Buell 2004 XB9S Service Manual

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2004 BUELL XB9S

SERVICE MANUAL

Part Number 99490-04Y

Section 1: Maintenance

Section 2: Chassis

Section 3: Engine

Section 4: Fuel System

Section 5: Starter

Section 6: Drive/Transmission

Section 7: Electrical

Appendices

Table of Contents

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Page 1 2004 BUELL XB9S SERVICE MANUAL Part Number 99490-04Y Section 1: Maintenance Section 2: Chassis Section 3: Engine Section 4: Fuel System Section 5: Starter Section 6: Drive/Transmission Section 7: Electrical Appendices...
Page 2 Edit Me: Printed September 26, 2003 2:32 pm...
Page 3 HOME APPENDIX A–TOOLS Part No. B-41174 Rear Wheel Support Stand and Part No. B-43993-7/-8 Wheel Bearing Collets Part No. B-41174-2 Replacement Pad Part No. B-42887 Brake Caliper Piston Remover Part No. B-45521 Steering Head Bearing Remover/ Installer Part No. B-43721 Front Fork Seal Driver Part No.
Page 4 HOME Part No. HD-01289 Rim Protectors Part No. HD-33418 Universal Puller Forcing Screw 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.
Page 5 HOME Bdhgkjsbkdv ' ksjjlkn lk CYLINDER LEAKDOWN TESTER knsdl hlno hslnsln nlslns finbp pffb odlbndpob nponno[bho Bdhgkjsbkdv ' ksjjlkn lk knsdl hlno hslnsln nlslns finbp pklhb knsdl hlno hslnsln nlslns finbp pffb odlbndpob nponno[bho knsdl hlno hslnsln nlslns finbp pffb Bdhgkjsbkdv Majjlkn Nolk odlbndpob npdb ndbno[bho...
Page 6 HOME Part No. HD-39964 Reamer Lubricant (Cool Tool) Part No. B-45524 Valve Guide Installer 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.
Page 7 HOME Part No. HD-94804-57 Rocker Arm Bushing Reamer Part No. HD-96333-51C Piston Ring Compressor Part No. HD-33446A Cylinder Torque Plates Part No. HD-95952-33B Connecting Rod and 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.
Page 8 HOME Part No. HD-95760-69A Bushing/Bearing Puller Tool Set. Part No. HD-35102 Wrist Pin Bushing Hone (20 mm) Set includes items 1-7. Items 8 (HD-95769-69), 9 (HD- 95770-69) and 10 (HD-95771-69) are optional. Part No. HD-39965 Deutsch Terminal Crimp Tool Part No. HD-38515-A Clutch Spring Compressing Tool and Part No.
Page 9: Amp Multilock Electrical Connectors
Pin terminal Secondary lock open Pin housing Socket housing Latch Latch Secondary lock open Button Latch Secondary lock open Socket terminal Figure B-1. 10-Place Amp Multilock Connector 2004 Buell Lightning: Appendix B...
Page 10 Figure B-3. Multilock Connector Cutaway View engage latches on both sides of connector. Insert the socket housing (plug) into the pin housing (receptacle) until it snaps in place. Install connector on retaining device, either attachment or rosebud clip. 2004 Buell Lightning: Appendix B...
Page 11 Pin terminal Socket housing Button Pin housing Secondary lock Pin terminal Secondary lock Socket terminal Latch Button Pin housing Latch Socket housing Secondary lock Socket terminal d0245x2x Figure B-4. 3-Place and 6-Place Amp Multilock Connectors 2004 Buell Lightning: Appendix B...
Page 12 Release contacts locking bar. locking bar GAUGE CRIMP TOOL WIRE NEST Front Middle Rear Close and squeeze crimp tool. Raise locking bar and remove contact. d0246x8x Figure B-5. Amp Multilock Crimping Procedure 2004 Buell Lightning: Appendix B...
Page 13 “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. 2004 Buell Lightning: Appendix B...
Page 14 (Part No. HD-41475-100). See Figure B-10. Figure B-9. Depress Terminal Latches/Back Out Pins Gently depress terminal latches inside pin housing and back out pins through holes in wire seal. 2004 Buell Lightning: Appendix B...
Page 15 The socket and pin halves of all other connectors are interchangeable, that is, the black may be mated with the gray, since the alignment tabs are absent and the orientation of the external latch is the same. 2004 Buell Lightning: Appendix B...
Page 16 When correctly positioned, the locking bar ﬁts snugly in the space between the contact band and the core crimp tails. 2004 Buell Lightning: Appendix B...
Page 17 SOCKET SIDE PIN SIDE Socket terminal Locking wedge Wire seal Latch cover Socket housing Pin housing External latch 10. Wire seal Internal seal 11. Pin terminal Locking wedge Figure B-13. 2-Pin, 3-pin and 4-pin Deutsch Connectors 2004 Buell Lightning: Appendix B...
Page 18 MAP sensor connector [80]. d0258x8x Locate tang on latch side of chamber. Push on wire end of lead to remove terminal. Pivot end of pin to depress tang. Raise tang and re-install terminal. Figure B-14. Packard Connectors B-10 2004 Buell Lightning: Appendix B...
Page 19 NOTE A series of Packard Electrical Terminal Crimp Tools are avail- able to install Packard pin and socket terminals on wires. If new terminals must be installed, see Crimping Instructions. 2004 Buell Lightning: Appendix B B-11...
Page 20 Repeat the step if the terminal is still locked in place. NOTE A series of Packard Electrical Terminal Crimp Tools are avail- able to install Packard pin and socket terminals on wires. If new terminals must be installed, see Crimping Instructions. B-12 2004 Buell Lightning: Appendix B...
Page 21 11. See Figure B-16. Inspect the quality of the core (3) and insulation/seal (2) crimps. Distortion should be minimal. Insulation Insulation crimp Core crimp Figure B-16. Inspect Core and Insulation/Seal Crimps 2004 Buell Lightning: Appendix B B-13...
Page 22: Electrical Connectors
HOME ELECTRICAL CONNECTORS GENERAL Connector numbers are listed in [brackets] in this manual. The following table provides a brief description of the connec- tors found on the Buell Lightning. Table B-2. Electrical Connector and Location Table CONNECTOR COMPONENT(S) DESCRIPTION LOCATION...
Page 23 [128] starter solenoid spade terminals top of starter [131] neutral switch 1-place bullet under sprocket cover [134] bank angle sensor 6-place Sumitomo under seat [137] oxygen sensor 1-place Packard behind rear cylinder head 2004 Buell Lightning: Appendix B B-15...
Page 24: Table Of Contents
INDEX TO WIRING DIAGRAMS Table B-3. Wiring Diagrams DIAGRAM PAGE Main harness B-17 Engine management circuit B-18 Lighting circuit B-19 Horn and instruments circuit B-20 Starting circuit B-21 Charging circuits B-22 Component Circuits B-23 B-16 2004 Buell Lightning: Appendix B...
Page 25: Main Harness
DATA LINK SPEEDOMETER BK/R LT.GN/R TN/LT.GN [91A] [39A] [77B] R/BK LH TURN SIGNAL [95B] GN/Y R/BK OIL PRESSURE SW [31B] [120B] CLUTCH SW R/BK GN/Y R/BK [120A] MALE R/BK FEMALE 2004 Lightning Models Main Harness 2004 Buell Lightning: Electrical B-17...
Page 26: Engine Management Circuit
BE/O [161A] [161B] IGNITION INJECTOR REAR OUTPUT GN/GY GY/O R/BK ACTIVE MUFFLER FEEDBACK TN/V Some 2004 XB9S models POSITION BANK ANGLE SENSOR LT.GN/GY SYSTEM GROUND B SENSOR may not have the circuitry TACHOMETER OUTPUT for the active muffler. FUEL PUMP...
Page 27: Lighting Circuit
LIGHTS R/BK KEY SWITCH [39B] 1 2 3 4 5 6 7 8 9 10 HEADLAMP FUSE/RELAY [24A] ASSEMBLY [38B] [62B] LH CONTROLS LH TURN SIGNAL SPEEDOMETER [39A] R/BK [31B] R/BK 2004 Lightning Lighting Circuit 2004 Buell Lightning: Electrical B-19...
Page 28: Horn And Instruments Circuit
1 2 3 4 5 6 7 8 9 10 [24A] 1 2 3 4 5 6 7 8 LH CONTROLS FUSE/RELAY ASSEMBLY [62B] SPEEDOMETER TN/LT.GN [39A] GN/Y [120B] OIL PRESSURE SW R/BK GN/Y [120A] 2004 Lightning Models Horn & Instruments Circuit 2004 Buell Lightning: Electrical B-20...
Page 29: Starting Circuit
R/BK KEY SWITCH [39B] 1 2 3 4 5 6 7 8 9 10 HEADLAMP FUSE/RELAY [24A] ASSEMBLY [38B] [62B] LH CONTROLS LH TURN SIGNAL SPEEDOMETER [39A] R/BK [31B] R/BK 2004 Lightning Models Starting Circuit 2004 Buell Lightning: Electrical B-21...
Page 30: Charging Circuits
HOME bs0021xx BATTERY CABLE STARTER SOLENOID [128A] BATTERY STARTER MOTOR [GRD2] FUSE/RELAY ASSEMBLY [61B] BATTERY, 30A TO VOLTAGE REGULATOR [77A] [77B] VOLTAGE REGULATOR STATOR (HD 3-PHASE) [46A] [46B] 2004 Lightning Models Charging Circuit 2004 Buell Lightning: Electrical B-22...
Page 31: Component Circuits
[18A] [30B] [84B] [85B] ENGINE TEMP SENSOR PK/Y [90A] [90B] FUEL PUMP MAIN HARNESS BANK ANGLE SENSOR [89A] BN/Y INTAKE AIR TEMP [86B] LT.GN/GY [89B] FUEL BK/W SENSOR [134B] [134A] 2004 Lightning Models Component Circuits 2004 Buell Lightning: Electrical B-23...
Page 32 44.45 79.37 114.30 .8268 2.126 3.425 4.724 10.160 45.72 80.96 115.89 .8661 2.165 3.464 4.764 11.112 46.04 81.28 116.84 .9055 2.205 3.504 4.803 12.700 47.62 82.55 117.47 .9449 2.244 3.543 4.842 14.288 48.26 83.82 119.06 2004 Buell Lightning: Appendix C...
Page 33 (Imp.) x 1.201 = pints (U.S.) liters x 2.113 = pints (U.S.) quarts (Imp.) x 1.201 = quarts (U.S.) liters x 1.057 = quarts (U.S.) gallons (Imp.) x 1.201 = gallons (U.S.) liters x 0.264 = gallons (U.S.) 2004 Buell Lightning: Appendix C...
Page 34 HOME HOSE AND WIRE ROUTING b1114xasx Front and Rear Brake Systems, Right Side View...
Page 35 HOME b1115xbsx Rear Brake Systems, Top View...
Page 36 HOME b1116xcsx Rear Brake Systems, Left Side View...
Page 37 HOME b1117xasx Carbon canister Evaporative Emissions Control, California Models, Top View...
Page 38 HOME b1118xbsx To induction module From fuel tank (California) From induction module (California) From fuel tank to atmosphere (49 state) Evaporative Emissions Control, California and 49 State Models, Left Side View...
Page 39 HOME b1119xasx Intake air temperature sensor (IAT) Fuel pump Wiring Harness, Left Side View...
Page 40 HOME b1120xbsx Fuel injector (2) Intake air temperature (IAT) sensor Throttle position sensor (TPS) Oxygen (O2) sensor Wiring Harness, Top View...
Page 41 HOME b1121xcsx Speedometer sensor Cable, starter to battery positive Solenoid Transmission vent line Voltage regulator Switch, oil pressure Cam position sensor Wiring Harness, Right Side View...
Page 42 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 Oil Lines, Right Side View...
Page 43 HOME b1123xbsx Vent line Feed oil line Return oil line Oil Lines, Bottom View...
Page 44 HOME b1124xasx Clutch Cable, Right Side View...
Page 45 HOME b1125xbsx Cable, seat lock Clutch, Throttle and Seat Release Cables, Left Side View...
Page 46 HOME b1126xcsx TPS adjuster Cable, seat lock Clutch, Throttle and Seat Release Cables, Top View...
Page 47 HOME NOTES D-14 2004 Buell Lightning: Appendix D...
Page 48 MAINTENANCE Table Of Contents SUBJECT PAGE NO. 1.1 General ............1.2 Fuel and Oil .
Page 50: General
Engine oil and transmission ﬂuid levels. Always clean around lines or covers before they are removed. Headlamp, passing lamp, tail lamp, brake lamp and turn Plug, tape or cap holes and openings to keep out dirt, dust signal operation. and debris. 2004 Buell Lightning: Maintenance...
Page 51: 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. 2004 Buell Lightning: Maintenance...
Page 52: 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. 2004 Buell Lightning: Maintenance...
Page 53: 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. 2004 Buell Lightning: Maintenance...
Page 54: Fuel And Oil
Always change the engine oil more often in winter. If the Buell motorcycles were designed to give the best perfor- engine is used for short runs, change the oil even more fre- mance using unleaded gasoline. Some fuel suppliers sell quently.
Page 55: Maintenance Schedule
Road test. Chart Codes: I - Inspect, & if necessary correct, clean or replace. R- Replace or change. A- Adjust. L- Lubricate with specified lubricant. T- Tighten to proper X- Perform. torque. 2004 Buell Lightning: Maintenance...
Page 56: 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 57: Battery Maintenance
BATTERY MAINTENANCE GENERAL BATTERY TESTING Voltmeter Test Buell motorcycle batteries are permanently sealed, mainte- Table 1-3. The voltmeter test provides a general indicator nance-free, valve-regulated, lead/calcium and sulfuric acid of battery condition. Check the voltage of the battery to verify batteries.
Page 58: 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 2004 Buell Lightning: Maintenance...
Page 59 Install seat. See 2.41 SEAT. sion which could result in death or serious injury. CAUTION Overtightening fasteners can damage battery terminals. 1-10 2004 Buell Lightning: Maintenance...
Page 60: 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. 2004 Buell Lightning: Maintenance 1-11...
Page 61 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 2004 Buell Lightning: Maintenance...
Page 62 ° 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 2004 Buell Lightning: Maintenance 1-13...
Page 63: Brake System Maintenance
To prevent death or serious ﬂuid is swallowed, induce vomiting by administering two injury, Buell recommends that all brake repairs be per- tablespoons of salt in a glass of warm water. Call a doc- formed by a Buell dealer or other qualiﬁed technician.
Page 64 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. 2004 Buell Lightning: Maintenance 1-15...
Page 65: 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 2004 Buell Lightning: Maintenance...
Page 66: 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 3. Install cover on master cylinder reservoir and tighten cap securely. 2004 Buell Lightning: Maintenance 1-17...
Page 67 130-173.5 in-lbs (14.7-19.6 Brake Pedal Nm). NOTE 8349 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 2004 Buell Lightning: Maintenance...
Page 68 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 2004 Buell Lightning: Maintenance 1-19...
Page 69: Brake Pad Replacement
(48-50 Nm). Tighten pin (2) to 11-14 ft-lbs (15-19 Nm). NOTE Avoid making hard stops for the ﬁrst 100 miles (160 km) to allow new brake pads to “wear in” properly with the rotor. 1-20 2004 Buell Lightning: Maintenance...
Page 70 “wear in” properly with the rotor. Rear caliper mounting fasteners Retainer, Rear caliper pin plug Rear caliper hanger pin Figure 1-16. Rear Brake Caliper 6487 Figure 1-17. Rear Brake Pad Spring 2004 Buell Lightning: Maintenance 1-21...
Page 71: Tires And Wheels
Replace bearings in A bump, bulge or split in the tire. sets only. Puncture, cut or other damage to the tire that cannot be repaired. 1-22 2004 Buell Lightning: Maintenance...
Page 72: 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 Correct chaincase lubricant level Figure 1-21. Fluid Level 2004 Buell Lightning: Maintenance 1-23...
Page 73 Jam nut adjusting screw clockwise until it aligns. Adjuster Figure 1-22. Clutch Cable Adjuster Mechanism NOTE Spring installs on outboard side of hex lockplate. 8405 Diaphragm spring Lockplate Adjusting screw Figure 1-23. Clutch Adjustment 1-24 2004 Buell Lightning: Maintenance...
Page 74 Figure 1-19. Install clutch inspection cover and new Figure 1-24. Adjusting Clutch Free Play gasket using three fasteners and washers and tighten to 84-108 in-lbs (10-12 Nm). Check clutch cable free play. See Step 6 above. 2004 Buell Lightning: Maintenance 1-25...
Page 75: Drive Belt
Keep dirt, grease, oil, and debris off the belt, idler pulley and sprockets. Clean the drive belt with a mild soap and water spray solution as required. Dry thoroughly. Do not immerse belt in solution. 1-26 2004 Buell Lightning: Maintenance...
Page 76 Clean and protect drive Cracks in back of belt Inspect/replace sprocket Cut by sharp debris (not at belt edge) Continue to run but monitor condition frequently Inspect/replace sprocket Cut by sharp debris at belt edge Inspect/replace belt 2004 Buell Lightning: Maintenance 1-27...
Page 77 Follow proper handling/installation procedure Damaged belt Inspect/replace belt Excessive drive noise Inspect/replace sprocket Debris stuck in belt Clean and protect drive Inspect/replace belt Inspect/replace sprocket Debris stuck in sprocket Follow proper handling/installation procedure Inspect/replace belt 1-28 2004 Buell Lightning: Maintenance...
Page 78: Primary Chain
Table 1-8. Primary Chain Free Play and new gasket to primary cover using two fasteners with captive washers. Tighten fasteners to 40-60 in-lbs ENGINE (5-7 Nm). TEMPERATURE Cold 3/8-1/2 9.5-12.7 Hot (normal running 1/4-3/8 6.4-9.5 temperature) 2004 Buell Lightning: Maintenance 1-29...
Page 79 Loosen locknut (1). Turn adjusting fastener (2): Clockwise (inward) to reduce free play. Counterclockwise (outward) to increase free play. Tighten locknut (1) to 20-25 ft-lbs (27-34 Nm). Locknut Adjusting Fastener Figure 1-28. Chain Tension Adjusting Fastener 1-30 2004 Buell Lightning: Maintenance...
Page 80: Suspension Damping Adjustments
170-190 77-86 2.25 1.25 190-210 86-95 1.25 210-230 95-104 1.25 1.25 1.75 230-250 104-113 1.25 0.75 250-GVWR 113-GVWR 3 1.25 0.75 * Note all compression and rebound settings are number of turns out from maximum. 2004 Buell Lightning: Maintenance 1-31...
Page 81 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. Table 1-10. 1-32 2004 Buell Lightning: Maintenance...
Page 82 Using a screwdriver, turn the slotted dial clockwise until it stops. This is the maximum rebound damping setting. Then turn the dial counterclockwise the recommended amount speciﬁed in Table 1-9. Table 1-10. Figure 1-32. Rear Shock Rebound Adjustment 2004 Buell Lightning: Maintenance 1-33...
Page 83 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. Figure 1-33. Rear Shock Compression Adjustment 1-34 2004 Buell Lightning: Maintenance...
Page 84: 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. 2004 Buell Lightning: Maintenance 1-35...
Page 85: 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 2004 Buell Lightning: Maintenance...
Page 86 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. 2004 Buell Lightning: Maintenance 1-37...
Page 87: Air Cleaner Filter
Thoroughly clean baseplate and inside of air cleaner Vapor Valve (XB9) cover. Figure 1-40. Make sure two crankcase breather hoses (1) and intake air sensor (2) are captured in base- plate behind velocity stack (3). 1-38 2004 Buell Lightning: Maintenance...
Page 88 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. 2004 Buell Lightning: Maintenance 1-39...
Page 89: Throttle Cable And Idle Speed Adjustment
Tighten cable adjuster lock on idle control cable. Recheck operation of throttle control. Recheck engine slow idle speed; adjust if required. 10. Install airbox, baseplate and intake cover assembly. See 4.30 AIRBOX. 1-40 2004 Buell Lightning: Maintenance...
Page 90 This ensures the system is working prop- For the next step in the procedure it will be necessary to erly. If you do not see the mark, verify previous cable adjust- obtain a permanent marker. ment. 2004 Buell Lightning: Maintenance 1-41...
Page 91 (1) is routed behind the frame lug (2) before installing air intake cover. CAUTION If cable is routed in front of the frame lug it will cause the mufﬂer valve to stay open not allowing it to work prop- erly. 12. Install air intake cover. 1-42 2004 Buell Lightning: Maintenance...
Page 92: Ignition Timing
Gently bump ﬂywheel forward in tiny increments. 10. See Figure 1-47. If the static timing is correct, the screen will switch to HIGH - 5 volts at the precise moment the timing mark exactly centers in the inspection window. 2004 Buell Lightning: Maintenance 1-43...
Page 93 If timing is retarded (mark appears on right side of window) rotate timing plate clockwise. Recheck timing. Figure 1-48. Timer Cover 8391 Figure 1-49. Cam Position Sensor b0964x1x Figure 1-50. Advanced Timing b0963x1x Figure 1-51. Retard Timing 1-44 2004 Buell Lightning: Maintenance...
Page 94: 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 1-52. Figure 1-53. Headlamp Switch Adjust headlamp alignment. See ADJUSTMENT section. 2004 Buell Lightning: Maintenance 1-45...
Page 95 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 1-54. Horizontal Headlamp Adjustment 9951 Figure 1-55. Vertical Headlamp Adjustment 1-46 2004 Buell Lightning: Maintenance...
Page 96: Throttle Position Sensor (Tps)
ADJUSTMENT Connect vehicle to Digital Technician. Figure 1-56. Idle Adjuster (behind left fork) Select calibrations screen/TPS Function. Select Buell TPS zero tab. Select TP volts on screen. Figure 1-56. Back off idle adjustment until TP volts stop decreasing and then continue to back out one full turn.
Page 97: 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. 1-48 2004 Buell Lightning: Maintenance...
Page 98: 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. 2004 Buell Lightning: Maintenance 1-49...
Page 99: Electrical System
Primary chain badly worn or links tight as a result of insufﬁcient lubrication. Wheels not aligned and/or tires worn. Poor Fuel Economy Internal engine problem. Oxygen sensor damaged or malfunctioning (bike running Wheels not balanced correctly. rich). See dealer. 1-50 2004 Buell Lightning: Maintenance...
Page 100 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. 2004 Buell Lightning: Maintenance 1-51...
Page 101 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. 1-52 2004 Buell Lightning: Maintenance...
Page 102 Table Of Contents CHASSIS SUBJECT PAGE NO. 2.1 Specifications ..........2.2 Tire Specifications .
Page 104: Specifications
Gross Vehicle Weight Rating (GVWR) (maximum allowable or serious injury. loaded vehicle weight) and corresponding Gross Axle Weight Ratings (GAWR) are given on an information decal located on the steering head. 2004 Buell Lightning: Chassis...
Page 105: Torque Values
17-19 ft-lbs 23-26 Nm LOCTITE 272 (red), page 2-52 Fork damper locknut 22-30 ft-lbs 30-40 Nm page 2-48 Front fender fasteners 12-36 in-lbs 1-4 Nm page 2-79 Front isolator bolt 49-51 ft-lbs 66-69 Nm page 2-59 2004 Buell Lightning: 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 2-75 Valve stem nut 40-44 in-lbs 4-5 Nm page 2-21 Wear Peg, rider 36-48 in-lbs 4.1-5.4 m page 2-76 2004 Buell Lightning: 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 2004 Buell Lightning: 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 4 = Domestic 5 = International...
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. 2004 Buell Lightning: 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
To prevent cosmetic damage to the wheel, center caliper 8441 between spokes before removal. 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. Figure 2-6. Front Wheel Removal 2004 Buell Lightning: 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. 2004 Buell Lightning: 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 2004 Buell Lightning: Chassis...
Page 114 Insert the forcing Remove the nut, bearing, washer, FRONT BEARING screw and backing plate into the wheel hub. INSTALLER (Part No. B-43993-9) and forcing screw. 2004 Buell Lightning: 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 under 2.5 FRONT Forcing screw WHEEL. Spacer Figure 2-16. Install the Spacer 10. See Figure 2-16. Install the spacer. 2-12 2004 Buell Lightning: 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. 2004 Buell Lightning: Chassis 2-13...
Page 117 2-20.Tighten the front axle pinch fasteners (2) to 20-22 ft-lbs (27-30 Nm). 8419 Install right side fender fasteners. See 2.32 FENDERS. Axle (left handed thread) Front axle pinch fasteners (2) (metric) Figure 2-20. Front Wheel Mounting 2-14 2004 Buell Lightning: Chassis...
Page 118: Rear Wheel
Remove idler pulley assembly by removing nuts and washers. See IDLER PULLEY REMOVAL 6.6 DRIVE BELT SYSTEM. Remove rear axle. 6.6 DRIVE BELT SYSTEM for proper handling. Slide drive belt out of the way and remove rear wheel. 2004 Buell Lightning: Chassis 2-15...
Page 119 HOME b0936x2x Rotor mounting fastener (6) Brake rotor Wheel bearing (2) Wheel spacer Wheel Sprocket Sprocket fastener (6) Axle Figure 2-23. Rear Wheel Assembly 2-16 2004 Buell Lightning: Chassis...
Page 120 (1) and tighten to 25-27 ft-lbs (34-37 Nm). INSTALLATION Center rear wheel in the swingarm at the same time slid- ing the drive belt onto the rear sprocket. With wheel centered in swingarm, lower bike to align swingarm and wheel hub. 2004 Buell Lightning: Chassis 2-17...
Page 121 WARNING 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. 2-18 2004 Buell Lightning: Chassis...
Page 122: Checking Cast Rim Runout
Wheel Truing and Balancing Stand (HD-99500-80) Table 2-9. Wheel Rim Runout b0758x2x RUNOUT Maximum lateral 0.040 1.02 Maximum radial 0.030 0.76 Gauge rod Figure 2-29. Checking Cast Rim Radial Runout Using Wheel Truing and Balancing Stand (HD-99500-80) 2004 Buell Lightning: Chassis 2-19...
Page 123: 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 2-30. Loosening Beads from Rim Flange front tire ONLY for a front tire.
Page 124 Apply air to stem to seat beads on rim. It may be neces- sary to use a TIRE BEAD EXPANDER (Part No. HD- 28700) on the tire until beads seal on rim. 2004 Buell Lightning: Chassis 2-21...
Page 125 Figure 2-33. Checking Tire Lateral Runout Install tire and again check tire radial runout. b0088x2x Gauge Figure 2-34. Checking Tire Radial Runout Table 2-10. Tire Runout RUNOUT Tire radial 0.060 1.52 Tire lateral 0.080 2.03 2-22 2004 Buell Lightning: Chassis...
Page 126: Wheel Balancing
Allow eight hours for adhesive to cure completely before using wheel. NOTE If wheel assembly is out of speciﬁcation (1 oz. front, 2 oz. rear) rotate tire on rim and rebalance until wheel is within speciﬁcation. 2004 Buell Lightning: Chassis 2-23...
Page 127: Brake Pedal
(5) to 22-24 ft-lbs (30-33 Nm). Install clevis pin (2). Rear master cylinder body Install new cotter pin (7). Clevis pin Pedal bushings (2) Shift brake pedal sleeve Brake pedal fastener Brake pedal Cotter pin Figure 2-36. Brake Pedal Assembly 2-24 2004 Buell Lightning: Chassis...
Page 128: 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 2-37. Front Brake Hand Lever Assembly 2004 Buell Lightning: Chassis 2-25...
Page 129 Circlip Figure 2-38. Piston Assembly in Master Cylinder Figure 2-38. Depress piston assembly (1) and remove internal circlip (2) and discard. Figure 2-37. Remove piston assembly (6) from front master cylinder reservoir (4) and discard. 2-26 2004 Buell Lightning: Chassis...
Page 130: Front Master Cylinder
Figure 2-39. Front Master Cylinder Piston Assembly Figure 2-39. Assemble new piston components placing small end of spring (5) behind primary seal of piston (4). Lubricate master cylinder body and piston seals with special lubricant found in the service parts kit. 2004 Buell Lightning: Chassis 2-27...
Page 131 To prevent death or serious Install brake lamp switch (11) with switch fastener injury, Buell recommends that all brake repairs be per- (10) and tighten to 7-10 in-lbs (0.8-1.0 Nm). formed by a Buell dealer or other qualiﬁed technician.
Page 132: Front Brake Line
Carefully inspect the brake line for dents, cuts, chafﬁng or other defects. Replace the brake line if any damage is noted. P-clamp Brake line Wire form Bleeder valve Banjo bolt Figure 2-42. Front Brake Line 2004 Buell Lightning: Chassis 2-29...
Page 133 WARNING 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. 2-30 2004 Buell Lightning: Chassis...
Page 134: Front Brake Caliper
Figure 2-44. Disconnect brake line at caliper. See 2.11 FRONT BRAKE LINE. Remove caliper mounting fasteners (5). Slide caliper down the rotor to clear fork lower and then remove off rotor. Figure 2-46. Removing Pistons (B-42887) 2004 Buell Lightning: Chassis 2-31...
Page 135 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). 2-32 2004 Buell Lightning: Chassis...
Page 136 HOME b0976x2x Pin hanger set Brake bleeder Bleeder cap Caliper Piston Piston o-rings Pad spring Small o-ring Caliper mounting fasteners 10. Brake pads 11. Caliper fasteners Figure 2-47. Front Caliper Assembly 2004 Buell Lightning: Chassis 2-33...
Page 137: Rear Brake Master Cylinder
Remote reservoir hose bled. Prevent damage to seating surfaces by carefully removing brake line components. Figure 2-49. Rear Master Cylinder On Vehicle Figure 2-49. Remove brake reservoir hose at master cylinder. Remove seat. See 2.41 SEAT. 2-34 2004 Buell Lightning: Chassis...
Page 138 Sleeve cylinder. Brake pedal fastener Brake pedal Remove fastener and washer (3) to detach reservoir 10. Cotter pin (1) from frame if necessary. 11. Rear master cylinder mount screw Figure 2-51. Rear Master Cylinder Assembly 2004 Buell Lightning: Chassis 2-35...
Page 139 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). 2-36 2004 Buell Lightning: Chassis...
Page 140 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 141: Rear Brake Line
Pump brake foot pedal to drain brake ﬂuid. Tighten bleeder valve to 36-60 in-lbs (4-7 Nm). Figure 2-56. Rear Brake Line Switch/Banjo Bolt Figure 2-56. Remove brake line switch/banjo bolt from rear master cylinder. Discard copper washer. Remove brake line from motorcycle. 2-38 2004 Buell Lightning: Chassis...
Page 142 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. 2004 Buell Lightning: Chassis 2-39...
Page 143: Rear Brake Caliper
Figure 2-59. Removing Rear Brake Caliper Piston Figure 2-59. Remove piston (3) using BRAKE CALI- PER PISTON REMOVER (1) (Part No. B-42887) with adaptor (2). Remove two o-rings from groove in caliper bore and dis- card. 2-40 2004 Buell Lightning: Chassis...
Page 144 Inspect brake pads for damage or excessive wear. tighten to 36-60 in-lbs (4-7 Nm). Replace both pads as a set if the friction material of either pad is worn to 0.04 in. (1.0 mm) or less. 2004 Buell Lightning: Chassis 2-41...
Page 145 To prevent death or serious which could result in death or serious injury. injury, Buell recommends that all brake repairs be per- formed by a Buell dealer or other qualiﬁed mechanic. CAUTION Turn ignition key switch to ON.
Page 146: Front Fork
Screw, pinch fastener (3 - upper) Triple clamp, upper Triple clamp assembly, lower Screw, pinch fastener (4 - lower) Figure 2-62. Upper and Lower Fork Clamp Assembly Figure 2-62. Loosen upper and lower fork clamp pinch fasteners (1, 4). 2004 Buell Lightning: Chassis 2-43...
Page 147 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 2-66. Removing Fork Cap From Outer Tube Figure 2-66. Remove fork cap from outer tube. 2-44 2004 Buell Lightning: Chassis...
Page 148 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 2-67. Expand fork and remove from FORK SPRING COMPRESSION TOOL. 2004 Buell Lightning: Chassis 2-45...
Page 149 24. Oil seal Inner slider piston o-ring 16. Spring 25. Oil seal stopper ring Snap ring 17. Spring joint 26. Dust seal Rebound adjuster assembly 18. Outer tube 27. Slider fork Figure 2-69. Front Fork Assembly 2-46 2004 Buell Lightning: Chassis...
Page 150 (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). 2004 Buell Lightning: Chassis 2-47...
Page 151: 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). 2-48 2004 Buell Lightning: Chassis...
Page 152 (3), Fork oil level 22. Apply fork oil or light grease to o-rings on preload adjuster and install preload adjuster (3). Figure 2-73. Measuring Fork Oil Level 23. Install snap ring (2). 2004 Buell Lightning: Chassis 2-49...
Page 153 11. Install front wheel. See 2.5 FRONT WHEEL. 12. Install front fender. See 2.32 FENDERS. 13. Check headlamp alignment. See 1.19 HEADLIGHTS. 14. Adjust front forks suspension to rider preferences. See 1.12 SUSPENSION DAMPING ADJUSTMENTS. 2-50 2004 Buell Lightning: Chassis...
Page 154: Fork Clamps, Upper And Lower
FORK. b1136x2x Stem capnut 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 2-75. Steering Stem Assembly 2004 Buell Lightning: 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 2004 Buell Lightning: Chassis...
Page 156: Steering Head Bearings
Figure 2-77. Install new upper and lower steering head bearings into the steering stem using STEERING HEAD BEARING RACE INSTALLER (Part No. HD- Figure 2-78. Steering Head Bearing Lip 2004 Buell Lightning: Chassis 2-53...
Page 157 17-19 ft-lbs (23-26 Nm). 13. Install headlight assembly and support bracket. See 2.25 HEADLIGHT ASSEMBLY AND SUPPORT BRACKET. Forcing screw Steering Head Bearing Installation Tool (B-45521) Lower bearing Bearing Washer Figure 2-79. Lower Bearing 2-54 2004 Buell Lightning: Chassis...
Page 158: Swingarm And Brace
Figure 2-83. Remove swingarm brace mounting fas- teners (11). Remove swingarm brace (12). b1087a2x Upper belt guard Upper belt guard fasteners (3) Lower belt guard Lower belt guard fasteners (3) Figure 2-82. Belt Guard Assembly 2004 Buell Lightning: Chassis 2-55...
Page 159 (black) from battery ﬁrst. See 1.5 BAT- TERY MAINTENANCE. Figure 2-83. Remove oil drain plug (8) and drain oil from swingarm. See Draining Oil 1.6 ENGINE LUBRI- CATION SYSTEM. Remove rear wheel. See 2.6 REAR WHEEL. 2-56 2004 Buell Lightning: Chassis...
Page 160 Remove rear fender. See 2.32 FENDERS. NOTE Figure 2-83. Remove swingarm bearings (5, 9) only if replacement is required. The complete bearing assembly must be replaced as a unit when replacement is necessary. Do not intermix bearing components. 2004 Buell Lightning: Chassis 2-57...
Page 161 18 ft-lbs (20-24 Nm). Right side passenger footpeg mount. Tighten to 15- 18 ft-lbs (20-24 Nm). Right side rider footpeg mount. Tighten to 108- 132 in-lbs (12-15 Nm). Heel guard. Remove rear wheel support stand. 2-58 2004 Buell Lightning: Chassis...
Page 162: Front And Rear Isolator
It is necessary to remove engine to access rear isolator. weight of motorcycle off front isolator by alternately tightening front isolator bolt and raising scissor jack to 3.4 STRIPPING MOTORCYCLE FOR ENGINE SER- support engine. VICE to access the rear isolator. 2004 Buell Lightning: 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 2004 Buell Lightning: 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 2-89. Rear Shock Absorber Assembly 2004 Buell Lightning: Chassis 2-61...
Page 165 (20.3-23 Nm). loss of control which could result in death or serious Install rear shock reservoir through reservoir clamp and injury. tighten clamp on reservoir to 96-120 in-lbs Install seat. See 2.41 SEAT. (11-14 Nm). 2-62 2004 Buell Lightning: 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 4.30 AIRBOX. 2004 Buell Lightning: Chassis 2-63...
Page 167: Clutch Hand Lever
(1) to 36-60 in-lbs (4- 7 Nm). Connect clutch cable ferrule (9) to hand lever clamp (2). Install cable strap attaching wiring harness to left handle- bar. Do not over tighten cable strap. Adjust clutch cable. See CLUTCH. 2-64 2004 Buell Lightning: Chassis...
Page 168: Headlight Assembly And Support Bracket
8994 Horn Screws (2) Horn connectors [122] Headlight assembly Horn bracket Screws (2) Horn fastener Headlight support bracket Headlight connector [38] 10. Left and right front modules Figure 2-95. Headlight Assembly and Support Bracket 2004 Buell Lightning: Chassis 2-65...
Page 169 Align and install headlight bulbs (3) into back of headlight housing (4). Boot (2) b1147x2x Bulb holder (2) Bulb (2) Headlight housing Wiring harness Position bulb socket (used for HDI only) b1150x2x Figure 2-96. Headlight Assembly 2-66 2004 Buell Lightning: 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 2-97. Headlight Assembly and Support Bracket 2004 Buell Lightning: 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 2-99. Remove the left front module. 10. See Figure 2-98. Remove the ﬁnal fastener and the right front module. 2-68 2004 Buell Lightning: Chassis...
Page 172 Figure 2-98. 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 2-99. Fairing Support Bracket Assembly 2004 Buell Lightning: 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 2004 Buell Lightning: Chassis...
Page 174 HOME b0945x2x Endcap (2) Handlebar Handlebar clamp Clamp fasteners (4) Left hand grip Figure 2-100. Handlebar Assembly 2004 Buell Lightning: 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). b1154x2x 9990 Mirror Adjuster nut Mount Bracket Figure 2-101. Mirrors and Mounting Hardware 2-72 2004 Buell Lightning: Chassis...
Page 176: Exhaust System
SERVICE. Remove oxygen sensor. See 4.19 OXYGEN SENSOR. Figure 2-103. Remove exhaust header (2) by removing mounting fasteners (3). Remove exhaust ring (4), retaining ring (5) and port gas- ket (6). 2004 Buell Lightning: Chassis 2-73...
Page 177 Interactive mufﬂer Front mufﬂer strap Front mufﬂer strap fastener Front mufﬂer mount Front strap fastener Front mufﬂer mount bushings Interactive exhaust cable 10. Rear mufﬂer bracket 11. Rear mufﬂer bracket fasteners (2) Figure 2-102. Mufﬂer Assembly 2-74 2004 Buell Lightning: Chassis...
Page 178 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 179: 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 2-104. Rider Footpeg, Mount and Heel Guard Assembly 2-76 2004 Buell Lightning: Chassis...
Page 180 Position footpeg mount (3) onto tail section. Heel guard fasteners b0933a2x Heel guard Footpeg mount Spring Ball Detent plate Clip Footpeg 10. Footpeg mount fastener 11. Jam nut Figure 2-105. Passenger Footpeg, Mount and Heel Guard Assembly 2004 Buell Lightning: Chassis 2-77...
Page 181: Sprocket Cover
(1, 3) and tighten all fasteners and washers (1, 3) to 12- 36 in-lbs (1-4 Nm). Figure 2-106. Chin Fairing Assembly, Right Rear Fasteners Install chin fairing. See 2.34 CHIN FAIRING. b0943a2x Long fastener and washer Cover Short fastener and washer (2) Figure 2-107. Sprocket Cover 2-78 2004 Buell Lightning: Chassis...
Page 182: 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 2-108. Front and Rear Fender 2004 Buell Lightning: Chassis 2-79...
Page 183: Belt Guards
ﬁrst. Removing swingarm brace without releasing Remove scissor jack from motorcycle. tension will cause swingarm brace damage. Remove swingarm brace by removing fasteners. See 2.19 SWINGARM AND BRACE. Remove upper belt guard (1) by removing fasteners from swingarm brace. 2-80 2004 Buell Lightning: Chassis...
Page 184 HOME b1064a2x Upper belt guard Upper belt guard fasteners (3) Lower belt guard fasteners (3) Lower belt guard Sprocket cover Sprocket cover fasteners (2 short, 1 long) Figure 2-109. Belt Guard Assembly 2004 Buell Lightning: Chassis 2-81...
Page 185: Chin Fairing
Turn wheel full right or left for easier access to center fas- Figure 2-110. Chin Fairing Assembly teners. Align center section (1) and install with center section fasteners and washers (2). Use LOCTITE 272 (red) on all fasteners tightening to 36-48 in-lbs (4-5 Nm). 2-82 2004 Buell Lightning: Chassis...
Page 186: Intake Cover Assembly
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. 2004 Buell Lightning: Chassis 2-83...
Page 187: Air Scoops
Oil cooler air scoop fastener and washer (2) Ram air scoop Oil cooler air scoop Engine scoop fastener and washer (3) Ram air scoop fastener and washer Engine scoop Figure 2-112. RAM Air Scoop, Engine Shroud, Oil Cooler 2-84 2004 Buell Lightning: 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. 2004 Buell Lightning: 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 2-113. Main Harness and Electrical Connectors Under Seat 2-86 2004 Buell Lightning: 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. 2004 Buell Lightning: Chassis 2-87...
Page 191 10. Seat latch assembly 11. Trunk pan assembly 12. Rear trunk pan fastener to center tail section (2) 13. Rear shock reservoir bracket 14. Plastic lugs (for manufacturing purposes only) Figure 2-114. Tail Frame and Trunk Pan Assembly 2-88 2004 Buell Lightning: 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. 2004 Buell Lightning: 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 2004 Buell Lightning: Chassis...
Page 194 Passenger footrest support fastener with jam nut Ground terminals [GRD1] & [GRD 3] Rear brake light switch connector [121] Right tail section Center tail section fastener to rear tail section Figure 2-115. Right Side Frame Section 2004 Buell Lightning: Chassis 2-91...
Page 195: Front Windscreen
Install four fasteners (3) and tighten to 10-12 in-lbs (1.1- bracket (1). 1.4 Nm). Figure 2-116. Remove four windscreen fasteners (3). Remove windscreen (4). b1153x2x Headlight mounting bracket Left front module Windscreen fastener (4) Windscreen Right front module Figure 2-116. Front Windscreen 2-92 2004 Buell Lightning: Chassis...
Page 196: Seat
Lift and remove seat (1). 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 2-117. Seat and Attachment 2004 Buell Lightning: 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 2004 Buell Lightning: Chassis...
Page 198 HOME b1152x2x Seat lock Plate Retainer Cable end Cable Latch screw Retainer Cable end Latch 10. Latch bracket 11. Trunk pan 2004 Buell Lightning: Chassis 2-95...
Page 199: Sidestand
Remove two fasteners from the left side of chin fairing. Remove sidestand leg (1). Retract sidestand leg. Remove sidestand spring (8) and spring extension plate (4) using SNAP-ON SPRING TOOL (Part No. HE-52B). Remove sidestand pivot bolt (5). Extend sidestand leg and remove. 2-96 2004 Buell Lightning: Chassis...
Page 200 Install sidestand to frame tightening the sidestand bracket fasteners to 25-27 ft-lbs (34-37 Nm). Install mufﬂer. See Mufﬂer and Straps 2.29 EXHAUST SYSTEM. Inspect sidestand. Figure 2-122. Lubricating Points (Shaded Areas) b1127x2x Figure 2-123. Threaded Area for Loctite Application 2004 Buell Lightning: Chassis 2-97...
Page 201 HOME NOTES 2-98 2004 Buell Lightning: Chassis...
Page 202 ENGINE Table Of Contents SUBJECT PAGE NO. 3.1 Specifications ..........3.2 Engine .
Page 204 59.1 mm 2.325. (min) 59.1 mm (min) Intake 1.850 in. (closed) 135 lbs 61.2 kg 1.300 in. (open) 312 lbs 141.5 kg Exhaust 1.850 in. (closed) 135 lbs 61.2 kg 1.300 in. (open) 312 lbs 141.5 kg 2004 Buell Lightning: 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 2004 Buell Lightning: 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 2004 Buell Lightning: Engine...
Page 207 32-36 ft-lbs 43.4-48.8 Nm page 3-33 Rear mufﬂer straps 48-60 in-lbs 5.4-6.8 Nm page 3-16 Reed valve fasteners 25-30 in-lbs 3.4-4.5 Nm page 3-79 Return oil line at oil reservoir 23-25 ft-lbs 31.2-33.9 Nm page 3-35 2004 Buell Lightning: Engine...
Page 208 V bracket to main frame 120-144 in-lbs 13.6-16.3 Nm page 3-14, 3-32 Vent oil line at gearcase cover 12-13 ft-lbs 16.3-17.6 Nm page 3-36 Vent oil line at oil reservoir 17-19 ft-lbs 23-26 Nm page 3-35 2004 Buell Lightning: Engine...
Page 209 “oxygenate” the gas. Your panied by blue-gray exhaust smoke and low engine compres- motorcycle will run normally using this type of gas. Buell sion, it indicates the piston rings need replacing. Low recommends you use it when possible, as an aid to compression by itself, however, may indicate improperly cleaner air in our environment.
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. 2004 Buell Lightning: 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 (Typical) 2004 Buell Lightning: Engine...
Page 212 Oxygen sensor connection [137] Throttle cables Figure 3-2. Electrical Connections and Throttle Cables (Typical) 11. See Figure 3-2. Disconnect the ignition coil (2) [83] and remove. 12. Disconnect the following sensors: Temperature sensor (3) [90]. Oxygen sensor (4) [137]. 2004 Buell Lightning: Engine...
Page 213 1.10 DRIVE BELT Loosen front mufﬂer mount (2). 2.13 REAR BRAKE MASTER CYLINDER. NOTE For XB12S with interactive exhaust systems see 7.6 INTER- ACTIVE EXHAUST SYSTEM (XB12S) for speciﬁc details on removal of interactive components. 3-10 2004 Buell Lightning: Engine...
Page 214 Slide clutch cable adjuster boot (2) up to access Figure 3-5. Clutch Cable Wire form and clutch adjuster. Adjuster Boot Loosen clutch adjuster to release tension from hand lever. Remove clutch cable ferrule from hand lever. 2004 Buell Lightning: Engine 3-11...
Page 215 Nut for one fastener for front tie bar assembly 20. Bolt 10. Center tie bar mount 21. Rear tie bar assembly 11. Fasteners for center tie bar mount (2) 22. Fasteners for rear tie bar assembly (2) Figure 3-6. Engine Mounting System 3-12 2004 Buell Lightning: Engine...
Page 216 28. Rotate engine down. Rear isolator bolt Rear tie bar Figure 3-7. Rear Isolator Bolt and Rear Tie Bar 24. See Figure 3-7. Remove rear tie bar from frame only. 25. Loosen rear isolator bolt. DO NOT REMOVE. 2004 Buell Lightning: 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 2004 Buell Lightning: Engine...
Page 218 H-D 20W50 engine oil. Wipe off any excess oil. Tighten return oil line to 19-21 ft-lbs (25.8-28.5 Nm) at oil cooler. 10501a Figure 3-12. Oil Cooler Feed and Return Oil Line 1/8-1/4 in. (3.175-6.35 mm) Clearance 2004 Buell Lightning: Engine 3-15...
Page 219 It is important that the front mufﬂer mount is tightened last in order to ensure proper alignment of the exhaust system. CAUTION When rear mufﬂer straps have been installed, it is impor- tant that strap fasteners do not contact idler pulley bracket. 3-16 2004 Buell Lightning: Engine...
Page 220 19. Connect the following sensors: Temperature sensor (3) [90]. Oxygen sensor (4) [137]. 20. 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). 2004 Buell Lightning: Engine 3-17...
Page 221 A loose seat may shift during vehicle operation 29. Install sprocket cover and tighten fasteners and washers and startle the rider, possibly causing loss of vehicle to 12-36 in-lbs (1-4 Nm). control resulting in death or serious injury. 3-18 2004 Buell Lightning: Engine...
Page 222: Stripping Motorcycle For Engine Service
Inadequate safety precautions could result in death or serious injury. 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 (Typical) 2004 Buell Lightning: Engine 3-19...
Page 223 Figure 3-17. Electrical Connections and Throttle Cables (Typical) 10. See Figure 3-17. Disconnect the ignition coil connector (2) and remove. 11. Disconnect the following sensors: Temperature sensor (3) [90]. Oxygen sensor (4) [137]. 12. Disconnect throttle cables from induction module/throttle body. 3-20 2004 Buell Lightning: Engine...
Page 224 16. 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. NOTE Loosen front mufﬂer mount. For XB12S with interactive exhaust system, see 7.6 INTER- ACTIVE EXHAUST SYSTEM (XB12S). 2004 Buell Lightning: Engine 3-21...
Page 225 20. Remove front and rear mufﬂer brackets. 21. Remove left and right side rider footrests and support plates. See 2.30 FOOTPEG, HEEL GUARD AND MOUNT. 3-22 2004 Buell Lightning: Engine...
Page 226 Remove clutch cable ferrule from hand lever. 23. See Figure 3-21. Remove sidestand assembly. b0946c2x Pivot bolt Spring extension plate Spring post Sidestand bracket Sidestand bracket fasteners (2) Sidestand leg Figure 3-21. Sidestand Assembly (Extended) 2004 Buell Lightning: Engine 3-23...
Page 227 Nut for one fastener for front tie bar assembly 20. Bolt 10. Center tie bar mount 21. Rear tie bar assembly 11. Fasteners for center tie bar mount (2) 22. Fasteners for rear tie bar assembly (2) Figure 3-22. Engine Mounting System 3-24 2004 Buell Lightning: Engine...
Page 228 Unbolt “V” bracket from main frame and remove from left side. 8717a Neutral switch [131] Speedometer sensor connector [65] Cam position sensor connector [14] Alternator connector [46] Voltage regulator connector [77] Interactive exhaust cable Figure 3-23. Electrical Connectors 2004 Buell Lightning: Engine 3-25...
Page 229 37. Lower engine with scissors lift all the way down. 38. Move the engine assembly from under the main frame to the right side of the lift. 39. Remove engine. Figure 3-25. Rear Isolator Bolt and Swingarm Pivot Shaft 3-26 2004 Buell Lightning: Engine...
Page 230 Figure 3-29. Swingarm pivot shaft pinch bolt threaded insert. Figure 3-30. Aluminum bushings from front exhaust mount. Right Side Timer cover. Figure 3-30. Front Exhaust Mount Bushings (2 piece) 8724 8729 Figure 3-29. Removing Threaded Insert 2004 Buell Lightning: Engine 3-27...
Page 231 43. Route a ratcheting tie down through the swingarm bear- ings, up over the main frame, through the top stabilizer area, back down to the ratchet mechanism and secure swingarm to main frame. 3-28 2004 Buell Lightning: Engine...
Page 232: Engine Installation
Center tie bar mount 25-27 ft-lbs (33.9-36.6 Nm). Figure 3-37. Front Exhaust Mount Bushings (2 piece) Figure 3-36. Apply LOCTITE 242 (blue) and install swingarm pivot shaft pinch bolt threaded insert. Figure 3-37. Aluminum bushings from front exhaust mount. 2004 Buell Lightning: 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 2004 Buell Lightning: 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 3-43. Engine Mounting System 2004 Buell Lightning: 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. 17. Remove scissors jack. 3-32 2004 Buell Lightning: Engine...
Page 236 At this point it will be necessary to install the oil lines. It is important to follow this procedure to ensure correct orientation of oil lines in order to establish the proper clearances needed between the oil lines and varied com- ponents on the vehicle. 2004 Buell Lightning: Engine 3-33...
Page 237 Feed oil line from oil pump to oil cooler Feed oil line from oil cooler to crankcase Oil tank drain plug Oil Filter Front mufﬂer mount 10. Rear mufﬂer bracket 11. Oil cooler 12. Interactive exhaust cable Figure 3-47. Oil Lines and Connections 3-34 2004 Buell Lightning: Engine...
Page 238 ﬁrst. 21. See Figure 3-48. Tighten the return oil line ﬁrst making sure to maintain the proper clearance between the oil line and the rear mufﬂer bracket. 23-25 ft-lbs (31.2-33.9 Nm). 2004 Buell Lightning: Engine 3-35...
Page 239 25. Also tighten the return oil line at the top front oil pump ﬁt- aligned with the feed and return lines after tightening. ting to 22-24 ft-lbs (29.8-32.5 Nm). When the oil line has been properly torqued, the orientation of the line should also be approximately 7 o’clock. 3-36 2004 Buell Lightning: 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. 2004 Buell Lightning: 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 2004 Buell Lightning: Engine...
Page 242 Figure 3-52. Oil Cooler Oil Lines b1031x3x Oil cooler feed line should be centered after line is torqued. Orientation of return line should be approximately 12 o’clock Figure 3-53. Oil Cooler Feed and Return Oil Lines Location and Orientation 2004 Buell Lightning: Engine 3-39...
Page 243 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 3-55. Correct Routing of Wiring Harnesses and Interactive Mufﬂer Cable 3-40 2004 Buell Lightning: Engine...
Page 244 For XB12S with interactive exhaust system, see 7.6 INTER- ACTIVE EXHAUST SYSTEM (XB12S). 32. See Figure 3-56. Pull clutch cable back up into the proper position. Connect clutch cable to handlebars and adjust to speciﬁcations. See SPECIFICATIONS. Install upper retaining clamp. 2004 Buell Lightning: Engine 3-41...
Page 245 NOTE For XB12Ss with interactive exhaust system see 7.6 INTER- ACTIVE EXHAUST SYSTEM (XB12S). CAUTION When rear mufﬂer straps have been installed, it is impor- tant that strap fasteners do not contact idler pulley bracket. 3-42 2004 Buell Lightning: Engine...
Page 246 Tighten front mufﬂer mount (2) to 22-55 ft-lbs (29.8- 33.9 Nm). 8708 Ignition coil Coil connection [83] Cylinder head temperature sensor connection [90] Oxygen sensor connection [137] Throttle cables Figure 3-58. Electrical Connections and Throttle Cables (Typical) 2004 Buell Lightning: Engine 3-43...
Page 247: Interactive Exhaust Cable Adjustment
A loose seat may shift during vehicle operation Install rear belt and idler pulley. See 1.10 DRIVE BELT and startle the rider, possibly causing loss of vehicle 2.13 REAR BRAKE MASTER CYLINDER. control resulting in death or serious injury. 3-44 2004 Buell Lightning: 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 3-60. Rocker Arm and Push Rod Cover Assemblies 2004 Buell Lightning: 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 3-62. Removing Rocker Arm Shafts 3-46 2004 Buell Lightning: Engine...
Page 250 No special tools are required to remove valve stem seal and lower collar assembly. Repeat the above procedure for the other valves. Figure 3-63. Head Screw Loosening/Tightening Sequence 8684 Figure 3-64. Valve Spring Compressor (Part No. HD-34736B) 2004 Buell Lightning: 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 3-65. Cylinder Head, Cylinder and Piston Assembly 3-48 2004 Buell Lightning: 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. 2004 Buell Lightning: Engine 3-49...
Page 253 Figure 3-68. Measure where rocker arm bush- Check end play of rocker arm with feeler gauge. ings ride. Replace rocker arm or lower cover or both if end play exceeds 0.025 in. (0.635 mm). 3-50 2004 Buell Lightning: 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. 2004 Buell Lightning: 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 3-73. Replacing Rocker Arm Bushings 3-52 2004 Buell Lightning: Engine...
Page 256 Figure 3-75. Thoroughly clean valve guide bores using VALVE GUIDE BRUSH (Part No. HD-34751) and hot soapy water. Valve guide brush (Part No. HD-34751) Cylinder head holding ﬁxture (Part No. HD-39786) Figure 3-75. Cleaning Valve Guides 2004 Buell Lightning: 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 2004 Buell Lightning: 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 3-77. Valve and Seat Dimensions 2004 Buell Lightning: 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 3-78. Cylinder Head, Cylinder and Piston Assembly 3-56 2004 Buell Lightning: 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. 2004 Buell Lightning: Engine 3-57...
Page 261 10. Insert valve keepers into upper collar, making sure they engage grooves in valve stem. 11. Release and remove from VALVE SPRING COMPRES- SOR. 12. Repeat Steps 4-11 for the remaining valve. 3-58 2004 Buell Lightning: 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. 2004 Buell Lightning: Engine 3-59...
Page 263: Cylinder Head Installation
Tighten each screw to 13-15 ft-lbs (18-20 Nm). Figure 3-86. Tightening Head Screws Figure 3-86. Mark cylinder head and head screw shoulder with a line as shown (View A). ° ° Turn all bolts an additional 85 -95 . 3-60 2004 Buell Lightning: 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 3-87. Rocker Arm and Push Rod Cover Assemblies 2004 Buell Lightning: 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 2004 Buell Lightning: Engine...
Page 266: Cylinder And Piston
Connecting rod 10. Piston pin bushing CAUTION Figure 3-89. 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. 2004 Buell Lightning: Engine 3-63...
Page 267 In the event that the circlip should ﬂy out, hold a shop towel over the bore during removal. Figure 3-92. To remove piston rings spread outward Remove circlip from claw and discard. until they clear grooves in piston and lift off. 3-64 2004 Buell Lightning: 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. 2004 Buell Lightning: Engine 3-65...
Page 269 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 2004 Buell Lightning: Engine...
Page 270 No. 240 grit ﬂexible hone to facilitate ring seating. Piston ring sets must be properly ﬁtted to piston and cyl- inder: Ring sets are available to ﬁt standard and oversize pistons. 2004 Buell Lightning: Engine 3-67...
Page 271 Figure 3-98. Ring End Gap Position Figure 3-98. Install rings so end gaps of adjacent rings are a minimum of 90° apart. Ring gaps are not to be within 10° of the thrust face centerline. 3-68 2004 Buell Lightning: 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. 2004 Buell Lightning: 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 2004 Buell Lightning: 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. 2004 Buell Lightning: Engine 3-71...
Page 275 HOME NOTES 3-72 2004 Buell Lightning: 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. 2004 Buell Lightning: Engine 3-73...
Page 277: Oil Hose Routing And Oil Reservoir
Return oil line 10. Rear mufﬂer bracket Feed oil line from oil pump to oil cooler 11. Oil cooler Return oil line from oil cooler to crankcase 12. Interactive exhaust cable Figure 3-110. Oil Lines and Connections 3-74 2004 Buell Lightning: Engine...
Page 278: Oil Pressure Indicator Switch
At 2500 RPM, oil pressure will vary from 10- Dead battery (see NOTE). ating engine). 12 psi (69-83 kPa). At idle speed (1050-1150 RPM), oil pres- sure will vary from 6-8 psi (42-55 kPa). 2004 Buell Lightning: Engine 3-75...
Page 279: Crankcase Breathing System
PCV Valves (2) Grommet The oil mist collects and eventually returns to the crankcase Rocker cover (2) through oil passageways in the cylinder head. Figure 3-113. Crankcase Breathing System 3-76 2004 Buell Lightning: Engine...
Page 280 Fasteners should be tightened to 30-40 in-lbs (3.4-4.5 Nm). b1033x3x Reed valve stop Reed valve Reed block Figure 3-114. Reed Valve Assembly 8759 8794 Reed valve stop Reed valve Stop screw Figure 3-115. Reed Valve Stop and Reed Valve 2004 Buell Lightning: 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. 2004 Buell Lightning: Engine 3-78...
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 3-116. Oil Pump 2004 Buell Lightning: Engine 3-79...
Page 283 Feed line connection Cover TORX screw (2) Return line Oil pump Mounting screw and washer (2) Steel line connection to oil cooler Connection from oil cooler to oil ﬁlter housing Figure 3-117. Oil Pump Hardware 3-80 2004 Buell Lightning: Engine...
Page 284 10. See Figure 3-117. 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. 2004 Buell Lightning: Engine 3-81...
Page 285: Oil Filter Mount
Apply several drops of LOCTITE 243 (blue) to last few threads on that end of the ﬁlter adapter which is installed into ﬁlter mount. Do not apply LOCTITE to adapter threads on ﬁlter element side. 3-82 2004 Buell Lightning: Engine...
Page 286: Hydraulic Lifters
Figure 3-121. Lifter Assembly (Typical) End clearance should be within 0.008-0.022 in. (0.203-0.559 mm). Replace lifters if clearance exceeds SERVICE WEAR LIMIT of 0.026 in. (0.660 mm). Soak lifters in clean engine oil. Keep covered until assembly. 2004 Buell Lightning: 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 2004 Buell Lightning: 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 3-124. Gearcase Cover & Cam Assembly 2004 Buell Lightning: Engine 3-85...
Page 289 8662a Front exhaust cam gear Front intake cam gear Rear intake cam gear Rear exhaust cam gear Pinion gear Pinion nut Timing V mark Figure 3-125. Cam and Pinion Gear Location and Timing Mark Indexing 3-86 2004 Buell Lightning: Engine...
Page 290 Table 3-25. 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. 2004 Buell Lightning: Engine 3-87...
Page 291 Figure 3-124. Install a new seal and new dry gear cover gasket on crankcase. Figure 3-128. Crankshaft Locking Tool (Part No. HD-43984) 3-88 2004 Buell Lightning: 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 3-130. Checking Cam Gear End Play 2004 Buell Lightning: 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 COVER. Remove starter motor. See 5.7 STARTER. 3-90 2004 Buell Lightning: Engine...
Page 294 (2.8-4.0 Nm). Figure 3-133. Piston Oil Jet Assemblies Figure 3-133. Remove two TORX screws from each piston jet assembly to free piston jets from right crank- case. Remove piston jet gaskets from right crankcase. 2004 Buell Lightning: 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 3-135. Crankcase and Flywheel Assembly 3-92 2004 Buell Lightning: Engine...
Page 296 Remove left main oil seal retaining ring. Figure 3-135. 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). 2004 Buell Lightning: Engine 3-93...
Page 297 1.2496-1.2498 in. Green (31.7398-31.7449 mm) (ID) of the outer race (crankcase bushing). A running clear- ance of 0.0002-0.0008 in. (0.0051-0.0203 mm) is established during crankcase set or ﬂywheel assembly replacement and engine rebuild. 3-94 2004 Buell Lightning: Engine...
Page 298 That is, a replacement crankcase set may have a class 1, 2 or 3 pinion bearing outer race. Replacement ﬂywheel assemblies will have either a class A or B inner race. 2004 Buell Lightning: 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 2004 Buell Lightning: Engine...
Page 300 The new outer race must be lapped slightly to true and align with left case bearing and to meet the following speciﬁcations in Table 3-33. LAPPING PINION SHAFT BEARING OUTER RACE. 2004 Buell Lightning: Engine 3-97...
Page 301 Table 3-34. Pinion Inner Race 1.2499 in. (31.747 mm) OD inner race, a blue bear- Speciﬁcations ing is required. Roundness within 0.0002 in. (0.0051 mm) Taper within 0.0002 in. (0.0051 mm) Surface ﬁnish 16 RMS 3-98 2004 Buell Lightning: Engine...
Page 302 Check connecting rod side play with a thickness gauge as shown. If side play measurement is greater than service wear limit listed below, replace ﬂywheel/connecting rod assembly. Service wear limit, 0.036 in. (0.8 mm) Figure 3-147. Checking Connecting Rod Side Play 2004 Buell Lightning: Engine 3-99...
Page 303 Make sure that the bearing assembly bottoms against the machined shoulder in the left crankcase half. b1046a3x Spacer, sprocket shaft Retaining ring, oil seal Oil seal Thrust washer Crankcase half Bearing Bearing retaining ring Figure 3-148. Left Main Bearing Assembly 3-100 2004 Buell Lightning: Engine...
Page 304 Install pinion shaft bearing. Bearing retaining ring Lubricate pinion shaft bearing with engine oil. Figure 3-149. Left Main Bearing Installation Slip bearing on pinion shaft. Install new retaining ring in groove of pinion shaft bearing inner race. 2004 Buell Lightning: 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 2004 Buell Lightning: 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. 2004 Buell Lightning: Engine 3-103...
Page 307 HOME NOTES 3-104 2004 Buell Lightning: Engine...
Page 308 Table Of Contents FUEL SYSTEM SUBJECT PAGE NO. 4.1 Specifications ..........4.2 Dynamic Digital Fuel Injection .
Page 309 4.38 Cooling Fan ..........4-107 4.39 Fuel Pump .
Page 310: Fuel System
54-61 Nm LOCTITE ANTI-SEIZE, page 4-101 Throttle position sensor 16-20 in-lbs 1.8-2.3 Nm LOCTITE 222 (purple), page 4-106 Timer plate studs 15-30 in-lbs 2-3 Nm page 4-98 Upper tie bar 25-27 ft-lbs 33.9-36.6 Nm page 4-103 2004 Buell Lightning: Fuel System...
Page 311 HOME NOTES 2004 Buell Lightning: Fuel System...
Page 312: Dynamic Digital Fuel Injection
DYNAMIC DIGITAL FUEL INJECTION (DDFI) INTRODUCTION GENERAL The Buell DDFI operates both as an open and closed loop The Buell Dynamic Digital Fuel Injection (DDFI) System pro- system which allows it to adjust for all possible operating con- vides microprocessor-based electronic engine management ditions.
Page 313 BE/O IGN Coil Throttle To cooling Position Cooling BK/O fan fuse Sensor BK/W BE/O TN/V BK/W LT GN/Y Sensor [165] Ground Interactive mufﬂer control To Brake/horn/ mufﬂer fuse Figure 4-1. Buell Dynamic Digital Fuel Injection 2004 Buell Lightning: 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. 2004 Buell Lightning: 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 2004 Buell Lightning: 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. 2004 Buell Lightning: 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. 2004 Buell Lightning: 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- tion. Let it run for at least 30 seconds. Turn the engine off. 2004 Buell Lightning: 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 2004 Buell Lightning: 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. 2004 Buell Lightning: Fuel System 4-11...
Page 321: Initial Diagnostic Check
AND IDLE SPEED bers on the diagnostic check ﬂow charts. See Diagnostic ADJUSTMENT. Check (Part 1 of EVAP hose disconnected Connect. Compare engine behavior to tables. from induction module (CA) Starts hard. Refer to Table 4-4. 4-12 2004 Buell Lightning: Fuel System...
Page 322 Cooling fan 4.26 TROUBLE CODE 36 Bank angle sensor 4.27 TROUBLE CODE 44 52, 53, 54, 55 ECM failure 4.28 TROUBLE CODES 52, 53, 54 AND 55 Cam sync failure 4.29 TROUBLE CODE 56 2004 Buell Lightning: 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 2004 Buell Lightning: 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). 2004 Buell Lightning: 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. 4.30 ELECTRONIC CONTROL MODULE. 7120 4-16 2004 Buell Lightning: Fuel System...
Page 326: Check Engine Lamp Not Illuminated At Key On 4.9
7 and ECM connector [10] (black) (3), pin 4. Table 4-9. ECM Connectors 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 2004 Buell Lightning: Fuel System 4-17...
Page 327 Electronic Control Module (ECM) Figure 4-14. Check Engine Lamp Circuit Table 4-10. 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 2004 Buell Lightning: 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 2004 Buell Lightning: 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 2004 Buell Lightning: Fuel System...
Page 330 Electronic Control Module (ECM) Figure 4-17. Check Engine Lamp Circuit Table 4-11. 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 2004 Buell Lightning: 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 4.30 ELECTRONIC trouble codes. See CONTROL MODULE. CHECKING FOR 7150 TROUBLE CODES. 4-22 2004 Buell Lightning: Fuel System...
Page 332: Engine Cranks But Will Not Start
Gasoline is extremely ﬂamma- ble and highly explosive. Inadequate safety precautions could result in death or serious injury. Purge fuel line of high pressure gasoline. See 4.39 FUEL PUMP. 2004 Buell Lightning: Fuel System 4-23...
Page 333 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 4-24 2004 Buell Lightning: Fuel System...
Page 334 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 2004 Buell Lightning: Fuel System 4-25...
Page 335 49-51 PSI (338-352 kPa). Adequate pressure? STOP Go to Test 4.11 Incorrect pressure. See 4.13 (Part 2 of 3). FUEL PRESSURE TEST. 7459 4-26 2004 Buell Lightning: Fuel System...
Page 336 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. 4.30 ELECTRONIC CONTROL MODULE. 7853 7870 2004 Buell Lightning: Fuel System 4-27...
Page 337 Replace cam position Mechanical failure. position sensor. See 4.31 7945 sensor. See 4.31 Inspect for loose CAM POSITION SENSOR CAM POSITION SEN- rotor cup and ROTOR. SOR AND ROTOR. sheared pinion 7952 gear key. 7952 7940 4-28 2004 Buell Lightning: Fuel System...
Page 338: No Ecm Power
ECM does not appear to be receiving power, check the bers on the Test 4.12 ﬂow chart. ground sources. A blown ignition fuse or ECM fuse can also Connect BREAKOUT BOX (Part No. HD-42682) to ECM. disable the ECM. 4.6 BREAKOUT BOX. 2004 Buell Lightning: Fuel System 4-29...
Page 339 Table 4-13. Wire Harness Connectors in Figure 4-21. 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 4-30 2004 Buell Lightning: Fuel System...
Page 340 Check for 12 volts wire between connector on right handlebar con- [22] and ignition relay. nector [22A] W/BK wire. Voltage present? Repair open on W/BK Replace handlebar wire between connector switch assembly. [22] and ignition relay. 2004 Buell Lightning: Fuel System 4-31...
Page 341: Fuel Pressure Test
Connect the fuel line (3) to fuel pressure gauge adapter. NOTE Figure 4-25. Verify that fuel valve (2) and air bleed pet- cock (5) on the gauge are closed. Attach FUEL PRESSURE GAUGE (Part No. HD-41182) (4) to fuel pressure gauge adapter (1). 4-32 2004 Buell Lightning: Fuel System...
Page 342 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 4-25. Fuel Pressure Gauge (Part No. HD-41182) 2004 Buell Lightning: Fuel System 4-33...
Page 343 Table 4-14. Wire Harness Connectors in Figure 4-26. 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 4-34 2004 Buell Lightning: Fuel System...
Page 344 Measure voltage relay and fuel pump. during first two seconds after key ON. Is voltage greater than 1 VDC? Locate and repair poor Replace ignition relay. connection between bat- tery and ignition relay. 2004 Buell Lightning: Fuel System 4-35...
Page 345 [10] (black) Termi- nal 3. Is continuity present? Replace fuel pump Repair fuel pump assembly. See 4.39 wiring. FUEL PUMP. Replace ECM. See 4.30 Locate and repair open ELECTRONIC CONTROL on BN/Y wire. MODULE. 4-36 2004 Buell Lightning: Fuel System...
Page 346: 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. 2004 Buell Lightning: Fuel System 4-37...
Page 347: Misfire
7.4 SPARK PLUG CABLES. Using an ohmmeter, touch probes to terminals on each end plug wire. Compare resistance values to Table 4-16. Replace cables not meeting speciﬁcations. Reinstall and repeat procedure on other spark plug cable. 4-38 2004 Buell Lightning: Fuel System...
Page 348 Table 4-17. Wire Harness Connectors in Figure 4-29. 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 2004 Buell Lightning: Fuel System 4-39...
Page 349 Switch coil with unit Replace known to be good. ignition coil. Perform spark test. Did spark jump gap during engine cranking? Original ignition coil Go to Test 4.15 is faulty. Replace. STOP (Part 2 of 2). 4-40 2004 Buell Lightning: Fuel System...
Page 350 Replace cam position sensor. 4.31 CAM POSITION Replace cam position Mechanical failure. SENSOR AND ROTOR. sensor. See 4.31 Inspect for loose CAM POSITION SEN- rotor cup and SOR AND ROTOR. sheared pinion gear key. 2004 Buell Lightning: Fuel System 4-41...
Page 351 HOME NOTES 4-42 2004 Buell Lightning: Fuel System...
Page 352: Trouble Code 11
TP sensor voltage (when throttle is closed) to greater than 4.0 volts (when throttle is held wide open). As the throttle is slowly moved, the voltage should change gradually without spikes or low voltages being observed. 2004 Buell Lightning: Fuel System 4-43...
Page 353 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 4-44 2004 Buell Lightning: Fuel System...
Page 354 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2004 Buell Lightning: Fuel System 4-45...
Page 355 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 4-46 2004 Buell Lightning: Fuel System...
Page 356: Trouble Code 13
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. 2004 Buell Lightning: Fuel System 4-47...
Page 357 Electronic Control Module (ECM) Figure 4-35. Oxygen Sensor Circuit Table 4-19. Wire Harness Connectors in Figure 4-35. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under seat [137] oxygen sensor 1-place Packard behind rear cylinder head 4-48 2004 Buell Lightning: Fuel System...
Page 358 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). 2004 Buell Lightning: Fuel System 4-49...
Page 359 Fuel injectors may be dirty. See Fuel Injectors 7663 under 4.42 THROTTLE BODY. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-50 2004 Buell Lightning: Fuel System...
Page 360 (4.30 now OK. ELECTRONIC CONTROL MODULE). Road test again 7672 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). 2004 Buell Lightning: Fuel System 4-51...
Page 361: Trouble Code 14
[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. 4-52 2004 Buell Lightning: Fuel System...
Page 362 (ECM) Figure 4-37. Engine Temperature Sensor Circuit Table 4-21. Wire Harness Connectors in Figure 4-37. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under seat [90] engine temperature sensor 1-place bullet beneath airbox base 2004 Buell Lightning: Fuel System 4-53...
Page 363 Dis- DIGITAL TECHNICIAN (Part No. HD-44750). regard the asterisk (but not the instruction box) if your normal progression through the chart brings you to this location. 4-54 2004 Buell Lightning: Fuel System...
Page 364 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2004 Buell Lightning: Fuel System 4-55...
Page 365: Trouble Code 15
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. 4-56 2004 Buell Lightning: Fuel System...
Page 366 Figure 4-39. Intake Air Temperature Sensor Circuit Table 4-23. Wire Harness Connectors in Figure 4-39. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under seat [89] intake air temperature sensor 2-place Amp in airbox base 2004 Buell Lightning: Fuel System 4-57...
Page 367 12 volts normal progression through the chart brings you to and repair. this location. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-58 2004 Buell Lightning: Fuel System...
Page 368 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2004 Buell Lightning: Fuel System 4-59...
Page 369: Trouble Code 16
A high voltage condition is usually caused by a faulty voltage regulator. 8892b Fuse block Ignition relay Key switch relay Start relay Figure 4-40. Fuse Block and Electrical Relays 4-60 2004 Buell Lightning: Fuel System...
Page 370 [10B] [11B] Connector Connector Electronic Control Module (ECM) [10A] [11A] Figure 4-41. Battery Voltage Circuit Table 4-24. Wire Harness Connectors in Figure 4-41. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat 2004 Buell Lightning: Fuel System 4-61...
Page 371 Replace ignition relay. STOP Go to Code 16 Test (Part 2 of 2). Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-62 2004 Buell Lightning: Fuel System...
Page 372 Is voltage drop greater than 0.5 volt? Replace R/Y wire between battery fuse and Replace main fuse. battery. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2004 Buell Lightning: Fuel System 4-63...
Page 373: Trouble Code 21
Using TEST CONNECTOR KIT (Part No. HD-41404), attach red probe and patch cord to [164B] (1, 2). Figure 4-42. Fuses and Diodes Using TEST CONNECTOR KIT (Part No. HD-41404), use gray male pin probe and patch cord. 4-64 2004 Buell Lightning: Fuel System...
Page 374 Table 4-25. Wire Harness Connectors in Figure 4-43. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [161] Interactive mufﬂer actuator 4-place Deutsch under air cleaner [164] 1-place Amp under seat [165] sub-harness 3-place Packard beneath airbox base 2004 Buell Lightning: Fuel System 4-65...
Page 375 [161B] pin 4. binding? Replace inter- active muffler 4-6 v actuator. Replace ECM Replace inter- Locate and repair Replace muffler Replace inter- active motor. short to voltage on assembly active muffler TN/Y wire. cable. 4-66 2004 Buell Lightning: Fuel System...
Page 376: Trouble Codes 23 And 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23 Trouble Codes 24 And
Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), purple pin probes and patch cord. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Use FUEL INJECTOR TEST LAMP (Part No. HD-34730- 2C). 2004 Buell Lightning: Fuel System 4-67...
Page 377 Table 4-26. Wire Harness Connectors in Figure 4-46. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [161] Interactive mufﬂer actuator 4-place Deutsch under air cleaner [164] 1-place Amp under seat [165] sub-harness 3-place Packard beneath airbox base 4-68 2004 Buell Lightning: Fuel System...
Page 378 Replace ECM. See 4.30 Perform 4.7 WIGGLE TEST. ELECTRONIC CONTROL Repair as necessary. MODULE. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2004 Buell Lightning: Fuel System 4-69...
Page 379 WIGGLE TEST to locate open wire. intermittents. Repair as necessary. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-70 2004 Buell Lightning: Fuel System...
Page 380 24 or 25. This condition is normal and does not by itself indicate a malfunction. Codes must be cleared if this condition occurs. Figure 4-48. Testing Ignition Coil Connectors 2004 Buell Lightning: Fuel System 4-71...
Page 381 Electronic Control Module (ECM) Figure 4-49. Ignition Coil Circuit Table 4-27. Wire Harness Connectors in Figure 4-49. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [83] ignition coil 3-place Packard beneath airbox base 4-72 2004 Buell Lightning: Fuel System...
Page 382 Repair as Replace ECM. See necessary. 4.30 ELECTRONIC CONTROL MODULE. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2004 Buell Lightning: Fuel System 4-73...
Page 383: Trouble Code 33
Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), red pin probe and patch cord. Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), gray socket probe and patch cord. 4-74 2004 Buell Lightning: Fuel System...
Page 384 Table 4-28. Wire Harness Connectors in Figure 4-51. 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 2004 Buell Lightning: Fuel System 4-75...
Page 385 Terminal 87 to Pin D of [86]. Continuity present? Repair open. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-76 2004 Buell Lightning: Fuel System...
Page 386: Trouble Code 35
Code 35 ﬂow chart. Breakout box Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Figure 4-52. Installed Breakout Box Replace instrument module. See 7.19 INSTRUMENT MODULE. 8893 8894 Figure 4-53. Instrument Module Connector [39] 2004 Buell Lightning: Fuel System 4-77...
Page 387 Electronic Control Module (ECM) [10A] [11A] Figure 4-54. Tachometer Circuit Table 4-29. Wire Harness Connectors in Figure 4-54. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [39] instrument module 20-place Multilock behind windscreen 4-78 2004 Buell Lightning: Fuel System...
Page 388 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. 7.19 INSTRUMENT 7886 MODULE 7883 2004 Buell Lightning: Fuel System 4-79...
Page 389: Trouble Code 36
The reference numbers below correlate with the circled num- bers on the Code 36 ﬂow charts. Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), gray pin probes and patch cord. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. 4-80 2004 Buell Lightning: Fuel System...
Page 390 Electronic Control Module (ECM) Figure 4-56. Cooling Fan Circuit Table 4-31. Wire Harness Connectors in Figure 4-56. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under seat [97] cooling fan 2-place Multilock behind rear cylinder 2004 Buell Lightning: Fuel System 4-81...
Page 391 Disregard the asterisk (but not the instruction box) if your normal pro- gression through the chart brings you to this location. Defective ECM or System ok. ECM connection. 4-82 2004 Buell Lightning: Fuel System...
Page 392 Place a jumper wire between fan Y/BN wire and battery positive. Place a System ok. jumper between fan BK Replace fan. wire and ground. Does fan run at full speed? Replace fan. System ok. 7879 2004 Buell Lightning: Fuel System 4-83...
Page 393: Trouble Code 44
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 4-58. Bank Angle Sensor 4-84 2004 Buell Lightning: 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 2004 Buell Lightning: Fuel System 4-85...
Page 395 0.25 in. (6.4 mm) of sides, face or ANGLE SENSOR. top of bank angle sensor? Replace bank angle sensor. See 4.35 Return to original BANK ANGLE SENSOR. configuration. Code 44 Test (Part 2 of 2) 4-86 2004 Buell Lightning: Fuel System...
Page 396 Repair short to ground Replace ECM. See on Lt GN/GY wire. 4.30 ELECTRONIC CONTROL MODULE. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2004 Buell Lightning: Fuel System 4-87...
Page 397: Trouble Codes 52, 53, 54 And 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29 Trouble Code 56
All of the following codes indicate a failure which requires replacement of the ECM. See 4.30 ELECTRONIC CONTROL MODULE. Code 52 - RAM failure. Code 53 - ROM failure. Code 54 - EE PROM failure. Code 55 - Microprocessor failure. 4-88 2004 Buell Lightning: Fuel System...
Page 398 Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), black pin probes and patch cord. Timer plate stud (2) 4.31 CAM POSITION SENSOR AND ROTOR. Sensor wiring Cam position sensor b0313a7x Figure 4-60. Cam Position Sensor 2004 Buell Lightning: Fuel System 4-89...
Page 399 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 4-90 2004 Buell Lightning: Fuel System...
Page 400 [11] and to ground. to voltage. TRONIC CON- [14]. [14]. TROL MODULE. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2004 Buell Lightning: Fuel System 4-91...
Page 401 Install original cam System position sensor. Replace ECM. See 4.30 ELECTRONIC CONTROL MODULE. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 4-92 2004 Buell Lightning: Fuel System...
Page 402: 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). 2004 Buell Lightning: Fuel System 4-93...
Page 403 Rear coil primary Sensor ground 1 Injector rear Vehicle speed sensor Interactive mufﬂer control feedback Engine temperature Bank angle sensor input Intake air temperature System ground B (coil) Serial data receive Tachometer Serial data transmit 4-94 2004 Buell Lightning: Fuel System...
Page 404: 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. 2004 Buell Lightning: Fuel System 4-95...
Page 405 12. Wireform, cable guide 13. Ignition coil 14. Front spark plug cable 15. Engine mount 16. Seal 17. Trigger rotor 18. Trigger rotor bolt 19. Cam position sensor 20. Inner cover b1164x4x Figure 7-66. Ignition Components 4-96 2004 Buell Lightning: Fuel System...
Page 406 HOME bs0017xx Figure 4-67. Ignition System Circuit 2004 Buell Lightning: Fuel System 4-97...
Page 407 Use of regular rivets can damage ignition system components and may allow water to enter the timing compartment. 10. Secure timer cover (2) to inner cover using new rivets (1). 11. Connect negative battery cable. 4-98 2004 Buell Lightning: Fuel System...
Page 408: Ignition Coil
An inﬁnite ohms (∞ or no continuity) resistance value indicates an open circuit (a break in the coil winding). Replace coil. 2004 Buell Lightning: Fuel System 4-99...
Page 409 Install intake cover assembly. See 2.35 INTAKE COVER Rear Cylinder Post ASSEMBLY. Coil Pin A (rear cylinder) Connect negative battery cable. Coil Pin B (12 VDC) Coil Pin C (front cylinder) Front Cylinder Post Figure 4-71. Ignition Coil 4-100 2004 Buell Lightning: Fuel System...
Page 410: Oxygen Sensor
Install cable straps (2). Install airbox assembly. See 4.44 AIRBOX. Install intake cover assembly. See 2.35 INTAKE COVER Oxygen sensor connector [137] ASSEMBLY. Cable straps Connect negative battery cable. Figure 4-74. Oxygen Sensor Connector [137] (1200 Models) 2004 Buell Lightning: Fuel System 4-101...
Page 411: Engine Temperature Sensor
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) Figure 4-76. Engine Temperature Sensor Connector Approximate Location [90] 4-102 2004 Buell Lightning: Fuel System...
Page 412 [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 4.44 AIRBOX. Install intake cover assembly. See 2.35 INTAKE COVER ASSEMBLY. Connect negative battery cable. 2004 Buell Lightning: Fuel System 4-103...
Page 413: Bank Angle Sensor
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. (70) Install seat. See 2.41 SEAT. 4-104 2004 Buell Lightning: Fuel System...
Page 414: Intake Air Temperature Sensor
Inspect sensor grommet for damage and replace as required. INSTALLATION Connect IAT sensor connector [89] to wiring harness. Install IAT sensor into grommet on air cleaner base from underneath. Install airbox. See 4.44 AIRBOX. Install negative battery cable. 2004 Buell Lightning: Fuel System 4-105...
Page 415: Throttle Position Sensor
[88A]. NOTE b0995x4x Throttle position sensor can only be calibrated using DIGITAL TECHNICIAN (Part No. HD-44750). Calibrate throttle position sensor. Figure 4-80. Throttle Position Sensor b0651x4x Figure 4-81. Tabs on TP Sensor Connector [88A] 4-106 2004 Buell Lightning: Fuel System...
Page 416: 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. 2004 Buell Lightning: Fuel System 4-107...
Page 417: 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). 4-108 2004 Buell Lightning: Fuel System...
Page 418 10. Place wrench onto nut and another wrench onto the bolt. Figure 4-86. Fuel Pump Removal Hold the bolt stationary and turn nut clockwise until fuel pump is pulled free from frame. 2004 Buell Lightning: Fuel System 4-109...
Page 419 Figure 4-88. Fuel Pump Assembly (right side) 11. See Figure 4-88. Tighten fuel ﬁlter clamps (3, 7). 12. See Figure 4-89. Install clips (1) into center grooves. 13. Install fuel pump assembly. See INSTALLATION in this section. 4-110 2004 Buell Lightning: Fuel System...
Page 420 Table 4-38. 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 4-90. Regulator Housing O-rings 2004 Buell Lightning: Fuel System 4-111...
Page 421 Install clips (1) into middle grooves. 16. See Figure 4-87. 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. 4-112 2004 Buell Lightning: Fuel System...
Page 422 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 4-93. Fuel Pump Installation 2004 Buell Lightning: Fuel System 4-113...
Page 423: Fuel Tank Vent Valve
Fastener (2) loss of control which could result in death or serious injury. (70) Figure 4-95. Fuel Tank Vent Valve 10. Install seat. See 2.41 SEAT. 4-114 2004 Buell Lightning: Fuel System...
Page 424: 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 4-97. Fuel Cap Retaining Ring 2004 Buell Lightning: Fuel System 4-115...
Page 425: 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. 4-116 2004 Buell Lightning: Fuel System...
Page 426 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 4-99. Two Piece Throttle Body/Intake Manifold Assembly (XB9S Model) 2004 Buell Lightning: Fuel System 4-117...
Page 427 10. Throttle position sensor 22. Mounting ﬂange, intake (1 front, 1 rear) 11. Clamp, wire spring, 49mm 23. Seal, intake manifold (2) 12. Velocity stack, 49mm Figure 4-100. One Piece Throttle Body/Intake Manifold Assembly (XB12 Model) 4-118 2004 Buell Lightning: Fuel System...
Page 428: 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. 2004 Buell Lightning: Fuel System 4-119...
Page 429 Front fuel injector evidence of raw fuel in throttle body manifold. Lower fuel rail fastener Install airbox cover. See 4.44 AIRBOX. Figure 4-104. Fuel Injectors Install intake cover assembly. See 2.35 INTAKE COVER ASSEMBLY. 4-120 2004 Buell Lightning: Fuel System...
Page 430 Connect EVAP hose to port at bottom of throttle body (California models only). Calibrate throttle position sensor if removed or replaced. 4.37 THROTTLE POSITION SENSOR. Install airbox. See 4.44 AIRBOX. 10. Check throttle cable adjustment. See 2.23 THROTTLE CONTROL. 2004 Buell Lightning: Fuel System 4-121...
Page 431: 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 4-122 2004 Buell Lightning: Fuel System...
Page 432 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. 2004 Buell Lightning: Fuel System 4-123...
Page 433: Airbox
Cable, interactive exhaust grommet and baseplate gasket (3). Replace as neces- Harness, interactive exhaust sary. Air box cover latch tabs Figure 1-110. Air box cover, Fuel Vent Tube and Fuel Vapor Valve (XB12 Models) 4-124 2004 Buell Lightning: Fuel System...
Page 434 Carefully lower baseplate into mounting position. Ensure Velocity stack sealing ring rubber sealing ring on velocity stack completely engages baseplate. Baseplate should be sandwiched between Figure 4-111. Base Plate (All Models) upper and lower rubber sealing rings. 2004 Buell Lightning: Fuel System 4-125...
Page 435 10. Install intake cover assembly. See 2.35 INTAKE COVER ASSEMBLY. b1030x4x Airbox cover Intake snorkel Rear cylinder breather hose Air ﬁlter Fasteners Front cylinder breather hose Airbox seal Baseplate Figure 4-112. Airbox (Typical XB9S) 4-126 2004 Buell Lightning: Fuel System...
Page 436 Harness, interactive exhaust 13. Shoulder screw (4) Cable bracket 14. Base plate assembly Interactive exhaust cable 15. Breather hoses, front and rear Upper isolator Figure 4-113. Air Cleaner Assembly (XB12) with Interactive Exhaust Components 2004 Buell Lightning: Fuel System 4-127...
Page 437 4.45 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 438 The barb is the larger outside diameter portion (bump) on the fuel ﬁtting. Figure 4-114. Connect two hoses to the canister. Make sure to push hoses all the way on to carbon canis- Figure 4-116. Canister Mounting Bracket ter ﬁttings. 2004 Buell Lightning: Fuel System 4-129...
Page 439 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 4-117. Emissions Hose Attachment, California Models Only 4-130 2004 Buell Lightning: Fuel System...
Page 440 ELECTRIC STARTER Table Of Contents SUBJECT PAGE NO. 5.1 Specifications ..........5.2 Electric Starter System .
Page 442 8 ft-lbs (11 Nm) (min.) @ 2.4 V TORQUE VALUES ITEM TORQUE NOTES Battery terminal fasteners 72-96 in-lbs 8-11 Nm page 5-19 Starter battery positive cable 60-85 in-lbs 7-10 Nm page 5-19 Starter mounting bolts 13-20 ft-lbs 18-27 Nm page 5-19 2004 Buell Lightning: Starter...
Page 443: 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). 2004 Buell Lightning: Starter...
Page 444 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 2004 Buell Lightning: Starter...
Page 445: Starting System Diagnosis
Is 12V present on starter relay Replace Starter Test 3: Relay Clicks. Terminal 86 with starter button solenoid. not pressed? 5845 Nothing clicks. See Starter Replace Replace Test 4: Nothing Clicks. right handlebar starter relay. switchgear. 5832 5818 2004 Buell Lightning: Starter...
Page 446 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 2004 Buell Lightning: Starter...
Page 447 (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 2004 Buell Lightning: Starter...
Page 448 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 2004 Buell Lightning: Starter...
Page 449: 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. 2004 Buell Lightning: Starter...
Page 450 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. 2004 Buell Lightning: Starter...
Page 451 HOME bs0022xx RH CONTROLS [33A] STARTER SOLENOID IGNITION SWITCH WIRING DIAGRAM [22A] KEY POSITION [128A] [33B] PARK LOCK [GRD2] WIRE COLOR R/BK R/GY GROUND [128B] WIRE SECT mm CONNECTING BATTERY USER + BATTERY USER + FUSE/RELAY ASSEMBLY [61B] BATTERY TN/Y TN/LT.GN DIODE IGNITION...
Page 452: 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 2004 Buell Lightning: Starter 5-11...
Page 453 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 2004 Buell Lightning: Starter...
Page 454 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. 2004 Buell Lightning: Starter 5-13...
Page 455 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 2004 Buell Lightning: Starter...
Page 456 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 2004 Buell Lightning: Starter 5-15...
Page 457 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 2004 Buell Lightning: Starter...
Page 458 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 2004 Buell Lightning: Starter 5-17...
Page 459 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 2004 Buell Lightning: Starter...
Page 460 If seat is loose, it could shift Starter during vehicle operation and startle the rider, causing loss of control which could result in death or serious Figure 5-26. Starter Mounting injury. Install seat. See 2.41 SEAT. 2004 Buell Lightning: Starter 5-19...
Page 461 Bearing cage 16. O-ring 17. Return spring 18. Ball 19. Gasket 20. Washer (2) 21. Mounting bolt (2) 22. Field wire 23. O-ring (2) 24. Field wire nut with washer (metric) Figure 5-27. Starter Assembly 5-20 2004 Buell Lightning: Starter...
Page 462 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). 2004 Buell Lightning: Starter 5-21...
Page 463 HOME NOTES 5-22 2004 Buell Lightning: Starter...
Page 464 Table Of Contents DRIVE/TRANSMISSION 6 SUBJECT PAGE NO. 6.1 Specifications ..........6.2 Primary Cover .
Page 466 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) 2004 Buell Lightning: Drive/Transmission...
Page 467 5.4-6.8 Nm LOCTITE 272 (red), Page 6-6 Transmission sprocket nut LOCTITE 262 (red), left hand threads, Special procedure special torque turn method, page 6-50 Transmission sprocket screws 90-110 in-lbs 10.2-12.4 Nm Replace after 3 removals, page 6-50 2004 Buell Lightning: Drive/Transmission...
Page 468 1.9 CLUTCH. Figure 6-1. Loosen locknut (6). Turn chain adjuster screw (5) counterclockwise to remove tension on primary chain. Remove three TORX screws with washers and clutch inspection cover. Figure 6-1. Remove clutch inspection cover (3). 2004 Buell Lightning: Drive/Transmission...
Page 469 16. Pedal bearing (2) 17. Bolt 18. Shifter lever 19. Oil seal 20. Sems screw (14) 21. Adjuster assembly 22. Chain adjustment nut 23. O-ring 24. Drain plug Figure 6-1. Primary Cover, Primary Chain Adjuster and Shifter Assembly 2004 Buell Lightning: Drive/Transmission...
Page 470 A 1/4-inch allen wrench may be inserted into end of adjuster screw to hold it while threading lock nut. Shoe, chain adjuster Chain limiting screw Chain adjusting nut Primary cover Figure 6-2. Primary Chain Adjuster 2004 Buell Lightning: Drive/Transmission...
Page 471 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. 2004 Buell Lightning: Drive/Transmission...
Page 472: 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 6-6. Clutch Release Mechanism 2004 Buell Lightning: Drive/Transmission...
Page 473 Connect negative battery cable to battery terminal. Tighten fastener to 72-96 in-lbs (8-11 Nm). Install seat. See 2.41 SEAT. Outer ramp Adjusting screw Coupling Cable end Lockplate Slot in primary cover Figure 6-8. Nut and Outer Ramp 2004 Buell Lightning: Drive/Transmission...
Page 474 Replace release ramps and/or balls. Clutch drags. Warped clutch steel plates. Replace clutch steel plates. Blade worn or damaged clutch gear splines. Replace clutch gear or hub as required. Overﬁlled primary. Drain lubricant to correct level. 2004 Buell Lightning: Drive/Transmission...
Page 475 27. Needle bearing Inner race Retaining ring 17. Pressure plate 28. Needle bearing 10. Spring seat 18. Friction plate, paper (7) 29. Clutch shell and sprocket 19. Steel plate (7) 30. Outer thrust washer Figure 6-9. Clutch Assembly 6-10 2004 Buell Lightning: Drive/Transmission...
Page 476 Thread the CLUTCH SPRING FORCING SCREW (Part No. HD-38515-91) onto the clutch adjusting screw. Place the bridge of SPRING COMPRESSING TOOL (Part No. HD-38515-A) against diaphragm spring. Install bearing and washer. Thread the tool handle onto end of forcing screw. 2004 Buell Lightning: Drive/Transmission 6-11...
Page 477 Install adjusting screw assembly into pressure plate. Figure 6-34. Align two tabs on perimeter of release plate with corresponding recesses (3) in pressure plate. Secure the adjusting screw assembly with new retaining ring. 6-12 2004 Buell Lightning: Drive/Transmission...
Page 478 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. 7738 Figure 6-14. Measuring Friction Plates 2004 Buell Lightning: Drive/Transmission 6-13...
Page 479: Assembly And Installation
ﬂats to prevent the forcing screw from turning. Spring seat Turn compressing tool handle clockwise until dia- Figure 6-18. Spring Seat Installation phragm spring compresses just enough to install new retaining ring into the groove in clutch hub prongs. 6-14 2004 Buell Lightning: Drive/Transmission...
Page 480 Washer Bearing Bridge Forcing screw Diaphragm spring Snap ring Pressure plate Spring seat Figure 6-19. Pressure Plate Assembly 8815 Adjusting screw assembly Retaining ring Tab recesses Figure 6-20. Clutch Adjusting Screw Assembly and Retaining Ring 2004 Buell Lightning: Drive/Transmission 6-15...
Page 481 TWO CLAW PULLER (Part No. HD-97292-61) and two bolts to loosen the engine sprocket. Figure 6-13. Remove adjusting screw assembly. Remove large retaining ring. Remove adjusting screw assembly from pressure plate. 6-16 2004 Buell Lightning: Drive/Transmission...
Page 482 Figure 6-24. New Needle Bearing in Clutch Shell 11. Replace damaged parts as necessary. 8804 Figure 6-25. Clutch Hub Bearing Race 2004 Buell Lightning: Drive/Transmission 6-17...
Page 483 Installation end of bearing tool Bearing guide, installer Figure 6-26. Clutch Shell Bearing Remover/Installer B-45926 8812 Figure 6-29. Installing Clutch Shell Needle Bearing Clutch Shell Bearing Remover/Installer B-45926 Figure 6-27. Removing Clutch Shell Needle Bearing 6-18 2004 Buell Lightning: Drive/Transmission...
Page 484 “out” facing the mainshaft nut or transmission may be b1061x6x damaged. b1060x6x Clutch hub Needle bearing Clutch shell Thrust washer, outer Mainshaft nut Washer Figure 6-30. Clutch Hub and Shell Assembly Clutch hub Figure 6-32. Mainshaft Nut and Washer 2004 Buell Lightning: Drive/Transmission 6-19...
Page 485 14. Install seat. See 2.41 SEAT. Adjusting screw assembly Retaining ring Tab recesses Figure 6-34. Clutch Adjusting Screw Assembly and Retaining Ring 6-20 2004 Buell Lightning: Drive/Transmission...
Page 486: Drive Belt System
Mishandling drive belt will result in premature failure. For maximum strength, integrity and longevity, avoid over bending (A and B), twisting (C), crimping, pinch- ing or kinking (D), and prying (E). Figure 6-35. Proper Drive Belt Handling 2004 Buell Lightning: Drive/Transmission 6-21...
Page 487 CAUTION When removing or installing belt, do not bend or twist belt, partially slide belt onto sprocket and "roll" wheel or belt damage will occur. Slide belt from sprocket and remove. 10. Remove rear axle. 6-22 2004 Buell Lightning: Drive/Transmission...
Page 488 48-52 ft-lbs (65.1-70.5 Nm). Tighten rear axle pinch fastener (2) to 40-45 ft-lbs (54- 61 Nm). 10. See Figure 6-37. Install front sprocket cover (2) by tight- ening fasteners to 12-36 in-lbs (1-4 Nm). See 2.31 SPROCKET COVER. 2004 Buell Lightning: Drive/Transmission 6-23...
Page 489 61 Nm). 8420 b1106x6x Axle Pinch bolt fastener Figure 6-41. Rear Wheel Mounting, Right Side Wheel Wheel nut Stud Idler pulley bracket Idler pulley bracket nut and washer Wheel fastener Figure 6-42. Idler Pulley Assembly 6-24 2004 Buell Lightning: Drive/Transmission...
Page 490 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 6-43. Transmission Power Flow 2004 Buell Lightning: Drive/Transmission 6-25...
Page 491: Case Disassembly For Transmission Removal
Remove clutch assembly, primary chain and engine sprocket. See CLUTCH. 8615 TORX screw Retention collar Shifter lever assembly Figure 6-44. Countershaft Retainer Figure 6-44. Place transmission in 1st gear. Remove countershaft TORX screw (1) and retention collar (2). 6-26 2004 Buell Lightning: Drive/Transmission...
Page 492 Figure 6-48. Rear Isolator Assembly 13. See Figure 6-48. Remove rear isolator assembly by removing the forward two fasteners ﬁrst and then the two rear fasteners (re-install with new fasteners). 2004 Buell Lightning: Drive/Transmission 6-27...
Page 493 No tools are required for this operation. 8621 8636 Figure 6-52. Separating Crankcase Halves Figure 6-53. Removing Flywheels from Left Case Half 17. See Figure 6-52. Separate crankcase halves. 18. See Figure 6-53. Remove the ﬂywheel assembly from left crankcase half. 6-28 2004 Buell Lightning: Drive/Transmission...
Page 494: Transmission Disassembly
Carefully tap on alternate sides of the shaft using the pro- Countershaft vided slots. Figure 6-56. Shifter Forks, Drum and Shafts 8628a Figure 6-55. Transmission Assembly Figure 6-55. Remove shifter drum and shifter forks. Remove mainshaft 2nd gear from mainshaft. 2004 Buell Lightning: Drive/Transmission 6-29...
Page 495 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 6-57. Shifter Mechanism 6-30 2004 Buell Lightning: Drive/Transmission...
Page 496 (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. 2004 Buell Lightning: Drive/Transmission 6-31...
Page 497 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 6-60. Transmission Assembly-Right Crankcase Half 6-32 2004 Buell Lightning: Drive/Transmission...
Page 498 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 6-61. Transmission Assembly-Left Crankcase Half 2004 Buell Lightning: Drive/Transmission 6-33...
Page 499 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 6-62. Transmission Mainshaft Assembly Once Removed from Left Crankcase/Disassembly 6-34 2004 Buell Lightning: Drive/Transmission...
Page 500 (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. 2004 Buell Lightning: Drive/Transmission 6-35...
Page 501: 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 6-65. Transmission Mainshaft Assembly/Reassembly 6-36 2004 Buell Lightning: Drive/Transmission...
Page 502 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 6-66. Transmission Countershaft Assembly/Reassembly 2004 Buell Lightning: Drive/Transmission 6-37...
Page 503: Main Drive Gear
(2). Install and tighten nut (6) until 5th gear (3) is free. 8681 Figure 6-68. Bearing Remover Cross Plate Mounting (Part No. B-45847) Figure 6-68. Place cross plate on crankcase as shown. 6-38 2004 Buell Lightning: Drive/Transmission...
Page 504 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). 2004 Buell Lightning: Drive/Transmission 6-39...
Page 505 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 6-73. Transmission Assembly Right Crankcase Half 6-40 2004 Buell Lightning: Drive/Transmission...
Page 506: 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. 2004 Buell Lightning: Drive/Transmission 6-41...
Page 507 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 6-76. Transmission Assembly Left Crankcase Half 6-42 2004 Buell Lightning: Drive/Transmission...
Page 508: 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. 2004 Buell Lightning: Drive/Transmission 6-43...
Page 509: Transmission Installation
Install mainshaft 2nd gear with shifter fork groove (Part No. B-43985-2) on arbor press. towards mainshaft 3rd gear. Install COUNTERSHAFT GUIDE ADAPTER Install shifter forks, shafts and shifter drum. (Part No. B-43985-4). 6.10 TRANSMISSION ASSEMBLY. 6-44 2004 Buell Lightning: Drive/Transmission...
Page 510 Figure 6-82. Installing Shift Fork Shafts NOTE Figure 6-82. 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 6-81. Shifter Forks, Drum and Shafts 2004 Buell Lightning: Drive/Transmission 6-45...
Page 511 HOME b1016x3x One Behind Shifter Mechanism Indicates Bolt Pattern Location Figure 6-83. Crankcase Fasteners 6-46 2004 Buell Lightning: Drive/Transmission...
Page 512 Figure 6-85. Gear Detent Assembly Aid ft-lbs (20.3-25 Nm). (Part No. B-45520) Figure 6-85. 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. 2004 Buell Lightning: Drive/Transmission 6-47...
Page 513: Shifter Shaft
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 6-89. Shifter Shaft Return Spring (Incorrectly Installed) 6-48 2004 Buell Lightning: Drive/Transmission...
Page 514: 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. 2004 Buell Lightning: Drive/Transmission 6-49...
Page 515 Since this compound remains effective for about three removal/installation cycles, the original screws may be reused up to three times. After the third removal/installation cycle, replace both screws with new screws identical to the original. 6-50 2004 Buell Lightning: Drive/Transmission...
Page 516 Tighten rear axle (1) to 23-27 ft-lbs (31.2-36.6 Nm), back off two full turns and then retighten to 48-52 ft-lbs (65.1-70.5 Nm). 18. Tighten pinch fastener (2) on right side of swingarm to 40-45 ft-lbs (54-61 Nm). 2004 Buell Lightning: Drive/Transmission 6-51...
Page 517 HOME NOTES 6-52 2004 Buell Lightning: Drive/Transmission...
Page 518 Table Of Contents SUBJECT PAGE NO. 7.1 Specifications ..........7.2 Ignition System .
Page 520 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 2004 Buell Lightning: Electrical...
Page 521 2.8-3.2 Nm page 7-49 Turn signal fasteners (front) 25-28 in-lbs 2.8-3.2 Nm page 7-49 Turn signal ﬂasher fastener 30-40 in-lbs 3-4 Nm page 7-50 Voltage regulator mounting screws 48-60 in-lbs 5.4-6.8 Nm Use new fasteners, page 7-32 2004 Buell Lightning: Electrical...
Page 522: 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. 2004 Buell Lightning: Electrical...
Page 523 12. Wireform, cable guide 13. Ignition coil 14. Front spark plug cable 15. Engine mount 16. Seal 17. Trigger rotor 18. Trigger rotor bolt 19. Cam position sensor 20. Inner cover b1164x4x Figure 7-1. Ignition Components 2004 Buell Lightning: Electrical...
Page 524 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 2004 Buell Lightning: Electrical...
Page 525 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 2004 Buell Lightning: Electrical...
Page 526 8899 8902 8904 Socket head fastener (1), with spacer behind switch Tamper-resistant Torx fasteners (2) Throttle cables Ignition switch as positioned on vehicle Fork stop pin (retracted) Figure 7-4. Ignition Switch 2004 Buell Lightning: Electrical...
Page 527 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 2004 Buell Lightning: Electrical...
Page 528 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). 2004 Buell Lightning: Electrical...
Page 529: Spark Plug Cables
Pulling on the cable will damage the cable’s carbon core. Remove airbox assembly. See 4.30 AIRBOX. Remove air scoop left side. Figure 7-8. Disconnect spark plug cables from igni- tion coil and spark plug terminals. Inspect cables for damage. 7-10 2004 Buell Lightning: Electrical...
Page 530 Fasten boots/caps securely. Tight connections provide the necessary moisture-proof environment for the ignition coil and spark plug terminals. Install airbox assembly. See 4.30 AIRBOX. Figure 7-10. Boot Gap Should Not exceed 1/8 in. (3.2 mm) 2004 Buell Lightning: Electrical 7-11...
Page 531 Place vehicle in neutral. Clutch lever not disengaged. Pull in clutch lever. Starter relay problems. Listen for starter relay “click”. If click is not heard, perform starter relay tests. Follow starter troubleshooting in Section 5. 7-12 2004 Buell Lightning: Electrical...
Page 532 Figure 7-11. Diode Polarity b1107c7x RELAY CENTER [95A] [95B] TN/LTGN Clutch Switch Empty Diode Acces. Diode Bk/Hn/Mflr Battery TN/Y Lights Spare [131B] Spare Key Sw [131A] TN/LTGN Neutral Start Switch Relay Figure 7-13. Diode Wiring 2004 Buell Lightning: Electrical 7-13...
Page 533 Diode OK? Check for ground at neutral switch terminal. Ground present? Repair open on TN/Y Diode installed backwards. Replace Replace neutral wire between neutral Reverse polarity. diode. switch. switch and Diode. 5064 5061 5062 5063 7-14 2004 Buell Lightning: Electrical...
Page 534 Check for ground on BK Repair open on TN/ wire of connector [95]. GN wire between Ground present? connector [95] and starter relay. 5073 Replace clutch Repair open on switch. BK wire between connector [95] and 5074 ground. 5075 2004 Buell Lightning: Electrical 7-15...
Page 535 0 ohms or little resistance. Replace the assembly with a new switch if necessary. 2.24 CLUTCH HAND LEVER. Clutch engaged (switch open) Clutch disengaged (switch closed) Connector [95] Figure 7-14. Clutch Switch 7-16 2004 Buell Lightning: Electrical...
Page 536 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 7-16. Starter Relay Test 2004 Buell Lightning: Electrical 7-17...
Page 537 Replace the diode by pulling it straight out. Ensure it is installed in the correct direction. Figure 7-17. Fuse Block (contains diodes) b1166x4x Empty Diode Acces. Bk/Hn/Mflr Battery Lights Spare Spare Key Sw Figure 7-18. Fuse Blocks 7-18 2004 Buell Lightning: Electrical...
Page 538 Exhaust valve Exhaust in Valve open (exhaust ﬂow - chamber C) Valve closed (exhaust ﬂow - chamber A to B to C) Chamber A Chamber B Chamber C Exhaust exit Figure 7-19. Interactive Exhaust System Mufﬂer 2004 Buell Lightning: Electrical 7-19...
Page 539 HOME b0064 Isolator, EVA, upper Cable Harness with connector [161B] Cable bracket Actuator Isolator, EVA, lower Air cleaner cover Figure 7-20. Interactive Control System (XB12S) 7-20 2004 Buell Lightning: Electrical...
Page 540 Interactive exhaust harness Figure 7-21. Airbox Cover (XB12 Only) Figure 7-21. Remove fuel vent tube (3) from fuel cell vent and groove on top of air cleaner cover (2). Move upper isolator (4) out of the way. 2004 Buell Lightning: Electrical 7-21...
Page 541 Install upper isolator and route fuel vent line and install. Attach interactive exhaust cable to bracket and cable wheel on actuator and adjust. See 1.17 INTERACTIVE EXHAUST CABLE (XB12S). Install intake cover assembly. See 4.30 AIRBOX. 7-22 2004 Buell Lightning: Electrical...
Page 542: Charging System
Wiring Check for corroded or loose connections in the charging cir- cuit. See Figure 7-25. Voltage Regulator Inspection Figure 7-24. The plug connector to stator must be clean and tight. 2004 Buell Lightning: Electrical 7-23...
Page 543 STOP 5310 Go to Test 7.7 (Part 2 of 2). NOTE Whenever a charging system component fails a test and is replaced, re-test the system to be sure the problem has been corrected. 7-24 2004 Buell Lightning: Electrical...
Page 544 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. 2004 Buell Lightning: Electrical 7-25...
Page 545 BATTERY CABLE STARTER SOLENOID [128A] BATTERY STARTER MOTOR [GRD2] Battery Fuse FUSE/RELAY ASSEMBLY [61B] BATTERY, 30A [35A] [35B] TO VOLTAGE REGULATOR [77A] [77B] VOLTAGE REGULATOR STATOR (HD 3-PHASE) [46A] [46B] Figure 7-25. Charging System Circuit 7-26 2004 Buell Lightning: Electrical...
Page 546 Reconnect regulator after testing. SPROCKET COVER WIRING. Start the motorcycle and run the engine at 3000 RPM. With ignition and all continuously running lights and accessories turned on (headlight on high beam), read the total current draw. 2004 Buell Lightning: Electrical 7-27...
Page 547 If the resistance is lower, the stator is damaged and must be replaced. NOTE Verify that meter reads 0 ohms when probes are shorted together. If not, subtract lowest value to resistance value of stator. 7-28 2004 Buell Lightning: Electrical...
Page 548 If output is good, charging problem might be faulty regulator/rectiﬁer. Replace as required. Check the output again as described under CURRENT AND VOLTAGE OUTPUT TEST page 7-28. b0997x7x Figure 7-30. Check for Stator Resistance b0998x7x Figure 7-31. Check Stator AC Voltage Output 2004 Buell Lightning: Electrical 7-29...
Page 549 Remove stator wiring grommet (3) from left crankcase half. Withdraw stator wiring (4) from grommet hole in left crankcase half. Remove stator. Stator fastener (4) Stator Grommet Stator wiring Connector [46] Figure 7-34. Stator Assembly 7-30 2004 Buell Lightning: Electrical...
Page 550 TORX screws (1). Tighten TORX screws to 30-40 in-lbs (3-4 Nm). Route stator wiring (4) behind rear cylinder and in front of transmission breather hose. See 7.26 SPROCKET COVER WIRING for remaining wire routing information. 2004 Buell Lightning: Electrical 7-31...
Page 551: Voltage Regulator
Voltage regulator loss of control which could result in death or serious Fastener (3) injury. (70) Install seat. See 2.41 SEAT. Figure 7-37. Voltage Regulator Test charging system. See 7.7 CHARGING SYSTEM. 7-32 2004 Buell Lightning: Electrical...
Page 552: Battery Cables
CAUTION Connect cables to correct terminals of battery or serious damage to motorcycle electrical system will occur. Figure 7-39. Negative Battery Cable 2004 Buell Lightning: Electrical 7-33...
Page 553 Attach negative cable to frame. Tighten to 48-72 in-lbs (5.4-8.1 Nm). Apply light coat of petroleum jelly or corrosion-retardant material to both battery terminals. Fastener with washer Positive battery cable Figure 7-40. Positive Battery Cable (Protective Boot Not Shown) 7-34 2004 Buell Lightning: Electrical...
Page 554 HOME BATTERY 7.11 GENERAL f1730x8x 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 555: Battery Testing
(black) cable. See Figure 7-44. could result in death or serious injury. Install the battery on the motorcycle. See BATTERY INSTALLATION AND CONNECTION. 7-36 2004 Buell Lightning: Electrical...
Page 556: 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. 2004 Buell Lightning: Electrical 7-37...
Page 557: Safety Precautions
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. 7-38 2004 Buell Lightning: Electrical...
Page 558 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. 2004 Buell Lightning: Electrical 7-39...
Page 559 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. 7-40 2004 Buell Lightning: Electrical...
Page 560 (not freezing), dry place. See Fig- ure 7-45. Charge the battery every month if stored at temperatures below 60˚ F. (16˚ C). Charge the battery more frequently if stored in a warm area above 60˚ F. (16˚ C). 2004 Buell Lightning: Electrical 7-41...
Page 561 2.25 HEADLIGHT ASSEMBLY AND SUPPORT BRACKET. 8917 Headlight Bulb holder (2) High beam connection [38] (left side) with ground Low beam connection [38] (right side) with ground Headlight bulbs Figure 7-46. Headlight Assembly/Rear View 7-42 2004 Buell Lightning: Electrical...
Page 562 If the rubber boots are not installed correctly the wiring har- Install seat. See 2.41 SEAT. nesses can contact the edge of the forward frame mount. The wiring harness guides must be installed at a 20º angle. 2004 Buell Lightning: Electrical 7-43...
Page 563 HOME 10525 10526 Figure 7-48. Headlight Housing 20º Alignment Marks for Rubber Boot Wiring Harness Guides or Spigots 7-44 2004 Buell Lightning: Electrical...
Page 564: Tail Lamp
Center tail section Screws (2) Bulb Lens Tail light Tail light wiring harness Tail light boot Figure 7-49. Tail Lamp Assembly 2004 Buell Lightning: Electrical 7-45...
Page 565: 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 7-51. License Plate Lamp 7-46 2004 Buell Lightning: Electrical...
Page 566: 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 7-53. Front Turn Signals 2004 Buell Lightning: Electrical 7-47...
Page 567 [18A] [18A] [18A] [18A] Right turn signal Figure 7-54. Rear Turn Signal Connections b1138x7x Turn signal (2) Jam nut and lockwasher (2) Turn signal bulb Center tail section Reﬂector bracket Figure 7-55. Rear Turn Signals 7-48 2004 Buell Lightning: Electrical...
Page 568 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. 2004 Buell Lightning: Electrical 7-49...
Page 569: Turn Signal Flasher
ﬂash. Figure 7-59. 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 WINDSCREEN. 7-50 2004 Buell Lightning: Electrical...
Page 570: 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 7-61. Left Handlebar Switch Connection 2004 Buell Lightning: Electrical 7-51...
Page 571 Brake Switch formed. Turn ignition key switch to ON. Figure 7-62. Right Handlebar Switch Connection Set ENGINE STOP SWITCH to RUN. Start motorcycle. Turn ignition key switch to OFF. Turn ignition key switch to OFF. 7-52 2004 Buell Lightning: Electrical...
Page 572 Set headlight to LOW beam. Press passing lamp switch. Headlight should ﬂash HIGH beam for as long as the switch is pressed. Figure 7-63. Left Handlebar Switch Connection Check left and right turn signals. Activate horn by pressing horn switch. 2004 Buell Lightning: Electrical 7-53...
Page 573 Center To battery Top View 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 7-65. Vehicle Speed Sensor Wiring 7-54 2004 Buell Lightning: Electrical...
Page 574 Install washers (4) and fasteners (5). Tighten fasteners to Instrument module connector [39] 12-36 in-lbs (1.4-4.1 Nm). Figure 7-68. Instrument Module Figure 7-67. Connect instrument module connector [39]. Install windscreen. See 2.40 WINDSCREEN. Install negative battery cable. 2004 Buell Lightning: Electrical 7-55...
Page 575: 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). 7-56 2004 Buell Lightning: Electrical...
Page 576 PORT STAND (Part No. B-41174). Place speedometer tester power switch in the ON posi- tion. Place signal switch in the IN position. Plug the speedometer tester into the test harness. Turn vehicle ignition switch ON. 2004 Buell Lightning: Electrical 7-57...
Page 577 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 7-58 2004 Buell Lightning: Electrical...
Page 578 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. 2004 Buell Lightning: Electrical 7-59...
Page 579 Does voltage fluctuate? instrument module Replace vehicle speed sensor. 6022 6010 Check speedometer speed Repair as necessary. sensor. Clean or replace sen- sor as required. Retest. 6008 Problem solved? System OK. Replace instrument module. 6029 6024 7-60 2004 Buell Lightning: Electrical...
Page 580 If seat is loose, it could shift Left Handlebar Switch during vehicle operation and startle the rider, causing loss of control which could result in death or serious injury. Figure 7-73. Horn Wiring Install seat. See 2.41 SEAT. 2004 Buell Lightning: Electrical 7-61...
Page 581 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 7.17 HANDLE- SWITCHES. 7-62 2004 Buell Lightning: Electrical...
Page 582: 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. 2004 Buell Lightning: Electrical 7-63...
Page 583 HOME BATTERY FUSE AND FUSES 7.23 GENERAL b1166x4xx Buell motorcycles feature two components which protect the electrical system. Fuses Empty The covered fuse block is under the seat. Diode Acces. Figure 7-77. The lights, key switch, brake/horn and igni- tion fuses are rated at 15 amps. The ECM, cooling fan and Bk/Hn/Mflr accessory fuses are rated at 7.5 amps.
Page 584: Main Wire Harness
[165B], (under main wiring harness) (XB12S only). 10. Remove fuse block and relay center from support bracket. 11. Remove the rear shock absorber assembly and reser- voir. See 2.22 REAR SHOCK ABSORBER. 12. Remove fan. See 4.24 COOLING FAN. 2004 Buell Lightning: Electrical 7-65...
Page 585 12. License plate lamp connector [45] Ground terminals (low voltage ground wires) 13. Tail light connectors [93] ECM connectors [10] & [11] 14. Interactive exhaust connector [165B], (XB12S only) Figure 7-80. Main Harness and Electrical Connectors Under Seat 7-66 2004 Buell Lightning: Electrical...
Page 586 17. Remove connector from oil pressure switch [120]. Oil pressure switch is located on front of engine. See 3.10 24. Remove all push pins. OIL PRESSURE INDICATOR SWITCH. 2004 Buell Lightning: Electrical 7-67...
Page 587 (1) at rear of frame. Install new plastic tree fasteners. Figure 7-82. Wire Harness Clip Figure 7-82. Install clamp over portion of harness that leads to engine connectors. Install clamp as shown using new plastic tree fastener. 7-68 2004 Buell Lightning: Electrical...
Page 588 3.10 OIL PRESSURE INDICATOR SWITCH. 14. Install sprocket cover wiring. See 7.26 SPROCKET COVER WIRING. 15. Connect fan connector [97]. 16. Install fan and tighten fasteners to 12-36 in-lbs (1.4-4.1 Nm). See 4.24 COOLING FAN. 2004 Buell Lightning: Electrical 7-69...
Page 589 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] & [164] (XB12S only) Figure 7-85. Main Harness and Electrical Connectors Under Seat 7-70 2004 Buell Lightning: Electrical...
Page 590 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. 2004 Buell Lightning: Electrical 7-71...
Page 591 Remove interactive exhaust cable from cable wheel. Remove actuator. Figure 7-87. Harness and Cable Routing 10559 Battery and actuator harness ground Harness to main wiring harness connector [165] Exhaust actuator harness Figure 7-88. Exhaust Actuator Harness Connector [165] 7-72 2004 Buell Lightning: Electrical...
Page 592 A loose seat may shift during vehicle operation and startle the rider, possibly causing loss of vehicle control resulting in death or serious injury. 11. Install seat. Frame lug Wire harness Cable Figure 1-90. Correct Cable Routing Behind Frame Lug 2004 Buell Lightning: Electrical 7-73...
Page 593: Sprocket Cover Wiring
Cam position sensor [14] Cam position sensor and neutral indicator switch wiring Neutral switch location Cam cover vent line Stator connector [46] Oil pressure switch wiring Interactive exhaust cable Figure 7-92. Cam Position Sensor Wiring 7-74 2004 Buell Lightning: Electrical...
Page 594 10. Install cable strap (5) securing main harness wiring. 11. Install cable strap (6) securing stator, cam position sen- sor and oil pressure switch wiring. 12. Add cable strap (7) to secure cam position sensor and voltage regulator wiring. 2004 Buell Lightning: Electrical 7-75...
Page 595 HOME NOTES 7-76 2004 Buell Lightning: Electrical...
Page 596 Table Of Contents SUBJECT PAGE NO. APPENDIX A-TOOLS ..........APPENDIX B-WIRING .

Buell 2004 XB9S Service Manual

Index to Wiring Diagrams B.5

Maintenance 1

Chassis 2

Fuel System 4

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