Front Modules - Buell 2003XB9S Service Manual

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FRONT MODULES

REMOVAL
1. Remove seat. See 2.41
11 1
WARNING
To protect against accidental start-up of vehicle and pos-
sible personal injury, disconnect the negative battery
cable before proceeding. Inadequate safety precautions
could cause a battery explosion, which could result in
death or serious injury.
2. Disconnect battery by unthreading fastener removing
negative cable (black) from battery first. See
TERY MAINTENANCE.
3. Remove windscreen. See
4. Remove headlight assembly and support bracket. See
2.25 HEADLIGHT
BRACKET.
5. Disconnect and remove instrument module. See
INSTRUMENT MODULE.
6. Remove ignition switch. See
KEY SWITCH.
NOTE
See Figure 2-95. Once the ignition switch has been removed
there will be two remaining fasteners.
7. See Figure 2-95. Remove fastener attaching p-clamp to
rear side of right front module.
NOTE
See Figure 2-96. Once the clamp load has been released on
the final fastener securing the right front module to the upper
triple clamp, the left front module can be removed.
8. See Figure 2-95. Loosen but do not remove final fastener
securing the right front module to upper triple clamp.
9. See 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
SEAT.
WARNING
1.5 BAT-
2.40 FRONT WINDSCREEN.
ASSEMBLY AND SUPPORT
7.3 IGNITION/HEADLIGHT
INSTALLATION
1. See Figure 2-95.
fastener loose.
2. After installing the left front module and aligning with
holes in upper triple clamp, tighten previously installed
single fastener to 12-14 ft-lbs (16.3-19 Nm).
3. Attach front brake line p-clamp to rear of right front mod-
ule and tighten fastener to 36-60 in-lbs (4.1-6.8 Nm).
4. Install ignition switch. See
KEY SWITCH.
5. Install and connect instrument module. See
INSTRUMENT
6. Install headlight assembly and support bracket.
HEADLIGHT ASSEMBLY AND SUPPORT
7. Install windscreen. See
7.18
Always connect the positive battery cable first. If the pos-
itive cable should contact ground with the negative cable
installed, the resulting sparks may cause a battery explo-
sion which could result in death or serious injury.
8. Install battery by threading positive cable (red) into
threaded hole first tightening to 72-96 in-lbs (8-11 Nm).
See 1.5 BATTERY
After installing seat, pull upward on front of seat to be
sure it is locked in position. 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.
9. Install seat. See
Install right front module leaving single
7.3 IGNITION/HEADLIGHT
MODULE.
BRACKET.
2.40 FRONT WINDSCREEN.
11 1
WARNING WARNING
MAINTENANCE.
11 1
WARNING WARNING
2.41 SEAT.
2.26
7.18
2.25