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XB12XT 2010
Buell XB12XT 2010 Manuals
Manuals and User Guides for Buell XB12XT 2010. We have
1
Buell XB12XT 2010 manual available for free PDF download: Service Manual
Buell XB12XT 2010 Service Manual (714 pages)
Brand:
Buell
| Category:
Motorcycle
| Size: 55.57 MB
Table of Contents
Table of Contents
9
Fastener Torque Values
23
Fastener Torque Values in this Chapter
23
General
25
Servicing a New Motorcycle
25
Safe Operating Maintenance
25
Shop Practices
25
Repair Notes
25
Safety
25
Removing Parts
25
Cleaning
25
Disassembly and Assembly
26
Checking Torques on Fasteners with Lock Patches
26
Magnetic Parts Trays
26
Repair and Replacement Procedures
26
Hardware and Threaded Parts
26
Threadlocking Agents
26
Wiring, Hoses and Lines
26
Instruments and Gauges
26
Bearings
26
Bushings
26
Gears
27
Shafts
27
Part Replacement
27
Exhaust System Leakage
27
Cleaning
27
Part Protection
27
Cleaning Process
27
Rust or Corrosion Removal
27
Bearings
27
Tool Safety
27
Punches/Chisels
28
Screwdrivers
28
Ratchets and Handles
28
Sockets
28
Storage Units
28
Fuel and Oil
29
Fuel
29
Gasoline Blends: Buell Models
29
Engine Lubrication
29
Winter Lubrication
30
Bulb Requirements
31
General
31
Maintenance Schedule
32
Service Intervals
32
Engine Oil and Filter
33
General
33
Engine Oil Level
33
Cold Check (Pre-Ride)
33
Hot Check
33
Change Engine Oil and Filter
34
Drain Oil
34
Change Filter
34
Fill Engine with Oil
34
Clear Oil Cooler
35
Return to Service
35
Air Cleaner and Exhaust System
36
Removal
36
Cleaning and Inspection
37
Installation
37
Exhaust System Leak Check
38
Tires and Wheels
39
Tire Inflation
39
Tire Wear
39
Wheel Bearings
40
Clutch/Transmission/Primary Fluid
41
Inspection
41
Transmission Fluid
41
Adjustment
42
Primary Chain
44
Inspection
44
Adjustment
44
Drive Belt Maintenance
46
General
46
Inspection
46
Rear Sprocket
46
Drive Belt
46
Idler Pulley
46
Cleaning
46
Throttle Cable
49
Throttle Cable Adjustment
49
Interactive Exhaust Cable
50
Adjustment
50
Brake System Maintenance
52
General
52
Bleeding Brakes
52
Bleeding Front Brake
53
Bleeding Rear Brake
54
Brake Pedal Adjustment
54
Brake Pad Thickness
55
Brake Rotor Thickness
56
Brake Pad Replacement
56
Front Pad Removal
56
Front Pad Installation
56
Rear Pad Removal
57
Rear Pad Installation
57
Spark Plugs
59
Inspection
59
Battery Maintenance
61
General
61
Battery Disconnection and Removal
62
Cleaning and Inspection
62
Voltmeter Test
62
Charging Battery
62
Safety Precautions
62
Steering Head Bearings
66
Front Fork Oil Replacement
67
Headlamp
68
Windshield Maintenance
71
Storage
72
Troubleshooting
73
Fastener Torque Values
81
Vehicle Identification Number (Vin)
99
Wheels
101
Front Wheel
103
Rear Wheel
111
Tires
122
Checking Cast Rim Runout
128
Front Brake: Eight Piston Caliper
129
Front Brake: Six Piston Caliper
138
Brake Pedal
146
Rear Brake Master Cylinder
147
Rear Brake Line
153
Installation: Firebolt
154
Rear Brake Caliper
158
Fenders
161
Front Forks
163
Fork Clamps
170
Removal: Lightning/Ulysses
171
Installation: Lightning/Ulysses
171
Steering Head Bearings
173
Removal
173
Installation
173
Swingarm and Brace
176
General
176
Brace
176
Removal
176
Installation
176
Removal: Swingarm
176
Disassembly
177
Swingarm
177
Cleaning and Inspection
177
Assembly
178
Swingarm
178
Installation: Swingarm
178
Front and Rear Isolators
180
Front Isolator
180
Removal
180
Installation
180
Rear Isolator
180
Frame Pucks
181
Removal
181
Installation
181
Frame
183
Removal
183
Installation
183
Rear Shock Absorber
184
General
184
Removal: Firebolt
186
Removal: Lightning
187
Removal: Ulysses
187
Installation: Firebolt
188
Installation: Lightning
188
Installation: Ulysses
189
Throttle Control
190
Removal and Disassembly
190
Cleaning and Inspection
190
Assembly and Installation
190
Throttle Cable Replacement
191
Removal
191
Installation
191
Clutch Control
193
General
193
Removal and Disassembly
193
Clutch Cable
193
Assembly and Installation
195
Clutch Cable
195
Headlamp Assembly and Support Bracket
197
Removal: Firebolt
197
Disassembly: Firebolt
197
Assembly: Firebolt
197
Installation: Firebolt
198
Removal: Lightning/Ulysses
199
Disassembly: Lightning/Ulysses
201
Assembly: Lightning/Ulysses
201
Installation: Lightning/Ulysses
202
Fairing Support Bracket: Firebolt
203
Removal
203
Installation
203
Deflectors
205
Removal and Disassembly
205
Assembly and Installation
205
Grille: Xb9Sx/Xb12X/Xb12Xp/Xb12Sx
206
General
206
Removal and Installation
206
Front Modules: Lightning and Ulysses Models
207
Removal
207
Installation
208
Handlebars: Firebolt
209
General
209
Removal
209
Right Clip-On
209
Left Clip-On
209
Installation
209
Handlebars: Lightning and Ulysses Models
210
Removal
210
Installation
210
Mirrors
212
Removal
212
Installation
212
Footpeg, Heel Guard and Mount: Firebolt and Lightning Models
213
Rider
213
Removal
213
Installation
213
Passenger
213
Installation
214
Heel Guard and Footpeg Mounts: Ulysses Models
215
Sprocket Cover
217
Belt Guards
218
Intake Cover
219
Subframe Tail Assembly and Body Work: Firebolt
221
Left Tail Section and Battery Pan: Lightning Models
226
Center Tail Section: Lightning Models
230
Right Tail Section: Lightning Models
231
Left and Right Tail Section: Ulysses Models
232
Center Tail Loop: Ulysses Models
236
Trunk and Battery Pan: Ulysses Models
238
Sidestand
239
Front Fairing, Windshield, and Mirrors: Firebolt
241
Windshield and Windscreen: Lightning and Ulysses Models
242
Air Scoops
246
Chin Fairing
250
Seat
251
Seat Locks
255
Triple Tail: Ulysses Models
259
Luggage: Xb12Xt
261
Luggage: Xb12Xp
265
Fastener Torque Values
269
Specifications
271
Hydraulic Lifters
273
Engine
275
General
277
Engine Rotation for Service
277
Engine Removal
282
Engine Installation
292
Removal
303
Cylinder Head
303
Cleaning and Inspection
308
Cylinder and Piston
319
Oiling System
328
Oil Pump
329
Oil Reservoir and Oil Hose Routing
335
Installation
337
Oil Line Fittings
337
Oil Cooler
339
Oil Pressure Indicator Switch
340
Crankcase Breathing System
342
Hydraulic Lifters
344
Gearcase and Cam Gears
346
General
346
Removal and Disassembly
347
Cleaning and Inspection
347
Cam and Pinion Gear Identification, Inspection and Selection
348
Assembly and Installation
348
Crankcase
350
General
350
Disassembly
350
Crankcase Halves
350
Oil Filter Adapter
351
Piston Jets
352
Removal
352
Installation
352
Removing Cylinder Base Studs
352
Flywheel Assembly
352
Pinion Shaft Bearing
354
General
354
Selection
356
Replacement
356
Lapping Pinion Shaft Bearing Outer Race
358
Checking Connecting Rod Side Play
359
Assembly
359
Crankcase Halves
359
Fastener Torque Values
367
Fastener Torque Values in this Chapter
367
Specifications
369
General
369
Air Cleaner Assembly
370
Removal
370
Inspection
371
Installation
371
Electronic Control Module (Ecm)
373
Firebolt
373
Lightning
373
Removal
373
Installation
373
Throttle Position Sensor (Tps)
376
Removal
377
Installation
377
Ignition Coil
377
Removal
378
Oxygen Sensors (O2)
378
General
378
Removal
381
Engine Temperature Sensor (Et)
381
General
381
Removal
383
Bank Angle Sensor (Bas)
383
General
383
Firebolt
383
Lightning
383
Firebolt
384
Lightning
384
Intake Air Temperature Sensor
386
General
386
Removal
386
Intake Air Temperature Sensor (Iat)
386
Installation
387
Cooling Fan
387
General
387
Removal
387
Installation
388
Fuel Tank Vent Valve
388
General
388
Removal
388
Installation
389
Fuel Cap Retaining Ring
389
Removal
389
Fuel Pump
390
Draining Fuel Tank
390
Removal
390
Installation
391
Throttle Body
393
General
393
Removal
393
Repair
396
Throttle Position Sensor
396
Fuel Pressure Sensor
396
Fuel Injectors
396
Installation
396
Injector Leak Testing
397
Fuel Pressure Sensor
398
Replacement
398
Removal
398
Installation
398
Fuel Pressure Test
399
Inspection
399
Intake Leak Test
401
General
401
Leak Tester
401
Parts List
401
Tester Assembly
401
Tester Adjustment
401
Procedure
401
Exhaust System
403
Removal and Disassembly
403
Muffler
403
Front Muffler Mount
403
Rear Muffler Bracket
403
Exhaust Header
403
Assembly and Installation
404
Exhaust Header
404
Rear Muffler Bracket
405
Front Muffler Mount
405
Muffler and Straps
405
Exhaust System Leak
406
Evaporative Emissions Control (Ca Models)
407
General
407
Troubleshooting
407
Removal: Firebolt
407
Vent Valve
407
Canister
407
Removal: Lightning/Ulysses
407
Installation: Firebolt
407
Installation: Lightning/Ulysses
408
Vent Valve
408
Canister
408
Hose Routing
409
Fastener Torque Values
413
Fastener Torque Values in this Chapter
413
Specifications
415
General
415
Primary Cover
416
Removal
416
Primary Chain Adjuster Replacement
417
Installation
418
Clutch Release Mechanism
420
Disassembly
420
Cleaning and Inspection
420
Assembly
421
Clutch
422
General
422
Removal
424
Clutch Pack Cleaning and Inspection
425
Adjusting Screw Disassembly/Assembly
425
Assembly and Installation
426
Primary Chain
429
General
429
Removal
429
Clutch Shell/Hub Inspection
430
Clutch Shell Bearing Replacement
431
Installation
432
Drive Belt and Idler Pulley
435
General
435
Drive Belt Removal
436
Drive Belt Installation
436
Idler Pulley Removal
437
Idler Pulley Installation
437
Transmission
439
General
439
Case Disassembly for Transmission Removal
440
General
440
Right Crankcase Removal
440
Transmission Disassembly
443
Transmission Removal from Left Crankcase
443
Mainshaft/Countershaft
447
Mainshaft Disassembly
447
Cleaning and Inspection
448
Countershaft Disassembly
448
Transmission Assembly
450
Mainshaft Assembly
450
Countershaft Assembly
450
Main Drive Gear and Bearing
452
General
452
Removal
452
Main Drive Gear Bearing
453
Disassembly
454
Assembly
454
Installation
455
Main Drive Gear Ball Bearing
455
Main Drive Gear
456
Transmission Right Case Bearings
459
Transmission Left Case Bearings
461
Transmission Installation
463
Shifter Shaft
467
Transmission Sprocket
469
Fastener Torque Values
475
Specifications
478
Ignition/Headlamp Key Switch
479
Spark Plug Cables
487
Charging System
489
Battery Cables
492
Starter
495
Starter Solenoid
499
Voltage Regulator
502
Alternator
504
Heated Hand Grips: Ulysses Models
506
Horn
509
Turn Signal Flasher
511
Removal
511
Installation
511
Front Turn Signals
513
Bulbs
513
Repair
513
Connections and Wire Routing
513
Firebolt
513
Removal
513
Installation
513
Lightning
513
Ulysses
514
Removal
514
Installation
514
Rear Turn Signals
516
Bulbs
516
Connections and Wire Routing
516
Firebolt
516
Removal
516
Installation
516
Lightning
517
Removal
517
Installation
518
Ulysses
518
Remove
518
Turn Signal Relocation Bracket: XB12XP
519
Removal
519
Installation
519
Interactive Exhaust System
521
General
521
Removal
523
Installation
524
Headlight
525
General
525
Headlight Bulbs: Firebolt
525
Removal
525
Installation
525
Headlight Bulbs: Lightning and Ulysses
526
Removal
526
Installation
527
Tail Lamp
530
Ulysses/Firebolt/Lightning
530
Removal
530
Installation
530
License Plate Lamp Assembly
532
Firebolt
532
Removal
532
Installation
532
Lightning
532
Ulysses
533
Removal and Disassembly
533
Assembly and Installation
533
Main Fuse and Fuses
534
General
534
Fuses
534
Main Fuse
534
Neutral Indicator Switch
537
General
537
Testing
537
Removal and Installation
537
Sidestand Switch (Hdi)
538
Removal
539
Installation
539
Crankshaft Position Sensor
539
General
539
Crankshaft Position Sensor (Ckp)
539
Removal
541
Installation
541
Vehicle Speed Sensor (Vss)
541
Instrument Module
542
Installation
543
Main Wire Harness
545
General
545
Removal
560
Auxiliary Harness: Xb12Xp
560
XB12XP Ulysses Police Model Auxiliary Harness
560
Installation
562
Interactive Exhaust Harness: Xb12 Models
564
Firebolt
564
Removal
564
Installation
564
Lightning
565
Removal
565
Installation
565
Ulysses
566
Removal
566
Installation
566
Sprocket Cover Wiring
568
General
568
Removal
568
Auxiliary Power Outlets: Ulysses Models
569
Amp Multilock Connectors
573
Autofuse Electrical Connectors
577
Delphi Connectors
578
Deutsch Electrical Connectors
580
Deutsch Standard Terminal Repair
584
Deutsch Solid Barrel Mini Terminal Repair
585
Deutsch Mini Terminal Repair
587
Packard 150 Metri-Pack Connectors
588
Packard 630 Metri-Pack Connectors
590
Packard Metri-Pack Terminals
591
Sealed Splice Connectors
593
Fluid Conversion
624
United States System
624
Metric System
624
British Imperial System
624
Torque Conversion
625
United States System
625
Metric System
625
Appendix D Hose and Wire Routing
629
Firebolt
629
Lightning
642
Ulysses
654
Appendix E Active Intake (Japanese Models)
669
Active Intake System (Japanese Models Only)
669
General
669
Active Intake System
669
Diagnostic Notes
669
Verify Settings
669
WOT Check
669
Cable
669
Adjustment
669
Throttle Stop Screw
671
Removal
672
Installation
673
Appendix F Glossary
675
Glossary
677
Acronyms and Abbreviations
677
II Tools
682
VIII Torque Values
688
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