Page 1 2003 BUELL XB9S SERVICE MANUAL Part Number 99490-03Y Section 1: Maintenance Section 2: Chassis Section 3: Engine Section 4: Fuel System Section 5: Starter Section 6: Drive/Transmission Section 7: Electrical Appendices...
Page 2 Part No. B-45521 Steering Head Bearing Remover/ Installer Part No. B-43721 Front Fork Seal Driver Part No. HD-39302 Steering Head Bearing Race Installer (Used with B-45521) Part No. B-46279 7/8" Axle Wrench (Hex) Part No. B-59000A Pro Level Oil Gauge 2003 Buell XB9S: Appendix A...
Page 3 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 2003 Buell XB9S: Appendix A...
Page 4 Part No. HD-96921-52A Oil Pressure Gauge Part No. HD-34902-B Bearing Race Remover/Installer 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 2003 Buell XB9S: Appendix A...
Page 5 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 2003 Buell XB9S: Appendix A...
Page 6 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 2003 Buell XB9S: Appendix A...
Page 7 Part No. HD-39965 Deutsch Terminal Crimp Tool and Part No. HD-38515-91 Forcing Screw Part No. J-5586 Transmission Shaft Part No. HD-41354 Speedometer Tester Retaining Ring Pliers Part No. HD-97292-61 Two Claw Puller Part No. HD-41609 Amp Terminal Crimp Tool 2003 Buell XB9S: Appendix A...
Page 8: Amp Multilock Electrical Connectors
Pin terminal Secondary lock open Pin housing Socket housing Latch Latch Secondary lock open Button Latch Secondary lock open Socket terminal Figure B-1. 10-Place Amp Multilock Connector 2003 Buell XB9S: Appendix B...
Page 9 Figure B-3. Multilock Connector Cutaway View engage latches on both sides of connector. Insert the socket housing (plug) into the pin housing (receptacle) until it snaps in place. Install connector on retaining device, either attachment or rosebud clip. 2003 Buell XB9S: Appendix B...
Page 10 Pin terminal Socket housing Button Pin housing Secondary lock Pin terminal Secondary lock Socket terminal Latch Button Pin housing Latch Socket housing Secondary lock Socket terminal d0245x2x Figure B-4. 3-Place and 6-Place Amp Multilock Connectors 2003 Buell XB9S: Appendix B...
Page 11 Release contacts locking bar. locking bar GAUGE CRIMP TOOL WIRE NEST Front Middle Rear Close and squeeze crimp tool. Raise locking bar and remove contact. d0246x8x Figure B-5. Amp Multilock Crimping Procedure 2003 Buell XB9S: Appendix B...
Page 12: 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. 2003 Buell XB9S: Appendix B...
Page 13 (Part No. HD-41475-100). See Figure B-10. Figure B-9. Depress Terminal Latches/Back Out Pins Gently depress terminal latches inside pin housing and back out pins through holes in wire seal. 2003 Buell XB9S: Appendix B...
Page 14 The socket and pin halves of all other connectors are interchangeable, that is, the black may be mated with the gray, since the alignment tabs are absent and the orientation of the external latch is the same. 2003 Buell XB9S: Appendix B...
Page 15 When correctly positioned, the locking bar ﬁts snugly in the space between the contact band and the core crimp tails. 2003 Buell XB9S: Appendix B...
Page 16 SOCKET SIDE PIN SIDE Socket terminal Locking wedge Wire seal Latch cover Socket housing Pin housing External latch 10. Wire seal Internal seal 11. Pin terminal Locking wedge Figure B-13. 2-Pin, 3-pin and 4-pin Deutsch Connectors 2003 Buell XB9S: Appendix B...
Page 17 MAP sensor connector [80]. d0258x8x Locate tang on latch side of chamber. Push on wire end of lead to remove terminal. Pivot end of pin to depress tang. Raise tang and re-install terminal. Figure B-14. Packard Connectors B-10 2003 Buell XB9S: Appendix B...
Page 18 NOTE A series of Packard Electrical Terminal Crimp Tools are avail- able to install Packard pin and socket terminals on wires. If new terminals must be installed, see Crimping Instructions. 2003 Buell XB9S: Appendix B B-11...
Page 19 Repeat the step if the terminal is still locked in place. NOTE A series of Packard Electrical Terminal Crimp Tools are avail- able to install Packard pin and socket terminals on wires. If new terminals must be installed, see Crimping Instructions. B-12 2003 Buell XB9S: Appendix B...
Page 20 11. See Figure B-16. Inspect the quality of the core (3) and insulation/seal (2) crimps. Distortion should be minimal. Insulation Insulation crimp Core crimp Figure B-16. Inspect Core and Insulation/Seal Crimps 2003 Buell XB9S: Appendix B B-13...
Page 21: Electrical Connectors
1-place spade (ground) [95] clutch switch 2-place Multilock underside of clutch lever assembly [97] cooling fan 2-place Multilock behind rear cylinder, under seat [120] oil pressure switch post terminal crankcase above oil ﬁlter B-14 2003 Buell XB9S: Appendix B...
Page 22 [131] neutral switch 1-place bullet under sprocket cover [133] sidestand switch 2-place Multilock top of sidestand [134] bank angle sensor 6-place Sumitomo under seat [137] oxygen sensor 1-place Packard behind rear cylinder head 2003 Buell XB9S: Appendix B B-15...
Page 23: Table Of Contents
INDEX TO WIRING DIAGRAMS Table B-3. XB9S 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 Charging circuits B-22 Component Circuits B-23 B-16 2003 Buell XB9S: Appendix B...
Page 24: Main Harness
[31A] [31B] TO TAIL LIGHT GROUND TACH IN [93B] VSS IN [95A] TO RH TURN SIGNAL UNUSED UNUSED [18A] [18B] SPEEDOMETER UNUSED UNUSED TO RH TURN SIGNAL [39A] [39B] [18A] [18B] 2003 XB9S Main Harness 2003 Buell XB9S: Electrical B-17...
Page 25: Engine Management Circuit
TO CLUTCH HIGH BEAM SWITCH BK/Y LT.GN/R CHECK ENGINE OIL PRESSURE UNUSED [95B] UNUSED UNUSED IGNITION [91A] GROUND TACH IN VSS IN [95A] UNUSED UNUSED SPEEDOMETER UNUSED UNUSED [39A] [39B] 2003 XB9S Engine Management Circuit 2003 Buell XB9S: Electrical B-18...
Page 26: Lighting Circuit
GROUND [31A] [31B] TO TAIL LIGHT GROUND TACH IN [93B] VSS IN TO RH TURN SIGNAL UNUSED [18A] [18B] UNUSED SPEEDOMETER UNUSED UNUSED TO RH TURN SIGNAL [39A] [39B] [18A] [18B] 2003 XB9S Lighting Circuit 2003 Buell XB9S: Electrical B-19...
Page 27: Horn And Instruments Circuit
NEUTRAL TN/Y LEFT TURN RIGHT TURN HIGH BEAM CHECK ENGINE OIL PRESSURE GN/Y UNUSED UNUSED UNUSED IGNITION GROUND TACH IN VSS IN UNUSED UNUSED SPEEDOMETER UNUSED UNUSED [39A] [39B] 2003 XB9S Horn & Instruments Circuit 2003 Buell XB9S: Electrical B-20...
Page 28: Starting Circuit
W/BK TN/LT.GN GY/O GY/O R/BK TN/W TN/W BK/R R/BK R/BK TO SIDESTAND SWITCH SWITCH TN/W R/BK [133A] [133B] GY/O TN/W TN/LT.GN TN/LT.GN TN/LT.GN TN/Y TOP VIEW TO CLUTCH SWITCH [95B] [95A] 2003 XB9S Starting Circuit 2003 Buell XB9S: Electrical B-21...
Page 29: Charging Circuits
HOME bs0013xx BATTERY [GRD2] IGNITION START KEY SWITCH TO VOLTAGE REGULATOR VOLTAGE REGULATOR STATOR TOP VIEW (HD 3-PHASE) [46A] [46B] 2003 XB9S Charging Circuit 2003 Buell XB9S: Electrical B-22...
Page 30: Component Circuits
[84A] FUEL SENSOR GN/Y [85B] OIL PRESSURE [84B] [120A] [120B] SWITCH ENGINE TEMP SENSOR [65A] GN/GY [90B] [90A] VEHICLE GN/Y SPEED MAIN HARNESS SENSOR PK/Y LT.GN/Y LT.GN/Y BK/W BK/W [89A] [89B] 2003 XB9S Component Circuits 2003 Buell XB9S: Electrical B-23...
Page 31 44.45 79.37 114.30 .8268 2.126 3.425 4.724 10.160 45.72 80.96 115.89 .8661 2.165 3.464 4.764 11.112 46.04 81.28 116.84 .9055 2.205 3.504 4.803 12.700 47.62 82.55 117.47 .9449 2.244 3.543 4.842 14.288 48.26 83.82 119.06 2003 Buell XB9S: Appendix C...
Page 32 SAE 8 150,000 MEDIUM STEEL CARBON ALLOY SOCKET 212,000 HIGH CARBON QUENCHED 140* SCREW TEMPERED STUDS Use SAE 2, 5 and 8 values when grade is known, with nut of sufﬁcient strength. *Torque values in in-lbs 2003 Buell XB9S: Appendix C...
Page 33 138.3 201.9 SCREW TEMPERED STUDS Use SAE 2, 5 and 8 values when grade is known, with nut of sufﬁcient strength. foot-pounds (ft-lbs) x 1.356 = Newton-meters (Nm)inch- pounds (in-lbs) x 0.113 = Newton-meters (Nm) 2003 Buell XB9S: Appendix C...
Page 34 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.) 2003 Buell XB9S: Appendix C...
Page 35 HOME HOSE AND WIRE ROUTING b1114xasx Figure D-1. Front and Rear Brake Systems, Right Side View...
Page 36 HOME b1115xbsx Figure D-2. Rear Brake Systems, Top View...
Page 37 HOME b1116xcsx Figure D-3. Rear Brake Systems, Left Side View...
Page 38 HOME b1117xasx Carbon canister Figure D-4. Evaporative Emissions Control, California Models, Top View...
Page 39 HOME b1118xbsx 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 40 HOME b1119xasx Intake air temperature sensor (IAT) Fuel pump Sidestand switch Figure D-6. Wiring Harness, Left Side View...
Page 41 HOME b1120xbsx Fuel injector (2) Intake air temperature (IAT) sensor Throttle position sensor (TPS) Oxygen (O2) sensor Figure D-7. Wiring Harness, Top View...
Page 42 HOME b1121xcsx 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 43 HOME b1122xasx 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 44 HOME b1123xbsx Vent line Feed oil line Return oil line Figure D-10. Oil Lines, Bottom View...
Page 45 HOME b1124xasx Figure D-11. Clutch Cable, Right Side View...
Page 46 HOME b1125xbsx Cable, seat lock Figure D-12. Clutch, Throttle and Seat Release Cables, Left Side View...
Page 47 HOME b1126xcsx TPS adjuster Cable, seat lock Figure D-13. Clutch, Throttle and Seat Release Cables, Top View...
Page 49 MAINTENANCE Table Of Contents SUBJECT PAGE NO. 1.1 General ............1.2 Fuel and Oil .
Page 51: Safe Operating Maintenance
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. 2003 Buell XB9S: Maintenance...
Page 52: 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. 2003 Buell XB9S: Maintenance...
Page 53: 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. 2003 Buell XB9S: Maintenance...
Page 54: 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. 2003 Buell XB9S: Maintenance...
Page 55: 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. 2003 Buell XB9S: Maintenance...
Page 56: Maintenance Schedule
Road test. Chart Codes: I - Inspect, & if necessary correct, clean or replace. R- Replace or change. A- Adjust. D- Disassemble (lube & inspect). L- Lubricate with specified lubricant. T- Tighten to proper torque. X- Perform. 2003 Buell XB9S: Maintenance...
Page 57: 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 58: Battery Maintenance
HOME BATTERY MAINTENANCE GENERAL BATTERY TESTING Voltmeter Test Buell motorcycle batteries are permanently sealed, mainte- nance-free, valve-regulated, lead/calcium and sulfuric acid Table 1-3. 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 59: Cleaning And Inspection
Inspect the battery case for cracks or leaks. at 77 ° F 75 % at 105 ° F 50 % M O N T H S O F S T A N D Figure 1-2. Battery Self-Discharge Rate 2003 Buell XB9S: Maintenance...
Page 60 Install seat. See 2.41 SEAT. sion which could result in death or serious injury. CAUTION Overtightening fasteners can damage battery terminals. 1-10 2003 Buell XB9S: Maintenance...
Page 61: Engine Lubrication System
If oil level is below lower registration mark, add only Do not overﬁll oil tank. Overﬁlling oil tank may result in enough oil to bring oil level between lower and upper oil carryover to the air cleaner, equipment damage and/or equipment malfunction. registration marks. 2003 Buell XB9S: Maintenance 1-11...
Page 62 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. 1-12 2003 Buell XB9S: Maintenance...
Page 63 ° 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 2003 Buell XB9S: Maintenance 1-13...
Page 64: Brake System Maintenance
At every 2500 miles (4000 km) service interval thereaf- ing or bleeding system. To prevent death or serious ter. injury, Buell recommends that all brake repairs be per- formed by a Buell dealer or other qualiﬁed technician. Every 2 years.
Page 65 Distorted, glazed or contaminated 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. 2003 Buell XB9S: Maintenance 1-15...
Page 66: Bleeding Front Brake
Verify master cylinder ﬂuid level as described in step 4. 10. Attach cover to front master cylinder reservoir and tighten fastener to 9-13 in-lbs (1.0-1.5 Nm). 11. Remove cover from molded-in-color surfaces, right han- dlebar switches and instrument panel. 1-16 2003 Buell XB9S: Maintenance...
Page 67: Bleeding Rear Brake
Repeat steps 5-6 until all air bubbles are purged. Tighten rear caliper bleeder valves (metric) to 36-60 in- lbs (4-7 Nm). Verify master cylinder ﬂuid level as described in step 4. Install cover on master cylinder reservoir and tighten cap securely. 2003 Buell XB9S: Maintenance 1-17...
Page 68 Return locknut (3) to ﬁt ﬂush against top surface of clevis and tighten to 130-173.5 in-lbs (14.7-19.6 8349 Nm). NOTE Brake pedal has no free play adjustment. Bottom of master cylinder Rod adjuster Locknut Clevis Clevis pin Figure 1-12. Rear Brake Pedal Pushrod Adjustment 1-18 2003 Buell XB9S: Maintenance...
Page 69 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 2003 Buell XB9S: Maintenance 1-19...
Page 70: Brake Pad Replacement
37 ft-lbs (48-50 Nm). Tighten pin (2) to 11-15 ft-lbs (15-20 Nm). NOTE Avoid making hard stops for the ﬁrst 100 miles (160 km) to allow new brake pads to “wear in” properly with the rotor. 1-20 2003 Buell XB9S: Maintenance...
Page 71 “wear in” properly with the rotor. Rear caliper mounting fasteners Retainer, brake pads Rear caliper pin plug Rear caliper hanger pin Figure 1-16. Rear Brake Caliper 6487 Figure 1-17. Pad Spring, Rear Brake 2003 Buell XB9S: Maintenance 1-21...
Page 72: Tires And Wheels
Tire cords or fabric become visible through cracked side- walls, snags or deep cuts. A bump, bulge or split in the tire. Puncture, cut or other damage to the tire that cannot be repaired. 1-22 2003 Buell XB9S: Maintenance...
Page 73: Clutch
84-108 in-lbs (10- 12 Nm). b1144x1x Clean up any ﬂuid that may have spilled on mufﬂer. Clutch diaphragm spring Clutch adjusting screw Primary cover Chaincase lubricant level Figure 1-21. Fluid Level 2003 Buell XB9S: Maintenance 1-23...
Page 74 ﬂats. If hex on lockplate does not align with recess in outer ramp, rotate adjusting screw clockwise until it aligns. 8405 NOTE Spring installs on outboard side of hex lockplate. Diaphragm spring Lockplate Adjusting screw Figure 1-23. Clutch Adjustment 1-24 2003 Buell XB9S: Maintenance...
Page 75 Install clutch inspection cover and gas- ket 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 2003 Buell XB9S: Maintenance 1-25...
Page 76: Drive Belt
If scribe or knife point digs in and leaves a visible mark, it is cutting the bare aluminum. A knife point will not penetrate the chrome plating. Replace rear sprocket if major tooth damage or loss of chrome exists. 1-26 2003 Buell XB9S: Maintenance...
Page 77 OK to run, but monitor condition Fuzzy edge cord OK to run, but monitor condition Hook wear Replace belt Stone damage Replace belt if damage is on the edge Bevel wear (outboard edge only) OK to run, but monitor condition 2003 Buell XB9S: Maintenance 1-27...
Page 78 HOME NOTES 1-28 2003 Buell XB9S: Maintenance...
Page 79: Primary Chain
Hot (normal running 1/4-3/8 in. 6.4-9.5 mm Figure 1-26. Install primary chain inspection cover temperature) and gasket to primary cover using two fasteners with captive washers. Tighten fasteners to 40-60 in-lbs (5- 7 Nm). 2003 Buell XB9S: Maintenance 1-29...
Page 80 Loosen locknut (1). Turn adjusting fastener (2): Clockwise (inward) to reduce free play. Counterclockwise (outward) to increase free play. Locknut Tighten locknut (1) to 20-25 ft-lbs (27-34 Nm). Adjusting screw Figure 1-28. Chain Tension Adjusting Fastener 1-30 2003 Buell XB9S: Maintenance...
Page 81: Suspension Damping Adjustments
170-190 (77-86) 1 1/2 1 1/2 1 3/4 1 1/2 190-210 (86-95) 1 1/4 1 1/2 1 1/2 1 1/4 210-230 (95-104) 1 1/4 1 1/2 1 1/4 230-400 load capacity 1 1/4 1 1/4 (104-181) 2003 Buell XB9S: Maintenance 1-31...
Page 82 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 1-9. 1-32 2003 Buell XB9S: Maintenance...
Page 83 Using a screwdriver, turn the slotted dial 8416 clockwise until it stops. This is the maximum rebound damping setting. Then turn the dial counterclockwise the recommended amount speciﬁed in Table 1-9. Figure 1-32. Rear Shock Rebound Adjustment 2003 Buell XB9S: Maintenance 1-33...
Page 84 If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install seat. See 2.41 SEAT. Figure 1-33. Rear Shock Compression Adjustment 1-34 2003 Buell XB9S: Maintenance...
Page 85: Steering Head Bearings
13-15 ft-lbs (18-20 Nm). RESISTANCE. 11. When adjustment is complete, attach clutch cable and When adjustment is complete, attach clutch cable and adjust. See 1.9 CLUTCH. adjust. See 1.9 CLUTCH. 12. Remove scissor jack. 2003 Buell XB9S: Maintenance 1-35...
Page 86: 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. 1-36 2003 Buell XB9S: Maintenance...
Page 87 If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. 16. Install seat. See 2.41 SEAT. 2003 Buell XB9S: Maintenance 1-37...
Page 88: Air Cleaner Filter
Thoroughly clean baseplate and inside of airbox. Figure 1-39. Make sure two crankcase breather hoses (1) and intake air sensor (2) are captured in base- plate behind velocity stack (3). 1-38 2003 Buell XB9S: Maintenance...
Page 89 If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install seat. See 2.41 SEAT. 2003 Buell XB9S: Maintenance 1-39...
Page 90: Throttle Cable And Idle Speed Adjustment
At every 5000 miles (8000 km) service interval thereafter. Regular idle speed is 1050-1100 RPM. Set idle speed using idle adjuster shown in Figure 1-41. Turn adjuster clockwise to increase idle speed or counterclockwise to decrease idle speed. 1-40 2003 Buell XB9S: Maintenance...
Page 91: Ignition Timing
HIGH - 5 volts as timing mark is just coming into view at left edge of window and will switch to LOW - 0 volts at same point as the timing mark continues through the window. (If this is observed, turn ﬂywheel forward one 2003 Buell XB9S: Maintenance 1-41...
Page 92 If timing is retarded (mark appears on right side of window) rotate timing plate clockwise. Recheck timing. Figure 1-44. Timer Cover 8391 Figure 1-45. Cam Position Sensor b0964x1x Figure 1-46. Advanced Timing b0963x1x Figure 1-47. Retard Timing 1-42 2003 Buell XB9S: Maintenance...
Page 93: 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 1-48. Figure 1-49. Headlamp Switch Adjust headlamp alignment. See ADJUSTMENT section. 2003 Buell XB9S: Maintenance 1-43...
Page 94 NOTE Only loosen headlamp alignment fasteners enough to adjust headlamp. Once headlights are aligned, tighten fasteners to 48-72 in-lbs (5-8 Nm). 9950 Figure 1-50. Horizontal Headlamp Adjustment 9951 Figure 1-51. Vertical Headlamp Adjustment 1-44 2003 Buell XB9S: Maintenance...
Page 95: Throttle Position Sensor (Tps)
NOTE This is to ensure that the throttle plate is completely closed before beginning recalibration. Select calibrations screen. Select the Buell calibrations tab. Select Zero TPS function. NOTE When calibration is complete, dialogue box will appear on Digital Tech screen with message display “Command Sent Successfully”.
Page 96: 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. 1-46 2003 Buell XB9S: Maintenance...
Page 97: 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. 2003 Buell XB9S: Maintenance 1-47...
Page 98: Electrical System
Dirt or other foreign matter between valve and its seat. Wheels not aligned and/or tires worn. Poor Fuel Economy Internal engine problem. O2 sensor damaged or malfunctioning (bike running Wheels not balanced correctly. rich). See dealer. 1-48 2003 Buell XB9S: Maintenance...
Page 99 See 1.12 SUSPENSION DAMPING ADJUSTMENTS. 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. 2003 Buell XB9S: Maintenance 1-49...
Page 100 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. 1-50 2003 Buell XB9S: Maintenance...
Page 101: Sidestand
(down) and retracted (up) positions. Check sidestand switch (starter interlock) for proper operation after the ﬁrst 1500 miles (2400 km) and every 2500 miles (4000 km) thereafter. See 7.5 STARTER INTERLOCK. 2003 Buell XB9S: Maintenance 1-51...
Page 102 HOME NOTES 1-52 2003 Buell XB9S: Maintenance...
Page 103 Table Of Contents CHASSIS SUBJECT PAGE NO. 2.1 Specifications ..........2.2 Tire Specifications .
Page 104: Specifications
Rear Lateral 0.0154 0.39 WARNING WARNING Do not inﬂate any tire beyond its maximum inﬂation pres- sure as speciﬁed on tire sidewall. Overinﬂation may cause tire to suddenly deﬂate which could result in death or serious injury. 2003 Buell XB9S: Chassis...
Page 105: Torque Values
Fork damper locknut 22-30 ft-lbs 30-40 Nm page 2-47 Front fender fasteners 12-36 in-lbs 1-4 Nm page 2-78 Front isolator bolt 49-51 ft-lbs 66-69 Nm page 2-59 Front isolator bracket mounting fastener 49-51 ft-lbs 66-69 Nm page 2-59 2003 Buell XB9S: Chassis...
Page 106 Switch housing fasteners, right 25-33 in-lbs 3-4 Nm page 2-63 Torca clamp 40-45 ft-lbs 54-61 Nm page 2-74 Valve stem nut 40-44 in-lbs 4-5 Nm page 2-20 Wear Peg, rider 36-48 in-lbs 4.1-5.4 m page 2-75 2003 Buell XB9S: Chassis...
Page 107: Tire Specifications
& POSITION RIM SIZE HOLE DIAMETER TIRE SIZE 17 in. – Front MT 3.5 x 17.0 DOT 0.33 in. 120/70 ZR17 D207FY 17 in. – Rear MT 5.5 x 17.0 DOT 0.33 in. 180/55 ZR17 D207U 2003 Buell XB9S: Chassis...
Page 108: Vehicle Identification Number
An abbreviated V.I.N. is stamped on the front left side of the crankcase. NOTE Figure 2-3. Always give the V.I.N. or abbreviated V.I.N. when ordering parts or making inquiries about your Buell motorcycle. Figure 2-2. Abbreviated V.I.N. Location Manufacturer: Buell Motorcycle Company Type Designation-Lightning XB9S...
Page 109: Wheels
Figure 2-4. Checking Tire Inﬂation Pressure Figure 2-4. Check tire inﬂation pressure at least once each week. At the same time, inspect tire tread for punctures, cuts, breaks and other damage. Repeat the inspection before long trips. 2003 Buell XB9S: Chassis...
Page 110 Always locate and eliminate the cause of the original your Buell dealer. Speed should not exceed 50 mph (80 tire failure. km/h) for the ﬁrst 24 hours after repair and the repaired Do not patch or vulcanize a tire casing.
Page 111: Front Wheel
Figure 2-5. Front Wheel Mounting Figure 2-6. Raise the wheel up until the rotor clears the caliper and rotate the fork leg counterclockwise allowing wheel clearance for removal. Remove wheel. 8441 Figure 2-6. Front Wheel Removal 2003 Buell XB9S: Chassis...
Page 112 Forcing screw Figure 2-9. Expand the Collet Figure 2-10. Place the bridge (1) against the wheel hub. Hold the forcing screw (2), and turn the nut (3) clockwise until the bearing is free of the hub. 2003 Buell XB9S: Chassis...
Page 113 Always replace brake pads in complete sets for correct brake operation. Never replace just one brake pad. Fail- ure to install brake pads as a set could result in death or serious injury. Inspect brake rotor and pads. See 1.7 BRAKE SYSTEM MAINTENANCE. 2-10 2003 Buell XB9S: Chassis...
Page 114: Bearing Installation
Install the Backing Plate (Part No. B- 43993-11) onto the long forcing screw from the Wheel Bearing Installer/Remover (Part No. HD-44060), with the smaller diameter toward the wheel hub. Insert the forcing screw and backing plate into the wheel hub. 2003 Buell XB9S: Chassis 2-11...
Page 115 15. Remove the nut, bearing, washer, FRONT BEARING INSTALLER (Part No. B-43993-10) and forcing screw. 16. Install the wheel. See INSTALLATION/2.5 FRONT Forcing screw WHEEL. Spacer Figure 2-16. Install the Spacer 10. See Figure 2-16. Install the spacer. 2-12 2003 Buell XB9S: Chassis...
Page 116 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. 2003 Buell XB9S: Chassis 2-13...
Page 117 (2) to 20-22 ft-lbs (27-30 Nm). Install right side fender fasteners. See 2.32 FENDERS. Figure 2-19. Front Wheel Installation 8419 Axle (left handed thread) Front axle pinch fasteners (2) (metric) Figure 2-20. Front Wheel Mounting 2-14 2003 Buell XB9S: Chassis...
Page 118: Rear Wheel
Remove rear wheel spacer (4). NOTE For wheel bearing removal follow identical procedure as used for front wheel. Axle Pinch bolt fastener Figure 2-22. Rear Wheel Mounting, Right Side Figure 2-22. Remove rear axle (1). Remove rear wheel. 2003 Buell XB9S: Chassis 2-15...
Page 119 Always test motorcycle brakes at low speed after servic- motorcycle. ing or bleeding system. To prevent death or serious injury, Buell recommends that all brakes repairs be per- Install rear wheel spacer (4). formed by a Buell dealer or other qualiﬁed mechanic.
Page 120 HOME b0936x2x Rotor mounting fastener (6) Wheel Brake rotor Sprocket Wheel bearing Sprocket fastener Wheel spacer Axle Figure 2-24. Rear Wheel Assembly 2003 Buell XB9S: Chassis 2-17...
Page 121: Checking Cast Rim Runout
Wheel Truing and Balancing Stand (HD-99500-80) Table 2-8. Wheel Runout b0758x2x CAST WHEEL Maximum Lateral 0.040 1.02 Runout Maximum Radial 0.030 0.76 Runout Gauge rod Figure 2-26. Checking Cast Rim Radial Runout Using Wheel Truing and Balancing Stand (HD-99500-80) 2-18 2003 Buell XB9S: Chassis...
Page 122: Tires
Installing a tire with the wrong rotation could result in death or serious injury. Dunlop front and rear tires for Buell motorcycles are not the same. They are not interchangeable. Use Figure 2-27. Loosening Beads from Rim Flange front tire ONLY for a front tire.
Page 123 This outward movement could cause the valve/cap to strike the adjacent components, damage the valve and cause rapid tire deﬂation. Rapid tire deﬂation could cause loss of control. These events could result in death or serious injury. 2-20 2003 Buell XB9S: Chassis...
Page 124 Figure 2-30. Checking Tire Lateral Runout RUNOUT. Replace rims not meeting speciﬁcations. Install tire and check tire tread radial runout again. b0088x2x Gauge Figure 2-31. Checking Tire Radial Runout Table 2-9. Tire Runout RUNOUT Radial 0.060 1.52 Lateral 0.080 2.03 2003 Buell XB9S: Chassis 2-21...
Page 125: 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 and rebalance until wheel is within speciﬁca- tion. 2-22 2003 Buell XB9S: Chassis...
Page 126: Brake Pedal
(5) to 22-24 ft-lbs (30-33 Nm). Install clevis pin (2). Install new cotter pin (7).ss Rear master cylinder body Clevis pin Pedal bushings (2) Shift brake pedal sleeve Brake pedal fastener Brake pedal Cotter pin Figure 2-33. Brake Pedal Assembly 2003 Buell XB9S: Chassis 2-23...
Page 127: Front Brake Master Cylinder And Hand Lever 2.10
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 2-34. Front Brake Hand Lever Assembly 2-24 2003 Buell XB9S: Chassis...
Page 128: Front Master Cylinder
Circlip Figure 2-35. Piston Assembly in Master Cylinder Figure 2-35. Depress piston assembly (1) and remove internal circlip (2) and discard. Figure 2-34. Remove piston assembly (6) from front master cylinder reservoir (4) and discard. 2003 Buell XB9S: Chassis 2-25...
Page 129 Figure 2-36. Front Master Cylinder Piston Assembly Figure 2-36. 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. 2-26 2003 Buell XB9S: Chassis...
Page 130 Always test motorcycle brakes at low speed after servic- ing or bleeding system. To prevent death or serious injury, Buell recommends that all brake repairs be per- formed by a Buell dealer or other qualiﬁed technician. 2003 Buell XB9S: Chassis...
Page 131: 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 2-39. Front Brake Line 2-28 2003 Buell XB9S: Chassis...
Page 132 Always test motorcycle brakes at low speed after servic- ing or bleeding system. To prevent death or serious injury, Buell recommends that all brake repairs be per- formed by a Buell dealer or other qualiﬁed mechanic. 2003 Buell XB9S: Chassis...
Page 133: Front Brake Caliper
Figure 2-41. 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 2-43. Removing Pistons (B-42887) 2-30 2003 Buell XB9S: Chassis...
Page 134 Install two new o-rings (6) in grooves of each piston bore. Install pistons (5) in each piston bore. Install new o-rings (8) between caliper halves. Clamp caliper together with caliper fasteners (11) and tighten to 15-19 ft-lbs (20-26 Nm). 2003 Buell XB9S: Chassis 2-31...
Page 135 HOME b0976x2x Pin hanger set Pad spring Brake bleeder Small o-ring Bleeder cap Caliper mounting fasteners Caliper 10. Brake pads Piston 11. Caliper fasteners Piston o-rings Figure 2-44. Front Caliper Assembly 2-32 2003 Buell XB9S: Chassis...
Page 136: Rear Brake Master Cylinder
Remove brake reservoir hose at master GUARD AND MOUNT. cylinder. Remove seat. See 2.41 SEAT. CAUTION Damaged banjo bolt surfaces will leak when reassem- bled. Prevent damage to seating surfaces by carefully removing brake line components. 2003 Buell XB9S: Chassis 2-33...
Page 137 11. Rear master cylinder mount screw Figure 2-48. Rear Master Cylinder Assembly Figure 2-48. Remove rear brake light switch (1) (metric) and two copper crush washers (3) to detach brake line (2) from master cylinder (4). Discard copper crush washers. 2-34 2003 Buell XB9S: Chassis...
Page 138 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). 2003 Buell XB9S: Chassis 2-35...
Page 139 2.30 FOOTPEG, ing or bleeding system. To prevent death or serious HEEL GUARD AND MOUNT. injury, Buell recommends that all brake repairs be per- formed by a Buell dealer or other qualiﬁed mechanic. WARNING WARNING 10. Add brake ﬂuid and bleed brake system. See 1.7 BRAKE...
Page 140: Rear Brake Line
Pump brake foot pedal to drain brake ﬂuid. Tighten bleeder valve to 36-60 in-lbs (4-7 Nm). Figure 2-53. Rear Brake Line Switch/Banjo Bolt Figure 2-53. Remove brake line switch/banjo bolt from rear master cylinder. Discard copper washer. Remove brake line from motorcycle. 2003 Buell XB9S: Chassis 2-37...
Page 141 If brakes are not operating properly or braking efﬁciency is poor, testing at high speeds could result in death or serious injury. 10. Test ride motorcycle and check for proper brake opera- tion. 2-38 2003 Buell XB9S: Chassis...
Page 142: Rear Brake Caliper
Figure 2-56. Removing Rear Brake Caliper Piston Figure 2-56. 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. 2003 Buell XB9S: Chassis 2-39...
Page 143 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. 2-40 2003 Buell XB9S: Chassis...
Page 144 Always test motorcycle brakes at low speed after servic- which could result in death or serious injury. ing or bleeding system. To prevent death or serious injury, Buell recommends that all brake repairs be per- CAUTION formed by a Buell dealer or other qualiﬁed mechanic.
Page 145: Front Fork
Screw, pinch fastener (3 - upper) Triple clamp, upper Triple clamp assembly, lower Screw, pinch fastener (4 - lower) Figure 2-59. Upper and Lower Fork Clamp Assembly Figure 2-59. Loosen upper and lower fork clamp pinch fasteners (1, 4). 2-42 2003 Buell XB9S: Chassis...
Page 146 TOOL (1) (Part No. HD-41177) in a vise and install the upper part of the front fork in the holding tool. Remove snap ring (2). Figure 2-63. Removing Fork Cap From Outer Tube Figure 2-63. Remove fork cap from outer tube. 2003 Buell XB9S: Chassis 2-43...
Page 147 PRESSION TOOL. NOTE Careful not to damage preload pins (2) while holding damper rod assembly (3). Remove preload washer (4) and slider piston (5). Figure 2-64. Uncompress fork and remove from FORK SPRING COMPRESSION TOOL. 2-44 2003 Buell XB9S: Chassis...
Page 148 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 2-66. Front Fork Assembly 2003 Buell XB9S: Chassis 2-45...
Page 149 (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). 2-46 2003 Buell XB9S: Chassis...
Page 150: Fork Assembly
Tighten the damper locknut (10) to 22- 11. Replace the sealing washer (13) and center bolt (14) 30 ft-lbs (30-40 Nm). (metric). Tighten the center bolt to 22-30 ft-lbs (30- Repeat for other fork assembly. 40 Nm). 2003 Buell XB9S: Chassis 2-47...
Page 151 (3), Fork oil level 22. Apply fork oil or light grease to o-rings on preload adjuster and install preload adjuster (3). Figure 2-70. Measuring Fork Oil Level 23. Install snap ring (2). 2-48 2003 Buell XB9S: Chassis...
Page 152 11. Install front wheel. See 2.5 FRONT WHEEL. 12. Install front fender. See 2.32 FENDERS. 13. Check headlamp alignment. See 1.18 HEADLIGHTS. 14. Adjust front forks suspension to rider preferences. See 1.12 SUSPENSION DAMPING ADJUSTMENTS. 2003 Buell XB9S: Chassis 2-49...
Page 153 HOME NOTES 2-50 2003 Buell XB9S: Chassis...
Page 154: Fork Clamps, Upper And Lower
FORK. Stem capnut b1136x2x Stem pinch fastener Upper fork clamp pinch fastener, (2) Upper fork clamp Head bearing (2) Lower fork clamp with stem Lower fork clamp pinch fastener (4) Figure 2-72. Steering Stem Assembly 2003 Buell XB9S: Chassis 2-51...
Page 155 Repeat previous two steps on second fork assembly. Tighten steering stem capnut to 38-42 ft-lbs (52-57 Nm). Install steering stem pinch bolt applying LOCTITE 272 and tightening to 17-19 ft-lbs (23-26 Nm). 2-52 2003 Buell XB9S: Chassis...
Page 156: Steering Head Bearings
Figure 2-74. Install new upper and lower steering head bearings into the steering stem using STEERING HEAD BEARING RACE INSTALLER (Part No. HD- 39302). STEERING HEAD BEARING INSTALLER (Part No. B-45521). 2003 Buell XB9S: Chassis 2-53...
Page 157 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). Forcing screw Steering Head Bearing Installation Tool (B-45521) Lower bearing Bearing Washer Figure 2-76. Lower Bearing 2-54 2003 Buell XB9S: Chassis...
Page 158: Swingarm And Brace
SWINGARM AND BRACE 2.19 GENERAL 8420 The swingarm also serves as the oil tank on the Buell XB9S. For information on the swingarm function as the oil tank, see 3.8 LUBRICATION SYSTEM. The swingarm features a removable brace on the right side to allow drive belt replacement.
Page 159 Loosen pivot shaft pinch fastener (7). Disconnect battery by unthreading fasteners removing Remove pivot shaft (10) with a special 7/8 in. hex tool negative cable (black) from battery ﬁrst. See 1.5 BAT- TERY MAINTENANCE. located in tool kit. 2-56 2003 Buell XB9S: Chassis...
Page 160 Remove rear fender. See 2.32 FENDERS. NOTE Figure 2-80. 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. 2003 Buell XB9S: Chassis 2-57...
Page 161 Install right side rider footpeg mount tightening fasteners to 108-132 in-lbs (12-15 Nm). See 2.30 FOOTPEG, HEEL GUARD AND MOUNT. 10. Install heel guard. See 2.30 FOOTPEG, HEEL GUARD MOUNT. 11. Remove rear wheel support stand. 2-58 2003 Buell XB9S: Chassis...
Page 162: Front And Rear Isolator
Tighten front isolator bolt (6) to 49-51 ft-lbs (66-69 Nm). Figure 2-82. Install clutch cable p-clamp. Tighten 3.4 STRIPPING MOTORCYCLE FOR ENGINE SER- fastener to 12-36 in-lbs (1-4 Nm). VICE to access the rear isolator. 2003 Buell XB9S: Chassis 2-59...
Page 163: Frame
Install rear shock. See 2.22 REAR SHOCK ABSORBER. Install tail frame. See 2.37 LEFT TAIL SECTION AND BATTERY PAN. Install exhaust header. See 2.29 EXHAUST SYSTEM. Rotate engine. See 3.3 ENGINE ROTATION FOR SER- VICE. 2-60 2003 Buell XB9S: Chassis...
Page 164: Rear Shock Absorber
Remote reservoir Upper shock mount fastener Lower shock mount nut 10. Lower shock mount Washers (2) 11. Shock spring retainer kit Lower shock mount sleeve 12. Rear shock spring Figure 2-86. Rear Shock Absorber Assembly 2003 Buell XB9S: Chassis 2-61...
Page 165 Install rear shock reservoir through reservoir clamp and loss of control which could result in death or serious tighten clamp on reservoir to 96-120 in-lbs injury. (11-14 Nm). Install seat. See 2.41 SEAT. 2-62 2003 Buell XB9S: Chassis...
Page 166: Throttle Control
Attach housings with two fasteners, installing longer fastener on bottom. Tighten to 25-33 in-lbs (3-4 Nm). Adjust cables. See 1.16 THROTTLE CABLE AND IDLE SPEED ADJUSTMENT. Install airbox assembly. See 4.43 AIRBOX. 2003 Buell XB9S: Chassis 2-63...
Page 167: Clutch Hand Lever
Connect clutch cable ferrule (9) to hand lever clamp (2). Install cable strap holding safety interlock switch and left switch housing on left upper fork. Do not over tighten cable strap. Adjust clutch cable. See CLUTCH. 2-64 2003 Buell XB9S: Chassis...
Page 168: Headlight Assembly And Support Bracket
Screws (2), upper headlight mounting Horn connectors [122] Headlight assembly Horn bracket Screws (2), headlight support bracket Horn fastener Headlight support bracket Headlight connector [38] 10. Left and right front modules Figure 2-92. Headlight Assembly and Support Bracket 2003 Buell XB9S: Chassis 2-65...
Page 169 (1) and install position bulb socket (6) between the headlights. Boot (2), headlight b1147x2x Bulb holder (2) Bulb (2) Headlight housing Wiring harness Position bulb socket, (used for HDI only) b1150x2x Figure 2-93. Headlight Assembly 2-66 2003 Buell XB9S: Chassis...
Page 170 Screws (2), upper headlight mounting Horn connectors [122] Headlight assembly Horn bracket Screws (2), headlight support bracket Horn fastener Headlight support bracket Headlight connector [38] 10. Left and right front modules Figure 2-94. Headlight Assembly and Support Bracket 2003 Buell XB9S: Chassis 2-67...
Page 171: Front Modules
Loosen but do not remove ﬁnal fastener securing the right front module to upper triple clamp. Install seat. See 2.41 SEAT. Figure 2-96. Remove the left front module. 10. See Figure 2-95. Remove the ﬁnal fastener and the right front module. 2-68 2003 Buell XB9S: Chassis...
Page 172 Figure 2-95. Right Front Module Fastener and Brake Line P-Clamp Fastener b1148x2x b1149x2x Left and right front module Right front module overlaps left front module Right front module Left front module Figure 2-96. Fairing Support Bracket Assembly 2003 Buell XB9S: Chassis 2-69...
Page 173: Handlebars
Place the upper handlebar clamp in position and thread the four screws in place after applying Loctite 272 (Red). Tighten both front screws to 10-12 ft-lbs (14-16 Nm). Then tighten both rear screws (2) 10-12 ft-lbs (14-16 Nm). 2-70 2003 Buell XB9S: Chassis...
Page 174 HOME b0945x2x Endcap (2) Handlebar Handlebar clamp Clamp fasteners (4) Left hand grip Figure 2-97. Handlebar Assembly 2003 Buell XB9S: Chassis 2-71...
Page 175: Mirrors
Loosen mount (3) and remove from bracket (4). NOTE Before tightening adjuster nut, position mirrors for rider. Install mirror (1) and tighten adjuster to 115-130 in-lbs (13-14.7 Nm). 9990 b1154x2x Mirror Mount Adjuster nut Bracket Figure 2-98. Mirrors and Mounting Hardware 2-72 2003 Buell XB9S: Chassis...
Page 176: Exhaust System
Front mufﬂer mount Rear mufﬂer strap (2) Front strap fastener Mufﬂer Front mufﬂer mount bushings Front mufﬂer strap Rear mufﬂer bracket Front mufﬂer strap fastener 10. Rear mufﬂer bracket fasteners (2) Figure 2-99. Mufﬂer Assembly 2003 Buell XB9S: Chassis 2-73...
Page 177 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 178: Footpeg, Heel Guard And Mount
Remove footpeg mount fasteners (2). 36-48 in-lbs (4.1-5.4 Nm). Remove footpeg mount (1). b0934a2x Footpeg mount Spring Footpeg mount fasteners Wear peg Heel guard Footpeg Heel guard fasteners Clip, footpeg Figure 2-101. Rider Footpeg, Mount and Heel Guard Assembly 2003 Buell XB9S: Chassis 2-75...
Page 179 Check that footpeg clicks in the up and down position. Remove footpeg mount (3). Heel guard fasteners b0933a2x Heel guard Footpeg mount Spring Ball Detent plate Clip Footpeg 10. Footpeg mount fastener 11. Jam nut Figure 2-102. Passenger Footpeg, Mount and Heel Guard Assembly 2-76 2003 Buell XB9S: Chassis...
Page 180: Sprocket Cover
(1) and tighten all fasteners and washers (1) to 12-36 in-lbs (1-4 Nm). Install chin fairing. See 2.34 CHIN FAIRING. Sprocket cover fastener and washers Sprocket cover Front belt guard Figure 2-104. Sprocket Cover 2003 Buell XB9S: Chassis 2-77...
Page 181: Fenders
Align rear fender (3) to frame. Install rear fender (3) with fasteners and washers (4). Tighten to 12-15 in-lbs (1-1.7 Nm). Front fender Front fender fastener Rear fender Rear fender fastener Figure 2-105. Front and Rear Fender 2-78 2003 Buell XB9S: Chassis...
Page 182: Belt Guards
16. Install right passenger footrest mount. use LOCTITE 272 NOTE (Red) and tighten fasteners to 25-28 ft-lbs (34-38 Nm). The rear wheel does not have to be removed to remove inner belt guard. 17. Remove scissor jack from motorcycle. 2003 Buell XB9S: Chassis 2-79...
Page 183 Spacer collar Lower belt guard Front belt guard Sprocket cover Sprocket cover fasteners Lower belt guard fasteners Upper belt guard fasteners, short Upper belt guard fasteners, long 10. Upper belt guard Figure 2-106. Belt Guard Assembly 2-80 2003 Buell XB9S: Chassis...
Page 184: Chin Fairing
(2). Use LOCTITE 272 on all fas- Left section teners tightening to 36-48 in-lbs (4-5 Nm). Left section fastener and washer Install sprocket cover. See 2.31 SPROCKET COVER. Right section Right section fastener and washer Figure 2-107. Chin Fairing Assembly 2003 Buell XB9S: Chassis 2-81...
Page 185: Intake Cover Assembly
(2). Tighten to 12-36 in-lbs (1-4 Nm). NOTE Front screws go in at a slight angle. Intake cover assembly Intake cover fasteners Install seat. See 2.41 SEAT. Figure 2-108. Intake Cover Assembly 2-82 2003 Buell XB9S: Chassis...
Page 186: Air Scoops
Remove three engine shroud air scoop fasteners (5). Remove engine shroud air scoop (6). Installation Figure 2-109. Position engine shroud air scoop (6). Install engine shroud air scoop (6) with three fasteners (5). Tighten to 12-36 in-lbs (1-4 Nm). 2003 Buell XB9S: Chassis 2-83...
Page 187 Oil cooler air scoop fastener and washer Ram air scoop Oil cooler air scoop Engine scoop fastener and washer (3) Ram air scoop fastener and washer Engine scoop Figure 2-109. RAM Air Scoop, Engine Shroud, Oil Cooler 2-84 2003 Buell XB9S: Chassis...
Page 188: Left Tail Section And Battery Pan
The cast aluminum tail section has a powder coat. Because the surface is not bare polished aluminum, it must be cleaned using only mild soap and warm water. After washing, always dry the surface using a clean, soft cloth. 2003 Buell XB9S: Chassis 2-85...
Page 189 14. Left and right front trunk pan fasteners (2) ECM connectors [10] & [11] 15. Left rear and right rear tail section fasteners (4) Fuse block and relay center Figure 2-110. Main Harness and Electrical Connectors Under Seat 2-86 2003 Buell XB9S: Chassis...
Page 190: Tail Section
If seat is loose, it could shift back to left side of vehicle. during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. 13. Install seat. See 2.41 SEAT. 2003 Buell XB9S: Chassis 2-87...
Page 191 Left tail section 13. Rear shock reservoir bracket Ground terminal fastener (2) 14. Plastic lugs (for manufacturing purposes only) Passenger footrest support fastener with jam nut (2) Figure 2-111. Tail Frame and Trunk Pan Assembly 2-88 2003 Buell XB9S: Chassis...
Page 192: Center Tail Section
If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install seat. See 2.41 SEAT. 2003 Buell XB9S: Chassis 2-89...
Page 193: Right Tail Section
If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install seat. See 2.41 SEAT. 2-90 2003 Buell XB9S: Chassis...
Page 194 Rear brake light switch connector [121] Passenger footrest support fastener with jam nut Right tail section Ground terminals [GRD1] & [GRD 3] Center tail section fastener to rear tail section Figure 2-112. Right Side Frame Section 2003 Buell XB9S: Chassis 2-91...
Page 195: Front Windscreen
(3) and tighten 10-12 in-lbs (1.1-1.4 bracket (1). Nm). Figure 2-113. Remove four windscreen fasteners (3) Remove windscreen (4). b1153x2x Headlight mounting bracket Windscreen Left front module Right front module Windscreen fastener (4) Figure 2-113. Front Windscreen 2-92 2003 Buell XB9S: Chassis...
Page 196: Seat
Remove ignition key from seat lock. 10049 Seat Opening in trunk pan for locating tab Rear seat tab Shouldered fasteners for seat hooks Seat hooks Slot in seat latch Locating tab Seat latch Figure 2-114. Seat and Attachment 2003 Buell XB9S: Chassis 2-93...
Page 197: Seat Lock
If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install seat. See 2.41 SEAT. 2-94 2003 Buell XB9S: Chassis...
Page 198 HOME b1152x2x Seat lock Plate Retainer Cable end Cable Screw, latch Retainer Cable end Latch 10. Latch bracket 11. Trunk pan Figure 2-115. Seat Lock Assembly 2003 Buell XB9S: Chassis 2-95...
Page 199: Sidestand Assembly
Sidestand pivot bolt hole in the sidestand leg (6). Spring post Sidestand bracket Install the switch fastener (1) tightening to 36-60 in- Sidestand leg lbs (4-7 Nm). Figure 2-117. Sidestand Switch 2-96 2003 Buell XB9S: Chassis...
Page 200 Figure 2-118. Install sidestand switch (6). See 2.43 SIDESTAND ASSEMBLY/ SIDESTAND SWITCH. Install two fasteners into the left side of chin fairing and tighten. Figure 2-120. Threaded Area for Loctite Application 2003 Buell XB9S: Chassis 2-97...
Page 201 HOME NOTES 2-98 2003 Buell XB9S: Chassis...
Page 202 ENGINE Table Of Contents SUBJECT PAGE NO. 3.1 Specifications ..........3.2 Engine .
Page 204 59.1 mm 2.2.325. (min) 59.1 mm (min) Intake 1.850 in. (closed) 135 lbs 61.2 kg 1.300 in. (open) 312 lbs 141.5 kg Exhaust 1.850 in. (closed) 135 lbs 61.2 kg 1.300 in. (open) 312 lbs 141.5 kg 2003 Buell XB9S: Engine...
Page 205 Side play between ﬂywheels 0.005-0.031 in. 0.1-0.8 mm 0.036 in. 0.9 mm Fit on crankpin (loose) 0.0004-0.0017 in. 0.0102-0.0432 mm 0.0027 in. 0.0686 mm Connecting rod race ID 1.6245-1.6250 in. 41.2623-41.2750 mm 1.6270 in. 41.3258 mm 2003 Buell XB9S: Engine...
Page 206 Table 3-14. Sprocket Shaft Bearing Speciﬁcations SPROCKET SHAFT BEARING NEW COMPONENTS SERVICE WEAR LIMITS Bearing outer race ﬁt in crankcase 0.006 in. 0.2 mm (tight) Interference fit Bearing inner race ﬁt on shaft 0.006 in. 0.2 mm (tight) Interference fit 2003 Buell XB9S: Engine...
Page 207 25-35 in-lbs 2.8-4 Nm Loctite 222, page 3-91 Pushrod cover screw 30-40 in-lbs 3-5 Nm page 3-84 Rear isolator assembly fasteners 25-27 ft-lbs 33.9-36.6 Nm page 3-29 Rear isolator bolt 49-51 ft-lbs 66.4-69.1 Nm page 3-14 2003 Buell XB9S: Engine...
Page 208 Alternator stator [46] Located under sprocket cover. Starter solenoid wire [128B] Disconnect at bottom of starter. Positive battery at starter [128A] Disconnect at rear of starter Side stand switch [60] Cable strapped under vehicle to sidestand. 2003 Buell XB9S: Engine...
Page 209 General Gasoline/alcohol Blends When an engine needs repair, it is not always possible to The Buell XB9S motorcycle has been designed to obtain the determine deﬁnitely beforehand whether repair is possible best performance and efﬁciency using a good quality with only cylinder head, cylinder and piston disassembled or unleaded gasoline.
Page 210: Diagnosing Smoking Engine Or High Oil Consumption
Valve guide seals. 35667A) and follow the speciﬁc instructions supplied with the tester. Valve guide-to-valve stem clearance. The following are some general instructions that apply to Buell motorcycle engines: Gasket surface of both head and cylinder. 2003 Buell XB9S: Engine...
Page 211: Engine Rotation For Service
8707 Fuel line connection Connection for throttle position sensor [88] Connections for fuel injectors [84 & 85] Figure 3-1. Fuel Line and DDFI Electrical Connections 2003 Buell XB9S: Engine...
Page 212 Oxygen sensor connection [137] Throttle cables Figure 3-2. Electrical Connections and Throttle Cables Figure 3-2. Disconnect the ignition coil (2) [83] and Figure 3-2. Disconnect the following sensors: remove. Temperature sensor (3) [90]. Oxygen sensor (4) [137]. 2003 Buell XB9S: Engine...
Page 213 12. Remove transmission sprocket side cover. Remove rear mufﬂer straps (13). 13. Remove rear belt and idler pulley. See 1.10 DRIVE BELT Loosen Torca clamp (1) and remove mufﬂer (14). 2.13 REAR BRAKE MASTER CYLINDER. Loosen front mufﬂer mount (2). 3-10 2003 Buell XB9S: Engine...
Page 214 Slide clutch cable adjuster boot (2) up to access clutch adjuster. Loosen clutch adjuster to release tension from hand lever. Remove clutch cable ferrule from hand lever. 8720 P-clamp Clutch cable adjuster boot Figure 3-5. Clutch Cable Retaining Clamp and Adjuster Boot 2003 Buell XB9S: Engine 3-11...
Page 215 20. Bolt, rear isolator 10. Mount, center tie bar 21. Tie bar assembly, rear 11. Fasteners for center tie bar mount (2) 22. Fasteners for rear tie bar assembly (2) Figure 3-6. Engine Mounting System 3-12 2003 Buell XB9S: Engine...
Page 216 24. Remove front isolator mount (2) from engine. Figure 3-7. Rear Isolator Bolt and Rear Tie Bar 25. Rotate engine down. 21. See Figure 3-7. Remove rear tie bar from frame only. 22. Loosen rear isolator bolt. DO NOT REMOVE. 2003 Buell XB9S: Engine 3-13...
Page 217 120-144 in-lbs (13.6-16.3 Nm). Figure 3-10. 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. Remove scissors jack. 3-14 2003 Buell XB9S: Engine...
Page 218 Verify that the clutch cable and feed line have a clearance of 1/8-1/4 in. (3.175-6.35 mm) between them. Verify that oil lines have a minimum clearance of 1/8 in. (3.175 mm) between them. Figure 3-12. Oil Cooler Feed and Return Oil Line Orientation and Clearances 2003 Buell XB9S: Engine 3-15...
Page 219 Tighten Torca clamp to 40-45 ft-lbs (54.2-61 Nm). CAUTION 14. Tighten front mufﬂer mount to 22-25 ft-lbs (29.8-33.9 When rear mufﬂer straps have been installed, it is impor- Nm). tant that strap fasteners do not contact idler pulley bracket. 3-16 2003 Buell XB9S: Engine...
Page 220 16. Connect the following sensors: Temperature sensor (3) [90]. Oxygen sensor (4) [137]. 17. See Figure 3-14. Install the ignition coil and connect (2) [83] and tighten fasteners to 120-144 in-lbs (13.6-16.3 Nm). 2003 Buell XB9S: Engine 3-17...
Page 221 120-144 in lbs (13.56-16.27 Nm). 25. Install sprocket cover and tighten fasteners and washers to 12-36 in-lbs (1-4 Nm). 26. Install chin fairing. See 2.34 CHIN FAIRING. 27. Install air scoops, right and left sides. See 2.36 AIR SCOOPS. 3-18 2003 Buell XB9S: Engine...
Page 222: Stripping Motorcycle For Engine Service
Disconnect fuel injector leads (3) [84 & 85]. Drain oil tank. 8707 Fuel line connection Connection for throttle position sensor [88] Connections for fuel injectors [84 & 85] Figure 3-16. Fuel Line and DDFI Electrical Connections 2003 Buell XB9S: Engine 3-19...
Page 223 Figure 3-17. Electrical Connections and Throttle Cables Figure 3-17. Disconnect the ignition coil connector (2) and remove. 10. Disconnect the following sensors: Temperature sensor (3) [90]. Oxygen sensor (4) [137]. 11. Disconnect throttle cables from induction module/throttle body. 3-20 2003 Buell XB9S: Engine...
Page 224 Alternately loosen rear strap fasteners (12) and 15. Remove rear belt and idler pulley. See 1.10 DRIVE BELT remove rear mufﬂer straps. 2.13 REAR BRAKE MASTER CYLINDER. Loosen Torca clamp and remove mufﬂer. Loosen front mufﬂer mount. 2003 Buell XB9S: Engine 3-21...
Page 225 Feed oil line from oil cooler to crankcase Figure 3-19. Oil Lines and Connections 17. See Figure 3-19. Remove oil ﬁlter. 19. Remove front and rear mufﬂer brackets. 18. Remove all oil lines (including lines to oil cooler). 3-22 2003 Buell XB9S: Engine...
Page 226 Remove upper retaining clamp (1) from front isola- tor. Slide clutch cable adjuster boot (2) up to access clutch adjuster. Loosen clutch adjuster to release tension from hand lever. Remove clutch cable ferrule from hand lever. 2003 Buell XB9S: Engine 3-23...
Page 227 20. Bolt, rear isolator 10. Mount, center tie bar 21. Tie bar assembly, rear 11. Fasteners for center tie bar mount (2) 22. Fasteners for rear tie bar assembly (2) Figure 3-23. Engine Mounting System 3-24 2003 Buell XB9S: Engine...
Page 228 34. Rotate engine down to remove exhaust header. Alternator [46]. Voltage regulator [77]. 8717 Neutral switch [131] Alternator connection [46] Speedometer sensor connection [65] Voltage regulator connection [77] Cam position sensor connection [14] Figure 3-24. Electrical Connections 2003 Buell XB9S: Engine 3-25...
Page 229 38. Lower engine with scissors lift all the way down. 39. Move the engine assembly from under the main frame to the right side of the lift. 40. Remove engine. Figure 3-26. Rear Isolator Bolt and Swingarm Pivot Shaft 3-26 2003 Buell XB9S: Engine...
Page 230 Figure 3-30. Swingarm pivot shaft pinch bolt threaded insert. Figure 3-31. Aluminum bushings from front Right Side exhaust mount. Timer cover. Figure 3-31. Front Exhaust Mount Bushings (2 piece) 8724 8729 Figure 3-30. Removing Threaded Insert 2003 Buell XB9S: Engine 3-27...
Page 231 44. Route a ratcheting tie down through the swingarm bear- ings, up over the main frame, through the top stabilizer area, back down to the ratchet mechanism and secure swingarm to main frame. 3-28 2003 Buell XB9S: Engine...
Page 232: Engine Installation
Figure 3-36. Center tie bar mount 25-27 ft-lbs Figure 3-38. Front Exhaust Mount Bushings (2 piece) (33.9-36.6 Nm). Figure 3-37. Swingarm pivot shaft pinch bolt threaded insert. Figure 3-38. Aluminum bushings from front exhaust mount. 2003 Buell XB9S: Engine 3-29...
Page 233 Install cable strap to secure transmission vent line in place. Inspect vent line to verify space between vent line and rear exhaust. 3-30 2003 Buell XB9S: Engine...
Page 234 20. Bolt, rear isolator 10. Mount, center tie bar 21. Tie bar assembly, rear 11. Fasteners for center tie bar mount (2) 22. Fasteners for rear tie bar assembly (2) Figure 3-44. Engine Mounting System 2003 Buell XB9S: Engine 3-31...
Page 235 120-144 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 2003 Buell XB9S: Engine...
Page 236 32-36 ft-lbs (43.4-48.8 Nm). DO NOT install mufﬂer at this time. It is necessary to install mufﬂer mounts ﬁrst in order to properly install oil lines. 20. Install front mufﬂer mount and leave loose at this time. 2003 Buell XB9S: Engine 3-33...
Page 237 Front mufﬂer mount Return oil line 10. Rear mufﬂer bracket Feed oil line from oil pump to oil cooler 11. Oil cooler Feed oil line from oil cooler to crankcase Figure 3-48. Oil Lines and Connections 3-34 2003 Buell XB9S: Engine...
Page 238 ﬁrst. 22. See Figure 3-49. Torque the return oil line ﬁrst making sure to maintain the proper clearance between the oil line and the rear mufﬂer bracket. 19-21 ft-lbs (25.8-28.5 Nm.) 2003 Buell XB9S: Engine 3-35...
Page 239 26. Also torque the return oil line at the top front oil pump ﬁt- with the feed and return lines after torquing. ting to 18-20 ft-lbs (24.4-27.1 Nm). When the oil line has been properly torqued, the orientation of the line should also be approximately 7 o’clock. 3-36 2003 Buell XB9S: Engine...
Page 240 NOTE the vehicle. The 5/16 in. clearance is between the crankcase and the steel oil line as shown. Not between the crankcase and the clamp. 2003 Buell XB9S: Engine 3-37...
Page 241 Also be aware of the 1/8- properly torque certain oil line ﬁttings. 1/4 (3.175-6.35 mm) clearance speciﬁed between the feed oil line and the clutch cable at the front of the crankcase. 3-38 2003 Buell XB9S: Engine...
Page 242 Oil cooler feed line should be centered after line is torqued. Orientation of return line should be approximately 4 o’clock Figure 3-54. Oil Cooler Feed and Return Oil Lines Location and Orientation 2003 Buell XB9S: Engine 3-39...
Page 243 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]. Figure 3-56. Correct Routing of Wiring Harnesses 3-40 2003 Buell XB9S: Engine...
Page 244 Figure 3-58. Clutch Cable Upper Retaining Clamp 39. See Figure 3-58. Pull clutch cable back up into the proper position. Connect clutch cable to handlebars and adjust to speciﬁcations. See SPECIFICATIONS. Install upper retaining clamp. 2003 Buell XB9S: Engine 3-41...
Page 245 Tighten Torca clamp (1) to 40-45 ft-lbs (54.2-61 Nm). When rear mufﬂer straps have been installed, it is impor- tant that strap fasteners do not contact idler pulley Tighten front mufﬂer mount (2) to 22-25 ft-lbs (29.8- bracket. 33.9 Nm). 3-42 2003 Buell XB9S: Engine...
Page 246 Temperature sensor [90]. Oxygen sensor [137] (Install wire tire on harness). 43. See Figure 3-60. Install the ignition coil and spark plug wires and connect [83]. Tighten ignition coil fasteners to 120-144 in-lbs (13.6-16.3 Nm). 2003 Buell XB9S: Engine 3-43...
Page 247 A loose seat may shift during vehicle operation and startle the rider, possibly causing loss of vehicle 53. Install sprocket cover and tighten fasteners and washers to 12-36 in-lbs (1-4 Nm). control resulting in death or serious injury. 3-44 2003 Buell XB9S: Engine...
Page 248: Cylinder Head
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 3-62. Rocker Arm and Push Rod Cover Assemblies 2003 Buell XB9S: Engine 3-45...
Page 249 Remove rocker arms; mark them for reassembly in their original locations. 10. Mark the location and orientation (top/bottom) of each push rod. Remove push rods. Figure 3-64. Removing Rocker Arm Shafts 3-46 2003 Buell XB9S: Engine...
Page 250 Repeat the above procedure for the other valves. Head Screw Loosening/Tightening Sequence Figure 3-65. Head Screw Loosening/Tightening Sequence 8684 Figure 3-66. Valve Spring Compressor (Part No. HD-34736B) 2003 Buell XB9S: Engine 3-47...
Page 251 11. Cylinder O-ring (4) 12. Cylinder insert 13. Cylinder w/piston & rings 14. Cylinder base gasket 15. Cylinder base stud 16. Exhaust valve 17. Exhaust valve seat Figure 3-67. Cylinder Head, Cylinder and Piston Assembly 3-48 2003 Buell XB9S: Engine...
Page 252 Never use a ﬁle or SERVICE WEAR LIMIT of 0.006 in. (0.152 mm). other hardened tool which could scratch or nick valve. Polish valve stem with very ﬁne emery cloth or steel wool. 2003 Buell XB9S: Engine 3-49...
Page 253 Figure 3-70. Measure where rocker arm bush- Check end play of rocker arm with feeler gauge. ings ride. Replace rocker arm or lower cover or both if end play exceeds 0.025 in. (0.635 mm). 3-50 2003 Buell XB9S: Engine...
Page 254: Valve Guides
If the seat is loose or is not fully seated in the head, then seat movement will prevent the proper transfer of heat from the valve. The seat surface must be ﬂush with (or below) the head surface. See 3.1 SPECIFICATIONS for valve seat-to-cylinder head ﬁt. 2003 Buell XB9S: Engine 3-51...
Page 255 Using remaining old bushing as a pilot, line ream new bushing with ROCKER ARM BUSHING REAMER (Part No. HD-94804-57). Repeat for other end of rocker arm. 8733 8734 Figure 3-75. Replacing Rocker Arm Bushings 3-52 2003 Buell XB9S: Engine...
Page 256 Valve guide brush (Part No. HD-34751) Cylinder head holding ﬁxture (Part No. HD-39786) Figure 3-77. Cleaning Valve Guides Figure 3-77. Thoroughly clean valve guide bores using VALVE GUIDE BRUSH (Part No. HD-34751) and hot soapy water. 2003 Buell XB9S: Engine 3-53...
Page 257 Clamp tool in vise and further tighten cylinder head onto the ﬁxture to prevent any movement during operation. Place cylinder head at a 45° angle or one that offers a comfortable working position. 3-54 2003 Buell XB9S: Engine...
Page 258 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 3-79. Valve and Seat Dimensions 2003 Buell XB9S: Engine 3-55...
Page 259 11. Cylinder O-ring (4) 12. Cylinder insert 13. Cylinder w/piston & rings 14. Cylinder base gasket 15. Cylinder base stud 16. Exhaust valve 17. Exhaust valve seat Figure 3-80. Cylinder Head, Cylinder and Piston Assembly 3-56 2003 Buell XB9S: Engine...
Page 260 (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. 2003 Buell XB9S: Engine 3-57...
Page 261 10. Insert valve keepers into upper collar, making sure they engage grooves in valve stem. The keeper gaps should be equal. 11. Release and remove from VALVE SPRING COMPRES- SOR. 12. Repeat Steps 4-11 for the remaining valve. 3-58 2003 Buell XB9S: Engine...
Page 262 17909-02 Orange/Brown (272.948 mm) CAUTION After head(s) have been installed do not turn engine over until both push rods can be turned with ﬁngers. Other- wise, damage to push rods or rocker arms may result. 2003 Buell XB9S: Engine 3-59...
Page 263: Cylinder Head Installation
Tighten each screw to 13-15 ft-lbs (18-20 Nm). Figure 3-88. Tightening Head Screws Figure 3-88. Mark cylinder head and head screw shoulder with a line as shown (View A). ° ° Turn all bolts an additional 85 -95 . 3-60 2003 Buell XB9S: Engine...
Page 264 20. Gasket (push rod cover) 21. Push rod cover 22. Screw (4) 23. O-ring (push rod cover - 2) 24. Push rod 25. Washer (4) 26. Bolt (4) b0960x3x Figure 3-89. Rocker Arm and Push Rod Cover Assemblies 2003 Buell XB9S: Engine 3-61...
Page 265 Place a new inner gaskets on lower rocker box assemblies. Place a new lower gaskets on lower rocker cover. Install upper rocker cover using screws with washers and new ﬁber seals. Tighten screws to 10-14 ft-lbs (13.6-19 Nm). 3-62 2003 Buell XB9S: Engine...
Page 266: Cylinder And Piston
Connecting rod 10. Piston pin bushing CAUTION Figure 3-91. Cylinder and Piston DO NOT re-use piston pin retaining rings. Removal may weaken retaining rings and they may break or dislodge if reinstalled resulting in engine damage. 2003 Buell XB9S: Engine 3-63...
Page 267 In the event that the circlip should ﬂy out, hold a shop towel over the bore during removal. Figure 3-94. To remove piston rings spread outward Remove circlip from claw and discard. until they clear grooves in piston and lift off. 3-64 2003 Buell XB9S: Engine...
Page 268 Lay a straightedge across the surface. Try to insert a feeler gauge between the straight- edge and the gasket surface. If cylinder base gasket surface is not ﬂat within 0.008 in. (0.203 mm), replace cylinder and piston. 2003 Buell XB9S: Engine 3-65...
Page 269: 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 2003 Buell XB9S: Engine...
Page 270 Oil control rings Figure 3-97. Piston Rings Table 3-24. Piston Ring End Gap Ring Type Ring End Gap inches Top compression ring 0.010-0.020 0.25-0.51 2nd compression ring 0.014-0.024 0.36-0.61 Oil control ring rails 0.010-0.050 0.25-1.27 2003 Buell XB9S: Engine 3-67...
Page 271 Figure 3-100. Ring End Gap Position 10. See Figure 3-100. Install rings so end gaps of adjacent rings are a minimum of 90° apart. Ring gaps are not to be within 10° of the thrust face centerline. 3-68 2003 Buell XB9S: Engine...
Page 272 Hone bushing to ﬁnal size using WRIST PIN BUSHING HONE (Part No. HD-35102). Use a liberal amount of honing oil to prevent damage to hone or bushing. Use care to prevent foreign material from falling into the crankcase. 2003 Buell XB9S: Engine 3-69...
Page 273 NOTE Install piston pin. Make sure the ring groove is clean. Ring must be fully seated in the groove with the gap away from the slot at the bottom. 3-70 2003 Buell XB9S: Engine...
Page 274 PISTON SUPPORT PLATE (Part No. HD-42322). Lubricate cylinder wall, piston, pin and rod bushing with engine oil. Remove protective sleeves from cylinder studs. Install a new cylinder base gasket. Make sure the piston does not bump the studs or crankcase. 2003 Buell XB9S: Engine 3-71...
Page 275 HOME NOTES 3-72 2003 Buell XB9S: Engine...
Page 276: 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. 2003 Buell XB9S: Engine 3-73...
Page 277: Oil Hose Routing And Oil Reservoir
Front mufﬂer mount Return oil line 10. Rear mufﬂer bracket Feed oil line from oil pump to oil cooler 11. Oil cooler Return oil line from oil cooler to crankcase Figure 3-112. Oil Lines and Connections 3-74 2003 Buell XB9S: Engine...
Page 278: Oil Pressure Indicator Switch
Dead battery (see NOTE). ating engine). temperature. At 2500 RPM, oil pressure will vary from 10- 12 psi (69-83 KPa). At idle speed (950-1050 RPM), oil pres- sure will vary from 6-8 psi (42-55 KPa). 2003 Buell XB9S: Engine 3-75...
Page 279: Crankcase Breathing System
PCV Valves (2) Grommet The oil mist collects and eventually returns to the crankcase Rocker cover, top (2) through oil passageways in the cylinder head. Figure 3-115. Crankcase Breathing System 3-76 2003 Buell XB9S: Engine...
Page 280 3.11 CRANKCASE BREATHING SYSTEM. When replacing the reed valve it is not necessary to Fasteners should be tightened to 30-40 in-lbs (3.4-4.5 Nm). replace the reed block. See Figure 3-116. 2003 Buell XB9S: Engine 3-77...
Page 281: Oiling System
The return gears pump oil back to the oil reservoir. travels to the right ﬂywheel where it is routed through the ﬂywheel to the crankpin. Oil is forced through the crank- pin to properly lubricate the rod bearing assembly. 3-78 2003 Buell XB9S: Engine...
Page 282: Oil Pump
Thrust washer Retaining ring Gerotor return set Separator plate 10. Gerotor feed set 11. Cover º 12. 45 Fitting 13. Sems screw (2) 14. TORX screw (2) 15. Rear connector ﬁtting Figure 3-118. Oil Pump 2003 Buell XB9S: Engine 3-79...
Page 283 Feed line connection Mounting screw and washer (2) Cover TORX screw (2) Steel line connection to oil cooler Return line Connection from oil cooler to oil ﬁlter housing Oil pump Figure 3-119. Oil Pump Hardware 3-80 2003 Buell XB9S: Engine...
Page 284 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. 2003 Buell XB9S: Engine 3-81...
Page 285: Oil Filter Mount
ﬁlter adapter which is installed into ﬁlter mount. Do not apply LOCTITE to adapter threads on ﬁlter element side. Install ﬁlter mount components. Place spring (4) and check ball (5) into threaded hole at center of mount. 3-82 2003 Buell XB9S: Engine...
Page 286: Hydraulic Lifters
End clearance should be within 0.008-0.022 in. (0.203-0.559 mm). Replace lifters if clearance exceeds SERVICE WEAR LIMIT of 0.026 in. (0.660 mm). Soak lifters in clean engine oil. Keep covered until assembly. 2003 Buell XB9S: Engine 3-83...
Page 287 Tighten screws evenly to 30-40 in-lbs (3-5 Nm). Place new o-rings on top of push rod cover. Install push rods, cylinder head, lower and upper rocker covers. See 3.6 CYLINDER HEAD. Repeat process for remaining cylinder head. 3-84 2003 Buell XB9S: Engine...
Page 288: Gearcase Cover And Cam Gears
Gear cover gasket 13. Oil pump drive gear Bushing, outer, intake camshaft gear 14. Pinion gear “E” Cam gear set 15. Nut Right crankcase half 16. bushing, gear shaft- pinion Figure 3-126. Gearcase Cover & Cam Assembly 2003 Buell XB9S: Engine 3-85...
Page 289 Check for minimum cam gear end play. Record readings. 8662a Front exhaust cam gear Rear exhaust cam gear Front intake cam gear Pinion gear Rear intake cam gear Pinion nut Figure 3-127. Cam and Pinion Gear Location and Timing Mark Indexing 3-86 2003 Buell XB9S: Engine...
Page 290 Table 3-26. Cam Identiﬁcation Stamp Location/Function Front Exhaust Front Intake Rear Intake Rear Exhaust NOTE Prior to changing any cam gears, check gear shaft ﬁt within corresponding bushings. Worn bushings can cause excessive backlash. 2003 Buell XB9S: Engine 3-87...
Page 291 Figure 3-126. Install a new seal and new dry gear cover gasket on crankcase. Figure 3-130. Crankshaft Locking Tool (Part No. HD-43984) 3-88 2003 Buell XB9S: Engine...
Page 292 Install cam position sensor and rotor in gearcase cover. See CAM POSITION SENSOR AND ROTOR section. Install any components removed to gain access to gear- case (i.e. exhaust system components, air cleaner, etc.). Figure 3-132. Checking Cam Gear End Play 2003 Buell XB9S: Engine 3-89...
Page 293 Remove oil pump. See 3.13 OIL PUMP. Remove gearcase components. See 3.16 GEARCASE COVER AND CAM GEARS. Remove primary cover and primary drive/clutch compo- nents. See 6.2 PRIMARY CHAIN. Remove starter motor. See 5.7 STARTER. 3-90 2003 Buell XB9S: Engine...
Page 294 (2.8-4.0 Nm). Figure 3-135. Piston Oil Jet Assemblies Figure 3-135. Remove two TORX screws from each piston jet assembly to free piston jets from right crank- case. Remove piston jet gaskets from right crankcase. 2003 Buell XB9S: Engine 3-91...
Page 295 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, left main bearing Figure 3-137. Crankcase and Flywheel Assembly 3-92 2003 Buell XB9S: Engine...
Page 296 Remove left main oil seal retaining ring. Figure 3-137. Remove left main oil seal (2) from crankcase using Snap-On Tool (Part No. CJ 114, Body Dent Puller) Remove outer thrust washer (4) next to left main bearing (6). 2003 Buell XB9S: Engine 3-93...
Page 297 (OD) of the inner race and the smallest measured inside diameter (ID) of the outer race (crankcase bushing). A running clearance of 0.0002-0.0008 in. (0.0051-0.0203 mm) is established during crankcase set or ﬂywheel assembly replacement and engine rebuild. 3-94 2003 Buell XB9S: Engine...
Page 298 (39.7459-39.7510 mm) ROLLER OD (*A) IDENTIFICATION* 1.5650-1.5652 in. Largest (39.7510-39.7561 mm) Blue White (Grey) Table 3-29. Outer races are identiﬁed at the factory Smallest Green as shown. Figure 3-145. Pinion bearings are identiﬁed as shown. 2003 Buell XB9S: Engine 3-95...
Page 299 1.2502 1.2504 1.2508 1.2510 1.2512 1.2514 1.2516 1.2518 31.740 31.745 31.750 31.755 31.760- 31.765 31.770 31.775 31.780 31.786 3.791- 31.745 31.750 31.765 31.796 31.755 31.760 31.770 31.755 31.780 31.786 31.791 FACTORY COLOR CODE Green White 3-96 2003 Buell XB9S: Engine...
Page 300 0.0002 in. (0.0051 mm) cast-in insert. Taper within 0.0002 in. (0.0051 mm) NOTE Figure 3-146. Dimensions are shown for fabrication of Surface ﬁnish 16 RMS tools used in pressing the outer race into or out of crankcase. 2003 Buell XB9S: Engine 3-97...
Page 301 Table 3-31. The ﬁnished inner race must meet the speciﬁcations in Table 3-34. Table 3-34. Pinion Inner Race Fitment Speciﬁcations Roundness within 0.0002 in. (0.0051 mm) Taper within 0.0002 in. (0.0051 mm) Surface ﬁnish 16 RMS 3-98 2003 Buell XB9S: Engine...
Page 302 Figure 3-149. Check connecting rod side play with a thickness gauge as shown. If side play measurement is greater than 0.036 in. (0.8 mm), replace ﬂywheel/connecting rod assembly. Figure 3-149. Checking Connecting Rod Side Play 2003 Buell XB9S: Engine 3-99...
Page 303 Lubricate all parts with Harley-Davidson 20W50 engine oil, and proceed as follows: b1046a3x Spacer, sprocket shaft Crankcase half Retaining ring, oil seal Bearing Oil seal Bearing retaining ring Thrust washer Figure 3-150. Left Main Bearing Assembly 3-100 2003 Buell XB9S: Engine...
Page 304 NOTE Make sure that the bearing assembly bottoms against the machined shoulder in the left crankcase half. Install new bearing retaining ring in left crankcase half. Install transmission. See 6.13 TRANSMISSION INSTAL- LATION. 2003 Buell XB9S: Engine 3-101...
Page 305 #732 CLEAR sealant to crankcase joint faces. Slide outer race in right crankcase over pinion shaft and bearing assembly. Tighten fasteners to 15-19 ft-lbs (20-26 Nm). NOTE According to manufacturing, there is no torque sequence to follow when tightening crankcase fasteners. 3-102 2003 Buell XB9S: Engine...
Page 306 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. 2003 Buell XB9S: Engine 3-103...
Page 307 HOME NOTES 3-104 2003 Buell XB9S: Engine...
Page 308 Table Of Contents FUEL SYSTEM SUBJECT PAGE NO. 4.1 Specifications ..........4.2 Dynamic Digital Fuel Injection .
Page 309 4.38 Fuel Pump ........... 4-104 4.39 Fuel Tank Vent Valve .
Page 310 54-61 Nm LOCTITE ANTI-SEIZE, page 1-97 Throttle position sensor 16-20 in-lbs 1.8-2.3 Nm LOCTITE 222 (purple), page 1-102 Timer plate studs 15-30 in-lbs 2-3 Nm page 1-94 Upper tie bar 25-27 ft-lbs 33.9-36.6 Nm page 1-99 2003 Buell XB9S: Fuel System...
Page 311 HOME NOTES 2003 Buell XB9S: Fuel System...
Page 312 INTRODUCTION GENERAL The Buell Dynamic Digital Fuel Injection (DDFI) System pro- The Buell DDFI operates both as an open and closed loop vides microprocessor-based electronic engine management system which allows it to adjust for all possible operating con- for the 984cc high performance engine. The DDFI system has ditions.
Page 313 Bank Angle Sensor BK/W Y/BE Front GN/W Sensor Rear BE/O BK/W IGN Coil Throttle Cooling Position To cooling BK/O Sensor fan fuse BK/W BK/W Sensor LT GN/Y Ground Figure 4-1. Buell Dynamic Digital Fuel Injection 2003 Buell XB9S: Fuel System...
Page 314: Diagnostic Introduction
Correct problems through the replacement and/or repair of the affected components. After repairs are performed, the work must be validated. This involves clearing the trouble codes and conﬁrming proper vehicle operation as indicated by the behavior of the check engine lamp. 2003 Buell XB9S: Fuel System...
Page 315: 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 2003 Buell XB9S: Fuel System...
Page 316 The fuel injection system provides two levels of diagnostics. The most sophisticated mode employs using a computer based diagnostic package called DIGITAL TECHNICIAN (Part No. HD-44750). The other mode requires using the check engine lamp. 4.5 CHECK ENGINE LAMP DIAGNOSTICS more information. 2003 Buell XB9S: Fuel System...
Page 317: Check Engine Lamp Diagnostics
Once all codes have been sent, the data string is repeated. When you have recorded the same trouble code twice, it is an indication that the transmission has been restarted and that all trouble codes have been retrieved. 2003 Buell XB9S: Fuel System...
Page 318 50 start and run cycles. To execute one run cycle: Remove diagnostic test wire and install protective cover Start the vehicle. over data link connector. Return data link to original posi- Let it run for at least 30 seconds. tion. Turn the engine off. 2003 Buell XB9S: Fuel System...
Page 319: Breakout Box
Attach black connector from the wiring harness to black connector on Breakout Box. 8890a Breakout box Breakout box grey and black connections at main harness Breakout box grey and black connections at ECM Figure 4-9. ECM and Breakout Box with Connections 4-10 2003 Buell XB9S: Fuel System...
Page 320: Wiggle Test
BOX. Set DVOM to read voltage changes. Start motorcycle engine and run at idle. Shake or wiggle harness to detect intermittents. If inter- mittents are present, radical voltage changes will register on the DVOM. 2003 Buell XB9S: Fuel System 4-11...
Page 321: General Information
ﬂow charts. See Diagnostic Check (Part 1 of Throttle plates not opening 1.16 THROTTLE CABLE fully AND IDLE SPEED Compare engine behavior to tables. ADJUSTMENT. Starts hard. See Table 4-4. 4-12 2003 Buell XB9S: Fuel System...
Page 322 Cooling fan 4.25 TROUBLE CODE 36 Bank angle sensor 4.26 TROUBLE CODE 44 52, 53, 54, 55 ECM failure 4.27 TROUBLE CODES 52, 53, 54 AND 55 Cam sync failure 4.28 TROUBLE CODE 56 2003 Buell XB9S: Fuel System 4-13...
Page 323 Figure 4-11. Diagnostic Check Table 4-8. Wire Harness Connectors in Figure 4-11. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [11] ECM (gray) 12-place Deutsch under seat [91A] data link 4-place Deutsch under seat 4-14 2003 Buell XB9S: Fuel System...
Page 324 Refer to applicable trouble code flow chart. Start with lowest trouble code. All diagnostic Refer to diagnostic codes are listed on page 4-13 in Table 4-7. tips in related trouble code chart (even if no code is set). 2003 Buell XB9S: Fuel System 4-15...
Page 325 ECM TERMINAL Wire Color Connector Lt. GN/R [11B] [10B] [11B] [10B] Continuity present in all four circumstances? Inspect terminals for damage or repair Replace ECM. See opens as necessary. 4.29 ELECTRONIC CONTROL MODULE. 7120 4-16 2003 Buell XB9S: Fuel System...
Page 326: Check Engine Lamp Not Illuminated At Key On
If connection is good, replace ECM. See 4.29 ELECTRONIC CONTROL MODULE. Check continuity between instrument connector [39] Pin 7 and ECM connector [10] (black), Pin 4. Figure 4-13. Electronic Control Module 2003 Buell XB9S: Fuel System 4-17...
Page 327 Electronic Control Module (ECM) Figure 4-14. Check Engine Lamp Circuit Table 4-9. Wire Harness Connectors in Figure 4-14. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [39] instrument module 20-place Multilock behind windscreen 4-18 2003 Buell XB9S: Fuel System...
Page 328 Repair open or Repair open on O short to voltage on wire that feeds bulb BK/Y wire between or open on wire connector [39] and from bulb to con- connector [10B]. nector [39]. 7145 7151 2003 Buell XB9S: Fuel System 4-19...
Page 329: Check Engine Lamp On Continuously
Test 4.10 ﬂow chart. Figure 4-15. If the lamp goes off when the black 8891 ECM connector [10] is unplugged, the BK/Y wire is not shorted to ground. Figure 4-16. Electronic Control Module 4-20 2003 Buell XB9S: Fuel System...
Page 330 Electronic Control Module (ECM) Figure 4-17. Check Engine Lamp Circuit Table 4-10. Wire Harness Connectors in Figure 4-17. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [39] instrument module 20-place Multilock behind windscreen 2003 Buell XB9S: Fuel System 4-21...
Page 331 Repair short to ground on BK/Y wire between connector [39] and connector [10]. 7165 Check engine lamp Replace ECM. See function OK. Check for 4.29 ELECTRONIC trouble codes. See CONTROL MODULE. CHECKING FOR 7150 TROUBLE CODES. 4-22 2003 Buell XB9S: Fuel System...
Page 332 DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [11] ECM (gray) 12-place Deutsch under seat [14] cam position sensor 3-place Deutsch under sprocket cover [83] ignition coil 3-place Amp beneath airbox base 2003 Buell XB9S: Fuel System 4-23...
Page 333 Cam Position Sensor Front Rear Injector Injector [84A] [85A] [14A] Ignition Relay A B C [85B] [84B] [14B] Dyno Loop [10B] [11B] [10A] [11A] Connector Connector Electronic Control Module (ECM) Figure 4-20. Ignition Circuit 4-24 2003 Buell XB9S: Fuel System...
Page 334 49-51 PSI (338-352 kPa). Adequate pressure? Go to Test 4.11 STOP Incorrect pressure. See 4.13 (Part 2 of 3). FUEL PRESSURE TEST. 7459 2003 Buell XB9S: Fuel System 4-25...
Page 335 Check for continuity between Ter- minal A connector [14B] and ground. Continuity present? Replace Replace ignition coil. spark plugs 7220 7520 Repair open circuit. 7875 Repair short Replace ECM. See to ground. 4.29 ELECTRONIC CONTROL MODULE. 7853 7870 4-26 2003 Buell XB9S: Fuel System...
Page 336 Replace cam position Mechanical failure. position sensor. See 4.30 7945 sensor. See 4.30 Inspect for loose CAM POSITION SENSOR CAM POSITION SEN- rotor cup and ROTOR. SOR AND ROTOR. sheared pinion 7952 gear key. 7952 7940 2003 Buell XB9S: Fuel System 4-27...
Page 337 Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. 8748a Clutch engaged (switch open), button depressed Clutch disengaged (switch closed), button extended Connector [95] Figure 4-23. Clutch Switch Transmission sprocket Neutral switch Figure 4-21. Neutral Switch 4-28 2003 Buell XB9S: Fuel System...
Page 338 Table 4-12. Wire Harness Connectors in Figure 4-24. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [22] right hand controls 4-place Multilock to the right of windscreen [95] clutch switch 2-place Multilock to the left of windscreen 2003 Buell XB9S: Fuel System 4-29...
Page 339 [22] and ignition relay. nector [22A] W/BK wire. Voltage present? 7277 Repair open on W/BK Replace handlebar wire between connector switch assembly. [22] and ignition relay. 7278 7277 4-30 2003 Buell XB9S: Fuel System...
Page 340: Fuel Pressure Test
Connect the fuel line (3) to fuel pressure gauge adapter. NOTE Figure 4-28. Verify that fuel valve (2) and air bleed pet- cock (5) on the gauge are closed. Attach FUEL PRESSURE GAUGE (Part No. HD-41182) (4) to fuel pressure gauge adapter (1). 2003 Buell XB9S: Fuel System 4-31...
Page 341 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 4-28. Fuel Pressure Gauge (Part No. HD-41182) 4-32 2003 Buell XB9S: Fuel System...
Page 342 Table 4-13. Wire Harness Connectors in Figure 4-29. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [39] instrument module 20-place Multilock behind windscreen [86] fuel pump 4-place Multilock left side of rear shock absorber 2003 Buell XB9S: Fuel System 4-33...
Page 343 ON. Is voltage greater than 1 VDC? Locate and repair poor Replace ignition relay. See Ignition Relay connection between bat- under 7.5 STARTER INTERLOCK. tery and ignition relay. 4-34 2003 Buell XB9S: Fuel System...
Page 344 3. Is continuity present? Replace fuel pump Repair fuel pump assembly. See 4.38 wiring. FUEL PUMP. 7463 7462 Replace ECM. See 4.29 Locate and repair open ELECTRONIC CONTROL on BN/Y wire. MODULE. 7463 2003 Buell XB9S: Fuel System 4-35...
Page 345: Idle Speed Control
An idle speed too low can cause poor throttle response. An idle speed too high can cause a slow return to idle. 1.16 THROTTLE CABLE AND IDLE SPEED ADJUST- MENT for more information on idle speed adjustment. 4-36 2003 Buell XB9S: Fuel System...
Page 346 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. 2003 Buell XB9S: Fuel System 4-37...
Page 347 Table 4-16. Wire Harness Connectors in Figure 4-32. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [22] right hand controls 4-place Multilock beneath windscreen [83] ignition coil 3-place Packard beneath airbox base 4-38 2003 Buell XB9S: Fuel System...
Page 348 Replace known to be good. ignition coil. Perform spark test. 7535 Did spark jump gap during engine cranking? Original ignition coil Go to Test 4.15 is faulty. Replace. STOP (Part 2 of 2). 7535 2003 Buell XB9S: Fuel System 4-39...
Page 349 4.30 CAM POSITION Replace cam position Mechanical failure. 7503 SENSOR AND ROTOR. sensor. See 4.30 Inspect for loose CAM POSITION SEN- rotor cup and 7542 SOR AND ROTOR. sheared pinion gear key. 7542 7504 4-40 2003 Buell XB9S: Fuel System...
Page 350 TP sensor voltage (when throttle is closed) to greater than 4.0 volts (when throttle is held wide open). As the throttle is slowly moved, the voltage should change gradually without spikes or low voltages being observed. 2003 Buell XB9S: Fuel System 4-41...
Page 351 ECM (gray) 12-place Deutsch under seat [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 under seat 4-42 2003 Buell XB9S: Fuel System...
Page 352 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2003 Buell XB9S: Fuel System 4-43...
Page 353 Replace BAS. between connector [88] Terminal A and Terminal C. Is resistance greater 7591 than 1 megaohm? Locate and repair short between R/W and BK/W Replace cam position wires. Reconnect [14]. sensor. 7589 7592 4-44 2003 Buell XB9S: Fuel System...
Page 354 If fresh air enters exhaust system, the O2 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. 2003 Buell XB9S: Fuel System 4-45...
Page 355 Electronic Control Module (ECM) Figure 4-38. Oxygen Sensor Circuit Table 4-18. Wire Harness Connectors in Figure 4-38. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under seat [137] oxygen sensor 1-place Packard behind rear cylinder head 4-46 2003 Buell XB9S: Fuel System...
Page 356 V/GY wire. CONTROL MODULE. CONTROL MODULE. 7657 7658 7659 7656 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2003 Buell XB9S: Fuel System 4-47...
Page 357 Fuel injectors may be dirty. See Fuel Injectors 7663 under 4.41 THROTTLE BODY. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-48 2003 Buell XB9S: Fuel System...
Page 358 (4.29 now OK. ELECTRONIC CONTROL 7672 MODULE). Road test again to verify. 7659 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2003 Buell XB9S: Fuel System 4-49...
Page 359 [10]). bers on the Code 14 ﬂow charts. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), gray pin probes and patch cord. 4-50 2003 Buell XB9S: Fuel System...
Page 360 (ECM) Figure 4-40. Engine Temperature Sensor Circuit Table 4-20. Wire Harness Connectors in Figure 4-40. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under seat [90] engine temperature sensor 1-place bullet beneath airbox base 2003 Buell XB9S: Fuel System 4-51...
Page 361 Dis- DIGITAL TECHNICIAN (Part No. HD-44750). regard the asterisk (but not the instruction box) if your normal progression through the chart brings you to this location. 4-52 2003 Buell XB9S: Fuel System...
Page 362 7690 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2003 Buell XB9S: Fuel System 4-53...
Page 363: Intake Air Temperature Sensor
If connections and harness check out OK, check intake air temperature reading while moving related connectors and wiring harness. If the failure is induced, the IAT sen- sor display will change. 4-54 2003 Buell XB9S: Fuel System...
Page 364 Figure 4-42. Intake Air Temperature Sensor Circuit Table 4-22. Wire Harness Connectors in Figure 4-42. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under seat [89] intake air temperature sensor 2-place Amp in airbox base 2003 Buell XB9S: Fuel System 4-55...
Page 365 7745 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). Code 15 Test (Part 2 of 2) 4-56 2003 Buell XB9S: Fuel System...
Page 366 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2003 Buell XB9S: Fuel System 4-57...
Page 367: Battery Voltage
Figure 4-43. Fuses and Diodes a signiﬁcant voltage drop is not present, condition may be caused by excessive starter current draw. 8892a Fuse block Ignition relay Key switch relay Start relay Figure 4-44. Fuse Block and Electrical Relays 4-58 2003 Buell XB9S: Fuel System...
Page 368 [10B] [11B] Connector Connector Electronic Control Module (ECM) [10A] [11A] Figure 4-45. Battery Voltage Circuit Table 4-23. Wire Harness Connectors in Figure 4-45. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat 2003 Buell XB9S: Fuel System 4-59...
Page 369 Replace ignition relay. STOP 7767 Go to Code 16 Test (Part 2 of 2). Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-60 2003 Buell XB9S: Fuel System...
Page 370 Replace R/Y wire between battery fuse and Replace main fuse. battery. 7779 7784 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2003 Buell XB9S: Fuel System 4-61...
Page 371: Trouble Codes 23 And
Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), purple pin probes and patch cord to BREAKOUT BOX (Part No. HD-42682) and gray socket probes and patch cord to FUEL INJECTOR TEST LAMP (Part No. HD-34730-2C). 4-62 2003 Buell XB9S: Fuel System...
Page 372 [10] ECM (black) 12-place Deutsch under seat [14] cam position sensor 3-place Deutsch under sprocket cover [84] front fuel injector 2-place Packard beneath airbox base [85] rear fuel injector 2-place Packard beneath airbox base 2003 Buell XB9S: Fuel System 4-63...
Page 373 4.29 Perform 4.7 WIGGLE TEST. ELECTRONIC CONTROL Repair as necessary. MODULE. 7815 7805 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-64 2003 Buell XB9S: Fuel System...
Page 374 WIGGLE TEST to locate open wire. intermittents. Repair 7825 as necessary. 7820 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2003 Buell XB9S: Fuel System 4-65...
Page 375: Trouble Codes 24 And
Use HARNESS CONNECTOR TEST KIT (Part No. HD- b0638x4x 41404), purple pin probes and patch cord. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Battery Figure 4-50. Testing Ignition Coil Connectors 4-66 2003 Buell XB9S: Fuel System...
Page 376 Electronic Control Module (ECM) Figure 4-51. Ignition Coil Circuit Table 4-25. Wire Harness Connectors in Figure 4-51. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [83] ignition coil 3-place Packard beneath airbox base 2003 Buell XB9S: Fuel System 4-67...
Page 377 7860 Repair as Replace ECM. See necessary. 4.29 ELECTRONIC CONTROL MODULE. 7865 7870 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-68 2003 Buell XB9S: Fuel System...
Page 378 Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), red pin probe and patch cord. Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), gray socket probe and patch cord. 2003 Buell XB9S: Fuel System 4-69...
Page 379 Table 4-26. Wire Harness Connectors in Figure 4-53. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [39] instrument module 20-place Multilock behind windscreen [86] fuel pump 4-place Multilock left side of rear shock absorber 4-70 2003 Buell XB9S: Fuel System...
Page 380 Terminal 87 to Pin D of [86]. Continuity present? 7896 Repair open. 7898 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2003 Buell XB9S: Fuel System 4-71...
Page 381 Code 35 ﬂow chart. Breakout box Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Figure 4-54. Installed Breakout Box Replace instrument module. See 7.18 INSTRUMENT MODULE. 8893 8894 Figure 4-55. Instrument Module Connector [39] 4-72 2003 Buell XB9S: Fuel System...
Page 382 Electronic Control Module [11A] (ECM) [10A] Figure 4-56. Tachometer Circuit Table 4-27. Wire Harness Connectors in Figure 4-56. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [39] instrument module 20-place Multilock in fairing 2003 Buell XB9S: Fuel System 4-73...
Page 383 MODULE. tents found? 7882 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). Repair. Replace instrument module. 7.18 INSTRUMENT 7886 MODULE 7883 4-74 2003 Buell XB9S: Fuel System...
Page 384 The reference numbers below correlate with the circled num- bers on the Code 36 ﬂow charts. Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), gray pin probes and patch cord. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. 2003 Buell XB9S: Fuel System 4-75...
Page 385 Electronic Control Module (ECM) Figure 4-58. Cooling Fan Circuit Table 4-29. Wire Harness Connectors in Figure 4-58. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under seat [97] cooling fan 2-place Multilock behind rear cylinder 4-76 2003 Buell XB9S: Fuel System...
Page 386 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. 6052 2003 Buell XB9S: Fuel System 4-77...
Page 387 Place a jumper wire between fan Y/BN wire and 7879 battery positive. Place a System ok. jumper between fan BK Replace fan. wire and ground. Does fan run at full speed? 7879 Replace fan. System ok. 7879 4-78 2003 Buell XB9S: Fuel System...
Page 388: Bank Angle Sensor
Code 44 ﬂow charts. Use HARNESS CONNECTOR TEST KIT (Part No. HD- 8895 41404), gray pin probes and patch cord. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Figure 4-60. Bank Angle Sensor 2003 Buell XB9S: Fuel System 4-79...
Page 389 ECM (gray) 12-place Deutsch under seat [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 under seat 4-80 2003 Buell XB9S: Fuel System...
Page 390 Install properly. See 4.34 BANK 0.25 in. (6.4 mm) of sides, face or ANGLE SENSOR. top of bank angle sensor? Replace bank angle sensor. See 4.34 Return to original BANK ANGLE SENSOR. configuration. 7976 2003 Buell XB9S: Fuel System 4-81...
Page 391 Replace ECM. See on Lt GN/GY wire. 4.29 ELECTRONIC CONTROL MODULE. 7973 7974 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-82 2003 Buell XB9S: Fuel System...
Page 392 Code 54 - EE PROM failure. Code 55 - Microprocessor failure. NOTE Dealership technicians ﬁling warranty claims should use job/ time code 7913 for all Code 52, 53, 54 and 55 ECM replace- ments. 2003 Buell XB9S: Fuel System 4-83...
Page 393 Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), black pin probes and patch cord. Timer plate stud (2) 4.30 CAM POSITION SENSOR AND ROTOR. Sensor wiring Cam position sensor b0313a7x Figure 4-62. Cam Position Sensor 4-84 2003 Buell XB9S: Fuel System...
Page 394 ECM (gray) 12-place Deutsch under seat [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 under seat 2003 Buell XB9S: Fuel System 4-85...
Page 395 TRONIC CON- [14]. [14]. TROL MODULE. 7970 7955 7965 7945 7945 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-86 2003 Buell XB9S: Fuel System...
Page 396 Install original cam System position sensor. Replace ECM. See 4.29 ELECTRONIC 7952 CONTROL MODULE. 7960 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2003 Buell XB9S: Fuel System 4-87...
Page 397 HOME NOTES 4-88 2003 Buell XB9S: Fuel System...
Page 398: Electronic Control Module
SEAT. NOTE If the ECM was replaced with a new component, it will be necessary to recalibrate Throttle Position Sensor. Throttle position sensor can only be calibrated using DIGITAL TECH- NICIAN (Part No. HD-44750). 2003 Buell XB9S: Fuel System 4-89...
Page 399 Fan control Rear coil primary Sensor ground 1 Injector rear Vehicle speed sensor Unused Engine temperature Bank angle sensor input Intake air temperature System ground B (coil) Serial data receive Tachometer Serial data transmit 4-90 2003 Buell XB9S: Fuel System...
Page 400: 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. 2003 Buell XB9S: Fuel System 4-91...
Page 401 12. Ignition coil 13. Front spark plug cable 14. Engine mount 15. Gearcase cover 16. Seal 17. Trigger rotor 18. Trigger rotor bolt 19. Cam position sensor 20. Inner cover b0990x4x Figure 4-68. Ignition Components 4-92 2003 Buell XB9S: Fuel System...
Page 402 HOME bs0001xx Figure 4-69. Ignition System Circuit 2003 Buell XB9S: Fuel System 4-93...
Page 403 Use of regular rivets can damage ignition system components and may allow water to enter the timing compartment. 10. Secure timer cover (2) to inner cover using new rivets (1). 11. Connect negative battery cable. 4-94 2003 Buell XB9S: Fuel System...
Page 404: Ignition Coil
An inﬁnite ohms (∞ or no continuity) resistance value indicates an open circuit (a break in the coil winding). Replace coil. 2003 Buell XB9S: Fuel System 4-95...
Page 405 Install intake cover assembly. See 2.35 INTAKE COVER Rear Cylinder Post ASSEMBLY. Coil Pin A (rear cylinder) Coil Pin B (12 VDC) Connect negative battery cable. Coil Pin C (front cylinder) Front Cylinder Post Figure 4-73. Ignition Coil 4-96 2003 Buell XB9S: Fuel System...
Page 406 ABSORBER. Figure 4-75. Connect 1-place connector [137] (1) to wiring harness. Install cable straps (2). Install airbox assembly. See 4.43 AIRBOX. Install intake cover assembly. See 2.35 INTAKE COVER ASSEMBLY. Connect negative battery cable. 2003 Buell XB9S: Fuel System 4-97...
Page 407 Slide rubber boot up ET sensor wire. Remove sensor from rear cylinder head using Snap-on socket M3503B. Engine temperature sensor connector [90] (approximate location) Upper tie bar fastener (right side) Figure 4-77. Engine Temperature Sensor Connector Approximate Location [90] 4-98 2003 Buell XB9S: Fuel System...
Page 408 [90] to wiring harness. Install right upper tie bar fastener (2). Tighten fastener to 25-27 ft-lbs (33.9-36.6 Nm). Install airbox. See 4.43 AIRBOX. Install intake cover assembly. See 2.35 INTAKE COVER ASSEMBLY. Connect negative battery cable. 2003 Buell XB9S: Fuel System 4-99...
Page 409 If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install seat. See 2.41 SEAT. 4-100 2003 Buell XB9S: Fuel System...
Page 410 Inspect sensor grommet for damage and replace as required. INSTALLATION Connect IAT sensor connector [89] to wiring harness. Install IAT sensor into grommet on air cleaner base from underneath. Install airbox. See 4.43 AIRBOX. Install negative battery cable. 2003 Buell XB9S: Fuel System 4-101...
Page 411 [88A]. NOTE b0995x4x Throttle position sensor can only be calibrated using DIGITAL TECHNICIAN (Part No. HD-44750). Calibrate throttle position sensor. Figure 4-81. Throttle Position Sensor b0651x4x Figure 4-82. Tabs on TP Sensor Connector [88A] 4-102 2003 Buell XB9S: Fuel System...
Page 412: Cooling Fan
Install fan and rotate counterclockwise into position. Install cooling fan fasteners. Tighten to 12-36 in-lbs (1.4- 4.1 Nm). Install shock absorber. See 2.22 REAR SHOCK ABSORBER. Connect negative battery cable. 2003 Buell XB9S: Fuel System 4-103...
Page 413: Fuel Pump
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). 4-104 2003 Buell XB9S: Fuel System...
Page 414 10. Place wrench onto nut and another wrench onto the bolt. Figure 4-87. Fuel Pump Removal Hold the bolt stationary and turn nut clockwise until fuel pump is pulled free from frame. 2003 Buell XB9S: Fuel System 4-105...
Page 415 Figure 4-89. Fuel Pump Assembly (right side) 11. See Figure 4-89. Tighten fuel ﬁlter clamps (3, 7). 12. See Figure 4-90. Install clips (1) into center grooves. 13. Install fuel pump assembly. See INSTALLATION in this section. 4-106 2003 Buell XB9S: Fuel System...
Page 416 Table 4-36. Fuel Pump Speciﬁcations SPECIFICATION DATA Pressure Setting 49 PSI Operating Voltage 13.2 volts Fuel Delivery 60 LPH @ 45 PSI [310 kPa] Clip grooves Current Draw 6.0 amps O-rings Figure 4-91. Regulator Housing O-rings 2003 Buell XB9S: Fuel System 4-107...
Page 417 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. 4-108 2003 Buell XB9S: Fuel System...
Page 418 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. Connector [86] Fuel supply ﬁtting Fuel supply stud Drain plug Fasteners Figure 4-94. Fuel Pump Installation 2003 Buell XB9S: Fuel System 4-109...
Page 419: Fuel Tank Vent Valve
Bracket during vehicle operation and startle the rider, causing Fastener (2) loss of control which could result in death or serious injury. Figure 4-96. Fuel Tank Vent Valve 10. Install seat. See 2.41 SEAT. 4-110 2003 Buell XB9S: Fuel System...
Page 420: 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 4-98. Fuel Cap Retaining Ring 2003 Buell XB9S: Fuel System 4-111...
Page 421: Throttle Body
Reconnect fuel pump connector. Label and detach throttle cables. See 2.23 THROTTLE CONTROL. Figure 4-101. On California models, pull EVAP hose from ﬁtting (1). Rotate engine for service. See 3.3 ENGINE ROTATION FOR SERVICE. 4-112 2003 Buell XB9S: Fuel System...
Page 422 10. Velocity stack fastener (2) 11. Ring seal 12. Intake manifold 13. Intake ﬂange fastener (2) 14. Intake ﬂange (2) 15. Intake seal (2) 16. Intake ﬂange fastener (2) Figure 4-100. Throttle Body/Intake Manifold Assembly 2003 Buell XB9S: Fuel System 4-113...
Page 423: Fuel Injectors
Separate fuel rail from injectors (2, 5) by gently rock- ing the fuel rail and pulling it away from the injectors. Remove fuel injectors (2, 5) from manifold by gently rock- ing and pulling it away from the manifold. 4-114 2003 Buell XB9S: Fuel System...
Page 424 Front fuel injector evidence of raw fuel in throttle body manifold. Lower fuel rail fastener Install airbox cover. See 4.43 AIRBOX. Figure 4-104. Fuel Injectors Install intake cover assembly. See 2.35 INTAKE COVER ASSEMBLY. 2003 Buell XB9S: Fuel System 4-115...
Page 425 Connect EVAP hose to port at bottom of throttle body (California models only). Calibrate throttle position sensor if removed or replaced. 4.36 THROTTLE POSITION SENSOR. Install airbox. See 4.43 AIRBOX. 10. Check throttle cable adjustment. See 2.23 THROTTLE CONTROL. 4-116 2003 Buell XB9S: Fuel System...
Page 426: Intake Leak Test
Figure 4-106. Flatten one end of copper tube to form a nozzle. Insert round side of copper tube into end of tubing. Nozzle Copper Tube Hose Valve Knob Propane bottle Figure 4-107. Leak Tester 2003 Buell XB9S: Fuel System 4-117...
Page 427 Figure 4-108. Aim nozzle toward possible sources of leak such as fuel injectors and intake tract. Figure 4-107. Push valve (4) to release propane. Tone of engine will change when propane enters source of leak. 4-118 2003 Buell XB9S: Fuel System...
Page 428: Airbox
Inspect breather hoses, intake air temperature sensor grommet and baseplate gasket (3). Replace as neces- Fasteners sary. Intake air temperature sensor (IAT) Gasket Baseplate Intake snorkel Breather hoses Velocity stack Velocity stack sealing ring Figure 4-110. Baseplate 2003 Buell XB9S: Fuel System 4-119...
Page 429 Carefully lower baseplate into mounting position. Ensure rubber sealing ring on velocity stack completely engages b1030x4x Airbox cover Intake snorkel Rear cylinder breather hose Air ﬁlter Fasteners Front cylinder breather hose Airbox seal Baseplate Figure 4-111. Airbox 4-120 2003 Buell XB9S: Fuel System...
Page 430 4.44 GENERAL 8915 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 431 The barb is the larger outside diameter portion (bump) on the fuel ﬁtting. Figure 4-112. Connect two hoses to the canister. Make sure to push hoses all the way on to carbon canis- ter ﬁttings. Figure 4-114. Canister Mounting Bracket 4-122 2003 Buell XB9S: Fuel System...
Page 432 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 4-115. Emissions Hose Attachment, California Models Only 2003 Buell XB9S: Fuel System 4-123...
Page 433 HOME NOTES 4-124 2003 Buell XB9S: Fuel System...
Page 434 ELECTRIC STARTER Table Of Contents SUBJECT PAGE NO. 5.1 Specifications ..........5.2 Electric Starter System .
Page 436 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 Nut 60-85 in-lbs 7-10 Nm page 5-19 Starter mounting bolts 13-20 ft-lbs 18-27 Nm page 5-19 2003 Buell XB9S: Starter...
Page 437: 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). 2003 Buell XB9S: Starter...
Page 438 Pinion gear Idler gear Field winding Armature Brush Ball bearing Solenoid plunger Main solenoid contacts Battery 10. Pull-in winding Starting circuit-see 11. Hold-in winding wiring diagram 12. Overrunning clutch 13. Clutch ring gear Figure 5-1. Starter Operation 2003 Buell XB9S: Starter...
Page 439: Starting System Diagnosis
Is 12V present on starter relay Replace Starter Test 3: Relay Clicks. Terminal 86 with starter button solenoid. not pressed? 5845 Nothing clicks. See Starter Replace Replace Test 4: Nothing Clicks. starter relay. right handlebar switchgear. 5832 5818 2003 Buell XB9S: Starter...
Page 440 Terminal 30 Replace grounds. Replace or Terminal 87 when starter on starter relay. solenoid. repair starter motor. button is pressed? 5827 5860 5817 Repair open on Replace GN wire between relay starter relay. and solenoid. 5832 5827 2003 Buell XB9S: Starter...
Page 441 (W/BK wire at connector [22]). Interlock Circuit relay. button to relay. Battery voltage present? or Correct 5832 Relay Ground. 5831 5828 Replace right han- Repair wiring to dlebar switchgear. starter button. 5816 5831 2003 Buell XB9S: Starter...
Page 442 Are test results within range? Remove spark plugs while in Test starter motor for 5th gear. Rotate rear wheel. opens, shorts or grounds. Check for engine, primary Replace or repair starter and/or crankshaft bind. motor. 5817 Use appropriate code 2003 Buell XB9S: Starter...
Page 443: Starter Activation Circuits
10. Start relay Main fuse (30 A) purposes only) 11. Solenoid Key switch fuse Ignition fuse 12. Starter Key switch Key switch relay Run/Stop switch Start switch Figure 5-3. Typical Circuity. Refer to wiring diagrams for more information. 2003 Buell XB9S: Starter...
Page 444 However, when sufﬁ- entire difference in potential displayed on the meter. cient current is passed through, the resistance caused by the powdered paint will cause a voltage drop or potential difference in the ground circuit. 2003 Buell XB9S: Starter...
Page 445 5-10 2003 Buell XB9S: Starter...
Page 446: Starter System Testing
Typical starter current draw will range between 140- 180 amperes. If starter current draw exceeds 180 amperes, then the problem may be in the starter or starter drive. Battery Remove starter for further tests. See STARTER. Figure 5-7. Starter Draw Test 2003 Buell XB9S: Starter 5-11...
Page 447 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 2003 Buell XB9S: Starter...
Page 448: Testing Assembled Starter
Solenoid motor terminal to negative battery post. Solenoid relay terminal to positive battery post. Observe starter pinion. If starter pinion pulls in strongly, solenoid is working properly. If starter pinion does not pull in, replace the sole- noid. 2003 Buell XB9S: Starter 5-13...
Page 449 If starter pinion returns to its original position, sole- Motor terminal noid is working properly. Relay terminal If starter pinion does not return to its original posi- tion, replace the solenoid. Battery Figure 5-13. Return Test 5-14 2003 Buell XB9S: Starter...
Page 450 1/32 in. (0.794 mm) deep. The slots should then be cleaned to remove any dirt or cop- per dust. Field frame Brush holder Brush spring (4) Armature Solenoid housing Figure 5-16. Starter Components 2003 Buell XB9S: Starter 5-15...
Page 451 Mica must not be left with a thin edge next to segments Mica Segments WRONG Mica must be cut away clean between segments Mica Undercutting mica with Segments piece of hacksaw blade RIGHT WAY Figure 5-17. Undercutting Mica Separators 5-16 2003 Buell XB9S: Starter...
Page 452 There should be continuity (0 ohms) at all test points. No continuity at any test point indicates armature is open and must be replaced. Figure 5-19. Grounded Armature Test 6012a Figure 5-20. Open Armature Test 2003 Buell XB9S: Starter 5-17...
Page 453 16. Remove drive (1), idler gear (2), idler gear bearing (3), and O-ring (4) from drive housing (O-ring is located in Figure 5-22. Open Field Test drive housing groove). s0164x5x Figure 5-23. Brush Holder Insulation Test 5-18 2003 Buell XB9S: Starter...
Page 454 If seat is loose, it could shift during vehicle operation and startle the rider, causing Figure 5-26. Starter Mounting loss of control which could result in death or serious injury. Install seat. See 2.41 SEAT. 2003 Buell XB9S: Starter 5-19...
Page 455 10. Drive housing 11. Solenoid housing 12. Drive assembly/ Overrunning clutch 13. Idler gear 14. Idler gear roller (5) 15. Idler gear Bearing cage 16. O-ring 17. Return spring 18. Ball 19. Gasket Figure 5-27. Starter Assembly 5-20 2003 Buell XB9S: Starter...
Page 456 Figure 5-28. Replace wire connection hardware as necessary. Install plunger (5) in solenoid housing (6). Install new gasket (4) onto cover (3). Position cover with gasket onto solenoid housing. Install clip (2) and screws (1). 2003 Buell XB9S: Starter 5-21...
Page 457 HOME NOTES 5-22 2003 Buell XB9S: Starter...
Page 458 Table Of Contents DRIVE/TRANSMISSION 6 SUBJECT PAGE NO. 6.1 Specifications ..........6.2 Primary Chain .
Page 460 ITEM NEW COMPONENTS SERVICE WEAR LIMITS Friction plate (ﬁber) (in.) 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) 2003 Buell XB9S: Drive/Transmission...
Page 461 1-52 Transmission sprocket screws 90-110 in-lbs 10.2-12.4 Nm Replace after 3 removals, page 1-52 Upper belt guard to swingarm 12-36 in-lbs 1-4 Nm page 6-24 Upper belt guard 12-36 in-lbs 1-4 Nm page 6-24 2003 Buell XB9S: Drive/Transmission...
Page 462 14. Bolt, ﬂange head 22. Nut, chain adjustment Gasket, inspection cover 15. Sleeve, shift/brake lever 23. O-ring Cover, inspection 16. Bearing, pedal (2) 24. Drain plug Figure 6-1. Primary Cover, Primary Chain Adjuster and Shifter Assembly 2003 Buell XB9S: Drive/Transmission...
Page 463 1.9 CLUTCH. Figure 6-2. Loosen locknut (6). Turn chain adjuster screw (5) counterclockwise to remove tension on primary chain. Remove three TORX screws with washers and clutch inspection cover. Figure 6-2. Remove clutch inspection cover (3). 2003 Buell XB9S: Drive/Transmission...
Page 464 Figure 6-4. Remove chain adjusting nut from the MARY CHAIN. chain limiting screw. Turn the chain limiting screw clockwise until it can be removed from the inside of the primary cover along with the chain adjuster shoe. 2003 Buell XB9S: Drive/Transmission...
Page 465 ﬁts in slot of primary cover. Thread nut on adjustment screw until slot of screw is accessible with a screwdriver. Fit nut hex into recess of outer ramp and turn adjustment screw counterclockwise. Adjust clutch. See ADJUSTMENT under 1.9 CLUTCH. 2003 Buell XB9S: Drive/Transmission...
Page 466: Clutch Release Mechanism
ﬂats of adjusting screw. b1057x6x TORX screw with washers (3) Ramp assembly Clutch inspection cover Adjusting screw assembly Clutch cover gasket Primary cover Spring 10. Coupling Lockplate 11. Drain plug and o-ring Figure 6-9. Clutch Release Mechanism 2003 Buell XB9S: Drive/Transmission...
Page 467 Connect negative battery cable to battery terminal. Tighten fastener to 60-96 in-lbs (6.8-10.9 Nm). Install seat. See 2.41 SEAT. Outer ramp Adjusting screw Coupling Cable end Lockplate Slot in primary cover Figure 6-11. Nut and Outer Ramp 2003 Buell XB9S: Drive/Transmission...
Page 468 Worn clutch release ramps or balls. Replace release ramps and/or balls. Warped clutch steel plates. Replace clutch steel plates. Blade worn or damaged clutch gear splines. Replace clutch gear or hub as required. Overﬁlled primary. Drain lubricant to correct level. 2003 Buell XB9S: Drive/Transmission...
Page 469 12. Retaining ring 23. Mainshaft nut 28. Needle bearing 13. Release plate 24. Washer 29. Clutch shell and sprocket 14. Retaining ring 25. Clutch hub 30. Thrust washer, outer 15. Bearing Figure 6-12. Clutch Assembly 6-10 2003 Buell XB9S: Drive/Transmission...
Page 470 ﬁber plate, one damper screw. spring and one damper spring seat. Place the bridge of SPRING COMPRESSING TOOL (Part No. HD-38515-A) against diaphragm spring. Install bearing and washer. Thread the tool handle onto end of forcing screw. 2003 Buell XB9S: Drive/Transmission 6-11...
Page 471 Replace damaged parts as necessary. 6251 Retaining ring Bearing and release plate Retaining ring Adjusting screw Figure 6-16. Adjusting Screw Assembly Figure 6-16. Remove adjusting screw assembly. Remove large retaining ring. Remove adjusting screw assembly from pressure plate. 6-12 2003 Buell XB9S: Drive/Transmission...
Page 472 Once the pressure plate assem- bly has been removed the clutch hub will slide out of the clutch shell. Remove clutch pack components. See Steps 3-4 of CLUTCH PACK under 6.4 PRIMARY DRIVE/CLUTCH. 2003 Buell XB9S: Drive/Transmission 6-13...
Page 473 If necessary, disassemble adjusting screw assem- bly. Remove and discard small retaining ring (6) and then separate the adjusting screw (8) from the bear- ing (7) and release plate (5). Remove bearing (7) from release plate (5). 6-14 2003 Buell XB9S: Drive/Transmission...
Page 474 The mini- mum thickness must be 0.661 in. (16.789 mm). If the thickness is less than speciﬁed, discard the ﬁber plates and steel plates. Install a new set of both friction and steel plates. 2003 Buell XB9S: Drive/Transmission 6-15...
Page 475 Inspect clutch shell bearing inner race replaced. See Replacing Clutch Shell Bearing. on the back side of the clutch hub for pitting and wear. If the inner race shows any of these signs the complete hub assembly must be replaced. 6-16 2003 Buell XB9S: Drive/Transmission...
Page 476 (Part No. B-45926) is clearly marked for removal and installa- shell. This will be the correct installed height. tion purposes. Figure 6-27. Insert removal end of tool into bearing assembly and remove bearing from clutch shell. Continue with CLEANING AND INSPECTION. 2003 Buell XB9S: Drive/Transmission 6-17...
Page 477 No tools are required for this operation. b1063x6x Narrow Plate Regular Plate Figure 6-31. Friction Plates Figure 6-31. Install the narrow friction plate on the clutch hub engaging tabs on plate with slots in clutch shell. 6-18 2003 Buell XB9S: Drive/Transmission...
Page 478 The spring seat provides an operating sur- face for the diaphragm spring at the same time preventing the retaining ring from coming out during operation. 2003 Buell XB9S: Drive/Transmission 6-19...
Page 479 Prior to installing engine sprocket nut and the clutch hub nut, the threads on the sprocket shaft, sprocket nut, mainshaft and clutch hub nut must be thoroughly cleaned to remove any oil that might contaminate and interfere with the locking agent. 6-20 2003 Buell XB9S: Drive/Transmission...
Page 480 Pull up on seat to verify that it is properly secured, front and rear. A loose seat may shift during vehicle operation and startle the rider, possibly causing loss of vehicle control resulting in death or serious injury. 10. Install seat. See 2.41 SEAT. 2003 Buell XB9S: Drive/Transmission 6-21...
Page 481: Drive Belt System
GENERAL INSPECTION & CLEANING 1.10 DRIVE BELT. There is no drive belt adjustment required for the Buell XB. 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 482 Sprocket cover fasteners Spacer collar Lower belt guard fasteners Lower belt guard Upper belt guard fasteners, short Front belt guard Upper belt guard fasteners, long Sprocket cover 10. Upper belt guard Figure 1-40. Belt Guard Assembly 2003 Buell XB9S: Drive/Transmission 6-23...
Page 483: Drive Belt Installation
Remove chin fairing fasteners. See 2.34 CHIN FAIRING. Remove front sprocket cover. See 2.31 SPROCKET COVER. Figure 1-43. Remove idler pulley bracket nuts and washers (5) from studs (3). Slide idler pulley bracket (4) off studs (3). 6-24 2003 Buell XB9S: Drive/Transmission...
Page 484 Tighten rear axle pinch fastener (2) to 40-45 ft-lbs (54- 61 Nm). Axle b1106x6x Pinch bolt fastener Figure 1-42. Rear Wheel Mounting, Right Side Wheel Wheel nut Stud Idler pulley bracket Idler pulley bracket nut and washer Wheel fastener Figure 1-43. Idler Pulley Assembly 2003 Buell XB9S: Drive/Transmission 6-25...
Page 485 HOME NOTES 6-26 2003 Buell XB9S: Drive/Transmission...
Page 486 Neutral 1st Gear Mainshaft Mainshaft Countershaft Countershaft 3rd Gear 2nd Gear Mainshaft Mainshaft Countershaft Countershaft 5th Gear 4th Gear Mainshaft Mainshaft Countershaft Countershaft – Sliding member – Power ﬂow Figure 6-44. Transmission Power Flow 2003 Buell XB9S: Drive/Transmission 6-27...
Page 487: Case Disassembly For Transmission Removal
Remove clutch assembly, primary chain and engine sprocket. See 6.4 PRIMARY DRIVE/CLUTCH. 8615 TORX screw Retention collar Shifter lever assembly Figure 6-45. Countershaft Retainer Figure 6-45. Place transmission in 1st gear. Remove countershaft TORX screw (1) and retention collar (2). 6-28 2003 Buell XB9S: Drive/Transmission...
Page 488 Figure 6-49. Rear Isolator Assembly 13. See Figure 6-49. Remove rear isolator assembly by removing the forward two fasteners ﬁrst and then the two rear fasteners (re-install with new fasteners). 2003 Buell XB9S: Drive/Transmission 6-29...
Page 489 No tools are required for this operation. 8621 8636 Figure 6-53. Separating Crankcase Halves Figure 6-54. Removing Flywheels from Left Case Half 17. See Figure 6-53. Separate crankcase halves. 18. See Figure 6-54. Remove the ﬂywheel assembly from left crankcase half. 6-30 2003 Buell XB9S: Drive/Transmission...
Page 490: Transmission Disassembly
Carefully tap on alternate sides of the shaft using the pro- Countershaft vided slots. Figure 6-57. Shifter Forks, Drum and Shafts 8628a Figure 6-56. Transmission Assembly Figure 6-56. Remove shifter drum and shifter forks. Remove mainshaft 2nd gear from mainshaft. 2003 Buell XB9S: Drive/Transmission 6-31...
Page 491 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 6-58. Shifter Mechanism 6-32 2003 Buell XB9S: Drive/Transmission...
Page 492 (4) on arbor press (1) and support transmission assembly on parallel supports (5). Press transmission assembly using TRANSMIS- SION REMOVER (2) (Part No. B-43895-1) to remove transmission assembly from crankcase half. Remove crankcase from press. 2003 Buell XB9S: Drive/Transmission 6-33...
Page 493 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 6-61. Transmission Assembly-Right Crankcase Half 6-34 2003 Buell XB9S: Drive/Transmission...
Page 494 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 6-62. Transmission Assembly-Left Crankcase Half 2003 Buell XB9S: Drive/Transmission 6-35...
Page 495 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 6-63. Transmission Mainshaft Assembly Once Removed from Left Crankcase/Disassembly 6-36 2003 Buell XB9S: Drive/Transmission...
Page 496 (11). Discard all retaining rings that were removed. Slide countershaft 1st gear (13) off end of shaft. Remove split bearing (12). Remove thrust washer (14). Expand remaining retaining ring (15) and slide off countershaft. 2003 Buell XB9S: Drive/Transmission 6-37...
Page 497: 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 6-66. Transmission Mainshaft Assembly/Reassembly 6-38 2003 Buell XB9S: Drive/Transmission...
Page 498 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 6-67. Transmission Countershaft Assembly/Reassembly 2003 Buell XB9S: Drive/Transmission 6-39...
Page 499: Main Drive Gear
(2). Install and tighten nut (6) until 5th gear (3) is free. 8681 Figure 6-69. Bearing Remover Cross Plate Mounting (Part No. B-45847) Figure 6-69. Place cross plate on crankcase as shown. 6-40 2003 Buell XB9S: Drive/Transmission...
Page 500 Place main drive gear on a press. Press in the outer bearing to a depth of 0.315-0.285 in. (8.001-7.239 mm). Press in the inner bearing to a depth of 0.080 in. (2.032 mm). 2003 Buell XB9S: Drive/Transmission 6-41...
Page 501 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 6-74. Transmission Assembly Right Crankcase Half 6-42 2003 Buell XB9S: Drive/Transmission...
Page 502: Transmission Right Case Bearings
ﬁt and wear. If bushing is to be replaced, use a BUSHING AND BEARING PULLER (Part No. HD-95760-69A) with a 1/2 in. collet (Part No. HD-95765-69A) to remove bushing from right crankcase half. 2003 Buell XB9S: Drive/Transmission 6-43...
Page 503 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 6-77. Transmission Assembly Left Crankcase Half 6-44 2003 Buell XB9S: Drive/Transmission...
Page 504: Transmission Left Case Bearings
If using a pressing tool larger than diam- eter of bushing, the pressing tool will bottom against crankcase when bushing is ﬂush with top surface. 2003 Buell XB9S: Drive/Transmission 6-45...
Page 505: 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). 6.9 TRANSMISSION ASSEMBLY. 6-46 2003 Buell XB9S: Drive/Transmission...
Page 506 Figure 6-83. Installing Shift Fork Shafts NOTE Figure 6-83. 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 6-82. Shifter Forks, Drum and Shafts 2003 Buell XB9S: Drive/Transmission 6-47...
Page 507 HOME b1016x3x One Behind Shifter Mechanism Indicates Bolt Pattern Location Figure 6-84. Crankcase Fasteners 6-48 2003 Buell XB9S: Drive/Transmission...
Page 508 Figure 6-86. Gear Detent Assembly Aid ft-lbs (20.3-25 Nm). (Part No. B-45520) Figure 6-86. Retract detent assembly in right case half and install GEAR DETENT ASSEMBLY AID (Part No. B-45520) until it has bottomed in right case half. 2003 Buell XB9S: Drive/Transmission 6-49...
Page 509: 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 6-90. Shifter Shaft Return Spring (Incorrectly Installed) 6-50 2003 Buell XB9S: Drive/Transmission...
Page 510: Transmission Sprocket
If pulley wheel needs replacement, remove fastener (6) and nut (2) 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. 2003 Buell XB9S: Drive/Transmission 6-51...
Page 511 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. 6-52 2003 Buell XB9S: Drive/Transmission...
Page 512 19. Remove engine from ENGINE SUPPORT STAND (Part No. HD-42310/HD-43646 or HD-43682). 20. Install engine in chassis. See 3.4 STRIPPING MOTOR- CYCLE FOR ENGINE SERVICE. 21. Fill transmission and engine to proper level with fresh lubricant. See 1.2 FUEL AND OIL. 2003 Buell XB9S: Drive/Transmission 6-53...
Page 513 HOME NOTES 6-54 2003 Buell XB9S: Drive/Transmission...
Page 514 Table Of Contents SUBJECT PAGE NO. 7.1 Specifications ..........7.2 Ignition System .
Page 516 License plate illumination lamp 0.37 53436-97 (European models only) Indicator Lamps, Indicator, Speedometer and Tachometer LED’s are part of the instrument module and are not Speedometer and replaceable. Entire assembly must be replaced if LED fails. Tachometer Illumination 2003 Buell XB9S: Electrical...
Page 517 2.8-3.2 Nm page 7-46 Turn signal fasteners (front) 25-28 in-lbs 2.8-3.2 Nm page 7-46 Turn signal ﬂasher fastener 30-40 in-lbs 3.4-4.5 Nm page 7-47 Voltage regulator mounting 48-60 in-lbs 5.4-6.8 Nm use new fasteners, page 7-30 screws 2003 Buell XB9S: Electrical...
Page 518: Ignition System
As See Section 4 Fuel System for troubleshooting information. the vehicle warms up to operating temperature the fuel mix- ture will lean and the spark advance will decrease. 2003 Buell XB9S: Electrical...
Page 519 12. Ignition coil 13. Front spark plug cable 14. Engine mount 15. Gearcase cover 16. Seal 17. Trigger rotor 18. Trigger rotor bolt 19. Cam position sensor 20. Inner cover b0990x4x Figure 7-1. Ignition System Components 2003 Buell XB9S: Electrical...
Page 520 Front and rear turn signals can be activated cannot be Horn can be 8886 activated activated ON position OFF position PUSH DETENT LOCK position PARKING LIGHT position Left headlamp module Figure 7-2. Ignition/Headlight Key Switch 2003 Buell XB9S: Electrical...
Page 521 Instrument cluster connector [39] Main harness Right handlebar connector [22] Horn fastener Left handlebar connector [24] 10. Horn mount Turn signal connectors [31] 11. Horn connector [122] Ignition switch 12. Horn Figure 7-3. Electrical Connectors Behind Windscreen 2003 Buell XB9S: Electrical...
Page 522 8899 8904 8902 Socket head fastener (1), with spacer behind switch Ignition switch as positioned on vehicle Tamper-resistant Torx fasteners (2) Fork stop pin (retracted) Throttle cables Figure 7-4. Ignition Switch 2003 Buell XB9S: Electrical...
Page 523 Instrument cluster connector [39] Main harness Right handlebar connector [22] Horn fastener Left handlebar connector [24] 10. Horn mount Turn signal connectors [31] 11. Horn connector [122] Ignition switch 12. Horn Figure 7-6. Electrical Connectors Under Windscreen 2003 Buell XB9S: Electrical...
Page 524 If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install seat. See 2.41 SEAT. 11. Install windscreen and tighten fasteners to 10-12 in-lbs (1.1-1.4 Nm). 2003 Buell XB9S: Electrical...
Page 525: Spark Plug Cables
Pulling on the cable will damage the cable’s carbon core. Remove airbox assembly. See 4.43 AIRBOX. Figure 7-8. Disconnect spark plug cables from igni- tion coil and spark plug terminals. Inspect cables for damage. 7-10 2003 Buell XB9S: Electrical...
Page 526 Connect spark plug cables to ignition coil and spark plugs. Fasten boots/caps securely. Tight connections provide the necessary moisture-proof environment for the ignition coil and spark plug terminals. Install airbox assembly. See 4.43 AIRBOX. 2003 Buell XB9S: Electrical 7-11...
Page 527 Listen for relay “click”. If click is not heard, perform stand retracted or clutch disengaged. ignition system tests. Motorcycle will not start after starter No spark at spark plug. Check for 12 VDC at coil W/BK wire. relay tests. Follow ignition system troubleshooting. 7-12 2003 Buell XB9S: Electrical...
Page 528 Ignition Diode 1 Key Switch Ignition 19 13 11 Accessory Diode 2 Fuse Block Battery Brake/Horn Relay Center Cooling Fan Top View Start Lights Spare Key Switch Spare 20 18 12 Figure 7-12. Diode Wiring 2003 Buell XB9S: Electrical 7-13...
Page 529 Diode OK? Check for ground at neutral switch terminal. Ground present? Repair open on TN/Y Diode installed backwards. Replace Replace neutral wire between neutral Reverse polarity. diode. switch. switch and Diode 2. 5064 5061 5062 5063 7-14 2003 Buell XB9S: Electrical...
Page 530 [95]. GN wire between Reverse polarity. Ground present? connector [95] and 5072 Diode 1. 5071 5073 Replace clutch Repair open on switch. BK wire between connector [95] and 5074 ground. 5075 2003 Buell XB9S: Electrical 7-15...
Page 531 To Starter Solenoid W/BK *ECM [10] Pin 1 also Switch provides power to Relay fuel pump, both fuel [10B] injectors and coil. R/BK [11B] Connector Connector [10A] Electronic Control Module (ECM) [11A] Figure 7-13. Interlock Circuit 7-16 2003 Buell XB9S: Electrical...
Page 532 0 ohms or little resistance. Replace the assembly with a new switch if necessary. Clutch engaged (switch open) 2.24 CLUTCH HAND LEVER. Clutch disengaged (switch closed) Connector [95] Figure 7-15. Clutch Switch 2003 Buell XB9S: Electrical 7-17...
Page 533 A 30 Amp battery fuse links the ignition key switch and the battery. The 30A battery fuse is located under the rider’s seat. 7.23 BATTERY FUSE AND FUSES for more information. Figure 7-17. Starter Relay Test 7-18 2003 Buell XB9S: Electrical...
Page 534 Figure 7-18. Fuse Block (contains diodes) b1003a4x Ignition Diode 1 Diode 2 Accessory Brake/Horn Battery Cooling Fan Lights Spare Key Switch Spare Figure 7-19. Fuses and Diodes 2003 Buell XB9S: Electrical 7-19...
Page 535 HOME NOTES 7-20 2003 Buell XB9S: Electrical...
Page 536: Charging System
Wiring Check for corroded or loose connections in the charging cir- cuit. See Figure 7-22. Voltage Regulator Inspection Figure 7-21. The plug connector to stator must be clean and tight. 2003 Buell XB9S: Electrical 7-21...
Page 537 STOP 5310 Go to Test 7.6 (Part 2 of 2). NOTE Whenever a charging system component fails a test and is replaced, re-test the system to be sure the problem has been corrected. 7-22 2003 Buell XB9S: Electrical...
Page 538 System Damaged or Replace Replace slipping rotor. stator. rotor. 5319 5314 5319 NOTE Whenever a charging system component fails a test and is replaced, re-test the system to be sure the problem has been corrected. 2003 Buell XB9S: Electrical 7-23...
Page 539 HOME b1091a7x Starter Battery Battery Fuse [35A] [35B] [77B] [77A] Voltage Regulator Stator [46A] [46B] Figure 7-22. Charging System Circuit 7-24 2003 Buell XB9S: Electrical...
Page 540 [46] under front sprocket cover See 7.25 SPROCKET COVER WIRING. Start the motorcycle and run the engine at 2000 RPM. With ignition and all continuously running lights and accessories turned on (headlight on high beam), read the total current draw. 2003 Buell XB9S: Electrical 7-25...
Page 541 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. 7-26 2003 Buell XB9S: Electrical...
Page 542 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 7-26. b0997x7x Figure 7-27. Check for Stator Resistance b0998x7x Figure 7-28. Check Stator AC Voltage Output 2003 Buell XB9S: Electrical 7-27...
Page 543 Remove stator wiring grommet (3) from left crankcase half. Withdraw stator wiring (4) from grommet hole in left crankcase half. Remove stator. Stator fastener (4) Stator Grommet Stator wiring Connector [46] Figure 7-31. Stator Assembly 7-28 2003 Buell XB9S: Electrical...
Page 544 Test charging system. See 7.6 CHARGING SYSTEM. to 30-40 in-lbs (3-4 Nm). Route stator wiring (4) behind rear cylinder and in front of transmission breather hose. See 7.25 SPROCKET COVER WIRING for remaining wire routing information. 2003 Buell XB9S: Electrical 7-29...
Page 545: Voltage Regulator
Voltage regulator loss of control which could result in death or serious Fastener (3) injury. Install seat. See 2.41 SEAT. Figure 7-34. Voltage Regulator Test charging system. See 7.6 CHARGING SYSTEM. 7-30 2003 Buell XB9S: Electrical...
Page 546: Battery Cables
CAUTION Connect cables to correct terminals of battery or serious damage to motorcycle electrical system will occur. Figure 7-36. Negative Battery Cable 2003 Buell XB9S: Electrical 7-31...
Page 547 Attach negative cable to frame. Tighten to 48-72 in-lbs (5.4-8.1 Nm). Apply light coat of petroleum jelly or corrosion-retardant material to both battery terminals. Fastener with washer Positive battery cable Figure 7-37. Positive Battery Cable (Protective Boot Not Shown) 7-32 2003 Buell XB9S: Electrical...
Page 548 7.10 GENERAL f1730x8x Warning Label All Buell batteries are permanently sealed, maintenance-free, valve-regulated, lead/calcium and sulfuric acid batteries. The batteries are shipped pre-charged and ready to be put into service. Do not attempt to open these batteries for any reason.
Page 549: Battery Testing
(black) cable. See Figure 7-41. could result in death or serious injury. Install the battery on the motorcycle. See BATTERY INSTALLATION AND CONNECTION. 7-34 2003 Buell XB9S: Electrical...
Page 550: Disconnection And Removal
Unthread fastener and remove battery negative cable Inspect the battery case for cracks or leaks. (black) from battery negative (-) terminal. Unthread fastener and remove battery positive cable (red) from battery positive (+) terminal. Unhook battery strap from frame. Remove battery. 2003 Buell XB9S: Electrical 7-35...
Page 551: Battery Charging
110˚F. (43˚C) during charging, discontinue Perform a load test to determine the condition of the bat- charging and allow the battery to cool. Overheating may tery. See BATTERY TESTING. result in plate distortion, internal shorting, dryout or other damage. 7-36 2003 Buell XB9S: Electrical...
Page 552 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. 2003 Buell XB9S: Electrical 7-37...
Page 553 Apply a light coat of petroleum jelly or corrosion retardant during vehicle operation and startle the rider, causing material to both battery terminals. loss of control which could result in death or serious injury. Install seat. See 2.41 SEAT. 7-38 2003 Buell XB9S: Electrical...
Page 554 (not freezing), dry place. See Fig- ure 7-42. Charge the battery every month if stored at temperatures below 60˚ F. (16˚ C). Charge the battery more frequently if stored in a warm area above 60˚ F. (16˚ C). 2003 Buell XB9S: Electrical 7-39...
Page 555 8917 Headlight Low beam connection [38] (right side) with ground Bulb holder (2) Headlight bulbs High beam connection [38] (left side) with ground Figure 7-43. Headlight Assembly/Rear View 7-40 2003 Buell XB9S: Electrical...
Page 556 Figure 7-43. Align tabs on bulb (5) with tabs on headlight (1). Insert bulb. Close the bulb holder (2). Connect the headlight bulb connector. Install rubber boot. Connect negative battery cable. 2003 Buell XB9S: Electrical 7-41...
Page 557: Tail Lamp
Center tail section Screws (2) Bulb Lens Tail light Tail light wiring harness Tail light boot Figure 7-45. Tail Lamp Assembly 7-42 2003 Buell XB9S: Electrical...
Page 558: License Plate Lamp Assembly
Install seat. See 2.41 SEAT. Jam nuts with washers (2) Center tail section Screws (2) Bulb Lamp lens License plate lamp Figure 7-47. License Plate Lamp 2003 Buell XB9S: Electrical 7-43...
Page 559: Turn Signals
Pull bullet connectors and wiring through hole in front module (3) and remove turn signal (1). Turn signal (2) b1141x7x Jam nut and lockwasher (2) Front module, left and right Windscreen Figure 7-49. Front Turn Signals 7-44 2003 Buell XB9S: Electrical...
Page 560 [18A] [18A] [18A] [18A] Right turn signal Figure 7-50. Rear Turn Signal Connections b1138x7x Turn signal (2) Jam nut and lockwasher (2) Turn signal bulb Center tail section Reﬂector bracket Figure 7-51. Rear Turn Signals 2003 Buell XB9S: Electrical 7-45...
Page 561 If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Install seat. See 2.41 SEAT. 7-46 2003 Buell XB9S: Electrical...
Page 562: Turn Signal Flasher
Figure 7-55. Turn Signal Controls Activate right turn signals using switch on left han- dlebar. Front and rear right turn signals must ﬂash. Turn ignition key switch to OFF. Install windscreen. See 2.40 FRONT WINDSCREEN. 2003 Buell XB9S: Electrical 7-47...
Page 563: Handlebar Switches
To headlamp Light power High beam Horn Y/BK Y/BK From ﬂasher BE/W V/BN Left turn Right turn Horn power To interlock circuit TN/LTGN To ground [95B] [95A] Clutch Switch Figure 7-57. Left Handlebar Switch Connection 7-48 2003 Buell XB9S: Electrical...
Page 564 Brake Switch formed. Turn ignition key switch to ON. Figure 7-58. Right Handlebar Switch Connection Set ENGINE STOP SWITCH to RUN. Start motorcycle. Turn ignition key switch to OFF. Turn ignition key switch to OFF. 2003 Buell XB9S: Electrical 7-49...
Page 565 Set headlight to LOW beam. Press passing lamp switch. Headlight should ﬂash HIGH beam for as long as the switch is pressed. Figure 7-59. Left Handlebar Switch Connection Check left and right turn signals. Activate horn by pressing horn switch. 7-50 2003 Buell XB9S: Electrical...
Page 566 Key Switch Fuse To battery Vehicle Speed Sensor Connector [39A] [39B] Instrument Module BK/W Vehicle Speed [65A] [65B] Sensor [10B] [11B] Connector Connector [10A] Electronic Control Module [11B] (ECM) Figure 7-61. Vehicle Speed Sensor Wiring 2003 Buell XB9S: Electrical 7-51...
Page 567 Install washers (4) and fasteners (5). Tighten fasteners to Instrument module connector [39] 12-36 in-lbs (1.4-4.1 Nm). Figure 7-64. Instrument Module Figure 7-63. Connect instrument module connector [39]. Install windscreen. See 2.40 FRONT WINDSCREEN. Install negative battery cable. 7-52 2003 Buell XB9S: Electrical...
Page 568: 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). 2003 Buell XB9S: Electrical 7-53...
Page 569 Rotate the motorcycle’s rear wheel. If reading on speedometer tester changes as wheel is rotated, speedometer sensor is OK. If reading does not change, vehicle speed sensor is suspect. Install a known, good vehicle speed sensor and test again. 7-54 2003 Buell XB9S: Electrical...
Page 570 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. 6020 Go to Speedometer Test: Chart 2003 Buell XB9S: Electrical 7-55...
Page 571 Go to If necessary, remove vehicle speed sensor Speedometer Test: and check for accumulation of debris. If Chart debris is not present, replace sensor. If debris is present, clean sensor and repeat test. Replace if necessary. 7-56 2003 Buell XB9S: Electrical...
Page 572 Does damage exist? Check speedometer speed Repair as necessary. sensor. Clean or replace sen- sor as required. Retest. 6016 Problem solved? System OK. Replace instrument module. 6029 6024 2003 Buell XB9S: Electrical 7-57...
Page 573: Tachometer Performance Check
Enter the result (33.3 for 2000 RPM) into the speedome- ter tester. The tachometer should respond by moving its nee- dle to the desired RPM. Test the tachometer at several different RPM read- ings to verify proper operation. 7-58 2003 Buell XB9S: Electrical...
Page 574 Module If testing CEN range, press 4 or 6. If testing HI range, press 7 or 9. Deutsch socket housing test connector Deutsch socket housing Deutsch pin housing Cam position sensor Figure 7-69. Testing Tachometer 2003 Buell XB9S: Electrical 7-59...
Page 575 If seat is loose, it could shift during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Figure 7-71. Horn Wiring Install seat. See 2.41 SEAT. 7-60 2003 Buell XB9S: Electrical...
Page 576 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. 2003 Buell XB9S: Electrical 7-61...
Page 577: Neutral Indicator Switch
(2) 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 2.31 SPROCKET COVER. 7-62 2003 Buell XB9S: Electrical...
Page 578 HOME BATTERY FUSE AND FUSES 7.23 GENERAL b1003a4x Buell motorcycles feature two components which protect the electrical system. Diode 1 Ignition Fuses The covered fuse block is under the seat. Diode 2 Accessory Figure 7-75. The lights, key switch, brake/horn and igni- tion fuses are rated at 15 amps.
Page 579: Main Wire Harness
10. Remove fuse block and relay center from support from battery positive (+) terminal. bracket. Remove battery. 11. Remove the rear shock absorber assembly and reser- voir. See 2.22 REAR SHOCK ABSORBER. 12. Remove fan. See 4.37 COOLING FAN. 7-64 2003 Buell XB9S: Electrical...
Page 580 Rear brake light switch connector [121] 12. License plate lamp connector [45] Ground terminals (low voltage ground wires) 13. Tail light connectors [93] ECM connectors [10] & [11] Figure 7-78. Main Harness and Electrical Connectors Under Seat 2003 Buell XB9S: Electrical 7-65...
Page 581 17. Remove heat shrink tubing and disconnect sidestand switch [133] (1). See 7.5 STARTER INTERLOCK. 18. Remove connector from oil pressure switch [120]. Oil pressure switch is located on front of engine. See 3.10 OIL PRESSURE INDICATOR SWITCH. 7-66 2003 Buell XB9S: Electrical...
Page 582 (1) at rear of frame. Install new plastic tree Figure 7-80. Wire Harness Clip fasteners. Figure 7-80. Install clamp over portion of harness that leads to engine connectors. Install clamp as shown using new plastic tree fastener. 2003 Buell XB9S: Electrical 7-67...
Page 583 14. Connect sidestand switch connector [133]. Install heat shrink tubing. Install cable strap securing sidestand Wire harness ground [GRD 2]. switch wiring to sidestand switch bracket. See STARTER INTERLOCK. 21. Install starter side of positive battery cable to starter. 7-68 2003 Buell XB9S: Electrical...
Page 584 Rear brake light switch connector [121] 12. License plate lamp connector [45] Ground terminals (low voltage ground wires) 13. Tail light connectors [93] ECM connectors [10] & [11] Figure 7-83. Main Harness and Electrical Connectors Under Seat 2003 Buell XB9S: Electrical 7-69...
Page 585 Rear cable strap (1) secures conduit to voltage reg- ulator wiring. 23. Verify that front forks can be turned from full left to full right lock without wire harness binding or pinching. 7-70 2003 Buell XB9S: Electrical...
Page 586: Sprocket Cover Wiring
Form a loop (2) as shown using wiring leading to cam position sensor. Cam position sensor [14] Cam position sensor and neutral indicator switch wiring Neutral switch location Cam cover breather hose Stator connector [46] Oil pressure switch wiring Figure 7-86. Cam Position Sensor Wiring 2003 Buell XB9S: Electrical 7-71...
Page 587 11. Install cable strap (5) securing main harness wiring. 12. Install cable strap (6) securing stator, cam position sen- sor and oil pressure switch wiring. 13. Add cable strap (7) to secure cam position sensor and voltage regulator wiring. 7-72 2003 Buell XB9S: Electrical...
Page 588 Table Of Contents SUBJECT PAGE NO. Appendix A-Tools ..........Appendix B-Wiring .

Buell 2003XB9S Service Manual

Index to Wiring Diagrams B.5

Maintenance 1

Chassis 2

Table of Contents

Quick Links

Chapters

Related Manuals for Buell 2003XB9S

Summary of Contents for Buell 2003XB9S