4.30 ELECTRONIC CONTROL MODULE. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2005 Buell Firebolt: Fuel System 4-87...
Page 357: Trouble Codes 52, 53, 54 And 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29 Trouble Code 56
All of the following codes indicate a failure which requires replacement of the ECM. See 4.30 ELECTRONIC CONTROL MODULE. Code 52 - RAM failure. Code 53 - ROM failure. Code 54 - EE PROM failure. Code 55 - Microprocessor failure. 4-88 2005 Buell Firebolt: Fuel System...
Page 358 Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), black pin probes and patch cord. Timer plate stud (2) 4.31 CAM POSITION SENSOR AND ROTOR. Sensor wiring Cam position sensor b0313a7x Figure 4-61. Cam Position Sensor 2005 Buell Firebolt: Fuel System 4-89...
Page 359 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 4-90 2005 Buell Firebolt: Fuel System...
Page 360 [11] and connectors [11] and to ground. to voltage. TROL MODULE. [14]. [14]. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2005 Buell Firebolt: Fuel System 4-91...
Page 361 Install original cam System position sensor. Replace ECM. See 4.30 ELECTRONIC CONTROL MODULE. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-92 2005 Buell Firebolt: Fuel System...
Page 362: Electronic Control Module
Install headlight bracket. See 2.25 HEADLIGHT ASSEM- Figure 4-63. ECM BLY AND SUPPORT BRACKET. Install front fairing. See 2.37 FRONT FAIRING, WIND- SHIELD, AND MIRRORS. Re calibrate throttle position sensor using DIGITAL TECHNICIAN (Part No. HD-44750). 2005 Buell Firebolt: Fuel System 4-93...
Page 363 Rear coil primary Sensor ground 1 Injector rear Vehicle speed sensor Interactive Mufﬂer control feedback Engine temperature Bank angle sensor input Intake air temperature System ground B (coil) Serial data receive Tachometer Serial data transmit 4-94 2005 Buell Firebolt: Fuel System...
Page 364: Cam Position Sensor And Rotor
Remove timer plate studs (4). Carefully remove cam position sensor. Remove bolt (18) and trig- ger rotor (17). 10. Carefully remove camshaft oil seal (16) if damaged or if there is any evidence of oil leakage past the seal. 2005 Buell Firebolt: Fuel System 4-95...
Page 365 11. Mounting fastener 12. Ignition coil 13. Front spark plug cable 14. Engine mount 15. Seal 16. Trigger rotor 17. Trigger rotor bolt 18. Cam position sensor 19. Inner cover b1164a4x Figure 4-67. Ignition Components 4-96 2005 Buell Firebolt: Fuel System...
Page 366 HOME bd0022xx Figure 4-68. Ignition System Circuit 2005 Buell Firebolt: Fuel System 4-97...
Page 367 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. 4-98 2005 Buell Firebolt: Fuel System...
Page 368: Ignition Coil
An inﬁnite ohms (∞ or no continuity) resistance value indicates an open circuit (a break in the coil winding). Replace coil. 2005 Buell Firebolt: Fuel System 4-99...
Page 369 Install intake cover assembly. See 2.34 INTAKE COVER ASSEMBLY. Rear cylinder post Connect negative battery cable. Coil pin A (rear cylinder) Coil pin B (12 VDC) Coil pin C (front cylinder) Front cylinder post Figure 4-72. Ignition Coil 4-100 2005 Buell Firebolt: Fuel System...
Page 370: Oxygen Sensor
Install cable straps (2). Install airbox assembly. See 4.45 AIRBOX. Install intake cover assembly. See 2.34 INTAKE COVER ASSEMBLY. Oxygen sensor connector [137] Cable straps Connect negative battery cable. Figure 4-75. Oxygen Sensor Connector [137] (1200 Models) 2005 Buell Firebolt: Fuel System 4-101...
Page 371: Engine Temperature Sensor
Install right upper tie bar fastener (2). Tighten fastener to 25-27 ft-lbs (33.9-36.6 Nm). Install airbox. See 4.45 AIRBOX. Install intake cover assembly. See 2.34 INTAKE COVER ASSEMBLY. Figure 4-76. Engine Temperature Sensor Location (rear cylinder) Connect negative battery cable. 4-102 2005 Buell Firebolt: Fuel System...
Page 372: Bank Angle Sensor
Tighten fastener to 12-36 in-lbs (1.4- 4.1 Nm). Figure 4-78. Install bank angle sensor connector [134]. Install front fairing. See 2.37 FRONT FAIRING, WIND- SHIELD, AND MIRRORS. Connect negative battery cable. 2005 Buell Firebolt: Fuel System 4-103...
Page 373: Intake Air Temperature Sensor
Inspect sensor grommet for damage and replace as required. INSTALLATION Connect IAT sensor connector [89] to wiring harness. Install IAT sensor into grommet on airbox base from underneath. Install airbox. See 4.45 AIRBOX. Install negative battery cable. 4-104 2005 Buell Firebolt: Fuel System...
Page 374: Throttle Position Sensor
XB9R. Calibrate throttle position sensor. Figure 4-81. Throttle Position Sensor b0651x4x Figure 4-82. Tabs on TP Sensor Connector [88A] 2005 Buell Firebolt: Fuel System 4-105...
Page 375: 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. 4-106 2005 Buell Firebolt: Fuel System...
Page 376: Fuel Pump/Early Model Year
(00002a) 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). 2005 Buell Firebolt: Fuel System 4-107...
Page 377 10. Place wrench onto nut and another wrench onto the bolt. Hold the bolt stationary and turn nut clockwise until fuel pump is pulled free from frame. 4-108 2005 Buell Firebolt: Fuel System...
Page 378 Figure 4-89. Fuel Pump Assembly (right side) 12. See Figure 4-89. Tighten fuel ﬁlter clamps (3, 7). 13. See Figure 4-90. Install clips (1) into center grooves. 14. Install fuel pump assembly. See INSTALLATION in this section. 2005 Buell Firebolt: Fuel System 4-109...
Page 379 Figure 4-91. Regulator Housing O-rings Table 4-37. Fuel Pump Speciﬁcations SPECIFICATION DATA Pressure Setting 49 PSI Operating Voltage 13.2 volts Fuel Delivery 60 LPH @ 45 PSI [310 kPa] Current Draw 6.0 amps 4-110 2005 Buell Firebolt: Fuel System...
Page 380 Install clips (1) into middle grooves. 16. See Figure 4-88. 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. 2005 Buell Firebolt: Fuel System 4-111...
Page 381 Fill tank with a small amount of fuel. Check for leaks. Connect fuel pump connector [86] (2) and push cable strap tab into hole in frame. Connector [86] Fuel supply ﬁtting Fuel supply stud Drain plug Fasteners Figure 4-94. Fuel Pump Installation 4-112 2005 Buell Firebolt: Fuel System...
Page 382: Fuel Pump/Late Model Year
(00002a) Remove drain plug (4) 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). 2005 Buell Firebolt: Fuel System 4-113...
Page 383 10. Place wrench onto nut and another wrench onto the bolt. Hold the bolt stationary and turn nut clockwise until fuel pump is pulled free from frame. 4-114 2005 Buell Firebolt: Fuel System...
Page 384 (3) in place. Spread the four clips and detach regulator (3) from regulator housing(4). 10937a Plastic retaining ring Fuel pressure regulator Plastic retainers Fuel pressure regulator housing Figure 4-98. Fuel Pressure Regulator 2005 Buell Firebolt: Fuel System 4-115...
Page 385 10935a Fuel supply stud Fuel pump connectors Fuel pump assembly Low fuel pressure regulator O-rings Fastener Fuel screen Fuel pressure regulator Fuel pump 10. Low fuel level sensor connector Figure 4-99. Fuel Pump Assembly 4-116 2005 Buell Firebolt: Fuel System...
Page 386 Bracket, fuel pump and fuel ﬁlter Low fuel level sensor 10. Overﬂow hose Fuel pump connectors 11. Fuel pump housing Low fuel level sensor connector 12. Ground fastener Figure 4-100. Fuel Pump Assembly (Left and Right Sides) 2005 Buell Firebolt: Fuel System 4-117...
Page 387 Plastic retaining ring, pressure regulator Fuel pump Fuel ﬁlter Low fuel level sensor E-clip Fuel pressure regulator housing Connectors, fuel pump Fuel pressure regulator 10. Fuel pump wiring harness Figure 4-101. Fuel Pump Assembly 4-118 2005 Buell Firebolt: Fuel System...
Page 388 (6). 11. Connect fuel pump connectors (8). Connectors are two different sizes. 12. Install fuel pump assembly. See INSTALLATION in this Safety pin section. Fuel pump connector Clips Figure 4-103. Fuel Pump Connector Disassembly 2005 Buell Firebolt: Fuel System 4-119...
Page 389 (3). Install new fastener. Tighten to 84-108 in-lbs (9.5-12.2 Nm). Fill tank with a small amount of fuel. Check for leaks. Connect fuel pump connector [86] (1) and push cable strap tab into hole in frame. 4-120 2005 Buell Firebolt: Fuel System...
Page 390: Fuel Tank Vent Valve
After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 10. Install seat. See 2.38 SEAT. 2005 Buell Firebolt: Fuel System 4-121...
Page 391: 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 4-108. Fuel Cap Retaining Ring 4-122 2005 Buell Firebolt: Fuel System...
Page 392: Throttle Body
CONTROL. Figure 4-111. On California models, pull EVAP hose from ﬁtting (1). Remove left and right air scoops. See 2.35 AIR SCOOPS. Remove airbox. See 4.45 AIRBOX. Remove ignition coil. See 4.32 IGNITION COIL. 2005 Buell Firebolt: Fuel System 4-123...
Page 393 21. Bolt (2) 11. Clamp, wire spring, 49mm 22. Mounting ﬂange, intake (1 front, 1 rear) 12. Velocity stack, 49mm 23. Seal, intake manifold (2) Figure 4-110. One Piece Throttle Body/Intake Manifold Assembly (XB9/12 Models) 4-124 2005 Buell Firebolt: Fuel System...
Page 394: Manifold
Remove fuel injectors (2, 5) from manifold by gently rock- Manifold to engine mount fastener ing and pulling it away from the manifold. Intake ﬂange fastener (2) Figure 4-112. Intake Manifold (primary side) NOTE Front and rear fuel injectors are not interchangeable. 2005 Buell Firebolt: Fuel System 4-125...
Page 395 Front fuel injector evidence of raw fuel in throttle body manifold. Lower fuel rail fastener Install airbox cover. See 4.45 AIRBOX. Figure 4-114. Fuel Injectors Install intake cover assembly. See 2.34 INTAKE COVER ASSEMBLY. 4-126 2005 Buell Firebolt: Fuel System...
Page 396 Connect EVAP hose to port at bottom of throttle body (California models only). Calibrate throttle position sensor if removed or replaced. 4.37 THROTTLE POSITION SENSOR. Install airbox. See 4.45 AIRBOX. Check throttle cable adjustment. See 2.23 THROTTLE CONTROL. 2005 Buell Firebolt: Fuel System 4-127...
Page 397: Intake Leak Test
Nozzle Figure 4-116. Flatten one end of copper tube to form Copper tube a nozzle. Hose Valve Insert round side of copper tube into end of tubing. Knob Propane bottle Figure 4-117. Leak Tester 4-128 2005 Buell Firebolt: Fuel System...
Page 398 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. 2005 Buell Firebolt: Fuel System 4-129...
Page 399: Airbox
Cover, airbox Upper isolator interactive exhaust actuator Fuel vent tube Cable, interactive exhaust Harness, interactive exhaust Airbox cover latch tabs Figure 4-120. Airbox cover, Fuel Vent Tube and Fuel Vapor Valve (XB12 Models) 4-130 2005 Buell Firebolt: Fuel System...
Page 400 Carefully lower baseplate into mounting position. Ensure Velocity stack sealing ring rubber sealing ring on velocity stack completely engages baseplate. Baseplate should be sandwiched between Figure 4-121. Baseplate upper and lower rubber sealing rings. 2005 Buell Firebolt: Fuel System 4-131...
Page 401 ONLY). 10. Install intake cover assembly. See 2.34 INTAKE COVER ASSEMBLY. b1030x4x Airbox cover Intake snorkel Rear cylinder breather hose Air ﬁlter Fasteners Front cylinder breather hose Airbox seal Baseplate Figure 4-122. Airbox Assembly 4-132 2005 Buell Firebolt: Fuel System...
Page 402 12. Intake snorkel Harness, interactive exhaust 13. Shoulder screw (4) Cable bracket 14. Baseplate assembly Interactive exhaust cable 15. Breather hoses, front and rear Upper isolator Figure 4-123. Airbox Assembly (XB12 Models) wish Interactive Exhaust Components 2005 Buell Firebolt: Fuel System 4-133...
Page 403 4.46 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 404 Make sure to push hoses all the way on to carbon canis- ter ﬁttings. 8354 Install upper tail body work. See 2.36 SUBFRAME TAIL ASSEMBLY AND BODY WORK. Adjuster screw Adjuster screw alignment hole Figure 4-127. Adjuster Screw Alignment 2005 Buell Firebolt: Fuel System 4-135...
Page 405 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 4-128. Emissions Hose Attachment, California Models Only 4-136 2005 Buell Firebolt: Fuel System...
Page 406 ELECTRIC STARTER Table Of Contents SUBJECT PAGE NO. 5.1 Specifications ..........5.2 Electric Starter System .
Page 408: Specifications
8 ft-lbs (11 Nm) (min.) @ 2.4 V TORQUE VALUES ITEM TORQUE NOTES Battery terminal fasteners 72-96 in-lbs 8-11 Nm page 5-19 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 2005 Buell Firebolt: Starter...
Page 409: 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 (1) shooting information. to disengage from the clutch ring gear (13). 2005 Buell Firebolt: Starter...
Page 410 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 2005 Buell Firebolt: Starter...
Page 411: 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. right handlebar starter relay. switchgear. 5832 5818 2005 Buell Firebolt: Starter...
Page 412 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 2005 Buell Firebolt: Starter...
Page 413 (W/BK wire at connector [22]). Interlock Circuit relay. button to relay. Battery voltage present? or Correct Relay Ground. 5832 5831 5828 Replace right han- Repair wiring to dlebar switchgear. starter button. 5816 5831 2005 Buell Firebolt: Starter...
Page 414 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 2005 Buell Firebolt: Starter...
Page 415: 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. 2005 Buell Firebolt: Starter...
Page 416: Diagnostics/Troubleshooting
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. 2005 Buell Firebolt: Starter...
Page 417 HOME bd0022ax RH CONTROLS [33A] STARTER SOLENOID IGNITION SWITCH WIRING DIAGRAM [22A] KEY POSITION [128A] [33B] PARK LOCK [GRD2] WIRE COLOR R/BK R/GY GROUND [128B] WIRE SECT mm CONNECTING BATTERY USER + BATTERY USER + [5A] J-FUSE ASSY TN/Y TN/LT.GN DIODE IGNITION GY/O...
Page 418: 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 2005 Buell Firebolt: Starter 5-11...
Page 419: Starter
Remove positive battery cable ring terminal (2). Detach solenoid wire (3). 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 2005 Buell Firebolt: Starter...
Page 420: 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. 2005 Buell Firebolt: Starter 5-13...
Page 421 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 2005 Buell Firebolt: Starter...
Page 422 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 2005 Buell Firebolt: Starter 5-15...
Page 423 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 2005 Buell Firebolt: Starter...
Page 424 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 2005 Buell Firebolt: Starter 5-17...
Page 425 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 2005 Buell Firebolt: Starter...
Page 426 While riding, a loose seat can shift causing loss of control, which could result in death Figure 5-26. Starter Mounting or serious injury. (00070a) Install seat. See 2.38 SEAT. 2005 Buell Firebolt: Starter 5-19...
Page 427 Bearing cage 16. O-ring 17. Return spring 18. Ball 19. Gasket 20. Washer (2) 21. Mounting bolt (2) 22. Field wire 23. O-ring (2) 24. Field wire nut with washer (metric) Figure 5-27. Starter Assembly 5-20 2005 Buell Firebolt: Starter...
Page 428: Starter Solenoid
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). 2005 Buell Firebolt: Starter 5-21...
Page 429 HOME NOTES 5-22 2005 Buell Firebolt: Starter...
Page 430 Table Of Contents DRIVE/TRANSMISSION 6 SUBJECT PAGE NO. 6.1 Specifications ..........6.2 Primary Cover .
Page 432: Specifications
Table 6-4. Wet Clutch Multiple Disc-Clutch Plate Thickness ITEM NEW COMPONENTS SERVICE WEAR LIMITS Friction plate (ﬁber) 0.0866 + 0.0031 in. (2.200 + 0.079 mm) Steel plate 0.0629 + 0.0020 in. (1.598 + 0.051 mm) Clutch pack (in.) 0.661 in. (16.789 mm) (minimum) 2005 Buell Firebolt: Drive/Transmission...
Page 433 22-24 ft-lbs 30-32.5 Nm page 6-6 LOCTITE 262 (red), left hand threads, special torque Special proce- Transmission sprocket nut dure turn method, page 6-50 Transmission sprocket screws 90-110 in-lbs 10.2-12.4 Nm Replace after 3 removals, page 6-50 2005 Buell Firebolt: Drive/Transmission...
Page 434: Primary Cover
Figure 6-1. 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. 10. See Figure 6-1. Remove clutch inspection cover (3). 2005 Buell Firebolt: Drive/Transmission...
Page 435 16. Pedal bearing 17. Bolt 18. Shifter lever 19. Oil seal 20. Sems screw, 21. Adjuster assembly 22. Chain adjustment nut 23. O-ring 24. Drain plug Figure 6-3. Primary Cover, Primary Chain Adjuster and Shifter Assembly 2005 Buell Firebolt: Drive/Transmission...
Page 436 1.9 CLUTCH. screw with nylon sealing surface toward cover. A 1/4-inch allen wrench may be inserted into end of adjuster screw Adjust primary chain tension. See 1.11 PRIMARY to hold it while threading lock nut. CHAIN. 2005 Buell Firebolt: Drive/Transmission...
Page 437 13. After applying LOCTITE 272, install ﬂange bolt (5) and shift pedal to primary cover, and tighten to 22-24 ft-lbs (30-32.5Nm). 14. After applying LOCTITE 272 (red), tighten engine shift lever pinch screw to 48-60 in-lbs (5.4-6.8 Nm). 2005 Buell Firebolt: Drive/Transmission...
Page 438: Clutch Release Mechanism
(7). As the adjusting screw is turned, 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 2005 Buell Firebolt: Drive/Transmission...
Page 439 After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) Install seat. See 2.38 SEAT. 2005 Buell Firebolt: Drive/Transmission...
Page 440: Clutch
Replace release ramps and/or balls. Clutch drags. 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. 2005 Buell Firebolt: Drive/Transmission...
Page 441 27. Needle bearing Inner race Retaining ring 17. Pressure plate 28. Needle bearing 10. Spring seat 18. Friction plate, paper (7) 29. Clutch shell and sprocket 19. Steel plate (7) 30. Outer thrust washer Figure 6-12. Clutch Assembly 6-10 2005 Buell Firebolt: Drive/Transmission...
Page 442 Thread the CLUTCH SPRING FORCING SCREW (Part No. HD-38515-91) onto the clutch adjusting screw. 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. 2005 Buell Firebolt: Drive/Transmission 6-11...
Page 443 Install adjusting screw assembly into pressure plate. Figure 6-37. Align two tabs on perimeter of release plate with corresponding recesses (3) in pressure plate. Secure the adjusting screw assembly with new retaining ring. 6-12 2005 Buell Firebolt: Drive/Transmission...
Page 444 See 6.5 PRIMARY CHAIN. Inspect slots that mate with the clutch plates on both clutch shell and hub. If slots are worn or damaged, replace shell and/or hub. See 6.5 PRIMARY CHAIN. 2005 Buell Firebolt: Drive/Transmission 6-13...
Page 445: Assembly And Installation
ﬂats to prevent the forcing screw from turning. Spring seat Turn compressing tool handle clockwise until dia- Figure 6-21. Spring Seat Installation phragm spring compresses just enough to install new retaining ring into the groove in clutch hub prongs. 6-14 2005 Buell Firebolt: Drive/Transmission...
Page 446 11. Install seat. See 2.38 SEAT. Forcing screw Diaphragm spring Snap ring Pressure plate Spring seat Figure 6-22. Pressure Plate Assembly 8815 Adjusting screw assembly Retaining ring Tab recesses Figure 6-23. Clutch Adjusting Screw Assembly and Retaining Ring 2005 Buell Firebolt: Drive/Transmission 6-15...
Page 447: Primary Chain
TWO CLAW PULLER (Part No. HD-97292-61) and two bolts to loosen the engine sprocket. Figure 6-16. Remove adjusting screw assembly. Remove large retaining ring. Remove adjusting screw assembly from pressure plate. 6-16 2005 Buell Firebolt: Drive/Transmission...
Page 448 Figure 6-27. Needle Bearing in Clutch Shell 11. Replace damaged parts as necessary. 8804 Figure 6-28. Clutch Hub Bearing Race 2005 Buell Firebolt: Drive/Transmission 6-17...
Page 449 Installation end of bearing tool Bearing guide, installer Figure 6-29. Clutch Shell Bearing Remover/Installer B-45926 8812 Figure 6-32. Installing Clutch Shell Needle Bearing Clutch Shell Bearing Remover/Installer B-45926 Figure 6-30. Removing Clutch Shell Needle Bearing 6-18 2005 Buell Firebolt: Drive/Transmission...
Page 450 Figure 6-35. Mainshaft Nut and Washer Clutch shell Thrust washer, outer NOTE Figure 6-33. Clutch Hub and Shell Assembly New mainshaft nut comes with a chemical lock patch making it unnecessary to use Loctite with new fastener. 2005 Buell Firebolt: Drive/Transmission 6-19...
Page 451 (00070a) 14. Install seat. See 2.38 SEAT. Adjusting screw assembly Retaining ring Tab recesses Figure 6-37. Clutch Adjusting Screw Assembly and Retaining Ring 6-20 2005 Buell Firebolt: Drive/Transmission...
Page 452: Drive Belt System
GENERAL INSPECTION & CLEANING 1.10 DRIVE BELT. There is no drive belt adjustment required for the Buell Fire- bolt. The system utilizes a ﬁxed idler pulley that maintains the desired tension throughout suspension travel and life of the belt. Forward bend must not be less than 5 in. (127 mm).
Page 453 CAUTION When removing or installing belt, do not bend or twist belt, partially slide belt onto sprocket and “roll” wheel or belt damage will occur. Slide belt from sprocket and remove. 10. Remove rear axle. 6-22 2005 Buell Firebolt: Drive/Transmission...
Page 454: Drive Belt Installation
(4-5 Nm). See 2.33 CHIN FAIRING. 12. Install right side rider footpeg mount and tighten fasten- ers to 108-132 in-lbs (12-15 Nm). See 2.29 FOOTPEG, HEEL GUARD AND MOUNT. 13. Remove scissor jack from motorcycle. 2005 Buell Firebolt: Drive/Transmission 6-23...
Page 455 61 Nm). 8420 b1106x6x Axle Pinch bolt fastener Figure 6-44. Rear Wheel Mounting, Right Side Wheel Wheel nut Stud Idler pulley bracket Idler pulley bracket nut and washer Wheel fastener Figure 6-45. Idler Pulley Assembly 6-24 2005 Buell Firebolt: Drive/Transmission...
Page 456: Transmission
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 6-46. Transmission Power Flow 2005 Buell Firebolt: Drive/Transmission 6-25...
Page 457: Case Disassembly For Transmission Removal
Remove clutch assembly, primary chain and engine sprocket. See CLUTCH. 8615 TORX screw Retention collar Shifter lever assembly Figure 6-47. Countershaft Retainer Figure 6-47. Place transmission in 1st gear. Remove countershaft TORX screw (1) and retention collar (2). 6-26 2005 Buell Firebolt: Drive/Transmission...
Page 458 Figure 6-51. Rear Isolator Assembly 13. See Figure 6-51. Remove rear isolator assembly by removing the forward two fasteners ﬁrst and then the two rear fasteners (re-install with new fasteners). 2005 Buell Firebolt: Drive/Transmission 6-27...
Page 459 No tools are required for this operation. 8621 8636 Figure 6-55. Separating Crankcase Halves Figure 6-56. Removing Flywheels from Left Case Half 17. See Figure 6-55. Separate crankcase halves. 18. See Figure 6-56. Remove the ﬂywheel assembly from left crankcase half. 6-28 2005 Buell Firebolt: Drive/Transmission...
Page 460: Transmission Disassembly
Carefully tap on alternate sides of the shaft using the pro- Countershaft vided slots. Figure 6-59. Shifter Forks, Drum and Shafts 8628a Figure 6-58. Transmission Assembly Figure 6-58. Remove shifter drum and shifter forks. Remove mainshaft 2nd gear from mainshaft. 2005 Buell Firebolt: Drive/Transmission 6-29...
Page 461 20. Bolt, shift lever 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 6-60. Shifter Mechanism 6-30 2005 Buell Firebolt: Drive/Transmission...
Page 462 (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. 2005 Buell Firebolt: Drive/Transmission 6-31...
Page 463 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 6-63. Transmission Assembly-Right Crankcase Half 6-32 2005 Buell Firebolt: Drive/Transmission...
Page 464 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 6-64. Transmission Assembly-Left Crankcase Half 2005 Buell Firebolt: Drive/Transmission 6-33...
Page 465 11. Thrust washer Split bearing Retaining ring 12. Retaining ring Mainshaft 4th Thrust washer 13. Mainshaft Thrust washer Split bearing Retaining ring 10. Mainshaft 3rd Figure 6-65. Transmission Mainshaft Assembly Once Removed from Left Crankcase/Disassembly 6-34 2005 Buell Firebolt: Drive/Transmission...
Page 466 Slide countershaft 1st gear (13) off end of shaft. Remove split bearing (12). Discard all retaining rings that were removed. Remove thrust washer (14). Expand remaining retaining ring (15) and slide off countershaft. 2005 Buell Firebolt: Drive/Transmission 6-35...
Page 467: 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 6-68. Transmission Mainshaft Assembly/Reassembly 6-36 2005 Buell Firebolt: Drive/Transmission...
Page 468 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 6-69. Transmission Countershaft Assembly/Reassembly 2005 Buell Firebolt: Drive/Transmission 6-37...
Page 469: Main Drive Gear
(2). Install and tighten nut (6) until 5th gear (3) is free. 8681 Figure 6-71. Bearing Remover Cross Plate Mounting (Part No. B-45847) Figure 6-71. Place cross plate on crankcase as shown. 6-38 2005 Buell Firebolt: Drive/Transmission...
Page 470 Insert threaded end of bolt (2) through installer cup (3) and thrust washer (1). Thread nut (6) onto end of bolt (2). Tighten nut (6) until shoulder on gear (4) bottoms against inner race of bearing. 2005 Buell Firebolt: Drive/Transmission 6-39...
Page 471 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 6-77. Transmission Assembly Right Crankcase Half 6-40 2005 Buell Firebolt: Drive/Transmission...
Page 472: 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. 2005 Buell Firebolt: Drive/Transmission 6-41...
Page 473 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 6-80. Transmission Assembly Left Crankcase Half 6-42 2005 Buell Firebolt: Drive/Transmission...
Page 474: 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. 2005 Buell Firebolt: Drive/Transmission 6-43...
Page 475: Transmission Installation
Install mainshaft 2nd gear with shifter fork groove (Part No. B-43985-2) on arbor press. towards mainshaft 3rd gear. Install COUNTERSHAFT GUIDE ADAPTER Install shifter forks, shafts and shifter drum. (Part No. B-43985-4). 6.10 TRANSMISSION ASSEMBLY. 6-44 2005 Buell Firebolt: Drive/Transmission...
Page 476 Figure 6-86. Installing Shift Fork Shafts NOTE Figure 6-86. 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 6-85. Shifter Forks, Drum and Shafts 2005 Buell Firebolt: Drive/Transmission 6-45...
Page 477 HOME b1016x3x One Behind Shifter Mechanism Indicates Bolt Pattern Location Figure 6-87. Crankcase Fasteners 6-46 2005 Buell Firebolt: Drive/Transmission...
Page 478 Figure 6-89. Gear Detent Assembly Aid ft-lbs (20.3-25 Nm). (Part No. B-45520) Figure 6-89. 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. 2005 Buell Firebolt: Drive/Transmission 6-47...
Page 479: Shifter Shaft Installation
Insert screw (1) through retention collar (2) and thread into end of shaft. Place transmission in gear and tighten TORX screw (1) to 13-17 ft-lbs (18-23 Nm). b0951x6x Figure 6-93. Shifter Shaft Return Spring (Incorrectly Installed) 6-48 2005 Buell Firebolt: Drive/Transmission...
Page 480: Transmission Sprocket
If pulley wheel needs replacement, remove fastener (6) and washer (3) from idler pulley bracket (4) 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. 2005 Buell Firebolt: Drive/Transmission 6-49...
Page 481 Since this compound remains effective for about three removal/installation cycles, the original screws may be reused up to three times. After the third removal/installation cycle, replace both screws with new screws identical to the original. 6-50 2005 Buell Firebolt: Drive/Transmission...
Page 482 Tighten rear axle (1) to 23-27 ft-lbs (31.2-36.6 Nm), back off two full turns and then retighten to 48-52 ft-lbs (65.1-70.5 Nm). 18. Tighten pinch fastener (2) on right side of swingarm to 40-45 ft-lbs (54-61 Nm). 2005 Buell Firebolt: Drive/Transmission 6-51...
Page 483 HOME NOTES 6-52 2005 Buell Firebolt: Drive/Transmission...
Page 484 Table Of Contents SUBJECT PAGE NO. 7.1 Specifications ..........7.2 Ignition System .
Page 486 Check engine 1.12 0.08 Y0163.02A8 High beam 0.05 Y0162.02A8 Oil indicator 1.12 0.08 Y0163.02A8 Instruments Neutral 1.12 0.08 Y0163.02A8 1.12 0.08 Y0163.02A8 Backlight 0.05 Y0162.02A8 Low fuel Replace instrument cluster if low fuel warning lamp fails. 2005 Buell Firebolt: Electrical...
Page 487 2.8-3.2 Nm page 7-47 Turn signal fasteners (front) 25-28 in-lbs 2.8-3.2 Nm page 7-47 Turn signal ﬂasher fastener 30-40 in-lbs 3.4-4.5 Nm page 7-48 Voltage regulator mounting 48-60 in-lbs 5.4-6.8 Nm use new fasteners, page 7-32 screws 2005 Buell Firebolt: Electrical...
Page 488: 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. 2005 Buell Firebolt: Electrical...
Page 489 10. Rear spark plug cable 11. Mounting fastener 12. Ignition coil 13. Front spark plug cable 14. Engine mount 15. Seal 16. Trigger rotor 17. Trigger rotor bolt 18. Cam position sensor 19. Inner cover b1164b4x Figure 7-1. Ignition Components 2005 Buell Firebolt: Electrical...
Page 490: Ignition/Headlight Key Switch
Front and rear turn signals can be activated cannot be 8345 Horn can be activated activated ON position OFF position PUSH DETENT LOCK position PARKING LIGHT position Upper triple clamp Figure 7-2. Ignition/Headlight Key Switch 2005 Buell Firebolt: Electrical...
Page 491 (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 2005 Buell Firebolt: Electrical...
Page 492 Install ignition switch body fasteners (1). Tighten to 12-36 Ignition switch in-lbs (1.4-4.0 Nm). Housing 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) 2005 Buell Firebolt: Electrical...
Page 493 After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 10. Install seat. See 2.38 SEAT. 2005 Buell Firebolt: Electrical...
Page 494: Spark Plug Cables
Pulling on the cable will damage the cable’s carbon core. Remove airbox assembly. See 4.45 AIRBOX. Figure 7-8. Disconnect spark plug cables from igni- tion coil and spark plug terminals. Inspect cables for damage. 2005 Buell Firebolt: Electrical...
Page 495 Fasten boots/caps securely. Tight connections provide the necessary moisture-proof environment for the ignition coil and spark plug terminals. Install airbox assembly. See 4.45 AIRBOX. Figure 7-10. Boot Gap Should Not exceed 1/8 in. (3.2 mm) 7-10 2005 Buell Firebolt: Electrical...
Page 496 Place vehicle in neutral. Clutch lever not disengaged. Pull in clutch lever. Starter relay problems. Listen for starter relay “click”. If click is not heard, perform starter relay tests. Follow starter troubleshooting in Section 5. 2005 Buell Firebolt: Electrical 7-11...
Page 497 Figure 7-11. Diode Polarity b1107d7x RELAY CENTER [95A] [95B] TN/LTGN Clutch Switch Empty Spare Spare Diode Diode Empty Bk/Hn/Mflr TN/Y Lights [131B] Acces. Key Sw [131A] TN/LTGN Neutral Start Switch Relay Figure 7-13. Diode Wiring 7-12 2005 Buell Firebolt: Electrical...
Page 498 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. 5064 5061 5062 5063 2005 Buell Firebolt: Electrical 7-13...
Page 499 Check for ground on BK Repair open on TN/ wire of connector [95]. GN wire between Ground present? connector [95] and starter relay. 5073 Replace clutch Repair open on switch. BK wire between connector [95] and 5074 ground. 5075 7-14 2005 Buell Firebolt: Electrical...
Page 500 With clutch disengaged (2) (switch closed), the switch should show 0 ohms or little resistance. Replace the assembly with a new switch if necessary. 2.24 CLUTCH CONTROL. Clutch engaged (switch open) Clutch disengaged (switch closed) Connector [95] Figure 7-14. Clutch Switch 2005 Buell Firebolt: Electrical 7-15...
Page 501: Main Fuse
A 30 Amp main fuse links the ignition key switch and the bat- tery. The 30 Amp main fuse is located under the rider’s seat. 7.22 MAIN FUSE AND FUSES for more information. Figure 7-16. Starter Relay Test 7-16 2005 Buell Firebolt: Electrical...
Page 502 Replace the diode by pulling it straight out. Ensure it is installed in the correct direction. Figure 7-17. Fuse Block (contains diode) b1165x4x Empty Spare Spare Diode Empty Bk/Hn/Mflr Lights Acces. Key Sw Figure 7-18. Fuse Block 2005 Buell Firebolt: Electrical 7-17...
Page 503 Exhaust valve Exhaust in Valve open (exhaust ﬂow - chamber C) Valve closed (exhaust ﬂow - chamber A to B to C) Chamber A Chamber B Chamber C Exhaust exit Figure 7-19. Interactive Exhaust System Mufﬂer 7-18 2005 Buell Firebolt: Electrical...
Page 504 HOME 8899 Upper EVA isolator Interactive exhaust cable Harness with connector [161B] Interactive exhaust cable bracket Actuator Lower EVA Isolator Air cleaner cover Figure 7-20. Interactive Control System (XB12 Models Only) 2005 Buell Firebolt: Electrical 7-19...
Page 505 Harness, interactive exhaust Figure 7-21. Airbox Cover (XB12 Models Only) Figure 7-21. Remove fuel vent tube (3) from fuel cell vent and groove on top of airbox cover (2). Move upper isolator (4) out of the way. 7-20 2005 Buell Firebolt: Electrical...
Page 506 Connect interactive exhaust harness to actuator [161B]. Install upper isolator and route fuel vent line and install. Attach interactive exhaust cable to bracket on actuator adjust. See 1.17 INTERACTIVE EXHAUST CABLE(XB12 MODELS ONLY). Install intake cover assembly. See 4.45 AIRBOX. 2005 Buell Firebolt: Electrical 7-21...
Page 507 HOME NOTES 7-22 2005 Buell Firebolt: Electrical...
Page 508: Charging System
Wiring Check for corroded or loose connections in the charging cir- cuit. See Figure 7-25. Voltage Regulator Inspection Figure 7-24. The plug connector to stator must be clean and tight. 2005 Buell Firebolt: Electrical 7-23...
Page 509 STOP 5310 Go to Test 7.7 (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. 7-24 2005 Buell Firebolt: Electrical...
Page 510 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. 2005 Buell Firebolt: Electrical 7-25...
Page 511 BATTERY CABLE STARTER SOLENOID [128A] BATTERY STARTER MOTOR [GRD2] TO J-FUSE ASSY 30A MAXIFUSE [5A] [35A] [35B] TO VOLTAGE REGULATOR [77B] [77A] VOLTAGE REGULATOR STATOR (HD 3-PHASE) MALE FEMALE [46A] [46B] Figure 7-25. Charging System Circuit 7-26 2005 Buell Firebolt: Electrical...
Page 512 Reconnect regulator after testing. INTERACTIVE EXHAUST HARNESS(XB12 MODELS). Start the motorcycle and run the engine at 3000 RPM. With ignition and all continuously running lights and accessories turned on (headlight on high beam), read the total current draw. 2005 Buell Firebolt: Electrical 7-27...
Page 513 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. 7-28 2005 Buell Firebolt: Electrical...
Page 514 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 7-28. b0997x7x Figure 7-30. Check for Stator Resistance b0998x7x Figure 7-31. Check Stator AC Voltage Output 2005 Buell Firebolt: Electrical 7-29...
Page 515 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 7-34. Stator Assembly 7-30 2005 Buell Firebolt: Electrical...
Page 516 TORX screws (1). Tighten TORX screws 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 INTERACTIVE EXHAUST HARNESS(XB12 MODELS) for remaining wire routing information. 2005 Buell Firebolt: Electrical 7-31...
Page 517: Voltage Regulator
While riding, a loose seat can Voltage regulator shift causing loss of control, which could result in death Fastener (3) or serious injury. (00070a) Install seat. See 2.38 SEAT. Figure 7-37. Voltage Regulator Test charging system. See 7.7 CHARGING SYSTEM. 7-32 2005 Buell Firebolt: Electrical...
Page 518: Battery Cables
Connect positive cable to positive (+) battery termi- nal using fastener. Connect negative cable to negative (-) battery termi- nal using fastener. Tighten terminal fasteners to 72-96 in-lbs (8-11 Nm). 2005 Buell Firebolt: Electrical 7-33...
Page 519 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 7-40. Positive Battery Cable (Protective Boot Not Shown) 7-34 2005 Buell Firebolt: Electrical...
Page 520 7.11 GENERAL Table 7-12. Battery Electrolyte Antidotes CONTACT SOLUTION All Buell batteries are permanently sealed, maintenance-free, valve-regulated, lead/calcium and sulfuric acid batteries. The External Flush with water. batteries are shipped pre-charged and ready to be put into service. Do not attempt to open these batteries for any...
Page 521: Battery Testing
Connect tester leads to battery posts and place induction sion, which could result in death or serious injury. pickup over negative (black) cable. See Figure 7-44. (00253a) Install the battery on the motorcycle. See BATTERY INSTALLATION AND CONNECTION. 7-36 2005 Buell Firebolt: Electrical...
Page 522: Disconnection And Removal
(black) from battery negative (-) terminal. Inspect the battery case for cracks or leaks. Unthread fastener and remove battery positive cable (red) from battery positive (+) terminal. Unhook battery strap from frame. Remove battery. 2005 Buell Firebolt: Electrical 7-37...
Page 523: Battery Charging
Overheating may result in plate distortion, internal shorting, dryout or other damage. Perform a voltmeter test to determine the state of charge. BATTERY TESTING. If battery needs to be charged, proceed to step 2. 7-38 2005 Buell Firebolt: Electrical...
Page 524 If a constant current charger is the only type available, do not exceed the charge times listed above and do not continue charging the battery if it gets hot. When charging, never exceed 15 volts for more than 30 minutes. 2005 Buell Firebolt: Electrical 7-39...
Page 525 (+) 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). 7-40 2005 Buell Firebolt: Electrical...
Page 526 (not freezing), dry place. See Fig- ure 7-45. 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). 2005 Buell Firebolt: Electrical 7-41...
Page 527 Failure to do so could result in bulb damage. (00210a) Figure 7-46. Disconnect headlight connection (1). Release wire retaining latch (5) from headlight housing clips. Pull bulb housing from headlight housing. 7-42 2005 Buell Firebolt: Electrical...
Page 528 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 1.19 HEADLIGHTS. 2005 Buell Firebolt: Electrical 7-43...
Page 529: Tail Lamp
After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) Install pillion seat. See 2.38 SEAT. 7-44 2005 Buell Firebolt: Electrical...
Page 530: 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 7-50. Front Turn Signals 2005 Buell Firebolt: Electrical 7-45...
Page 531 HOME b1008a7x Turn signal Turn signal bulb Reﬂector bracket License plate bracket Washer (2) Fastener (2) Tail section Figure 7-51. Rear Turn Signals 7-46 2005 Buell Firebolt: Electrical...
Page 532 After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) Install seat. See 2.38 SEAT. 2005 Buell Firebolt: Electrical 7-47...
Page 533: Turn Signal Flasher
Front and rear left turn sig- Figure 7-54. Turn Signal Controls 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. 7-48 2005 Buell Firebolt: Electrical...
Page 534: 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 Fused power To stoplight Brake Switch [121] Figure 7-55. Right Handlebar Switch Connection 2005 Buell Firebolt: Electrical 7-49...
Page 535 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. 7-50 2005 Buell Firebolt: Electrical...
Page 536 Fuse Key Sw Acces. [5A] Vehicle Speed Sensor Connector Vehicle Speed [39A] [39B] Sensor BK/W Instrument Module [65A] [65B] [10B] [11B] Connector Connector Electronic Control Module [10A] [11B] (ECM) Figure 7-58. Vehicle Speed Sensor Wiring 2005 Buell Firebolt: Electrical 7-51...
Page 537 HOME bd0020xx bd0020xx Figure 7-59. Vehicle Speed Sensor Wiring 7-52 2005 Buell Firebolt: Electrical...
Page 538: Bulb Replacement
Remove the nine fasteners securing the back of the module housing to the display and remove back cover. CAUTION Do not turn display over. Speedometer and Tachometer will fall out possibly causing damage to instruments. 2005 Buell Firebolt: Electrical 7-53...
Page 539 (00070a) Headlight support bracket Install seat. See 2.38 SEAT. Instrument module Grommet (3) Washer (3) Fastener (3) 8426 Instrument module connector [39] Figure 7-64. Instrument Module Figure 7-63. Instrument Module Connector [39] 7-54 2005 Buell Firebolt: Electrical...
Page 540: Speedometer Performance Check
Verify that speedometer display reads the corre- sponding speed. To change the test frequency, press CLEAR to cancel and enter the new fre- quency. Press ENTER to begin and reverify. NOTE The speedometer should be accurate within 0-5 MPH (0-8 KPH). 2005 Buell Firebolt: Electrical 7-55...
Page 541 PORT STAND (Part No. B-41174). Place speedometer tester power switch in the ON posi- tion. Place signal switch in the IN position. Plug the speedometer tester into the test harness. Turn vehicle ignition switch ON. 7-56 2005 Buell Firebolt: Electrical...
Page 542 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 2005 Buell Firebolt: Electrical 7-57...
Page 543 If necessary, remove vehicle speed sensor and check for accumulation of debris. If Go to Speedometer Test: debris is not present, replace sensor. If Chart debris is present, clean sensor and repeat test. Replace if necessary. 7-58 2005 Buell Firebolt: Electrical...
Page 544 Does voltage fluctuate? Replace vehicle speed sensor. 6022 6010 Repair as necessary. Check speedometer speed sensor. Clean or replace sen- 6008 sor as required. Retest. Problem solved? System OK. Replace instrument module. 6029 6024 2005 Buell Firebolt: Electrical 7-59...
Page 545 After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) Install seat. See 2.38 SEAT. 7-60 2005 Buell Firebolt: Electrical...
Page 546 If horn is faulty, replace unit as an assembly. 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 7.16 HANDLE- SWITCHES. 2005 Buell Firebolt: Electrical 7-61...
Page 547: 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. 7-62 2005 Buell Firebolt: Electrical...
Page 548: Main Fuse And Fuses
HOME MAIN FUSE AND FUSES 7.22 GENERAL 10960 Buell motorcycles feature two components which protect the electrical system. Fuses Figure 7-73.The covered fuse block is behind the fairing on the right hand side of the motorcycle. Figure 7-74. The lights, key switch, brake/horn and igni- tion fuses are rated at 15 Amps.
Page 549: Main Wire Harness
Cable strap 11. Remove the rear shock absorber assembly and reser- Foot brake light switch connector [121] voir. See 2.22 REAR SHOCK ABSORBER. Figure 7-77. Battery Tray Wiring 12. Remove fan. See 4.38 COOLING FAN. 7-64 2005 Buell Firebolt: Electrical...
Page 550 23. Remove fuse and relay bundle clamps. 24. Remove fuse block and relay block from their brackets. 25. Remove any remaining cable straps and clamps secur- ing wire harness and remove harness from front of vehi- cle. 2005 Buell Firebolt: Electrical 7-65...
Page 551 72-96 in-lbs (8.1-10.8 Nm). 13. Repeat previous steps for relay block. 14. 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). 7-66 2005 Buell Firebolt: Electrical...
Page 552 After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 31. Install seat. See 2.38 SEAT. 2005 Buell Firebolt: Electrical 7-67...
Page 553 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 7-82. Fairing Wiring (viewed from underneath fairing) 7-68 2005 Buell Firebolt: Electrical...
Page 554 See INTERACTIVE EXHAUST SYSTEM(XB12 MOD- ONLY). Remove interactive exhaust cable from cable wheel. 8478 Remove actuator. Main battery ground Wire harness ground Main fuse case Figure 2-84. Battery and Harness Ground (battery removed for clarity) 2005 Buell Firebolt: Electrical 7-69...
Page 555 After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 12. Install seat and pillion. 7-70 2005 Buell Firebolt: Electrical...
Page 556: 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 Gear cover vent line Stator connector [46] Oil pressure switch wiring Interactive exhaust cable Figure 7-88. Cam Position Sensor Wiring 2005 Buell Firebolt: Electrical 7-71...
Page 557 Interactive exhaust cable Figure 7-92. Assembled Wiring Figure 7-89. Neutral Switch Connector [131] 10549 Cam position sensor connector [14] Neutral switch location Cam position sensor wiring Neutral switch connector [131] Cable strap Figure 7-90. Neutral Switch Wiring 7-72 2005 Buell Firebolt: Electrical...
Page 558 Table Of Contents SUBJECT PAGE NO. APPENDIX A-TOOLS ..........APPENDIX B-WIRING .
Page 560: Appendix A-Tools
Part No. B-42887 Brake Caliper Piston Remover Installer Part No. HD-39302 Steering Head Bearing Race Installer Part No. B-43721 Front Fork Seal Driver (Used with B-45521) Part No. B-46279 7/8" Axle Wrench (Hex) Part No. B-59000B Pro Level Oil Gauge 2005 Buell Firebolt: Appendix A...
Page 561 Part No. HD-45966 Fork Spring Compressing Tool Part No. HD-94700-52C Shock Spanner Preload Adjustment Tool Part No. HD-28700 Tire Bead Expander Part No. HD-44060 Wheel Bearing Remover/Installer Part No. HD-33416 Universal Driver Handle Part No. HD-99500-80 Wheel Truing and Balancing Stand 2005 Buell Firebolt: Appendix A...
Page 562 Part No. HD-35457 Black Light Leak Detector Part No. HD-43984 Crankshaft Locking Tool Part No. HD-33223-1 Cylinder Compression Gauge Part No. HD-38362 Sprocket Locking Link (XB9 Models) Part No. HD-46283 Sprocket Locking Link (XB12 Models) 2005 Buell Firebolt: Appendix A...
Page 563 Part No. HD-39782 Cylinder Head Support Part No. B-45523 Valve Guide Reamer (7mm) 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 2005 Buell Firebolt: Appendix A...
Page 564 Torque Plate Bolts Part No. HD-33446-86 Clamping Tool Part No. HD-34623C Piston Pin Part No. HD-95970-32D Piston Pin Bushing Tool Retaining Ring Installer/Remover Part No. HD-42322 Piston Support Plate Part No. HD-94800-26A Connecting Rod Bushing Reamers and Pilots 2005 Buell Firebolt: Appendix A...
Page 565 Set includes items 1-7. Items 8 (HD-95769-69), 9 (HD- 95770-69) and 10 (HD-95771-69) are optional. Part No. J-5586 Transmission Shaft Part No. HD-39965 Deutsch Terminal Crimp Tool Retaining Ring Pliers Part No. HD-41609 Amp Terminal Crimp Tool 2005 Buell Firebolt: Appendix A...
Page 566 HOME HD-47258 Part No. HD-47258 Rocker Cover Wrench Part No. HD-41354 Speedometer Tester ˙HD-47248 Part No. HD-47248 Rocker Housing Wrench HD-47250 Part No. HD-47250 Intake Manifold Wrench 2005 Buell Firebolt: Appendix A...
Page 567 HOME NOTES 2005 Buell Firebolt: Appendix A...
Page 568: 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 2005 Buell Firebolt: Appendix B...
Page 569 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. 2005 Buell Firebolt: Appendix B...
Page 570 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 2005 Buell Firebolt: Appendix B...
Page 571 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 2005 Buell Firebolt: Appendix B...
Page 572: 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 properly locked in place. 2005 Buell Firebolt: Appendix B...
Page 573 (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. 2005 Buell Firebolt: Appendix B...
Page 574 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. 2005 Buell Firebolt: Appendix B...
Page 575 When correctly positioned, the locking bar ﬁts snugly in the space between the contact band and the core crimp tails. 2005 Buell Firebolt: Appendix B...
Page 576 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 2005 Buell Firebolt: Appendix B...
Page 577 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 2005 Buell Firebolt: Appendix B...
Page 578 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. 2005 Buell Firebolt: Appendix B B-11...
Page 579 HOME PUSH-TO-SEAT TERMINALS Installing Push-to-Seat Terminals NOTE The Packard push-to-seat terminal connectors are Buell Fire- For wire location purposes, alpha characters are stamped bolts. onto the secondary locks or onto the wire end of the connec- tor housing. Removing Push-to-Seat Terminals...
Page 580 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 2005 Buell Firebolt: Appendix B B-13...
Page 581: 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 2005 Buell Firebolt: Appendix B...
Page 582 [134] bank angle sensor 6-place Sumitomo in fairing [137] oxygen sensor 1-place Packard behind rear cylinder head [164] Interactive exhaust circuit to ECM under seat [161] Interactive exhaust to solenoid under airbox cover 2005 Buell Firebolt: Appendix B B-15...
Page 583: Appendix B-Wiring
INDEX TO WIRING DIAGRAMS Table B-3. 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 2005 Buell Firebolt: Appendix B...
Page 584 DATA LINK SPEEDOMETER BK/R LT.GN/R TN/LT.GN [91A] [77B] R/BK LH TURN SIGNAL [39A] OIL PRESSURE SW GN/Y R/BK [31B] [120B] [95B] R/BK GN/Y CLUTCH SW R/BK [120A] MALE R/BK FEMALE 2005 XB Firebolt Main Harness 2005 Buell Firebolt: Electrical B-17...
Page 585 HOME 2005 XB Firebolt Main Harness 2005 XB Firebolt Main Harness B-18 2005 Buell Firebolt: Electrical...
Page 586 BK/W GN/W GN/W W/BK BK/W BK/W BANK ANGLE SENSOR GY/O [14B] [14A] [134B] GY/O [38A] DATA LINK SPEEDOMETER LT.GN/R [39A] [95B] CLUTCH SW [91A] R/BK R/BK MALE R/BK FEMALE 2005 XB Firebolt Engine Management Circuit 2005 Buell Firebolt: Electrical B-19...
Page 587 HOME 2005 XB Firebolt Engine Management Circuit 2005 XB Firebolt Engine Management Circuit B-20 2005 Buell Firebolt: Electrical...
Page 588 R/BK KEY SWITCH [39B] 1 2 3 4 5 6 7 8 9 10 HEADLAMP [24A] LH CONTROLS [62B] RELAY CENTER [38A] SPEEDOMETER LH TURN SIGNAL [39A] [31B] R/BK R/BK 2005 XB Firebolt Lighting Circuit 2005 Buell Firebolt: Electrical B-21...
Page 589 HOME 2005 XB Firebolt Lighting Circuit 2005 XB Firebolt Lighting Circuit B-22 2005 Buell Firebolt: Electrical...
Page 590 1 2 3 4 5 6 7 8 9 10 [24A] RELAY CENTER 1 2 3 4 5 6 7 8 [62B] LH CONTROLS SPEEDOMETER TN/LT.GN [39A] GN/Y [120B] R/BK GN/Y OIL PRESSURE SW MALE [120A] FEMALE 2005 XB Firebolt Horn & Instruments Circuit 2005 Buell Firebolt: Electrical B-23...
Page 591 HOME 2005 XB Firebolt Horn & Instruments Circuit 2005 XB Firebolt Horn & Instruments Circuit B-24 2005 Buell Firebolt: Electrical...
Page 592 DIODE TN/Y TN/LT.GN IGNITION GY/O R/BK KEY SWITCH NEUTRAL SW TN/Y [131B] [131A] [62B] RELAY CENTER W/BK W/BK GY/O GY/O BK/R TN/LT.GN R/BK [95B] CLUTCH SW R/BK MALE R/BK FEMALE 2005 XB Firebolt Starting Circuit 2005 Buell Firebolt: Electrical B-25...
Page 593 HOME 2005 XB Firebolt Starting Circuit 2005 XB Firebolt Starting Circuit B-26 2005 Buell Firebolt: Electrical...
Page 594 BATTERY CABLE STARTER SOLENOID [128A] BATTERY STARTER MOTOR [GRD2] TO J-FUSE ASSY 30A MAXIFUSE [5A] TO VOLTAGE REGULATOR [77B] [77A] VOLTAGE REGULATOR STATOR (HD 3-PHASE) MALE FEMALE [46A] [46B] 2005 XB Firebolt Starting & Charging Circuit 2005 Buell Firebolt: Electrical B-27...
Page 595 HOME 2005 XB Firebolt Starting & Charging Circuit 2005 XB Firebolt Starting & Charging Circuit B-28 2005 Buell Firebolt: Electrical...
Page 596 [85B] FUEL PUMP [84B] ENGINE TEMP SENSOR PK/Y [90B] [90A] MAIN HARNESS BN/Y [86B] [89A] BANK ANGLE SENSOR FUEL INTAKE AIR TEMP SENSOR LT.GN/GY [89B] BK/W MALE [134B] [134A] FEMALE 2005 XB Firebolt Component Circuits 2005 Buell Firebolt: Electrical B-29...
Page 597 HOME 2005 XB Firebolt Component Circuits 2005 XB Firebolt Component Circuits B-30 2005 Buell Firebolt: Electrical...
Page 598: Appendix C-Metric Conversions
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 2005 Buell Firebolt: Appendix C...
Page 599 2.113 = pints (U.S.) pints (Imp.) x 1.201 = pints (U.S.) liters x 1.057 = quarts (U.S.) quarts (Imp.) x 1.201 = quarts (U.S.) liters x 0.264 = gallons (U.S.) gallons (Imp.) x 1.201 = gallons (U.S.) 2005 Buell Firebolt: Appendix C...
Page 600: Appendix D-Hose And Wire Routing
HOME HOSE AND WIRE ROUTING b1114xax Figure D-1. Front and Rear Brake Systems, Right Side View...
Page 601 HOME b1115xbx Figure D-2. Rear Brake Systems, Top View...
Page 602 HOME b1116xcx Figure D-3. Rear Brake Systems, Left Side View...
Page 603 HOME b1117xax Carbon canister Figure D-4. Evaporative Emissions Control, California Models, Top View...
Page 604 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 605 HOME b1119xdx To ECM Active intake solenoid (Japan only) Fuel pump Intake air temperature sensor (IAT) Figure D-6. Wiring Harness, Left Side View...
Page 606 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 607 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 608 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 609 HOME b1123xbx Vent line Feed oil line Return oil line Figure D-10. Oil Lines, Bottom View...
Page 610 HOME b1124xax Exhaust valve actuator Mufﬂer valve Figure D-11. Clutch, Throttle Cables and Interactive Exhaust System (1200 Only), Right Side View...
Page 611 HOME b1125xbx Exhaust valve actuator Cable, seat lock Mufﬂer valve Figure D-12. Clutch, Throttle Seat Release Cables and Interactive Exhaust System (1200 Only), Left Side View...
Page 612 HOME b1126xdxa TPS adjuster Cable, seat lock Clip to functional airbox cover. Exhaust valve actuator mounted functional airbox cover. Figure D-13. Clutch, Throttle Seat Release Cables and Active Intake System with Exhaust Valve Actuator (1200 Only), Top View...
Page 613 HOME NOTES D-14 2005 Buell Firebolt: Appendix D...
Page 614: Appendix E-Active Intake System (Japan Only
Using TEST CONNECTOR KIT (Part No. HD-41404), attach that the throttle plate is fully open. Brown pin probe and patch cord to [179] (1,2). If the throttle plate does not fully open, see CABLE ADJUST- MENT this section. 2005 Buell Lightning: Appendix E...
Page 615 (1) inward to the fully retracted position. 10957 Solenoid shaft Solenoid bracket Cable adjusting and jam nuts Cable housing Figure E-1. Checking for Freeplay in the Solenoid Shaft in the Fully Retracted Position 2005 Buell Lightning: Appendix E...
Page 616 1/32 in. (0.79 mm) or greater. 10956 Solenoid shaft Solenoid bracket Cable adjusting and jam nuts Cable housing Figure E-2. Checking for Freeplay in the Solenoid Shaft in the Fully Extended Position 2005 Buell Lightning: Appendix E...
Page 617 Adjust stop screw, while reading the TPS on Digital 1.15 AIR CLEANER FILTER. Technician, until setting is between the range of 10.4 to 10.9. 10925 10924 Cable stop screw Active cable wheel Figure E-3. Active Intake Cable Stop Screw 2005 Buell Lightning: Appendix E...
Page 618 HOME Active Intake Solenoid [178A] [178B] Figure E-4. Active Intake System 2005 Buell Lightning: Appendix E...
Page 619 Continuity present? Go to page 2 Repair open in Page 2 of 2 W/GY wire. Repair open in GY/O wire. DIAGNOSTIC NOTE If DTC is historic, wiggle harness while performing measurements in chart to locate intermittents. 2005 Buell Lightning: Appendix E...
Page 620 Does solenoid attempt to pull throttle almost closed? Replace solenoid Hold throttle wide open. Energize active intake solenoid. Does throttle close to an angle less than 11 degrees? Replace ECM CABLE ADJUSTMENT in this section. 2005 Buell Lightning: Appendix E...
Page 621 Cable connector Active intake cable Fasteners (2), bracket to solenoid Cable adjusting nut Active intake solenoid Cable bracket Solenoid bracket Active cable jam nut 10. Air cleaner baseplate assembly Figure E-5. Disconnecting Active Intake System 2005 Buell Lightning: Appendix E...

This manual is also suitable for:

2005 xb9r firebolt

Buell 2005 FIREBOLT Service Manual

Maintenance 1

Chassis 2

Engine 3

Fuel System 4

Electric Starter 5

Drive/Transmission 6

Electrical 7

Appendices

Quick Links

Chapters

Troubleshooting

Related Manuals for Buell 2005 FIREBOLT

Summary of Contents for Buell 2005 FIREBOLT