Buell 2006LIGHTNING MODELS Service Manual

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2006 BUELL LIGHTNING MODELS

SERVICE MANUAL

Part Number 99490-06Y

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 2006 BUELL LIGHTNING MODELS SERVICE MANUAL Part Number 99490-06Y 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 3 Part No. B-45521 Steering Head Bearing Remover/ Installer Part No. B-43721 Front Fork Seal Driver Part No. HD-39302 Steering Head Bearing Race Installer (Used with B-45521) Part No. B-46279 7/8" Axle Wrench (Hex) Part No. B-59000B Pro Level Oil Gauge 2006 Buell Lightning: Appendix A...
Page 4 Part No. HD-45966 Fork Spring Compressing Tool Part No. HD-33418 Universal Puller Forcing Screw Part No. HD-41177 Fork Tube Holder Part No. HD-B-45520 Gear Detent Assembly Aid Part No. HD-44060 Wheel Bearing Remover/Installer Part No. HD-28700 Tire Bead Expander 2006 Buell Lightning: Appendix A...
Page 5 Part No. HD-35758-B Neway Valve Seat Cutter Set Part No. HD-35667A Cylinder Leakdown Tester Part No. HD-96921-52A Oil Pressure Gauge Part No. HD-34902-B Bearing Race Remover/Installer Part No. HD-35457 Black Light Leak Detector Part No. HD-43984 Crankshaft Locking Tool 2006 Buell Lightning: Appendix A...
Page 6 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 2006 Buell Lightning: Appendix A...
Page 7 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 2006 Buell Lightning: Appendix A...
Page 8 (HD-95770-69) and 8 (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. HD-38515-91 Forcing Screw Part No. HD-41354 Speedometer Tester Part No. J-5586 Transmission Shaft Retaining Ring Pliers 2006 Buell Lightning: Appendix A...
Page 9 Main Drive Gear Bearing Installer HD-47250 Part No. HD-47250 Intake Manifold Wrench Part No. HD-38515-A Clutch Spring Compressor HD-47258 Part No. HD-47258 Rocker Cover Wrench Part No. HD-44750-P29 Panasonic Toughbook (touch screen) and HD-44750-P50 Panasonic Toughbook (non-touch screen) 2006 Buell Lightning: Appendix A...
Page 10 Installer Part No. HD-95635-46 All-Purpose Claw Puller Part No. HD-45926 Clutch Shell Bearing Remover (use with HD-95637-46A) Part No. HD-95637-46A Wedge Attachment for Claw Puller Part No. B-45676 Sprocket Shaft Seal Installer (use with HD-95635-46) 2006 Buell Lightning: Appendix A...
Page 11 HOME Part No. B-45522 Fuel Pressure Gauge Adapter Part No. HD-26792 Spark Tester Part No. B-45657 Fuel Pump Puller Part No. HD-39978 Fluke 78 Multimeter (DVOM)F 2006 Buell Lightning: Appendix A...
Page 12 HOME A-10 2006 Buell Lightning: Appendix A...
Page 13: 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 2006 Buell Lightning: Appendix B...
Page 14 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. 2006 Buell Lightning: Appendix B...
Page 15 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 2006 Buell Lightning: Appendix B...
Page 16 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 2006 Buell Lightning: Appendix B...
Page 17 “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. 2006 Buell Lightning: Appendix B...
Page 18 (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. 2006 Buell Lightning: Appendix B...
Page 19 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. 2006 Buell Lightning: Appendix B...
Page 20 When correctly positioned, the locking bar ﬁts snugly in the space between the contact band and the core crimp tails. 2006 Buell Lightning: Appendix B...
Page 21 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 2006 Buell Lightning: Appendix B...
Page 22 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 2006 Buell Lightning: Appendix B...
Page 23 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. 2006 Buell Lightning: Appendix B B-11...
Page 24 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 2006 Buell Lightning: Appendix B...
Page 25 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 2006 Buell Lightning: Appendix B B-13...
Page 26: 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 27 Interactive exhaust circuit to ECM under seat under air cleaner assembly baseplate [161] Interactive exhaust to solenoid cover under air cleaner assembly baseplate [178] Active intake system to solenoid cove [179] Active intake system to ECM under seat 2006 Buell Lightning: Appendix B B-15...
Page 28: Table Of Contents
INDEX TO WIRING DIAGRAMS Table B-3. Wiring Diagrams DIAGRAM PAGE Main harness B-17 Engine management circuit B-19 Lighting circuit B-21 Horn and instruments circuit B-23 Starting circuit B-25 Charging circuits B-27 Component circuits B-29 B-16 2006 Buell Lightning: Appendix B...
Page 29: 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 2006 Lightning Models Main Harness 2006 Buell Lightning: Electrical B-17...
Page 30 HOME 2006 Lightning Models Main Harness 2006 Lightning Models Main Harness B-18 2006 Buell Lightning: Electrical...
Page 31: Engine Management Circuit
LT.GN/GY ASSEMBLY W/BK BK/W GN/W GN/W W/BK BK/W BK/W BANK ANGLE SENSOR [14B] [14A] GY/O GY/O [38B] DATA LINK SPEEDOMETER LT.GN/R [95B] [39A] [91A] CLUTCH SW R/BK R/BK R/BK 2006 Lightning Models Engine Management Circuit 2006 Buell Lightning: Electrical B-19...
Page 32 HOME 2006 Lightning Models Engine Management Circuit 2006 Lightning Models Engine Management Circuit B-20 2006 Buell Lightning: Electrical...
Page 33: Lighting Circuit
KEY SWITCH 15 AMP [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 2006 Lightning Lighting Circuit 2006 Buell Lightning: Electrical B-21...
Page 34 HOME 2006 Lightning Lighting Circuit 2006 Lightning Lighting Circuit B-22 2006 Buell Lightning: Electrical...
Page 35: 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 OIL PRESSURE SW [120B] R/BK GN/Y [120A] 2006 Lightning Models Horn & Instruments Circuit 2006 Buell Lightning: Electrical B-23...
Page 36 HOME 2006 Lightning Models Horn & Instruments Circuit 2006 Lightning Models Horn & Instruments Circuit B-24 2006 Buell Lightning: Electrical...
Page 37: Starting Circuit
15 AMP GY/O R/BK KEY SWITCH 15 AMP NEUTRAL SW TN/Y [131B] [131A] [62B] RELAY CENTER W/BK W/BK GY/O GY/O BK/R TN/LT.GN R/BK [95B] CLUTCH SW R/BK MALE R/BK FEMALE 2006 Lightning Models Starting Circuit 2006 Buell Lightning: Electrical B-25...
Page 38 HOME 2006 Lightning Models Starting Circuit 2006 Lightning Models Starting Circuit B-26 2006 Buell Lightning: Electrical...
Page 39: 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) [46B] [46A] 2006 Lightning Models Charging Circuit 2006 Buell Lightning: Electrical B-27...
Page 40 HOME 2006 Lightning Models Charging Circuit 2006 Lightning Models Charging Circuit B-28 2006 Buell Lightning: Electrical...
Page 41: Component Circuits
[18A] [30B] [84B] [85B] ENGINE TEMP SENSOR PK/Y [90B] [90A] FUEL PUMP MAIN HARNESS BANK ANGLE SENSOR [89A] BN/Y INTAKE AIR TEMP [86B] LT.GN/GY [89B] BK/W FUEL SENSOR [134B] [134A] 2006 Lightning Models Component Circuits 2006 Buell Lightning: Electrical B-29...
Page 42 HOME 2006 Lightning Models Component Circuits 2006 Lightning Models Component Circuits B-30 2006 Buell Lightning: Electrical...
Page 43 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 2006 Buell Lightning: Appendix C...
Page 44 (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.) 2006 Buell Lightning: Appendix C...
Page 45 HOME HOSE AND WIRE ROUTING b1114xasx Figure D-1. Front and Rear Brake Systems, Right Side View...
Page 46 HOME b1115xbsx Figure D-2. Rear Brake Systems, Top View...
Page 47 HOME b1116xcsx Figure D-3. Rear Brake Systems, Left Side View...
Page 48 HOME b1117xasxL Carbon canister Figure D-4. Evaporative Emissions Control, California Models, Top View...
Page 49 HOME b1118xbsxL To induction module From fuel tank (California) From induction module (California) From fuel tank to atmosphere (49 state) Figure D-5. Evaporative Emissions Control, California and 49 State Models, Left Side View...
Page 50 HOME b1119xasxL To active intake solenoid (Japan only) Fuel pump Intake air temperature sensor (IAT) Active intake to ECM (Japan only) Figure D-6. Wiring Harness, Left Side View...
Page 51 HOME b1120xbsxL Fuel injector (2) Intake air temperature (IAT) sensor Throttle position sensor (TPS) Oxygen (O2) sensor Figure D-7. Wiring Harness, Top View...
Page 52 HOME b1121xcsxL Speedometer sensor Cable, starter to battery positive Solenoid Transmission vent line Voltage regulator Switch, oil pressure Cam position sensor Figure D-8. Wiring Harness, Right Side View...
Page 53 HOME b1122xasxL Vent line Feed oil line from the oil pump to the oil cooler Feed oil line Return oil line from the oil cooler to the oil ﬁlter housing Return oil line Figure D-9. Oil Lines, Right Side View...
Page 54 HOME b1123xbsxL Vent line Feed oil line Return oil line Figure D-10. Oil Lines, Bottom View...
Page 55 HOME b1124xasxL Exhaust valve actuator Mufﬂer valve Figure D-11. Clutch Cable and Exhaust Valve Actuator (1200 only), Right Side View...
Page 56 HOME b1125xbsxL Exhaust valve actuator Cable, seat lock Mufﬂer valve Figure D-12. Clutch, Throttle, Seat Release Cables and Exhaust Valve Actuator (1200 only), Left Side View...
Page 57 HOME b1126xcsxL TPS adjuster Clips into functional Cable, seat lock airbox cover. EVA mounted on top of functional airbox cover. Figure D-13. Clutch, Throttle, Seat Release Cables and Exhaust Valve Actuator, Top View...
Page 58 HOME NOTES D-14 2006 Buell Lightning: Appendix D...
Page 59 Using TEST CONNECTOR KIT (Part No. HD-41404), attach that the throttle plate is fully open. Brown pin probe and patch cord to [179] (1,2). If the throttle plate does not fully open, see CABLE ADJUST- MENT this section. 2006 Buell Lightning: Appendix E...
Page 60 (4) away from the solenoid bracket (3) until free- play is achieved. 10957f Solenoid shaft Solenoid bracket Cable adjusting and jam nuts Cable housing Figure E-1. Checking for Freeplay in the Solenoid Shaft in the Fully Retracted Position 2006 Buell Lightning: Appendix E...
Page 61 1/32 in. (0.79 mm) or greater. 10956f Solenoid shaft Solenoid bracket Cable adjusting and jam nuts Cable housing Figure E-2. Checking for Freeplay in the Solenoid Shaft in the Fully Extended Position 2006 Buell Lightning: Appendix E...
Page 62 Adjust stop screw, while reading the TPS on Digital 1.14 AIR CLEANER FILTER. Technician, until setting is between the range of 10.4 to 10.9. 10925 10924 Cable stop screw Active cable wheel Figure E-3. Active Intake Cable Stop Screw 2006 Buell Lightning: Appendix E...
Page 63 HOME Active Intake Solenoid [178A] [178B] Figure E-4. Active Intake System 2006 Buell Lightning: Appendix E...
Page 64 Continuity present? Go to page 2 Repair open in Page 2 of 2 W/GY wire. Repair open in GY/O wire. DIAGNOSTIC NOTE If DTC is historic, wiggle harness while performing measurements in chart to locate intermittents. 2006 Buell Lightning: Appendix E...
Page 65 Does solenoid attempt to pull throttle almost closed? Replace solenoid. Hold throttle wide open. Energize active intake solenoid. Does throttle close to an angle less than 11 degrees? Replace ECM. CABLE ADJUSTMENT in this section. 2006 Buell Lightning: Appendix E...
Page 66 Cable connector Active intake cable Fasteners (2), bracket to solenoid Cable adjusting nut Active intake solenoid Cable bracket Solenoid bracket Active cable jam nut 10. Air cleaner baseplate assembly Figure E-5. Disconnecting Active Intake System 2006 Buell Lightning: Appendix E...
Page 67 MAINTENANCE Table Of Contents SUBJECT PAGE NO. 1.1 General ............1.2 Fuel and Oil .
Page 69: 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. 2006 Buell Lightning: Maintenance...
Page 70: 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. 2006 Buell Lightning: Maintenance...
Page 71: 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. 2006 Buell Lightning: Maintenance...
Page 72: 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. 2006 Buell Lightning: Maintenance...
Page 73: Fuel And Oil
Water mixed with oil forms a sludge that causes accelerated engine wear. In freezing tempera- Buell motorcycles were designed to give the best perfor- tures, the water becomes slush or ice, which may clog oil mance using unleaded gasoline.
Page 74: Maintenance Schedule
Engine mounts and stabilizer links Inspect Road test Verify component and system functions NOTES: Should be performed by an authorized Harley-Davidson/Buell dealer, unless you have the proper tools, service data and are mechanically qualiﬁed. Change brake ﬂuid every two (2) years. 2006 Buell Lightning: Maintenance...
Page 75 Minimum brake disc thickness 0.18 in. (4.5 mm) or less Drive belt Replace drive belt and idler pulley At every 25,000 mi (40,000 km) service interval. assembly: Air cleaner Air cleaner cover screw torque 12-36 in-lbs (4-4 Nm) 2006 Buell Lightning: Maintenance...
Page 76 HYDRAULIC FORK OIL (TYPE E) Part No. 99884-80 4.21 in. (107 mm) from the top of the fork tube Battery Lubricant ELECTRICAL CONTACT LUBRICANT Part No. 99861-02 (1 oz.) Battery terminal torque 72-96 in-lbs (8-11 Nm) 2006 Buell Lightning: Maintenance...
Page 77: Battery Maintenance
HOME BATTERY MAINTENANCE GENERAL BATTERY TESTING Buell motorcycle batteries are permanently sealed, mainte- Voltmeter Test nance-free, valve-regulated, lead/calcium and sulfuric acid Table 1-4. The voltmeter test provides a general indicator batteries. The batteries are shipped pre-charged and ready to of battery condition. Check the voltage of the battery to verify be put into service.
Page 78: Cleaning And Inspection
Inspect the battery case for cracks or leaks.] 100 % at 77 ° F at 105 ° F 50 % M O N T H S O F S T A N D Figure 1-2. Battery Self-Discharge Rate 1-10 2006 Buell Lightning: Maintenance...
Page 79 (00068a) CAUTION Do not over-tighten bolts on battery terminals. Use rec- ommended torque values. Over-tightening battery termi- nal bolts could result in damage to battery terminals. (00216a) 2006 Buell Lightning: Maintenance 1-11...
Page 80: Engine Lubrication System
Ride motorcycle for approximately 10 minutes to ensure the oil is hot and the engine is at normal operating temperature. The motorcycle must be on level ground, on the side- stand, with the engine off. 1-12 2006 Buell Lightning: Maintenance...
Page 81 (00047b) tank/swingarm. Wipe any accumulated debris from mag- netic tip on drain plug. 11140 Figure 1-5. Dipstick Location Figure 1-5. Unscrew and remove dipstick from oil ﬁll hole on top of oil tank/swingarm. 2006 Buell Lightning: Maintenance 1-13...
Page 82 ° 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 1-14 2006 Buell Lightning: Maintenance...
Page 83: Brake System Maintenance
(00239a) ify D.O.T. 4 ﬂuid on the reservoir cap. Mixing different types of ﬂuid may adversely affect braking ability and lead to brake failure which could result in death or seri- ous injury. 2006 Buell Lightning: Maintenance 1-15...
Page 84 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. 1-16 2006 Buell Lightning: Maintenance...
Page 85: Bleeding Front Brake
Verify master cylinder ﬂuid level as described in step 4. 10. Attach cover to front master cylinder reservoir and tighten fasteners to 9-13 in-lbs (1.0-1.5 Nm). 11. Remove cover from molded-in-color surfaces, right han- dlebar switches and instrument panel. 2006 Buell Lightning: Maintenance 1-17...
Page 86: Bleeding Rear Brake
Repeat steps 5-6 until all air bubbles are purged. Tighten rear caliper bleeder valve (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. 1-18 2006 Buell Lightning: Maintenance...
Page 87 Figure 1-11. Critical Measurements with Typical Nm). Brake Pedal NOTE Brake pedal has no free play adjustment. 8349 Bottom of master cylinder Rod adjuster Locknut Clevis Clevis pin Figure 1-12. Rear Brake Pedal Pushrod Adjustment 2006 Buell Lightning: Maintenance 1-19...
Page 88 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. 2.12 FRONT BRAKE CALIPER 2.15 REAR BRAKE CALIPER for procedure. Figure 1-14. Front Brake Rotor 1-20 2006 Buell Lightning: Maintenance...
Page 89: Brake Pad Replacement
Tighten pin (2) to 11-14 ft-lbs (15-19 Nm). Check brake ﬂuid level. NOTE Avoid making hard stops for the ﬁrst 100 miles (160 km) to allow new brake pads to “wear in” properly with the rotor. 2006 Buell Lightning: Maintenance 1-21...
Page 90 ERS. 12. Check ﬂuid level. NOTE Avoid making hard stops for the ﬁrst 100 miles (160 km) to allow new brake pads to “wear in” properly with the rotor. Figure 1-17. Rear Brake Pad Spring 1-22 2006 Buell Lightning: Maintenance...
Page 91: Tires And Wheels
WARNING WARNING Never use compressed air to “spin-dry” bearings. Very Use only Buell approved tires. See a Buell dealer. Using high bearing speeds can damage unlubricated bearings. non-approved tires can adversely affect stability, which Spinning bearings with compressed air can also cause a could result in death or serious injury.
Page 92: Clutch
84-108 in-lbs (10- Clutch adjusting screw 12 Nm). Primary cover Correct chaincase lubricant level 10. Clean up any ﬂuid that may have spilled on mufﬂer. Figure 1-22. Fluid Level 1-24 2006 Buell Lightning: Maintenance...
Page 93 Adjuster adjusting screw clockwise until it aligns. Figure 1-23. Clutch Cable Adjuster Mechanism NOTE Spring installs on outboard side of hex lockplate. 8405 Diaphragm spring Lockplate Adjusting screw Figure 1-24. Clutch Adjustment 2006 Buell Lightning: Maintenance 1-25...
Page 94 Each time the clutch inspection cover is removed the gasket must be replaced. Figure 1-20. Install clutch inspection cover and new Figure 1-25. Adjusting Clutch Free Play gasket using three fasteners and washers and tighten to 84-108 in-lbs (10-12 Nm). 1-26 2006 Buell Lightning: Maintenance...
Page 95: 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. Do not direct pressurized water on belt. 2006 Buell Lightning: Maintenance 1-27...
Page 96 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 1-28 2006 Buell Lightning: Maintenance...
Page 97 Inspect/replace belt Excessive drive noise Inspect/replace sprocket Clean and protect drive Debris stuck in belt Inspect/replace belt Missing/damaged belt guards Inspect/replace sprocket Follow proper handling/installation procedure Debris stuck in sprocket Inspect/replace belt Missing/damaged belt guards 2006 Buell Lightning: Maintenance 1-29...
Page 98 HOME NOTES 1-30 2006 Buell Lightning: Maintenance...
Page 99: Primary Chain
Install primary chain inspection cover ENGINE and new gasket to primary cover using two fasteners TEMPERATURE with captive washers. Tighten fasteners to 84-108 in-lbs (10-12 Nm). Cold 3/8-1/2 9.5-12.7 Hot (normal running 1/4-3/8 6.4-9.5 temperature) 2006 Buell Lightning: Maintenance 1-31...
Page 100 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 1-29. Chain Tension Adjusting Fastener 1-32 2006 Buell Lightning: Maintenance...
Page 101: Suspension Damping Adjustments
Inspect your GVWR is the sum of the weight of the motorcycle, acces- tires regularly and see a Buell dealer for replacements. sories, and the maximum weight of the rider, passenger Riding with excessively worn, unbalanced or under- and cargo that can be safely carried.
Page 102 77-86 1.50 2.25 1.25 190-210 86-95 1.50 1.25 210-230 95-104 1.25 1.25 1.75 230-250 104-113 1.25 0.75 250-GVWR 113-GVWR 1.25 0.75 * Note all compression and rebound settings are number of turns out from maximum. 1-34 2006 Buell Lightning: Maintenance...
Page 103 Using a screwdriver, turn the slotted dial clockwise until it stops. This is the maximum compression damping setting. Figure 1-31. Front Fork Compression Damping Adjuster Then turn the dial counterclockwise the recommended amount specified in Table 1-10. Table 1-11. 2006 Buell Lightning: Maintenance 1-35...
Page 104 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 1-10., Table 1-11. Table 1- Figure 1-33. Rear Shock Rebound Adjustment 1-36 2006 Buell Lightning: Maintenance...
Page 105 While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) If removed, install seat. See 2.43 SEAT. Figure 1-35. Rear Shock Compression Damping Adjuster (XB12Ss) 2006 Buell Lightning: Maintenance 1-37...
Page 106: Steering Head Bearings
Tighten steering stem capnut to 38-42 ft-lbs (52-57 Nm). or damaged steering or suspension systems. Contact a Turn front wheel all the way to the right. Buell dealer for repairs. Loose, worn or damaged steer- ing or suspension components can adversely affect sta- Figure 1-36.
Page 107: 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. 2006 Buell Lightning: Maintenance 1-39...
Page 108 After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) 16. Install seat. See 2.43 SEAT. 1-40 2006 Buell Lightning: Maintenance...
Page 109: Air Cleaner Filter
Figure 1-45. Make sure two crankcase breather hoses (1) and intake air sensor (2) are captured in base- plate behind velocity stack (3). Figure 1-41. Actuator Cover for XB12 Models with translucent body panel. 2006 Buell Lightning: Maintenance 1-41...
Page 110 SEAT. 12145 Filter element Breather hoses (2) Baseplate assembly Intake air sensor Air cleaner cover latch tabs Velocity stack Velocity stack Figure 1-44. Installed Air Cleaner Filter Element Figure 1-45. Air Cleaner Base Plate Assembly 1-42 2006 Buell Lightning: Maintenance...
Page 111: Throttle Cable And Idle Speed Adjustment
1050 - 1150 RPM. 10. Recheck engine slow idle speed; adjust if required. 11. Install air scoop. See 2.38 AIR SCOOPS. 12. If removed, install baseplate, air cleaner, and intake cover assembly. See 4.44 AIR CLEANER ASSEMBLY. 2006 Buell Lightning: Maintenance 1-43...
Page 112: Interactive Exhaust Cable (Xb12 Models)
Adjust cable as needed using cable adjuster (1). Adjuster Interactive exhaust cable Jam nut Cable wheel Figure 1-48. Interactive Exhaust Cable Figure 1-48. Loosen jam nut (3). Remove cable (2) from bracket and cable wheel (4). 1-44 2006 Buell Lightning: Maintenance...
Page 113 When the exhaust valve moves to the open position, you should see the mark on the cable core made previously. This ensures the system is working prop- erly. If you do not see the mark, verify previous cable adjust- ment. 2006 Buell Lightning: Maintenance 1-45...
Page 114: Ignition Timing
Gently bump ﬂywheel forward in tiny increments. Figure 1-52. If the static timing is correct, the screen will switch to HIGH - 5 volts at the precise moment the timing mark exactly centers in the inspection window. Figure 1-52. Correct Timing 1-46 2006 Buell Lightning: Maintenance...
Page 115 Tighten sensor plate fasteners to 15-30 in-lbs (1.7-3.4 Nm). Recheck timing. Figure 1-55. Advanced Timing 12136 b1248x1x Figure 1-53. Timer Cover 8391 Figure 1-56. Retarded Timing Figure 1-54. Cam Position Sensor 2006 Buell Lightning: Maintenance 1-47...
Page 116: 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 1-57. Figure 1-58. Headlamp Switch Adjust headlamp alignment. See ADJUSTMENT section. 1-48 2006 Buell Lightning: Maintenance...
Page 117 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 1-59. Horizontal Headlamp Adjustment 9951 Figure 1-60. Vertical Headlamp Adjustment 2006 Buell Lightning: Maintenance 1-49...
Page 118: Throttle Position Sensor (Tps)
If closed throttle TP degree reading is not between 5.1° - 6.2°, TPS should be re-calibrated. See ADJUSTMENT below. Connect vehicle to Digital Technician. Select calibrations screen/TPS Function. Select Buell TPS zero tab. Select TP volts on screen. Figure 1-61. Back off idle adjustment until TP volts stop decreasing and then continue to back out one full turn.
Page 119: Storage
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. 2006 Buell Lightning: Maintenance 1-51...
Page 120: Troubleshooting
18. TP Sensor/fast idle screw not set properly. See dealer. 20. Inoperative fuel injector. See dealer. 19. No output from CMP sensor. See dealer. 21. Obstructed fuel tank vent valve or pinched vent tube. 20. Inoperative fuel pump. See dealer. See dealer. 1-52 2006 Buell Lightning: Maintenance...
Page 121: Electrical System
Primary chain badly worn or links tight as a result of insufﬁcient lubrication. Poor Fuel Economy Wheels not aligned and/or tires worn. Oxygen sensor damaged or malfunctioning (bike running Internal engine problem. rich). See dealer. Wheels not balanced correctly. Air intake screen covered or restricted. 2006 Buell Lightning: Maintenance 1-53...
Page 122 See 1.11 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. 1-54 2006 Buell Lightning: Maintenance...
Page 123 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. 2006 Buell Lightning: Maintenance 1-55...
Page 124 HOME NOTES 1-56 2006 Buell Lightning: Maintenance...
Page 125 Table Of Contents CHASSIS SUBJECT PAGE NO. 2.1 Specifications ..........2.2 Tire Specifications .
Page 127: Specifications
Table 2-6. Brake Rotor Runout WEIGHT-U.S. MODELS LBS. RUNOUT Wet weight Front radial 0.0177 0.45 GVWR Front lateral 0.0248 0.63 GAWR - front Rear radial 0.0177 0.45 GAWR - rear Rear lateral 0.0154 0.39 Load capacity 2006 Buell Lightning: Chassis...
Page 128: Torque Values
23-25 ft-lbs 31.2-33.8 Nm LOCTITE 272 (red), page 2-55 Fork damper locknut 22-30 ft-lbs 30-40 Nm page 2-51 Front fender fasteners 36-48 in-lbs 4-5.4 Nm page 2-88 Front isolator bolt 49-51 ft-lbs 66-69 Nm page 2-63 2006 Buell Lightning: Chassis...
Page 129 1-4 Nm page 2-87 Sprocket fasteners 35-37 ft-lbs 48-50 Nm Replace with new, page 2-20 Steering stem capnut 38-42 ft-lbs 52-57 Nm page 2-55 Steering stem pinch fastener 23-25 ft-lbs 31.2-33.8 Nm LOCTITE 272, page 2-55 (XB9SX) 2006 Buell Lightning: Chassis...
Page 130 Torca clamp 28-30 ft-lbs 38-40.6 Nm page 2-84 Valve stem nut 40-44 in-lbs 4.5-4.9 Nm page 2-24 Wear peg, rider 36-48 in-lbs 4.1-5.4 Nm LOCTITE 272 (red), page 2-85 Windscreen fasteners 10-12 in-lbs 1.1-1.4 Nm page 2-100 2006 Buell Lightning: Chassis...
Page 131: Tire Specifications
8423 WARNING WARNING Tires must be correctly matched to wheel rims. Use only Buell approved tires. See a Buell dealer. Using non- approved tires can adversely affect stability, which could result in death or serious injury. (00133a) Figure 2-1. Tire sizes are molded on the sidewall. Rim size and contour are marked on the rim’s exterior surface.
Page 132: Vehicle Identification Number
Figure 2-2. Buell Vehicle Identiﬁcation Number (V.I.N.) Typical (All Models Built Before May 2005) Table 2-8. Buell 2006 XB Models V.I.N. Description (All Models Built Before May 2005) ITEM...
Page 133 HOME b1203x1x Figure 2-3. Typical 2006 Buell Vehicle Identiﬁcation Number (All Models Built After May 2005) Table 2-9. Buell 2006 XB Models V.I.N. Description (All Models Built After May 2005) ITEM DESCRIPTION POSSIBLE VALUES WMI Code 4MZ = Buell vehicles originally manufactured for sale...
Page 134: 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. 2006 Buell Lightning: Chassis...
Page 135 Damper tubes. Check for leaks. See 2.16 FRONT FORK. Shock absorbers. Check damping action and mounts. See 1.11 SUSPENSION DAMPING ADJUSTMENTS. Swingarm bearings. Check for proper torque and replace worn or damaged bearings. 2.19 SWINGARM AND BRACE. 2006 Buell Lightning: Chassis...
Page 136 (00118a) WARNING WARNING Buell tires are equipped with wear bars that run horizon- tally across the tread. When wear bars become visible and only 1/32 in. (0.8 mm) tread depth remains, replace tire immediately.
Page 137: Front Wheel
Figure 2-6. Raise the wheel up until the rotor clears the caliper and rotate the fork leg counterclockwise 8441 allowing wheel clearance for removal. Remove wheel. Figure 2-6. Front Wheel Removal 2006 Buell Lightning: Chassis 2-11...
Page 138 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. 2-12 2006 Buell Lightning: Chassis...
Page 139 Always replace brake pads in complete sets for correct and safe brake operation. Improper brake operation could result in death or serious injury. (00111a) Inspect brake rotor and pads. See 1.6 BRAKE SYSTEM MAINTENANCE and 2.12 FRONT BRAKE CALIPER. 2006 Buell Lightning: Chassis 2-13...
Page 140: Bearing Installation
Bearing Installer/Remover (Part No. HD-44060), with the Remove the nut, bearing, washer, FRONT BEARING smaller diameter toward the wheel hub. Insert the forcing INSTALLER (Part No. B-43993-9) and forcing screw. screw and backing plate into the wheel hub. 2-14 2006 Buell Lightning: Chassis...
Page 141 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. 2006 Buell Lightning: Chassis 2-15...
Page 142 (8) toward center of wheel. which could result in death or serious injury. Align reference dot on front rotor with the valve stem. 2-16 2006 Buell Lightning: Chassis...
Page 143 2-20.Tighten the front axle pinch fasteners (2) to 20-22 ft-lbs (27-30 Nm). Install right side fender fasteners. See 2.34 FENDERS. 8419 Axle (left handed thread) Front axle pinch fasteners (2) (metric) Figure 2-20. Front Wheel Mounting 2006 Buell Lightning: Chassis 2-17...
Page 144: Rear Wheel
44060). Remove idler pulley assembly by removing nuts and washers. See IDLER PULLEY REMOVAL 6.6 DRIVE Remove rear wheel spacer (4). BELT SYSTEM. Remove lower belt guard. See 2.35 BELT GUARDS. 2-18 2006 Buell Lightning: Chassis...
Page 145 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 2006 Buell Lightning: Chassis 2-19...
Page 146 Tighten pinch fastener (2) on right side of swingarm to Position rear brake rotor (2) on wheel (5). 40-45 ft-lbs (54-61 Nm). Install brake rotor (2) with new rotor mounting fas- teners (1) and tighten to 25-27 ft-lbs (34-37 Nm). 2-20 2006 Buell Lightning: Chassis...
Page 147 WARNING After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) 2006 Buell Lightning: Chassis 2-21...
Page 148: Checking Cast Rim Runout
Wheel Truing and Balancing Stand (HD-99500-80) Table 2-11. 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) 2-22 2006 Buell Lightning: Chassis...
Page 149: Tires
Inadequate tread depth can cause an accident which could result in death or serious injury. Buell front and rear tires are not the same. Inter- changing front and rear tires can cause tire failure, which could result in death or serious injury.
Page 150 Installing a tire with the wrong rotation could result in death or serious injury. Buell front and rear tires are not the same. Inter- Figure 2-33. Starting Bead on Rim (Typical) changing front and rear tires can cause tire failure, which could result in death or serious injury.
Page 151 Figure 2-34. Checking Tire Lateral Runout Install tire and again check tire radial runout. b0088x2x Gauge Figure 2-35. Checking Tire Radial Runout Table 2-12. Tire Runout RUNOUT Tire radial 0.060 1.52 Tire lateral 0.080 2.03 2006 Buell Lightning: Chassis 2-25...
Page 152: Wheel Balancing
Allow eight hours for adhesive to cure completely before using wheel. NOTE If wheel assembly is out of speciﬁcation (1 oz. front, 2 oz. rear) rotate tire on rim and rebalance until wheel is within speciﬁcation. 2-26 2006 Buell Lightning: Chassis...
Page 153: 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 2-37. Brake Pedal Assembly 2006 Buell Lightning: Chassis 2-27...
Page 154: 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 2-38. Front Brake Hand Lever Assembly 2-28 2006 Buell Lightning: Chassis...
Page 155 Circlip Figure 2-39. Piston Assembly in Master Cylinder Figure 2-39. Depress piston assembly (1) and remove internal circlip (2) and discard. Figure 2-38. Remove piston assembly (6) from front master cylinder reservoir (4) and discard. 2006 Buell Lightning: Chassis 2-29...
Page 156: Front Master Cylinder
Figure 2-40. Front Master Cylinder Piston Assembly Figure 2-40. Assemble new piston components placing small end of spring (5) behind primary seal of piston (4). Lubricate master cylinder body and piston seals with special lubricant found in the service parts kit. 2-30 2006 Buell Lightning: Chassis...
Page 157 Bleed brake system. See 1.6 BRAKE SYSTEM MAINTE- NANCE. 10. See Figure 2-38. Attach master cylinder cover (2) and cover gasket (3). Tighten two cover fasteners (1) to 9- 13 in-lbs (1.0-1.5 Nm). NOTE XB9SX 2.24 DEFLECTORS/HANDLEBARS (XB9SX). 2006 Buell Lightning: Chassis 2-31...
Page 158: 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 2-43. Front Brake Line 2-32 2006 Buell Lightning: Chassis...
Page 159 WARNING After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) 2006 Buell Lightning: Chassis 2-33...
Page 160: Front Brake Caliper
Figure 2-45. 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 2-47. Removing Pistons (B-42887) 2-34 2006 Buell Lightning: Chassis...
Page 161 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). 2006 Buell Lightning: Chassis 2-35...
Page 162 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 2-48. Front Caliper Assembly 2-36 2006 Buell Lightning: Chassis...
Page 163: Rear Brake Master Cylinder
Damaged banjo bolt seating surfaces will leak when reas- Figure 2-50. Rear Master Cylinder On Vehicle sembled. Prevent damage to seating surfaces by carefully Figure 2-50. Remove brake reservoir hose at master removing brake line components. cylinder. Remove seat. See 2.43 SEAT. 2006 Buell Lightning: Chassis 2-37...
Page 164 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 2-52. Rear Master Cylinder Assembly 2-38 2006 Buell Lightning: Chassis...
Page 165 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). 2006 Buell Lightning: Chassis 2-39...
Page 166 (3). Tighten to 48-72 in- lbs (5.4-8.1 Nm). Attach hose (3) to rear brake reservoir using clamp. Figure 2-51. Connect brake line switch connector under seat. Install heel guard. See 2.32 FOOTPEG, HEEL GUARD AND MOUNT. 2-40 2006 Buell Lightning: Chassis...
Page 167: Rear Brake Line
On XB12Ss models only, remove rear fender. See 2.34 FENDERS. Figure 2-57. Rear Brake Line Switch/Banjo Bolt Figure 2-57. Remove brake line switch/banjo bolt from rear master cylinder. Discard copper washer. 10. Remove brake line from motorcycle. 2006 Buell Lightning: Chassis 2-41...
Page 168 ERS. result in death or serious injury. (00289a) Bleed brakes. See BLEEDING BRAKES in 1.6 BRAKE SYSTEM MAINTENANCE. 11. Test ride motorcycle and check for proper brake opera- tion. 2-42 2006 Buell Lightning: Chassis...
Page 169: Rear Brake Caliper
PER PISTON REMOVER (1) (Part No. B-42887) with Figure 2-58. Rear Brake Caliper adaptor (2). Figure 2-58. Remove caliper mounting fasteners (6 Remove two o-rings from groove in caliper bore and dis- and 7). card. 2006 Buell Lightning: Chassis 2-43...
Page 170 Install a new bleeder valve (metric) if necessary and Replace both pads as a set if the friction material of tighten to 36-60 in-lbs (4-7 Nm). either pad is worn to 0.04 in. (1.0 mm) or less. 2-44 2006 Buell Lightning: Chassis...
Page 171 Bleed brake system. NOTE 1.6 BRAKE SYSTEM MAINTENANCE. Avoid making hard stops for the ﬁrst 100 miles (160 km) to allow new brake pads to “wear in” properly with the brake rotor. 2006 Buell Lightning: Chassis 2-45...
Page 172: Front Fork
Remove fork from lower fork clamp (3). Repeat 4 through 6 on opposite side. Screw, pinch fastener Steering stem pinch fastener Triple clamp, upper Triple clamp assembly, lower Screw, pinch fastener Figure 2-63. Upper and Lower Fork Clamp Assembly 2-46 2006 Buell Lightning: Chassis...
Page 173 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 2-67. Removing Fork Cap From Outer Tube Figure 2-67. Remove fork cap from outer tube. 2006 Buell Lightning: Chassis 2-47...
Page 174 FORK SPRING COMPRESSING TOOL (HD-45966) assembly. comes with a cup and screw that are for FLT models only and not to be used with Buell. Remove preload washer (4) and slider piston (5). Figure 2-68. Expand fork and remove from FORK When using the FORK SPRING COMPRESSING TOOL SPRING COMPRESSION TOOL.
Page 175 Slider piston Inner slider piston o-ring 16. Spring joint 25. Oil seal stopper ring Snap ring 17. Spring 26. Dust seal Rebound adjuster assembly 18. Outer tube 27. Slider fork Figure 2-70. Front Fork Assembly 2006 Buell Lightning: Chassis 2-49...
Page 176 (9) counter clockwise till it stops. Holding the damper locknut (10), unscrew the rebound adjuster assembly (9) and remove from damper rod assembly (11). Remove damper locknut (10) from damper rod assembly (11). 2-50 2006 Buell Lightning: Chassis...
Page 177: Fork Assembly
Tighten the damper locknut (10) to 22- 30 ft-lbs (30-40 Nm). 11. Replace the sealing washer (13) and center bolt (14) (metric). Tighten the center bolt to 22-30 ft-lbs (30- Repeat for other fork assembly. 40 Nm). 2006 Buell Lightning: Chassis 2-51...
Page 178 Thread fork cap (3) into fork tube (18) and tighten to 25 ft-lbs (33.89 Nm). 24. Apply fork oil or light grease to o-rings on preload adjuster and install preload adjuster (3). 25. Install snap ring (2). 2-52 2006 Buell Lightning: Chassis...
Page 179 11. Install front wheel. See 2.5 FRONT WHEEL. 12. Install front fender. See 2.34 FENDERS. 13. Check headlamp alignment. See 1.18 HEADLIGHTS. 14. Adjust front forks suspension to rider preferences. See 1.11 SUSPENSION DAMPING ADJUSTMENTS. 2006 Buell Lightning: Chassis 2-53...
Page 180 HOME NOTES 2-54 2006 Buell Lightning: Chassis...
Page 181: 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 2-76. Steering Stem Assembly 2006 Buell Lightning: Chassis 2-55...
Page 182 Tighten steering stem capnut to 38-42 ft-lbs (52-57 Nm). Install steering stem pinch bolt applying LOCTITE 272 (red) and tightening to 20-22 ft-lbs (27.1-29.8 Nm) for all models except for the XB9SX which should be tightened to 23-25 ft-lbs (31.2-33.8 Nm). 2-56 2006 Buell Lightning: Chassis...
Page 183: Steering Head Bearings
(upper bearing removed for clarity) NOTE Wheel Bearing Backing Plate (Part No. B-43993-12) Discard steering head bearings and replace with new. Steer- ing head bearings are not reusable. Figure 2-78. Steering Head Bearings Installation Tools 2006 Buell Lightning: Chassis 2-57...
Page 184 Install the bearing (4), washer (5) and nut (6) from the STEERING HEAD BEARING RACE INSTALLER (Part No. HD-39302) onto the forcing screw (1). Tighten the nut (6) by hand, until the bearing is started into the bore in the steering head. 2-58 2006 Buell Lightning: Chassis...
Page 185 15. Install front modules. See 2.28 FRONT MODULES. 16. Install brake line p-clamp to the rear of the right headlight module and tighten fastener to 36-60 in-lbs (4-7 Nm). 17. Install windscreen. See 2.42 WINDSCREEN. Figure 2-81. Install Bearings 2006 Buell Lightning: Chassis 2-59...
Page 186: Swingarm And Brace
Remove swingarm brace (11). 11810 Rear inner fender/belt guard Axle Stone guard Pinch bolt fastener Lower belt guard Figure 2-82. Rear Wheel Mounting, Right Side (XB12Ss) Figure 2-84. Belt Guard and Rear Fender Assembly (XB12Ss) 2-60 2006 Buell Lightning: Chassis...
Page 187 12. Remove pivot shaft (9) with a special 7/8 in. hex tool Remove drive belt. See 6.6 DRIVE BELT SYSTEM. located in tool kit. Remove rear wheel. See 2.6 REAR WHEEL. Remove rear fenders. See 2.34 FENDERS. 13. Remove swingarm from vehicle. 2006 Buell Lightning: Chassis 2-61...
Page 188 Remove stone guard. See 2.35 BELT GUARDS. NOTE Figure 2-85. Remove swingarm bearings (5) only if replacement is required. The complete bearing assembly must be replaced as a unit when replacement is necessary. Do not intermix bearing components. 2-62 2006 Buell Lightning: Chassis...
Page 189 Tighten rear axle pinch fastener (12) to 40-45 ft-lbs (54- 61 Nm). Install right side rider footpeg mount. Tighten fasteners to 108-132 in-lbs (12-15 Nm). See 2.32 FOOTPEG, HEEL GUARD AND MOUNT. Remove rear wheel support stand. 2006 Buell Lightning: Chassis 2-63...
Page 190: Front And Rear Isolator
10. Tighten front isolator bolt (6) to 49-51 ft-lbs (66-69 Nm). 11. See Figure 2-87. Install clutch cable wire form. Tighten fastener to 84-92 in-lbs (9.5-10.4 Nm). 2-64 2006 Buell Lightning: Chassis...
Page 191: Frame
Install rear shock. See 2.22 REAR SHOCK ABSORBER. Install tail frame. See 2.39 LEFT TAIL SECTION AND BATTERY PAN. Install exhaust header. See 2.31 EXHAUST SYSTEM. Rotate engine. See 3.3 ENGINE ROTATION FOR SER- VICE. 2006 Buell Lightning: Chassis 2-65...
Page 192: Rear Shock Absorber
Washers (2) Lower shock mount sleeve Lower shock mount fastener Shock reservoir body Upper shock mount fastener 10. Lower shock mount 11. Shock spring retainer kit 12. Rear shock spring Figure 2-90. Rear Shock Absorber Assembly 2-66 2006 Buell Lightning: Chassis...
Page 193 Install seat. See 2.43 SEAT. 10658a Remote reservoir clamp Cable tie securing vent hose Figure 2-91. Rear Shock Absorber and Remove Reservoir Figure 2-92. Rear Shock Absorber Remote Reservoir (XB12Ss shown) Clamp (XB12S shown) and Compression Dial 2006 Buell Lightning: Chassis 2-67...
Page 194: Throttle Control
Attach housings with two fasteners, installing longer fastener on bottom. Tighten to 25-33 in-lbs (3-4 Nm). Adjust cables. See 1.15 THROTTLE CABLE AND IDLE SPEED ADJUSTMENT. Install air cleaner assembly. See 4.44 AIR CLEANER ASSEMBLY. 2-68 2006 Buell Lightning: Chassis...
Page 195: Deflectors/Handlebars (Xb9Sx)
Install deﬂector fasteners (2) and tighten to 24-36 in-lbs (2.7-4 Nm). b1170x2x Deﬂectors Pivot shaft jam nut Deﬂector fasteners (4) Brake pivot shaft Clutch pivot shaft Handlebar end cap Pivot shaft riser Figure 2-95. Deﬂectors 2006 Buell Lightning: Chassis 2-69...
Page 196: Clutch Control/Cable
Hand lever pinch fastener and nut engine. Clutch hand lever Clutch adjuster Remove cable strap securing clutch cable to voltage reg- Clutch cable adjuster boot ulator wire. Clutch cable ferrule Figure 2-98. Clutch Hand Control Assembly 2-70 2006 Buell Lightning: Chassis...
Page 197 Figure 2-100. Clutch Release Mechanism (Typical) 16. See Figure 2-100. Remove the outer ramp and hook (1) from the cable end (3) and coupling (2). Remove cable end from slot in coupling. See 6.3 CLUTCH RELEASE MECHANISM. 2006 Buell Lightning: Chassis 2-71...
Page 198 D.1 HOSE AND WIRE ROUTING in Appendix D. Route clutch cable through upper triple clamp. Engine shift lever Primary cover Clutch inspection cover Flange head bolt Chain adjuster screw Locknut Shift linkage assembly Figure 2-102. Installing Shift Linkage 2-72 2006 Buell Lightning: Chassis...
Page 199 11. Install new clutch cover gasket. 12. See Figure 2-99. Install clutch inspection cover (4) with three TORX screws with washers. Tighten screws in a crosswise pattern to 84-108 in-lbs (9.5-12.2 Nm). 2006 Buell Lightning: Chassis 2-73...
Page 200: Headlight Assembly With Grille (Xb9Sx)
If this happens simply compress the grille until it ﬁts snugly on the headlight assemblies. 10728 Headlight assemblies Headlight grille Figure 2-104. XB9SX Headlight Grille 2-74 2006 Buell Lightning: Chassis...
Page 201: Headlight Assembly And Support Bracket
Fasteners (2), upper headlight mounting Horn connectors [122] Headlight assembly Horn bracket Fasteners (2), headlight support bracket Horn fastener Headlight support bracket Headlight connector [38] 10. Left and right front modules Figure 2-105. Electrical Connectors Behind Windscreen 2006 Buell Lightning: Chassis 2-75...
Page 202 For proper alignment of rubber boots see 7.12 HEADLIGHT. Boot (2) b1147x2x Bulb holder (2) Bulb (2) Headlight housing Wiring harness Position bulb socket (used for HDI only) b1150x2x Figure 2-106. Headlight Assembly 2-76 2006 Buell Lightning: Chassis...
Page 203 Fasteners (2), upper headlight mounting Horn connectors [122] Headlight assembly Horn bracket Fasteners (2), headlight support bracket Horn fastener Headlight support bracket Headlight connector [38] 10. Left and right front modules Figure 2-107. Electrical Connectors Behind Windscreen 2006 Buell Lightning: Chassis 2-77...
Page 204: Front Modules
Install seat. See 2.43 SEAT. tener securing the right front module to upper triple clamp. Figure 2-109. Remove the left front module. 10. See Figure 2-108. Remove the ﬁnal fastener and the right front module. 2-78 2006 Buell Lightning: Chassis...
Page 205 Figure 2-108. Right Front Module Fastener and Brake Line P-Clamp Fastener (Typical) b1148x2x b1149x2x Left and right front module Right front module overlaps left front module Right front module Left front module Figure 2-109. Fairing Support Bracket Assembly 2006 Buell Lightning: Chassis 2-79...
Page 206: 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). 2-80 2006 Buell Lightning: Chassis...
Page 207 HOME b1258x1x XB9SX XB12S, XB12Scg, XB12Ss Endcap (2) Handlebar Handlebar clamp Clamp fasteners (4) Left hand grip Figure 2-110. Handlebar Assembly 2006 Buell Lightning: Chassis 2-81...
Page 208: Mirrors
Install mirror (1) and while holding in position for rider vision, tighten adjuster to 115-130 in-lbs (13-14.7 Nm). 9990 Mirror Adjuster nut Mount Bracket Figure 2-111. Mirrors and Mounting Hardware (Typical) 2-82 2006 Buell Lightning: Chassis...
Page 209: Exhaust System
Loosen Torca clamp (1) and lower mufﬂer. Remove oxygen sensor. See 4.33 OXYGEN SENSOR. Figure 2-113. Remove exhaust header (2) by removing mounting fasteners (3). Remove exhaust ring (4), retaining ring (5) and port gas- ket (6). 2006 Buell Lightning: Chassis 2-83...
Page 210 Front mufﬂer strap Front mufﬂer strap fastener Front mufﬂer mount Front mufﬂer mount fastener Front mufﬂer mount bushings Interactive exhaust cable 10. Rear mufﬂer bracket 11. Rear mufﬂer bracket fasteners (2) Figure 2-112. Mufﬂer Assembly 2-84 2006 Buell Lightning: Chassis...
Page 211 Torca mufﬂer clamps have eliminated the need for sili- cone or graphite tape during assembly. To ensure sealing integrity of mufﬂer clamps and prevent the possibility of leakage, Buell recommends that mufﬂer clamp assem- blies be discarded and replaced each time they are removed.
Page 212: Footpeg, Heel Guard And Mount
36-48 in-lbs (4.1-5.4 Nm). Figure 2-114. Position footpeg mount (1). b0934a2x Footpeg mount Spring Footpeg mount fasteners Wear peg Heel guard Footpeg Heel guard fasteners Clip, footpeg Figure 2-114. Rider Footpeg, Mount and Heel Guard Assembly 2-86 2006 Buell Lightning: Chassis...
Page 213 Check that footpeg clicks in the up and down position. Remove footpeg mount (3). Heel guard fasteners b0933a2x Heel guard Footpeg mount Spring Ball Detent plate Clip Footpeg 10. Footpeg mount fastener 11. Jam nut Figure 2-115. Passenger Footpeg, Mount and Heel Guard Assembly 2006 Buell Lightning: Chassis 2-87...
Page 214: Sprocket Cover
36 in-lbs (1-4 Nm). Figure 2-116. Chin Fairing Assembly, Right Rear Fasteners Install chin fairing. See 2.36 CHIN FAIRING. b1187x2x Long fastener and washer Sprocket cover Short fastener and washer (2) Figure 2-117. Sprocket Cover 2-88 2006 Buell Lightning: Chassis...
Page 215: Fenders
Front fender Front fender fastener (4) Rear fender (XB9SX, XB12S, XB12Scg) Rear fender fastener (2) Rear fender (XB12Ss) XB12Ss rear fender fastener (5) Figure 2-118. Front and Rear Fender 2006 Buell Lightning: Chassis 2-89...
Page 216: Belt Guards
Fasteners, stone guard Upper belt guard and stone guard fasteners (2) Stone guard Lower belt guard Sprocket cover Lower belt guard fasteners (2) Sprocket cover fasteners (2 short, 1 long) Figure 2-119. Belt Guard Assembly 2-90 2006 Buell Lightning: Chassis...
Page 217: Chin Fairing
Turn wheel full right or left for easier access to center fas- Figure 2-120. 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). 2006 Buell Lightning: Chassis 2-91...
Page 218: Intake Cover Assembly
(00070a) Install seat. See 2.43 SEAT. Position intake cover assembly over top of air cleaner cover. b1262x1x X-Guard (XB9SX only) Intake cover assembly Intake cover fasteners (4) Figure 2-121. Intake Cover Assembly 2-92 2006 Buell Lightning: Chassis...
Page 219: 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 2-122. RAM Air Scoop, Engine Shroud, Oil Cooler 2006 Buell Lightning: Chassis 2-93...
Page 220: 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. 2-94 2006 Buell Lightning: Chassis...
Page 221 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 2-123. Main Harness and Electrical Connectors Under Seat (Typical) 2006 Buell Lightning: Chassis 2-95...
Page 222 While riding, a loose seat can Move rear main harness and shock absorber reservoir shift causing loss of control, which could result in death back to left side of vehicle. or serious injury. (00070a) 13. Install seat. See 2.43 SEAT. 2-96 2006 Buell Lightning: Chassis...
Page 223 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 2-124. Tail Frame and Trunk Pan Assembly 2006 Buell Lightning: Chassis 2-97...
Page 224: Center Tail Section
After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) Install seat. See 2.43 SEAT. 2-98 2006 Buell Lightning: Chassis...
Page 225: Right Tail Section
After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) Install seat. See 2.43 SEAT. 2006 Buell Lightning: Chassis 2-99...
Page 226 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 2-125. Right Side Frame Section (Typical) 2-100 2006 Buell Lightning: Chassis...
Page 227: Windscreen
Install four fasteners (3) and tighten to 10-12 in-lbs (1.1- Figure 2-126. Remove four windscreen 1.4 Nm). fasteners (3). Remove windscreen (4). b1153x2x Headlight mounting bracket Left front module Windscreen fastener (4) Windscreen Right front module Figure 2-126. Front Windscreen 2006 Buell Lightning: Chassis 2-101...
Page 228: Seat
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 2-127. Seat and Attachment (Inset XB12Ss seat) 2-102 2006 Buell Lightning: Chassis...
Page 229: Seat Lock
After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) Install seat. See 2.43 SEAT. 2006 Buell Lightning: Chassis 2-103...
Page 230 HOME b1152x2x Seat lock Plate Retainer Cable end Cable Latch screw Retainer Cable end Latch 10. Latch bracket 11. Trunk pan Figure 2-128. Seat Lock Assembly 2-104 2006 Buell Lightning: Chassis...
Page 231: Sidestand
Remove two fasteners from the left side of chin fairing. Figure 2-130. Remove sidestand leg. Retract sidestand leg (5). Remove sidestand spring and spring extension plate using SNAP-ON SPRING TOOL (Part No. HE-52B). Remove sidestand pivot bolt (1). Extend sidestand leg and remove. 2006 Buell Lightning: Chassis 2-105...
Page 232 Install sidestand to frame tightening the sidestand bracket fasteners to 25-27 ft-lbs (34-37 Nm). Install mufﬂer. See Mufﬂer and Straps 2.31 EXHAUST SYSTEM. Inspect sidestand. Figure 2-132. Lubricating Points (Shaded Areas) b1127x2x Figure 2-133. Threaded Area for Loctite Application 2-106 2006 Buell Lightning: Chassis...
Page 233 ENGINE Table Of Contents SUBJECT PAGE NO. 3.1 Specifications ..........3.2 Engine .
Page 235 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 2006 Buell Lightning: Engine...
Page 236 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 2006 Buell Lightning: Engine...
Page 237 Bearing outer race ﬁt in crankcase 0.006 in. 0.2 mm (tight) Interference fit Bearing inner race ﬁt on shaft 0.006 in. 0.2 mm (tight) Interference fit Flywheel endplay in crankcase .003-.010 in. 0.08-0.25 mm .010 in. 0.25 mm 2006 Buell Lightning: Engine...
Page 238 5.4-8 Nm page 3-36 Oil pressure signal light switch 50-70 in-lbs 6-8 Nm page 3-84 Oil pump cover screws 70-80 in-lbs 8-9 Nm TORX, page 3-83 Oil pump mounting screws 125-150 in-lbs 14-17 Nm page 3-83 2006 Buell Lightning: Engine...
Page 239 23-25.8 Nm page 3-31 Swingarm pivot shaft 24-26 ft-lbs 32.5-35.2 Nm page 3-31 V bracket to main frame 120-144 in-lbs 13.6-16.3 Nm page 3-14, 3-33 Vent oil line at gearcase cover 12-13 ft-lbs 16.3-17.6 Nm page 3-36 2006 Buell Lightning: Engine...
Page 240 “oxygenate” the gas. Your compression by itself, however, may indicate improperly motorcycle will run normally using this type of gas. Buell seated valves, in addition to or in lieu of worn piston rings. recommends you use it when possible, as an aid to cleaner air in our environment.
Page 241: Diagnosing Smoking Engine Or High Oil Consumption
Use a CYLINDER LEAKDOWN TESTER (Part No. HD- 35667A) and follow the speciﬁc instructions supplied with the tester. The following are some general instructions that apply to Buell motorcycle engines: Run engine until it reaches normal operating tempera- ture. 2006 Buell Lightning: Engine...
Page 242: Engine Rotation For Service
This step is always performed in order to purge fuel lines. 10646a 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) 2006 Buell Lightning: Engine...
Page 243 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]. 2006 Buell Lightning: Engine...
Page 244 Remove rear mufﬂer straps (13). Loosen Torca clamp (1) and remove mufﬂer (14). NOTE For 1200 models with interactive exhaust systems see Loosen front mufﬂer mount (2). INTERACTIVE EXHAUST SYSTEM (XB12 MODELS) speciﬁc details on removal of interactive components. 3-10 2006 Buell Lightning: Engine...
Page 245 Slide clutch cable adjuster boot (2) up to access clutch adjuster. Loosen clutch adjuster to release tension from hand lever. Remove clutch cable ferrule from hand lever. Wire form Clutch cable adjuster boot Figure 3-4. Clutch Cable Wire form and Adjuster Boot 2006 Buell Lightning: Engine 3-11...
Page 246 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 3-5. Engine Mounting System 3-12 2006 Buell Lightning: Engine...
Page 247 23. Loosen rear isolator bolt. DO NOT REMOVE. Figure 3-7. Front Isolator and Tie Bar Assemblies 24. See Figure 3-7. Remove front isolator bolt (1). 25. Remove front isolator mount (2) from engine. 26. Rotate engine down. 2006 Buell Lightning: Engine 3-13...
Page 248 120-144 in-lbs (13.6-16.3 Nm). Figure 3-8. Install front tie-bar (4) 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 2006 Buell Lightning: Engine...
Page 249 See CLUTCH. Install wire form and tighten fastener to 84-92 in-lbs (9.5-10.4 Nm). Figure 3-9. Clutch Cable Wire form 10501a Figure 3-10. Oil Cooler Feed and Return Oil Line 1/8-1/4 in. (3.175-6.35 mm) Clearance 2006 Buell Lightning: Engine 3-15...
Page 250 Figure 3-11. Electrical Connections and Throttle Cables (Typical) 11. Connect the following sensors: Temperature sensor (3) [90]. Oxygen sensor (4) [137]. 12. See Figure 3-11. Install the ignition coil and connect (2) [83] and tighten fasteners to 120-144 in-lbs (13.6-16.3 Nm). 3-16 2006 Buell Lightning: Engine...
Page 251 It is important that the front mufﬂer mount is tightened last in order to ensure proper alignment of the exhaust system. When rear mufﬂer straps have been installed, it is impor- tant that strap fasteners do not contact idler pulley bracket. 2006 Buell Lightning: Engine 3-17...
Page 252 108-132 in-lbs (12.2-14.9 Nm). 22. Install sprocket cover and tighten fasteners and washers to 12-36 in-lbs (1-4 Nm). 23. Install chin fairing. See 2.36 CHIN FAIRING. 24. Install air scoops, right and left sides. See 2.38 AIR SCOOPS. 3-18 2006 Buell Lightning: Engine...
Page 253: Stripping Motorcycle For Engine Service
Disconnect fuel injector leads (3) [84 & 85]. Drain oil tank. 10646a Fuel line connection Connection for throttle position sensor [88] Connections for fuel injectors [84 & 85] Figure 3-14. Fuel Line and DDFI Electrical Connections (Typical) 2006 Buell Lightning: Engine 3-19...
Page 254 Figure 3-15. Electrical Connections and Throttle Cables (Typical) Figure 3-15. Disconnect the ignition coil connector (2) and remove. 10. Disconnect the following sensors: Temperature sensor (3) [90]. Oxygen sensor (4) [137]. 11. Disconnect throttle cables from induction module/throttle body. 3-20 2006 Buell Lightning: Engine...
Page 255 13. Remove complete chin fairing, bolts. 14. Remove transmission sprocket side cover. 15. Remove rear belt and idler pulley. See 6.6 DRIVE BELT SYSTEM. NOTE For 1200 models with interactive exhaust system, see INTERACTIVE EXHAUST SYSTEM (XB12 MODELS). 2006 Buell Lightning: Engine 3-21...
Page 256 When removing the right side rider footrest and support plate, 18. Remove left and right side rider footrests and support also remove rear brake pedal assembly and remote reservoir plates. See 2.32 FOOTPEG, HEEL GUARD AND and secure towards rear of vehicle. MOUNT. 3-22 2006 Buell Lightning: Engine...
Page 257 Disconnect vent oil line at swingarm/oil reservoir (1) Positive battery cable at starter. and remove. See 3.10 OIL LINE FITTINGS/ Starter solenoid [128]. REMOVAL. Oil pressure switch [120]. Alternator connector [46]. Voltage regulator connector [77]. 2006 Buell Lightning: Engine 3-23...
Page 258 Figure 3-19. Removing Convolute Cover From Oil Line lever. 28. Remove clutch cable ferrule from hand lever. 10502 Wire form retainer Clutch cable adjuster boot Lower retaining clamp Figure 3-20. Clutch Cable Wire Form Retainer, Retaining Clamp and Adjuster Boot 3-24 2006 Buell Lightning: Engine...
Page 259 “V” bracket and then the engine. When reinstalling the tie bar, ﬁrst mount to engine and then to “V” bracket in order to prevent damage to threaded area of crankcase. 30. Support engine with wide scissors jack. 2006 Buell Lightning: Engine 3-25...
Page 260 Figure 3-22. Engine Mounting System NOTE Figure 3-23. At this point it is necessary to support main frame with overhead hoist in order to remove rear isolator bolt. Failure to do this will result in main frame dropping slightly. 3-26 2006 Buell Lightning: Engine...
Page 261 36. See Figure 3-22. Remove center tie-bar from engine. 37. Remove rear tie bar from frame. 38. Move the engine assembly from under the main frame to the right side of the lift. 39. Remove engine. 2006 Buell Lightning: Engine 3-27...
Page 262 Aluminum bushings from front exhaust mount. Timer cover. Figure 3-29. Front Exhaust Mount Bushings (2 piece) Figure 3-30. Wire guard located under the sprocket cover. 8724 8729 Figure 3-30. Wire Guard Figure 3-28. Removing Threaded Insert 3-28 2006 Buell Lightning: Engine...
Page 263 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. 2006 Buell Lightning: Engine 3-29...
Page 264: Engine Installation
Remove pivot shaft after installing the Right Side threaded insert. Figure 3-36. Apply LOCTITE 242 (blue) and install swingarm pivot shaft pinch bolt threaded insert. Figure 3-37. Front Exhaust Mount Bushings (2 piece) 3-30 2006 Buell Lightning: Engine...
Page 265 Install cable strap to secure transmission vent line in place. Inspect vent line to verify space between vent line and rear exhaust. 2006 Buell Lightning: Engine 3-31...
Page 266 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 3-32 2006 Buell Lightning: Engine...
Page 267 Front isolator fasteners (2) Front isolator bolt Figure 3-44. Front Isolator 10. See Figure 3-44. Insert front isolator bolt (3) through front isolator (1) and loosely thread into frame. Do not tighten at this point. 2006 Buell Lightning: Engine 3-33...
Page 268 At this point it will be necessary to install the oil lines. It is important to follow this procedure to ensure correct ori- entation of oil lines in order to establish the proper clear- ances needed between the oil lines and varied components on the vehicle. 3-34 2006 Buell Lightning: Engine...
Page 269 Leave all oil line ﬁttings loose at the engine at this time. See 3.10 OIL LINE FITTINGS. NOTE The feed oil line (3) is routed through the right side of the rear mufﬂer bracket (10). 2006 Buell Lightning: Engine 3-35...
Page 270 48-72 in- lbs (5.4-8 Nm). 25. See Figure 3-46. Install oil line clamp (13) attaching vent oil line (2) to return oil line (4) in front of starter motor and tighten to 40-50 in-lbs (5-5.5 Nm). 3-36 2006 Buell Lightning: Engine...
Page 271 30. Verify that the clutch cable and feed line have 1/8-1/4 in. (3.175-6.35 mm) clearance. NOTE When torquing the oil cooler feed and return lines to the oil cooler, verify that the lines do not twist while torquing. 2006 Buell Lightning: Engine 3-37...
Page 272 Figure 3-49. Oil Cooler Oil Lines b1031x3x Oil cooler feed line should be centered after line is torqued. Orientation of return line should be approximately 6 o’clock Figure 3-50. Oil Cooler Feed and Return Oil Lines Location and Orientation 3-38 2006 Buell Lightning: Engine...
Page 273 Neutral switch [131]. Speedometer sensor [65] (install cable strap). Cam position sensor [14]. Alternator [46]. Voltage regulator [77]. Positive battery cable at starter. Starter solenoid [128]. Oil pressure switch [120]. 2006 Buell Lightning: Engine 3-39...
Page 274 Connect clutch cable to handlebars and adjust to speciﬁcations. See 1.8 CLUTCH Install wire form retainer and tighten fastener to 84- 92 in-lbs (9.5-10.4 Nm). Figure 3-52. Correct Routing of Wiring Harnesses and Interactive Mufﬂer Cable 3-40 2006 Buell Lightning: Engine...
Page 275 It is important that the front mufﬂer mount is tightened last in order to ensure proper alignment of the exhaust system. When rear mufﬂer straps have been installed, it is impor- tant that strap fasteners do not contact idler pulley bracket. 2006 Buell Lightning: Engine 3-41...
Page 276 [83s]. Tighten ignition coil fasteners to 120-144 in-lbs (13.6-16.3 Nm). 10647a Ignition coil Coil connection [83] Cylinder head temperature sensor connection [90] Oxygen sensor connection [137] Throttle cables Figure 3-55. Electrical Connections and Throttle Cables (Typical) 3-42 2006 Buell Lightning: Engine...
Page 277 (00070a) 48. Install rear belt and idler pulley. See 6.6 DRIVE BELT SYSTEM. 54. Install seat. See 2.43 SEAT. 2006 Buell Lightning: Engine 3-43...
Page 278: 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 3-57. Rocker Arm and Push Rod Cover Assemblies 3-44 2006 Buell Lightning: Engine...
Page 279 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 3-59. Removing Rocker Arm Shafts 2006 Buell Lightning: Engine 3-45...
Page 280 No special tools are required to remove valve stem seal and lower collar assembly. Repeat the above procedure for the other valves. Figure 3-60. Head Screw Loosening/Tightening Sequence 8684 Figure 3-61. Valve Spring Compressor (Part No. HD-34736B) 3-46 2006 Buell Lightning: Engine...
Page 281 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 3-62. Cylinder Head, Cylinder and Piston Assembly 2006 Buell Lightning: Engine 3-47...
Page 282 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. 3-48 2006 Buell Lightning: Engine...
Page 283 Figure 3-65. 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). 2006 Buell Lightning: Engine 3-49...
Page 284: 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. 3-50 2006 Buell Lightning: Engine...
Page 285 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 3-70. Replacing Rocker Arm Bushings 2006 Buell Lightning: Engine 3-51...
Page 286 Figure 3-72. 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 3-72. Cleaning Valve Guides 3-52 2006 Buell Lightning: Engine...
Page 287 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. 2006 Buell Lightning: Engine 3-53...
Page 288 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 3-74. Valve and Seat Dimensions 3-54 2006 Buell Lightning: Engine...
Page 289 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 3-75. Cylinder Head, Cylinder and Piston Assembly 2006 Buell Lightning: Engine 3-55...
Page 290 Failure to use a protective sleeve on the valve stem keeper groove when installing the valve stem seal and collar assem- bly will result in damage to the seal causing leakage around the valve stem, excessive oil consumption and valve sticking. 3-56 2006 Buell Lightning: Engine...
Page 291 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. 2006 Buell Lightning: Engine 3-57...
Page 292 17909-02 Orange/Brown (272.948 mm) NOTE After head(s) have been installed do not turn engine over until both push rods can be turned with ﬁngers. Otherwise, dam- age to push rods or rocker arms may result. 3-58 2006 Buell Lightning: Engine...
Page 293: Cylinder Head Installation
Tighten each screw to 13-15 ft-lbs (18-20 Nm). Figure 3-83. Tightening Head Screws Figure 3-83. Mark cylinder head and head screw shoulder with a line as shown (View A). ° ° Turn all bolts an additional 85 -95 . 2006 Buell Lightning: Engine 3-59...
Page 294 When installing a particular rocker box it will be necessary to turn the engine over until both lifters are on the base circle (the lowest position) of the cams for that rocker box to be installed. 3-60 2006 Buell Lightning: Engine...
Page 295 Place a new inner gaskets on lower rocker box assemblies. Place a new lower gaskets on lower rocker cover. Install upper rocker cover using screws with washers and new ﬁber seals. Tighten screws to 120-156 in- lbs (13.6-17.6 Nm). 2006 Buell Lightning: Engine 3-61...
Page 296: Cylinder And Piston
Ring set stalled resulting in engine damage. Piston Piston pin Retaining ring (2) Dowel and o-ring Cylinder Base gasket Cylinder stud (4) Connecting rod 10. Piston pin bushing Figure 3-86. Cylinder and Piston 3-62 2006 Buell Lightning: Engine...
Page 297 Figure 3-89. Removing Piston Rings Remove circlip from claw and discard. Figure 3-89. To remove piston rings spread outward until they clear grooves in piston and lift off. 2006 Buell Lightning: Engine 3-63...
Page 298 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. 3-64 2006 Buell Lightning: Engine...
Page 299: Deglazing Cylinder
If cylinder clearance exceeds service wear limit, cylinders and remains white. The cylinder is now clean. pistons should be replaced with new components. See SPECIFICATIONS. With the cylinder at room temperature, check the cylinder clearance. See SPECIFICATIONS. 2006 Buell Lightning: Engine 3-65...
Page 300 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. 3-66 2006 Buell Lightning: Engine...
Page 301 Figure 3-95. Ring End Gap Position Figure 3-95. 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. 2006 Buell Lightning: Engine 3-67...
Page 302 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. 3-68 2006 Buell Lightning: Engine...
Page 303 Make sure the ring groove is clean. Ring must be fully seated pointing towards the front of the engine. in the groove with the gap away from the slot at the bottom. Install piston pin. 2006 Buell Lightning: Engine 3-69...
Page 304 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. 3-70 2006 Buell Lightning: Engine...
Page 305: Lubrication System
A vehicle used only for short runs in cold 1.5 ENGINE LUBRICATION SYSTEM for more informa- weather must have the engine oil drained frequently. tion on checking oil level and changing oil and ﬁlter. 2006 Buell Lightning: Engine 3-71...
Page 306 Feed oil line from oil pump to oil cooler 12. P-clamp Feed oil line from oil cooler to crankcase 13. Oil line clamp Oil tank drain plug 14. Oil pump Figure 3-107. Oil Lines and Connections 3-72 2006 Buell Lightning: Engine...
Page 307: Oil Line Fittings
Repeat to remove the remaining oil lines. Remove oil line ﬁttings and plug the holes until they can Figure 3-108. Oil Line Remover (B-41623-B) be replaced. 10369 Figure 3-109. Oil Line Fitting with Spring Clip 2006 Buell Lightning: Engine 3-73...
Page 308 ﬁtting and the spring clip is seated in the oil line ﬁtting groove. Check oil level and add oil if required. After running engine, Inspect oil ﬁttings for oil leaks. Check oil level and add oil if required. Figure 3-110. Flanged Oil Line 3-74 2006 Buell Lightning: Engine...
Page 309: Oil Cooler
Place a container under the motorcycle to catch excess oil. NOTE Remove clamp (3) from oil cooler oil lines. The oil cooler should be checked for dirt and debris. 2006 Buell Lightning: Engine 3-75...
Page 310 Feed oil line to oil cooler 1/8-1/4 in. (3.175-6.35 mm) clearance Return oil line from oil cooler Feed oil line Figure 3-112. Oil Cooler Feed Oil Line Orientation (Approximately 2 O’Clock) and Oil Line Clearances 3-76 2006 Buell Lightning: Engine...
Page 311: Oil Pressure Indicator Switch
Dead battery (see NOTE). temperature. At 2500 RPM, oil pressure will vary from 10- 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). 2006 Buell Lightning: Engine 3-77...
Page 312: 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 3-115. Crankcase Breathing System 3-78 2006 Buell Lightning: Engine...
Page 313 Remove the fastener (1), the reed valve stop (2) and the reed valve (3). b1033x3x Reed valve stop Reed valve Reed block Figure 3-116. Reed Valve Assembly 8759 8794 Reed valve stop Reed valve Stop screw Figure 3-117. Reed Valve Stop and Reed Valve 2006 Buell Lightning: Engine 3-79...
Page 314: Oiling System
The return gears pump oil back to the oil reservoir. travels to the right ﬂywheel where it is routed through the ﬂywheel to the crankpin. Oil is forced through the crank- pin to properly lubricate the rod bearing assembly. 3-80 2006 Buell Lightning: Engine...
Page 315: Oil Pump
Thrust washer Retaining ring Gerotor return set Separator plate 10. Gerotor feed set 11. Cover º 12. 45 Fitting 13. Sems screw (2) 14. TORX screw (2) 15. Rear connector ﬁtting Figure 3-118. Oil Pump 2006 Buell Lightning: Engine 3-81...
Page 316 6) on both sides of the oil pump. 11973 Feed line connection Cover TORX screw (2) Return line Oil pump Mounting screw and washer (2) Feed connection to oil cooler Convolute covering (for return oil line only) Figure 3-119. Oil Pump Hardware 3-82 2006 Buell Lightning: Engine...
Page 317 10. See Figure 3-119. Attach return line connection. 11. Attach feed line connections to both sides of the oil pump. 12. Install new oil ﬁlter and ﬁll oil reservoir with proper oil. 1.5 ENGINE LUBRICATION SYSTEM. 2006 Buell Lightning: Engine 3-83...
Page 318: 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. 3-84 2006 Buell Lightning: Engine...
Page 319: Hydraulic Lifters
Figure 3-123. Lifter Assembly (Typical) End clearance should be within 0.008-0.022 in. (0.203-0.559 mm). Replace lifters if clearance exceeds SERVICE WEAR LIMIT of 0.026 in. (0.660 mm). Soak lifters in clean engine oil. Keep covered until assembly. 2006 Buell Lightning: Engine 3-85...
Page 320 Tighten screws evenly to 30-40 in-lbs (3-5 Nm). Place new o-rings on top of push rod cover. Install push rods, cylinder head, lower and upper rocker covers. See 3.6 CYLINDER HEAD. Repeat process for remaining cylinder head. 3-86 2006 Buell Lightning: Engine...
Page 321: Gearcase Cover And Cam Gears
Gear cover gasket 13. Oil pump drive gear Bushing, outer, intake camshaft gear 14. Pinion gear “E” Cam gear set 15. Nut Right crankcase half 16. bushing, gear shaft- pinion Figure 3-126. Gearcase Cover and Cam Assembly 2006 Buell Lightning: Engine 3-87...
Page 322 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 3-127. Cam and Pinion Gear Location and Timing Mark Indexing 3-88 2006 Buell Lightning: Engine...
Page 323 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. 2006 Buell Lightning: Engine 3-89...
Page 324 Figure 3-126. Install a new seal and new dry gear cover gasket on crankcase. Figure 3-130. Crankshaft Locking Tool (Part No. HD-43984) 3-90 2006 Buell Lightning: Engine...
Page 325 Install cam position sensor and rotor in gearcase cover. See CAM POSITION SENSOR AND ROTOR section. Install any components removed to gain access to gear- case (i.e. exhaust system components, air cleaner, etc.). Figure 3-132. Checking Cam Gear End Play 2006 Buell Lightning: Engine 3-91...
Page 326 Remove oil pump. See 3.15 OIL PUMP. Remove gearcase components. See 3.18 GEARCASE COVER AND CAM GEARS. Remove primary cover and primary drive/clutch compo- nents. See 6.2 PRIMARY COVER. Remove starter motor. See 5.7 STARTER. 3-92 2006 Buell Lightning: Engine...
Page 327 (2.8-4.0 Nm). Figure 3-135. Piston Oil Jet Assemblies Figure 3-135. Remove two TORX screws from each piston jet assembly to free piston jets from right crank- case. Remove piston jet gaskets from right crankcase. 2006 Buell Lightning: Engine 3-93...
Page 328 11. Inner race Thrust washer 12. Gear shaft bearing Crankcase half 13. Retaining ring 14. Outer bearing race Bearing Bearing retaining ring 15. Crankshaft case Inner race, sprocket shaft bearing Figure 3-137. Crankcase and Flywheel Assembly 3-94 2006 Buell Lightning: Engine...
Page 329 Remove sprocket shaft oil seal retain- ing ring. Figure 3-137. Remove sprocket shaft oil seal (3) from crankcase using Snap-On Tool (Part No. CJ 114, Body Dent Puller) Remove outer thrust washer (4) next to sprocket shaft bearing (6). 2006 Buell Lightning: Engine 3-95...
Page 330 1.2496-1.2498 in. Green (31.7398-31.7449 mm) (ID) of the outer race (crankcase bushing). A running clear- ance of 0.0002-0.0008 in. (0.0051-0.0203 mm) is established during crankcase set or ﬂywheel assembly replacement and engine rebuild. 3-96 2006 Buell Lightning: Engine...
Page 331 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. 2006 Buell Lightning: Engine 3-97...
Page 332 1.2502 1.2504 1.2508 1.2510 1.2512 1.2514 1.2516 1.2518 31.740 31.745 31.750 31.755 31.760- 31.765 31.770 31.775 31.780 31.786 3.791- 31.745 31.750 31.765 31.796 31.755 31.760 31.770 31.755 31.780 31.786 31.791 FACTORY COLOR CODE Green White 3-98 2006 Buell Lightning: Engine...
Page 333 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. 2006 Buell Lightning: Engine 3-99...
Page 334 Table 3-34. Pinion Inner Race 1.2499 in. (31.747 mm) OD inner race, a blue bear- Speciﬁcations ing is required. Roundness within 0.0002 in. (0.0051 mm) Taper within 0.0002 in. (0.0051 mm) Surface ﬁnish 16 RMS 3-100 2006 Buell Lightning: Engine...
Page 335 If side play measurement is greater than service wear limit listed below, replace ﬂywheel/connecting rod assembly. The service wear limit is, 0.036 in. (0.8 mm). Figure 3-149. Checking Connecting Rod Side Play 2006 Buell Lightning: Engine 3-101...
Page 336 HD-46663), install sprocket shaft bearing into left crankcase half from the inside. b1046a3x Spacer, sprocket shaft Retaining ring, oil seal Oil seal Thrust washer Crankcase half Bearing Bearing retaining ring Figure 3-150. Sprocket Shaft Bearing Assembly 3-102 2006 Buell Lightning: Engine...
Page 337 Install pinion shaft bearing. Bearing retaining ring Lubricate pinion shaft bearing with engine oil. Figure 3-151. Sprocket Shaft Bearing Installation Slip bearing on pinion shaft. Install new retaining ring in groove of pinion shaft bearing inner race. 2006 Buell Lightning: Engine 3-103...
Page 338 Slide outer race in right crankcase over pinion shaft and bearing assembly. Tighten fasteners to 15-19 ft-lbs (20-26 Nm). NOTE According to manufacturing, there is no torque sequence to follow when tightening crankcase fasteners. 3-104 2006 Buell Lightning: Engine...
Page 339 Be sure to reﬁll transmission to proper level with fresh lubri- cant. See 1.10 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. 2006 Buell Lightning: Engine 3-105...
Page 340 HOME NOTES 3-106 2006 Buell Lightning: Engine...
Page 341 Table Of Contents FUEL SYSTEM SUBJECT PAGE NO. 4.1 Specifications ..........4.2 Dynamic Digital Fuel Injection .
Page 342 4.38 Cooling Fan ..........4-106 4.39 Fuel Pump .
Page 343: 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 4-105 Timer plate studs 15-30 in-lbs 2-3 Nm page 4-98 Upper tie bar 25-27 ft-lbs 33.9-36.6 Nm page 4-102 2006 Buell Lightning: Fuel System...
Page 344 HOME NOTES 2006 Buell Lightning: Fuel System...
Page 345: 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 346 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 2006 Buell Lightning: Fuel System...
Page 347: 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. 2006 Buell Lightning: Fuel System...
Page 348: 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 2006 Buell Lightning: Fuel System...
Page 349 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. 2006 Buell Lightning: Fuel System...
Page 350: 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. 2006 Buell Lightning: Fuel System...
Page 351 50 start and run cycles. To execute one run cycle: Remove diagnostic test wire and install protective cover Start the vehicle. over data link connector. Return data link to original posi- Let it run for at least 30 seconds. tion. Turn the engine off. 2006 Buell Lightning: Fuel System...
Page 352: Breakout Box
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 (Typical) 4-10 2006 Buell Lightning: Fuel System...
Page 353: 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. 2006 Buell Lightning: Fuel System 4-11...
Page 354: 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 2006 Buell Lightning: Fuel System...
Page 355 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 2006 Buell Lightning: Fuel System 4-13...
Page 356 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 2006 Buell Lightning: Fuel System...
Page 357 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). 2006 Buell Lightning: Fuel System 4-15...
Page 358 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 2006 Buell Lightning: Fuel System...
Page 359: Check Engine Lamp Not Illuminated At Key On 4.9
Check engine lamp Figure 4-12. Check Engine Lamp 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 2006 Buell Lightning: Fuel System 4-17...
Page 360 Electronic Control Module (ECM) Figure 4-15. Check Engine Lamp Circuit Table 4-10. Wire Harness Connectors in Figure 4-15. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [39] instrument module 20-place Multilock behind windscreen 4-18 2006 Buell Lightning: Fuel System...
Page 361 Repair open or Disassemble short to voltage on instrument and BK/Y wire between inspect bulb. connector [39] and Bulb Failed? connector [10B]. 7145 7151 Replace instrument mod- Replace bulb.. ule. See 7.19 INSTRU- MENT MODULE. 2006 Buell Lightning: Fuel System 4-19...
Page 362: Check Engine Lamp On Continuously
If the lamp goes off when the black 12150 ECM connector [10] is unplugged, the BK/Y wire is not shorted to ground. Figure 4-17. Electronic Control Module, (XB12Ss) 8891 Figure 4-18. Electronic Control Module (Typical) 4-20 2006 Buell Lightning: Fuel System...
Page 363 Electronic Control Module (ECM) Figure 4-19. Check Engine Lamp Circuit Table 4-11. Wire Harness Connectors in Figure 4-19. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [39] instrument module 20-place Multilock behind windscreen 2006 Buell Lightning: Fuel System 4-21...
Page 364 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 2006 Buell Lightning: Fuel System...
Page 365: Engine Cranks But Will Not Start
To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely ﬂammable and highly explosive, which could result in death or serious injury. (00275a) Purge fuel line of high pressure gasoline. See 4.39 FUEL PUMP. 2006 Buell Lightning: Fuel System 4-23...
Page 366 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 air cleaner baseplate 4-24 2006 Buell Lightning: Fuel System...
Page 367 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 4-22. Ignition Circuit 2006 Buell Lightning: Fuel System 4-25...
Page 368 49-51 PSI (338-352 kPa). Adequate pressure? Go to Test 4.11 STOP Incorrect pressure. See 4.13 (Part 2 of 3). FUEL PRESSURE TEST. 7459 4-26 2006 Buell Lightning: Fuel System...
Page 369 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 2006 Buell Lightning: Fuel System 4-27...
Page 370 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 2006 Buell Lightning: Fuel System...
Page 371: 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. 2006 Buell Lightning: Fuel System 4-29...
Page 372 Table 4-13. Wire Harness Connectors in Figure 4-23. 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 2006 Buell Lightning: Fuel System...
Page 373 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. 2006 Buell Lightning: Fuel System 4-31...
Page 374: Fuel Pressure Test
Connect the fuel line (3) to fuel pressure gauge adapter. NOTE Figure 4-27. 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 2006 Buell Lightning: Fuel System...
Page 375 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 4-27. Fuel Pressure Gauge (Part No. HD-41182) 2006 Buell Lightning: Fuel System 4-33...
Page 376 Table 4-14. Wire Harness Connectors in Figure 4-28. 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 2006 Buell Lightning: Fuel System...
Page 377 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. 2006 Buell Lightning: Fuel System 4-35...
Page 378 [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 2006 Buell Lightning: Fuel System...
Page 379: 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. 1.15 THROTTLE CABLE AND IDLE SPEED ADJUST- MENT for more information on idle speed adjustment. 2006 Buell Lightning: Fuel System 4-37...
Page 380: 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 2006 Buell Lightning: Fuel System...
Page 381 Table 4-17. Wire Harness Connectors in Figure 4-31. 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 air cleaner assembly baseplate 2006 Buell Lightning: Fuel System 4-39...
Page 382 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 2006 Buell Lightning: Fuel System...
Page 383 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. 2006 Buell Lightning: Fuel System 4-41...
Page 384 HOME NOTES 4-42 2006 Buell Lightning: Fuel System...
Page 385: Trouble Code 11 (Tp Sensor)
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. 2006 Buell Lightning: Fuel System 4-43...
Page 386 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 2006 Buell Lightning: Fuel System...
Page 387 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2006 Buell Lightning: Fuel System 4-45...
Page 388 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 2006 Buell Lightning: Fuel System...
Page 389: Trouble Code 14
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. 2006 Buell Lightning: Fuel System 4-47...
Page 390 Electronic Control Module (ECM) Figure 4-37. Oxygen Sensor Circuit Table 4-19. Wire Harness Connectors in Figure 4-37. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under seat [137] oxygen sensor 1-place Packard behind rear cylinder head 4-48 2006 Buell Lightning: Fuel System...
Page 391 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). 2006 Buell Lightning: Fuel System 4-49...
Page 392 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 2006 Buell Lightning: Fuel System...
Page 393 (4.30 now OK. ELECTRONIC CONTROL 7672 MODULE). Road test again to verify. 7659 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2006 Buell Lightning: Fuel System 4-51...
Page 394: Trouble Code 16
[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 2006 Buell Lightning: Fuel System...
Page 395 Figure 4-39. Engine Temperature Sensor Circuit Table 4-21. Wire Harness Connectors in Figure 4-39. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under seat [90] engine temperature sensor 1-place bullet beneath air cleaner assembly baseplate 2006 Buell Lightning: Fuel System 4-53...
Page 396 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 2006 Buell Lightning: Fuel System...
Page 397 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2006 Buell Lightning: Fuel System 4-55...
Page 398: Trouble Code 21
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 2006 Buell Lightning: Fuel System...
Page 399 Figure 4-41. Intake Air Temperature Sensor Circuit Table 4-23. Wire Harness Connectors in Figure 4-41. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under seat [89] intake air temperature sensor 2-place Amp in air cleaner assembly baseplate 2006 Buell Lightning: Fuel System 4-57...
Page 400 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 2006 Buell Lightning: Fuel System...
Page 401 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2006 Buell Lightning: Fuel System 4-59...
Page 402: Battery Voltage
The ECM is monitoring voltage at ECM connector [10] (black) Terminal 1. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. See 4.6 BREAKOUT BOX. 10658 Fuse block Ignition relay Key switch relay Start relay Figure 4-43. Fuse Block and Electrical Relays (Typical) 4-60 2006 Buell Lightning: Fuel System...
Page 403 [10B] [11B] Connector Connector Electronic Control Module (ECM) [10A] [11A] Figure 4-44. Battery Voltage Circuit Table 4-24. Wire Harness Connectors in Figure 4-44. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat 2006 Buell Lightning: Fuel System 4-61...
Page 404 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 2006 Buell Lightning: Fuel System...
Page 405 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). 2006 Buell Lightning: Fuel System 4-63...
Page 406 Code 21 ﬂow charts. Using TEST CONNECTOR KIT (Part No. HD-41404), attach red probe and patch cord to [164B]. Using TEST CONNECTOR KIT (Part No. HD-41404), use gray male pin probe and patch cord. 4-64 2006 Buell Lightning: Fuel System...
Page 407 [ 1 2 1 A ] [ 1 2 1 B ] Y / B K Ground Brake/Horn/Muffler 1 2 3 4 5 6 7 8 LH Controls R/BK Figure 4-46. Interactive Exhaust Circuit 2006 Buell Lightning: Fuel System 4-65...
Page 408 Does valve Replace ECM. Replace inter- Locate and repair arm move freely without active motor. short to voltage on binding? TN/Y wire. Replace inter- active muffler actuator. Replace muffler Replace inter- assembly. active muffler cable. 4-66 2006 Buell Lightning: Fuel System...
Page 409: 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. Figure 4-48. Fuel Injector Connector Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Use FUEL INJECTOR TEST LAMP (Part No. HD-34730- 2C). 2006 Buell Lightning: Fuel System 4-67...
Page 410 DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [161] Interactive mufﬂer actuator 4-place Deutsch under intake cover assembly [164] 1-place Amp under seat [165] sub-harness 3-place Packard beneath air cleaner assembly baseplate 4-68 2006 Buell Lightning: Fuel System...
Page 411 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). 2006 Buell Lightning: Fuel System 4-69...
Page 412 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 2006 Buell Lightning: Fuel System...
Page 413 24 or 25. This condition is normal and does not by itself indicate a malfunction. Codes must be cleared if this condition occurs. Figure 4-51. Testing Ignition Coil Connectors 2006 Buell Lightning: Fuel System 4-71...
Page 414 (ECM) Figure 4-52. Ignition Coil Circuit Table 4-26. Wire Harness Connectors in Figure 4-52. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [83] ignition coil 3-place Packard beneath air cleaner assembly baseplate 4-72 2006 Buell Lightning: Fuel System...
Page 415 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). 2006 Buell Lightning: Fuel System 4-73...
Page 416: 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 2006 Buell Lightning: Fuel System...
Page 417 Table 4-27. 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 [86] fuel pump 4-place Multilock left side of rear shock absorber 2006 Buell Lightning: Fuel System 4-75...
Page 418 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 2006 Buell Lightning: Fuel System...
Page 419: Trouble Code 35
Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Replace instrument module. See 7.19 INSTRUMENT MODULE. 8890 Figure 4-56. ECM Connections (XB12Ss) 10635a Breakout box Figure 4-55. Installed Breakout Box (Typical) 10654a Figure 4-57. Instrument Module Connector [39] (Typical) 2006 Buell Lightning: Fuel System 4-77...
Page 420 Electronic Control Module (ECM) [10A] [11A] Figure 4-58. Tachometer Circuit Table 4-28. Wire Harness Connectors in Figure 4-58. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch under seat [39] instrument module 20-place Multilock behind windscreen 4-78 2006 Buell Lightning: Fuel System...
Page 421 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 2006 Buell Lightning: Fuel System 4-79...
Page 422: 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 2006 Buell Lightning: Fuel System...
Page 423 Electronic Control Module (ECM) Figure 4-60. Cooling Fan Circuit Table 4-30. Wire Harness Connectors in Figure 4-60. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch under seat [97] cooling fan 2-place Multilock behind rear cylinder 2006 Buell Lightning: Fuel System 4-81...
Page 424 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 2006 Buell Lightning: Fuel System...
Page 425 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 2006 Buell Lightning: Fuel System 4-83...
Page 426: Trouble Code 44
Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Disable Mode 2.8-4.8 volts Weighted pendulum Figure 4-63. Bank Angle Sensor (Typical) Run Mode 0.25-2.7 volts b1085x4x Figure 4-61. Bank Angle Sensor Operation 4-84 2006 Buell Lightning: Fuel System...
Page 427 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 2006 Buell Lightning: Fuel System 4-85...
Page 428 Are ferrous metals located within Install properly. See 4.35 BANK 0.25 in. (6.4 mm) of sides, face or ANGLE SENSOR. top of bank angle sensor? Replace bank angle sensor. See 4.35 Return to original BANK ANGLE SENSOR. configuration. 4-86 2006 Buell Lightning: Fuel System...
Page 429 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). 2006 Buell Lightning: Fuel System 4-87...
Page 430: Trouble Codes 52, 53, 54 And 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29 Trouble Code 56
4.30 ELECTRONIC CONTROL MODULE. Code 52 - RAM failure. Code 53 - ROM failure. Code 54 - EE PROM failure. Code 55 - Microprocessor failure. 12154 Figure 4-66. ECM (Typical) Figure 4-65. ECM (XB12Ss) 4-88 2006 Buell Lightning: Fuel System...
Page 431 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 4-67. Cam Position Sensor 2006 Buell Lightning: Fuel System 4-89...
Page 432 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 2006 Buell Lightning: Fuel System...
Page 433 [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). 2006 Buell Lightning: Fuel System 4-91...
Page 434 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 2006 Buell Lightning: Fuel System...
Page 435: Electronic Control Module
(00070a) Install seat. See 2.43 SEAT. NOTE If the ECM was replaced with a new component, it will be necessary to recalibrate Throttle Position Sensor. Throttle 2006 Buell Lightning: Fuel System 4-93...
Page 436 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 2006 Buell Lightning: Fuel System...
Page 437: Cam Position Sensor And Rotor
10. Carefully remove camshaft oil seal (15) if damaged or if Sensor wiring there is any evidence of oil leakage past the seal. Cam position sensor Scribe mark b0313a7x Figure 4-73. Marking Ignition Timing 2006 Buell Lightning: Fuel System 4-95...
Page 438 11. Mounting fastener 12. Ignition coil 13. Front spark plug cable 14. Engine mount 15. Seal 16. Trigger rotor 17. Trigger rotor bolt 18. Cam position sensor 19. Inner cover b1164a4x Figure 4-74. Ignition Components 4-96 2006 Buell Lightning: Fuel System...
Page 439 HOME bs0017aL Figure 4-75. Ignition System Circuit 2006 Buell Lightning: Fuel System 4-97...
Page 440 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 2006 Buell Lightning: Fuel System...
Page 441: Ignition Coil
This is most noticeable in NORMAL wet weather or after the motorcycle has been washed. OHMMETER WINDING RESISTANCE RANGE SCALE (IN OHMS) Primary R x 1 0.5-0.7 Secondary R x 1K 5.5K-7.5K 2006 Buell Lightning: Fuel System 4-99...
Page 442 Install intake cover assembly. See 2.37 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 4-79. Ignition Coil 4-100 2006 Buell Lightning: Fuel System...
Page 443: Oxygen Sensor
Install air cleaner assembly. See 4.44 AIR CLEANER ASSEMBLY. Install intake cover assembly. See 2.37 INTAKE COVER Oxygen sensor connector [137] ASSEMBLY. Cable straps Connect negative battery cable. Figure 4-82. Oxygen Sensor Connector [137] (XB12 Models) 2006 Buell Lightning: Fuel System 4-101...
Page 444: Engine Temperature Sensor
While riding, a loose seat can shift causing loss of control, which could result in death Figure 4-83. Engine Temperature Sensor Location (rear or serious injury. (00070a) cylinder) Install seat. See 2.43 SEAT. 4-102 2006 Buell Lightning: Fuel System...
Page 445: Bank Angle Sensor
Seat latch bracket or serious injury. (00070a) BAS fasteners Install seat. See 2.43 SEAT. Figure 4-85. Bank Angle Sensor Location Top (Lightning), Bottom (XB12Ss) 2006 Buell Lightning: Fuel System 4-103...
Page 446: Intake Air Temperature Sensor
INSTALLATION Connect IAT sensor connector [89] to wiring harness. Install IAT sensor into grommet on air cleaner assembly baseplate from underneath. Install air cleaner assembly. See 4.44 AIR CLEANER ASSEMBLY. Install negative battery cable. 4-104 2006 Buell Lightning: Fuel System...
Page 447: Throttle Position Sensor
[88A]. b0995x4x NOTE Throttle position sensor can only be calibrated using DIGITAL TECHNICIAN (Part No. HD-44750). Calibrate throttle position sensor. Figure 4-88. Throttle Position Sensor b0651x4x Figure 4-89. Tabs on TP Sensor Connector [88A] 2006 Buell Lightning: Fuel System 4-105...
Page 448: 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. 4-106 2006 Buell Lightning: Fuel System...
Page 449: Fuel Pump
(00002a) Remove drain plug (4) and drain fuel into appropriate container. Discard plug. When fuel tank is empty, replace with new drain plug. Tighten to 84-108 in-lbs (9.5-12.2 Nm). 2006 Buell Lightning: Fuel System 4-107...
Page 450 10. Place wrench onto nut and another wrench onto the bolt. Figure 4-94. Fuel Pump Removal Hold the bolt stationary and turn nut clockwise until fuel pump is pulled free from frame. 4-108 2006 Buell Lightning: Fuel System...
Page 451 (3) in place. Spread the four clips and detach regulator (3) from regulator housing (4). 10937a Plastic retaining ring Fuel pressure regulator Plastic retainers Fuel pressure regulator housing Figure 4-95. Fuel Pressure Regulator 2006 Buell Lightning: Fuel System 4-109...
Page 452 10935a Fuel supply stud Fuel pump connectors Fuel pump assembly Low fuel pressure regulator O-rings Fastener Fuel screen Fuel pressure regulator Fuel pump 10. Low fuel level sensor connector Figure 4-96. Fuel Pump Assembly 4-110 2006 Buell Lightning: Fuel System...
Page 453 Bracket, fuel pump and fuel ﬁlter Low fuel level sensor 10. Overﬂow hose Fuel pump connectors 11. Fuel pump housing Low fuel level sensor connector 12. Ground fastener Figure 4-97. Fuel Pump Assembly (Left and Right Sides) 2006 Buell Lightning: Fuel System 4-111...
Page 454 Plastic retaining ring, pressure regulator Fuel pump Fuel ﬁlter Low fuel level sensor E-clip Fuel pressure regulator housing Connectors, fuel pump Fuel pressure regulator 10. Fuel pump wiring harness Figure 4-98. Fuel Pump Assembly 4-112 2006 Buell Lightning: Fuel System...
Page 455 (6). 11. Connect fuel pump connectors (8). Connectors are two different sizes. 12. Install fuel pump assembly. See INSTALLATION in this Safety pin section. Fuel pump connector Clips Figure 4-100. Fuel Pump Connector Disassembly 2006 Buell Lightning: Fuel System 4-113...
Page 456 (3). Install new fastener. Tighten to 84-108 in-lbs (9.5-12.2 Nm). Fill tank with a small amount of fuel. Check for leaks. Connect fuel pump connector [86] (1) and push cable strap tab into hole in frame. 4-114 2006 Buell Lightning: Fuel System...
Page 457: Fuel Tank Vent Valve
After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) Install seat. See 2.43 SEAT. 2006 Buell Lightning: Fuel System 4-115...
Page 458: Fuel Cap Retaining Ring
Insert fuel cap retaining ring into fuel ﬁller neck. Fuel cap retaining ring Install fasteners (4). Tighten to 62-71 in-lbs (7-8 Nm). Fastener (5) Install fuel ﬁller cap. Figure 4-103. Fuel Cap Retaining Ring 4-116 2006 Buell Lightning: Fuel System...
Page 459: Throttle Body
Label and detach throttle cables. See 2.23 THROTTLE CONTROL. Figure 4-106. On California models, pull EVAP hose from ﬁtting (1). Remove left and right air scoops. See 2.38 AIR SCOOPS. Remove ignition coil. See 4.32 IGNITION COIL. 2006 Buell Lightning: Fuel System 4-117...
Page 460 21. Bolt (2) 11. Clamp, wire spring, 49mm 22. Mounting ﬂange, intake (1 front, 1 rear) 12. Velocity stack, 49mm 23. Seal, intake manifold (2) Figure 4-105. One Piece Throttle Body/Intake Manifold Assembly (all models) 4-118 2006 Buell Lightning: Fuel System...
Page 461: Fuel Injectors
Remove fuel injectors (2, 5) from manifold by gently rock- ing and pulling it away from the manifold. NOTE Front and rear fuel injectors are not interchangeable. Manifold to engine mount fastener Intake ﬂange fastener (2) Figure 4-107. Intake Manifold (primary side) 2006 Buell Lightning: Fuel System 4-119...
Page 462 Clip (2) evidence of raw fuel in throttle body manifold. Front fuel injector Install air cleaner cover. See 4.44 AIR CLEANER Figure 4-109. Fuel Injectors ASSEMBLY. Install intake cover assembly. See 2.37 INTAKE COVER ASSEMBLY. 4-120 2006 Buell Lightning: Fuel System...
Page 463 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 air cleaner assembly. See 4.44 AIR CLEANER ASSEMBLY. Check throttle cable adjustment. See 2.23 THROTTLE CONTROL. 2006 Buell Lightning: Fuel System 4-121...
Page 464: Intake Leak Test
Nozzle Figure 4-111. Flatten one end of copper tube to form Copper Tube a nozzle. Hose Valve Insert round side of copper tube into end of tubing. Knob Propane bottle Figure 4-112. Leak Tester 4-122 2006 Buell Lightning: Fuel System...
Page 465 Figure 4-113. Aim nozzle toward possible sources of leak such as fuel injectors and intake tract. Figure 4-112. Push valve (4) to release propane. Tone of engine will change when propane enters source of leak. 2006 Buell Lightning: Fuel System 4-123...
Page 466: Air Cleaner Assembly
Vapor Valve (XB12 “Translucid” models) Inspect IAT sensor and replace if faulty. See 4.36 INTAKE AIR TEMPERATURE SENSOR. Inspect breather hoses, intake air temperature sensor grommet and air cleaner cover seal (3). Replace as nec- essary. 4-124 2006 Buell Lightning: Fuel System...
Page 467 Baseplate should be sandwiched between upper and lower rubber sealing rings. 8373 Fasteners Intake air temperature sensor (IAT) Gasket Baseplate Breather hoses Velocity stack Velocity stack sealing ring Figure 4-117. baseplate (all models) 2006 Buell Lightning: Fuel System 4-125...
Page 468 Cover screw (XB9SX) (2) “Translucid” air cleaner cover (XB9SX) Cover, air cleaner Filter element Air cleaner cover seal Shoulder screw (4) baseplate assembly Breather hoses, front and rear Grommet Figure 4-118. Air Cleaner Assembly (XB9SX) 4-126 2006 Buell Lightning: Fuel System...
Page 469 Harness, interactive exhaust 12. Breather hoses, front and rear Cable bracket 13. Grommet Interactive exhaust cable 14. Activator cover (XB12 “Translucid” cover) Cover, air cleaner Figure 4-119. Air Cleaner Assembly (XB12 Models) with Interactive Exhaust Components 2006 Buell Lightning: Fuel System 4-127...
Page 470 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 471 The barb is the larger outside diameter portion (bump) on the fuel ﬁtting. Figure 4-120. Connect two hoses to the canister. Make sure to push hoses all the way on to carbon canis- ter ﬁttings. Figure 4-122. Canister Mounting Bracket 2006 Buell Lightning: Fuel System 4-129...
Page 472 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 4-123. Emissions Hose Attachment, California Models Only 4-130 2006 Buell Lightning: Fuel System...
Page 473 ELECTRIC STARTER Table Of Contents SUBJECT PAGE NO. 5.1 Specifications ..........5.2 Electric Starter System .
Page 475 8 ft-lbs (11 Nm) (min.) @ 2.4 V TORQUE VALUES ITEM TORQUE NOTES Battery terminal fasteners 72-96 in-lbs 8-11 Nm page 5-19 Starter battery positive cable nut 60-85 in-lbs 7-10 Nm page 5-19 Starter mounting bolts 13-20 ft-lbs 18-27 Nm page 5-19 2006 Buell Lightning: Starter...
Page 476: 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). 2006 Buell Lightning: Starter...
Page 477 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 2006 Buell Lightning: Starter...
Page 478: Starting System Diagnosis
Is 12V present on starter relay Replace Starter Test 3: Relay Clicks. Terminal 86 with starter button solenoid. not pressed? 5845 Nothing clicks. See Starter Replace Replace Test 4: Nothing Clicks. starter relay. right handlebar switchgear. 5832 5818 2006 Buell Lightning: Starter...
Page 479 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 2006 Buell Lightning: Starter...
Page 480 (W/BK wire at connector [22]). interlock circuit relay. button to relay. Battery voltage present? or correct relay 5832 ground. 5831 5828 Replace right han- Repair wiring to dlebar switchgear. starter button. 5816 5831 2006 Buell Lightning: Starter...
Page 481 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 2006 Buell Lightning: Starter...
Page 482: 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. 2006 Buell Lightning: Starter...
Page 483 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. 2006 Buell Lightning: Starter...
Page 484 HOME bs0022bxbL 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 BATTERY, 30A [61B] TN/Y TN/LT.GN DIODE...
Page 485: 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 2006 Buell Lightning: Starter 5-11...
Page 486 Remove positive battery cable (2) ring terminal . Detach solenoid wire (3). Remove starter and gasket from the gearcase cover side. Fastener with washer (metric) Positive battery cable Solenoid wire Figure 5-9. Starter Wires (protective boot not shown) 5-12 2006 Buell Lightning: Starter...
Page 487 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. 2006 Buell Lightning: Starter 5-13...
Page 488 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 2006 Buell Lightning: Starter...
Page 489 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 2006 Buell Lightning: Starter 5-15...
Page 490 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 2006 Buell Lightning: Starter...
Page 491 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 2006 Buell Lightning: Starter 5-17...
Page 492 (6). Remove drive housing from solenoid hous- ing. 16. Remove drive, idler gear, idler gear bearing, and o-ring from drive housing (o-ring is located in drive housing Figure 5-22. Open Field Test groove). s0164x5x Figure 5-23. Brush Holder Insulation Test 5-18 2006 Buell Lightning: Starter...
Page 493 While riding, a loose seat can Mounting bolts and washers shift causing loss of control, which could result in death Starter or serious injury. (00070a) Figure 5-26. Starter Mounting Install seat. See 2.43 SEAT. 2006 Buell Lightning: Starter 5-19...
Page 494 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 2006 Buell Lightning: Starter...
Page 495 Replace wire connection hardware as Figure 5-28. Starter Solenoid 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). 2006 Buell Lightning: Starter 5-21...
Page 496 HOME NOTES 5-22 2006 Buell Lightning: Starter...
Page 497 Table Of Contents DRIVE/TRANSMISSION 6 SUBJECT PAGE NO. 6.1 Specifications ..........6.2 Primary Cover .
Page 499 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) 2006 Buell Lightning: Drive/Transmission...
Page 500 22-24 ft-lbs 30-32.5 Nm page 6-6 Special procedure, LOCTITE 262 (red), left hand Transmission sprocket nut threads, special torque turn method, page 6-54 Transmission sprocket screws 90-110 in-lbs 10.2-12.4 Nm Replace after 3 removals, page 6-54 2006 Buell Lightning: Drive/Transmission...
Page 501 Figure 6-1. Loosen locknut (7). Turn chain adjuster screw (6) counterclockwise to remove tension on primary chain. Remove three TORX screws with washers and clutch inspection cover. 10. See Figure 6-1. Remove clutch inspection cover (3). 2006 Buell Lightning: Drive/Transmission...
Page 502 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 6-3. Primary Cover, Primary Chain Adjuster and Shifter Assembly 2006 Buell Lightning: Drive/Transmission...
Page 503 1.8 CLUTCH. screw with nylon sealing surface toward cover. A 1/4-inch allen wrench may be inserted into end of adjuster screw Adjust primary chain tension. See 1.10 PRIMARY to hold it while threading lock nut. CHAIN. 2006 Buell Lightning: Drive/Transmission...
Page 504 13. After applying LOCTITE 272, install ﬂange bolt (5) and shift pedal to primary cover, and tighten to 22-24 ft-lbs (30-32.5Nm). 14. After applying LOCTITE 272 (red), tighten engine shift lever pinch screw to 48-60 in-lbs (5.4-6.8 Nm). 2006 Buell Lightning: Drive/Transmission...
Page 505: Clutch Release Mechanism
(7). As the adjusting screw is turned, b1057x6x TORX screw with washers (3) Ramp assembly Clutch inspection cover Adjusting screw assembly Clutch cover gasket Primary cover Spring 10. Coupling Lockplate 11. Drain plug and o-ring Figure 6-9. Clutch Release Mechanism 2006 Buell Lightning: Drive/Transmission...
Page 506 After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) Install seat. See 2.43 SEAT. 2006 Buell Lightning: Drive/Transmission...
Page 507 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. 2006 Buell Lightning: Drive/Transmission...
Page 508 27. Needle bearing Inner race Retaining ring 17. Pressure plate 28. Needle bearing 10. Spring seat 18. Friction plate, paper (7) 29. Clutch shell and sprocket 19. Steel plate (7) 30. Outer thrust washer Figure 6-12. Clutch Assembly 6-10 2006 Buell Lightning: Drive/Transmission...
Page 509 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. 2006 Buell Lightning: Drive/Transmission 6-11...
Page 510 Install adjusting screw assembly into pressure plate. Figure 6-37. Align two tabs on perimeter of release plate with corresponding recesses (3) in pressure plate. Secure the adjusting screw assembly with new retaining ring. 6-12 2006 Buell Lightning: Drive/Transmission...
Page 511 See 6.5 PRIMARY CHAIN. Inspect slots that mate with the clutch plates on both clutch shell and hub. If slots are worn or damaged, replace shell and/or hub. See 6.5 PRIMARY CHAIN. 2006 Buell Lightning: Drive/Transmission 6-13...
Page 512 ﬂats to prevent the forcing screw from turning. Spring seat Turn compressing tool handle clockwise until dia- Figure 6-21. Spring Seat Installation phragm spring compresses just enough to install new retaining ring into the groove in clutch hub prongs. 6-14 2006 Buell Lightning: Drive/Transmission...
Page 513 11. Install seat. See 2.43 SEAT. Diaphragm spring Snap ring Pressure plate Spring seat Figure 6-22. Pressure Plate Assembly 8815 Adjusting screw assembly Retaining ring Tab recesses Figure 6-23. Clutch Adjusting Screw Assembly and Retaining Ring 2006 Buell Lightning: Drive/Transmission 6-15...
Page 514 TWO CLAW PULLER (Part No. HD-97292-61) and two bolts to loosen the engine sprocket. Figure 6-16. Remove adjusting screw assembly. Remove large retaining ring. Remove adjusting screw assembly from pressure plate. 6-16 2006 Buell Lightning: Drive/Transmission...
Page 515 If the inner race shows any of these signs the complete hub assembly must be replaced. 8804 11. Replace damaged parts as necessary. Figure 6-28. Clutch Hub Bearing Race 2006 Buell Lightning: Drive/Transmission 6-17...
Page 516 Installation end of bearing tool Needle bearing Bearing guide, installer Figure 6-29. Clutch Shell Bearing Remover/Installer B-45926 8812 Figure 6-32. Installing Clutch Shell Needle Bearing Clutch Shell Bearing Remover/Installer B-45926 Figure 6-30. Removing Clutch Shell Needle Bearing 6-18 2006 Buell Lightning: Drive/Transmission...
Page 517 Clutch hub Mainshaft nut Needle bearing Washer Clutch shell Clutch hub Thrust washer, outer Figure 6-35. Mainshaft Nut and Washer Figure 6-33. Clutch Hub and Shell Assembly 2006 Buell Lightning: Drive/Transmission 6-19...
Page 518 (00070a) 14. Install seat. See 2.43 SEAT. Adjusting screw assembly Retaining ring Tab recesses Figure 6-37. Clutch Adjusting Screw Assembly and Retaining Ring 6-20 2006 Buell Lightning: Drive/Transmission...
Page 519: 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, pinching or kink- ing (D), and prying (E). Figure 6-38. Proper Drive Belt Handling 2006 Buell Lightning: Drive/Transmission 6-21...
Page 520 2.19 SWINGARM AND BRACE. NOTE When removing or installing belt, do not bend or twist belt, partially slide belt onto sprocket and "roll" wheel or belt dam- age will occur. 11. Slide belt from sprocket and remove. 6-22 2006 Buell Lightning: Drive/Transmission...
Page 521: Drive Belt Installation
12. Remove scissor jack from motorcycle. Drive belt not fully seated in rear sprocket Squeezing drive belt in order to seat in pulleys Drive belt fully seated in rear sprocket Figure 6-42. Seating Drive Belt Into Pulley Teeth 2006 Buell Lightning: Drive/Transmission 6-23...
Page 522 61 Nm). b1106x6x 8420 Axle Pinch bolt fastener Figure 6-43. Rear Wheel Mounting, Right Side Wheel Wheel nut Stud Idler pulley bracket Idler pulley bracket nut and washer Wheel fastener Figure 6-44. Idler Pulley Assembly 6-24 2006 Buell Lightning: Drive/Transmission...
Page 523 1st Gear Neutral Countershaft Countershaft Mainshaft Mainshaft 2nd Gear 3rd Gear Countershaft Countershaft Mainshaft Mainshaft 5th Gear 4th Gear Countershaft Countershaft - IN - SLIDING MEMBER - POWER FLOW - OUT Figure 6-45. Transmission Power Flow 2006 Buell Lightning: Drive/Transmission 6-25...
Page 524: Case Disassembly For Transmission Removal
Figure 6-48. With transmission still in neutral, scribe Figure 6-46. Place transmission in 1st gear. Remove a line on the end of the shifter drum at the 12 o’clock position for later reference. hex fastener. 6-26 2006 Buell Lightning: Drive/Transmission...
Page 525 Figure 6-49. Remove shifter shaft assembly. Figure 6-51. Rear Isolator Assembly 14. See Figure 6-51. Remove rear isolator assembly by removing the forward two fasteners ﬁrst and then the two rear fasteners (re-install with new fasteners). 2006 Buell Lightning: Drive/Transmission 6-27...
Page 526 No tools are required for this operation. 8621 8636 Figure 6-53. Separating Crankcase Halves Figure 6-54. Removing Flywheels from Left Case Half 16. See Figure 6-53. Separate crankcase halves. 17. See Figure 6-54. Remove the ﬂywheel assembly from left crankcase half. 6-28 2006 Buell Lightning: Drive/Transmission...
Page 527: Transmission Disassembly
11495 Figure 6-56. Slots For Removing Shifter Fork Shafts 11349 Mainshaft Left Right Shifter drum Shifter fork (3) Mainshaft Mainshaft 2nd gear Countershaft Figure 6-57. Transmission Assembly Countershaft Figure 6-55. Shifter Forks, Drum and Shafts 2006 Buell Lightning: Drive/Transmission 6-29...
Page 528 Pin, shifter stop 21. Bolt, shift lever 10. Spring, shifter return 22. Pad, rubber, shift lever 11. Spring, extension 23. Linkage assembly, shifter 12. Shifter lever assembly 24. Bolt, linkage assembly Figure 6-58. Shifter Mechanism 6-30 2006 Buell Lightning: Drive/Transmission...
Page 529 SION REMOVER (2) (Part No. B-43895-1) to remove transmission assembly from crankcase half. Remove crankcase from press. Arbor press Transmission remover (Part No. B-43985-1) Crankcase Transmission assembly Parallel supports Figure 6-59. Removing Transmission Assembly from Left Case Half 2006 Buell Lightning: Drive/Transmission 6-31...
Page 530 30. Retaining ring 15. Mainshaft 2nd gear 31. Countershaft retaining screw 16. Mainshaft bearing Mainshaft 2nd and 3rd gears are integral to the shaft. Countershaft 5th gear is integral to the shaft. Figure 6-60. Transmission Assembly 6-32 2006 Buell Lightning: Drive/Transmission...
Page 531 Split bearing Retaining ring Mainshaft Thrust washer Mainshaft 3rd gear Mainshaft 4th gear Mainshaft 2nd gear Mainshaft 2nd and 3rd gears are integral to the shaft. Figure 6-62. Transmission Mainshaft Assembly Once Removed from Left Crankcase/Disassembly 2006 Buell Lightning: Drive/Transmission 6-33...
Page 532 Thrust washer 12. Countershaft 3rd gear 19. Spacer Retaining ring 13. Thrust washer Dog ring 14. Retaining ring Countershaft 5th gear is integral to the shaft. Figure 6-63. Transmission Countershaft Assembly Once Removed from Left Crankcase/Disassembly 6-34 2006 Buell Lightning: Drive/Transmission...
Page 533: Transmission Assembly
Left Crankcase Mainshaft 1st gear Split bearing Retaining ring Mainshaft Thrust washer Mainshaft 3rd gear Mainshaft 4th gear Mainshaft 2nd gear Mainshaft 2nd and 3rd gears are integral to the shaft. Figure 6-64. Transmission Mainshaft Assembly/Reassembly 2006 Buell Lightning: Drive/Transmission 6-35...
Page 534 Thrust washer 12. Countershaft 3rd gear 19. Spacer Retaining ring 13. Thrust washer Dog ring 14. Retaining ring Countershaft 5th gear is integral to the shaft. Figure 6-65. Transmission Countershaft Assembly Once Removed from Left Crankcase/Disassembly 6-36 2006 Buell Lightning: Drive/Transmission...
Page 535 Fifth gear mainshaft Bearing (Outer) O-ring Oil seal Right crankcase half Ball bearing with spacer Retaining ring 10. Oil seal 11. Bearing, (closed end) countershaft 12. Bushing, shifter drum Figure 6-66. Transmission Assembly-Right Crankcase Half 2006 Buell Lightning: Drive/Transmission 6-37...
Page 536 (2). Install and tighten nut (6) until 5th mainshaft 5th gear. Discard seal. 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 2006 Buell Lightning: Drive/Transmission...
Page 537 Main drive gear Figure 6-70. Removing Main Drive Gear Bearing (Typical) Inner bearing race (not visible in this photo) Bearing race puller (Part no. HD-95637-46A) Press ram Figure 6-71. Removing Inner Bearing Race From Main Drive Gear 2006 Buell Lightning: Drive/Transmission 6-39...
Page 538 0.315 in. (8.001 mm) from the end of the main drive gear. Press ram Needle bearing installation tool (Part No. HD-47855) Needle bearing Main drive gear Figure 6-73. Pressing Outer Needle Bearing Assembly into Main Drive Gear 6-40 2006 Buell Lightning: Drive/Transmission...
Page 539 AND PRIMARY CHAINCASE LUBRICANT (Part No. Cross plate (Part No. B-45847) 99851-05). 8 in. bolt (Part No. HD-35316-4A) Main drive gear bearing Bearing driver (Part No. HD-35316-8) Nice bearing Flat washer Figure 6-75. Installing Main Drive Gear Bearing 2006 Buell Lightning: Drive/Transmission 6-41...
Page 540 MARY CHAINCASE LUBRICANT (Part No. 99851-05). NOTE Figure 6-77. Installing Main Drive Gear (Typical) Figure 6-67. Make sure to install new o-ring (5) onto main drive gear before installing main drive gear into crank- case. 6-42 2006 Buell Lightning: Drive/Transmission...
Page 541 1) over ADAPTER until cupped end of installer is ﬂat against seal. Figure 6-79. Install Main Drive Gear Seal (Typical) Figure 6-79. Place seal over pilot and position seal squarely in end of crankcase bore. 2006 Buell Lightning: Drive/Transmission 6-43...
Page 542 ﬂush with outer edge of crank- case bore. NOTE It is acceptable to recess seal to about 0.030 in. (0.762 mm) below outer edge of bore. Seal will be controlled by tool. Remove nut, installer, adapter and pilot. 6-44 2006 Buell Lightning: Drive/Transmission...
Page 543: Transmission Right Case Bearings
Bearing (Inner) Ball bearing with spacer Fifth gear mainshaft Retaining ring Bearing (Outer) 10. Oil seal O-ring 11. Needle bearing, (closed end) countershaft Oil seal 12. Bushing, shifter drum Figure 6-84. Transmission Assembly-Right Crankcase Half 2006 Buell Lightning: Drive/Transmission 6-45...
Page 544: 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. 6-46 2006 Buell Lightning: Drive/Transmission...
Page 545: Transmission Installation
Remove transmission assembly and left crankcase half from ﬁxture. Re-install transmission assembly and left crankcase half in engine stand. Arbor press Guide tool (Part No. B-43985-4) Transmission assembly Transmission Remover/Installer ﬁxture (Part No. HD-46285) Figure 6-87. Transmission Assembly in Fixture (Typical) 2006 Buell Lightning: Drive/Transmission 6-47...
Page 546 Figure 6-90. Installing Shift Fork Shafts NOTE Figure 6-90. 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 6-89. Shifter Forks, Drum and Shafts 6-48 2006 Buell Lightning: Drive/Transmission...
Page 547 No. B-45520) until it has bottomed in right case half. Place Transmission in the 1st gear position. Lubricate main drive gear needle bearing assemblies, the mating surface of the mainshaft and countershaft with HARLEY-DAVIDSON SPECIAL PURPOSE GREASE (Part No. 99857-97). 2006 Buell Lightning: Drive/Transmission 6-49...
Page 548 HOME b1016x3x One Behind Shifter Mechanism Indicates Bolt Pattern Location Figure 6-94. Crankcase Fasteners 6-50 2006 Buell Lightning: Drive/Transmission...
Page 549: Shifter Shaft
The shifter shaft return spring can be installed incorrectly and then assembled in the left crankcase half. Failure to install the spring properly will result in improper shifting. b0951x6x Figure 6-96. Shifter Shaft Return Spring (Incorrectly Installed) 2006 Buell Lightning: Drive/Transmission 6-51...
Page 550 Continue assembling engine. See appropriate sections 3.19 CRANKCASE 3.6 CYLINDER HEAD/3.7 CYLINDER AND PISTON. Install primary chain and engine sprocket, clutch assem- bly and primary cover. See 6.5 PRIMARY CHAIN. Install engine in chassis. See 3.5 ENGINE INSTALLA- TION. 6-52 2006 Buell Lightning: Drive/Transmission...
Page 551: Transmission Sprocket
(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. Figure 6-102. Removing Transmission Sprocket Locknut 2006 Buell Lightning: Drive/Transmission 6-53...
Page 552 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. 6-54 2006 Buell Lightning: Drive/Transmission...
Page 553 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). 13. Tighten pinch fastener (2) on right side of swingarm to 40-45 ft-lbs (54-61 Nm). 2006 Buell Lightning: Drive/Transmission 6-55...
Page 554 HOME NOTES 6-56 2006 Buell Lightning: Drive/Transmission...
Page 555 Table Of Contents SUBJECT PAGE NO. 7.1 Specifications ..........7.2 Ignition System .
Page 557 (European models only) Tail/Stop Lamp 5/21 0.42/1.75 68169-90A Turn signal lamp (front and rear 10.0 0.84 Y0042.K 1 bulb each) Marker lamps License plate illumination lamp 0.37 53436-97 (European models only) License plate illumination lamp 0.37 Y0514B.C 2006 Buell Lightning: Electrical...
Page 558 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 36-60 in-lbs 4.1-6.8 Nm Use new fasteners, page 7-32 2006 Buell Lightning: Electrical...
Page 559: 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. 2006 Buell Lightning: Electrical...
Page 560 10. Rear spark plug cable 11. Mounting fastener 12. Ignition coil 13. Front spark plug cable 14. Engine mount 15. Seal 16. Trigger rotor 17. Trigger rotor bolt 18. Cam position sensor 19. Inner cover b1164b4x Figure 7-1. Ignition Components 2006 Buell Lightning: Electrical...
Page 561 Front and rear turn signals Can be activated 8886 Cannot be Horn Can be activated activated ON position OFF position PUSH DETENT LOCK position PARKING LIGHT position Left headlamp module Figure 7-2. Ignition/Headlight Key Switch 2006 Buell Lightning: Electrical...
Page 562 Main harness Left handlebar connector [24] Horn fastener Right handlebar connector [22] (Behind No. #1) 10. Horn mount Turn signal connectors [31] 11. Horn connector [122] Ignition switch 12. Horn Figure 7-3. Electrical Connectors Behind Windscreen 2006 Buell Lightning: Electrical...
Page 563 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 (Typical) 2006 Buell Lightning: Electrical...
Page 564 Main harness Left handlebar connector [24] Horn fastener Right handlebar connector [22] (Behind No. #1) 10. Horn mount Turn signal connectors [31] 11. Horn connector [122] Ignition switch 12. Horn Figure 7-6. Electrical Connectors Behind Windscreen 2006 Buell Lightning: Electrical...
Page 565 While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) Install seat. See 2.43 SEAT. 11. Install windscreen and tighten fasteners to 10-12 in-lbs (1.1-1.4 Nm). 2006 Buell Lightning: Electrical...
Page 566: Spark Plug Cables
Remove air cleaner assembly. See 4.44 AIR CLEANER ASSEMBLY. 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 2006 Buell Lightning: Electrical...
Page 567 Fasten boots/caps securely. Tight connections provide the necessary moisture-proof environment for the ignition coil and spark plug terminals. Install air cleaner assembly. See 4.44 AIR CLEANER ASSEMBLY. Figure 7-10. Boot Gap Should Not exceed 1/8 in. (3.2 mm) 2006 Buell Lightning: Electrical 7-11...
Page 568 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 2006 Buell Lightning: Electrical...
Page 569 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 2006 Buell Lightning: Electrical 7-13...
Page 570 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 2006 Buell Lightning: Electrical...
Page 571 Check for ground on BK Repair open on TN/ wire of connector [95]. LTGN 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 2006 Buell Lightning: Electrical 7-15...
Page 572 0 ohms or little resistance. Replace the assembly with a new switch if necessary. 2.25 CLUTCH CONTROL/CABLE. Clutch engaged (switch open) Tighten fasteners to 7-10 in-lbs (0.8-1.12 Nm). Clutch disengaged (switch closed) Connector [95] Figure 7-14. Clutch Switch 7-16 2006 Buell Lightning: Electrical...
Page 573 The 30 Amp battery fuse is located under the rider’s seat. See 7.23 BATTERY FUSE AND FUSES for more infor- mation. Figure 7-16. Relay Block (XB12Ss) b0755x5x Ohmmeter Battery Figure 7-17. Starter Relay Test 2006 Buell Lightning: Electrical 7-17...
Page 574 Replace the diode by pulling it straight out. Ensure it is installed in the correct direction. Figure 7-18. Fuse Block (contains diode) 12154 Figure 7-19. Fuse Block (XB12Ss) (contains diode) b1166x4x Empty Acces. Diode Bk/Hn/Mflr Battery Lights Spare Spare Key Sw Figure 7-20. Fuse Blocks 7-18 2006 Buell Lightning: Electrical...
Page 575 Butterﬂy 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 7-21. Interactive Exhaust System Mufﬂer 2006 Buell Lightning: Electrical 7-19...
Page 576 11. Base plate assembly Cable bracket 12. Breather hoses, front and rear Interactive exhaust cable 13. Grommet Cover, air cleaner 14. Activator cover (XB12 “Translucid” cover) Figure 7-22. Air Cleaner Assembly (XB12 Models) with Interactive Exhaust Components 7-20 2006 Buell Lightning: Electrical...
Page 577 Figure 7-23. Air Cleaner Cover, Fuel Vent Tube and Fuel Vapor Valve (XB12 solid color models) Figure 7-23. Remove fuel vent tube (3) from fuel cell vent and groove on top of air cleaner cover (2). 2006 Buell Lightning: Electrical 7-21...
Page 578 Connect interactive exhaust harness to actuator [161B]. Route fuel vent line and install. Attach interactive exhaust cable to bracket and cable wheel on actuator and adjust. See 1.16 INTERACTIVE EXHAUST CABLE (XB12 MODELS). Install intake cover assembly. See. 7-22 2006 Buell Lightning: Electrical...
Page 579: Charging System
Figure 7-26. Stator Connector [46] Wiring Check for corroded or loose connections in the charging cir- cuit. See Figure 7-27. Voltage Regulator Inspection Figure 7-26. The plug connector to stator must be clean and tight. 2006 Buell Lightning: Electrical 7-23...
Page 580 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 2006 Buell Lightning: Electrical...
Page 581 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. 2006 Buell Lightning: Electrical 7-25...
Page 582 Battery Cable Starter Solenoid [128A] Battery Starter Motor [GRD2] Battery Fuse Fuse/Relay Assembly Battery, 30A [61B] [35A] [35B] To Voltage Regulator [77A] [77B] Voltage Regulator Stator H-D 3-Phase [46A] [46B] Figure 7-27. Charging System Circuit 7-26 2006 Buell Lightning: Electrical...
Page 583 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. 2006 Buell Lightning: Electrical 7-27...
Page 584 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 2006 Buell Lightning: Electrical...
Page 585 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 7-32. Check for Stator Resistance b0998x7x Figure 7-33. Check Stator AC Voltage Output 2006 Buell Lightning: Electrical 7-29...
Page 586 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 7-36. Stator Assembly 7-30 2006 Buell Lightning: Electrical...
Page 587 Install retainer plate and tighten fasteners to 56 in-lbs (6.3 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. 2006 Buell Lightning: Electrical 7-31...
Page 588 Voltage regulator mount bracket shift causing loss of control, which could result in death Voltage regulator or serious injury. (00070a) Fastener (3) Install seat. See 2.43 SEAT. Figure 7-39. Voltage Regulator Test charging system. See 7.7 CHARGING SYSTEM. 7-32 2006 Buell Lightning: Electrical...
Page 589: Battery Cables
(00068a) CAUTION Connect the cables to the correct battery terminals. Fail- ure to do so could result in damage to the motorcycle electrical system. (00215a) 2006 Buell Lightning: Electrical 7-33...
Page 590 Connect positive cable to positive (+) battery termi- nal using fastener. Connect negative cable to negative (-) battery termi- nal using fastener. Tighten terminal fasteners to 72-96 in-lbs (8-11 Nm). 7-34 2006 Buell Lightning: Electrical...
Page 591 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 592: Battery Testing
After dis- connecting the battery cables from the battery, retest the 12.7 100% battery using the out-of-vehicle test before replacing. 12.6 12.3 12.0 x0661x3x 11.8 Figure 7-46. Battery Test Results–Printout 7-36 2006 Buell Lightning: Electrical...
Page 593: Disconnection And Removal
Voltage reading after 15 seconds should battery has been frozen, overheated or overcharged. be 9.6V or more at 70° F. (21° C). Inspect the battery case for cracks or leaks. 2006 Buell Lightning: Electrical 7-37...
Page 594: Safety Precautions
Perform a voltmeter test to determine the state of charge. BATTERY TESTING. If battery needs to be charged, proceed to step 2. CAUTION Remove battery from motorcycle before charging. Elec- trolyte leakage will damage motorcycle parts. (00213a) 7-38 2006 Buell Lightning: Electrical...
Page 595 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. 2006 Buell Lightning: Electrical 7-39...
Page 596 After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) Install seat. See 2.43 SEAT. 7-40 2006 Buell Lightning: Electrical...
Page 597 (not freezing), dry place. See Fig- ure 7-50. 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). 2006 Buell Lightning: Electrical 7-41...
Page 598 8917 Headlight Bulb holder (2) High beam connection [38] (left side) with ground Low beam connection [38] (right side) with ground Headlight bulbs Figure 7-51. Headlight Assembly/Rear View 7-42 2006 Buell Lightning: Electrical...
Page 599 If the rubber boots are not installed correctly the wiring har- nesses can contact the edge of the forward frame mount. The Install seat. See 2.43 SEAT. wiring harness guides must be installed at a 20 degree angle. Figure 7-53. Install rubber boot. 2006 Buell Lightning: Electrical 7-43...
Page 600 HOME 10525 10526 Figure 7-53. Headlight Housing 20 Degree Alignment Marks for Rubber Boot Wiring Harness Guides or Spigots 7-44 2006 Buell Lightning: Electrical...
Page 601: Tail Lamp
Low visibility of rider can result in death or serious injury. (00316a) b1139x7x Center tail section Screws (2) Bulb Lens Tail lamp Tail lamp wiring harness Tail lamp boot Figure 7-54. Tail Lamp Assembly 2006 Buell Lightning: Electrical 7-45...
Page 602: License Plate Lamp Assembly
(00070a) Install seat. See 2.43 SEAT. Jam nuts with washers (2) Center tail section Screws (2) Bulb Lamp lens License plate lamp Figure 7-56. License Plate Lamp 7-46 2006 Buell Lightning: Electrical...
Page 603: 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 7-58. Front Turn Signals 2006 Buell Lightning: Electrical 7-47...
Page 604 [18A] [18A] Right turn signal Figure 7-59. Rear Turn Signal Connections b1261x7x Turn signal (2) Jam nut and lockwasher (2) Turn signal bulb Center tail section Reﬂector bracket Bungee hooks Figure 7-60. Rear Turn Signals 7-48 2006 Buell Lightning: Electrical...
Page 605 After installing seat, pull upward on front of seat to be sure it is in locked position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) Install seat. See 2.43 SEAT. 2006 Buell Lightning: Electrical 7-49...
Page 606: Turn Signal Flasher
Right turn signal Activate right turn signals using switch on left han- dlebar. Front and rear right turn signals must ﬂash. Figure 7-64. Turn Signal Controls Turn ignition key switch to OFF. Install windscreen. See 2.42 WINDSCREEN. 7-50 2006 Buell Lightning: Electrical...
Page 607: 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 7-66. Left Handlebar Switch Connection 2006 Buell Lightning: Electrical 7-51...
Page 608 Brake Switch Turn ignition key switch to ON. Set ENGINE STOP SWITCH to RUN. Figure 7-67. Right Handlebar Switch Connection Start motorcycle. Turn ignition key switch to OFF. Turn ignition key switch to OFF. 7-52 2006 Buell Lightning: Electrical...
Page 609 Set headlight to LOW beam. Press passing lamp switch. Headlight should ﬂash HIGH beam for as long as the switch is pressed. Check left and right turn signals. Figure 7-68. Left Handlebar Switch Connection Activate horn by pressing horn switch. 2006 Buell Lightning: Electrical 7-53...
Page 610 Center To battery Top View Vehicle Speed Sensor Connector Vehicle Speed [39A] [39B] Sensor Instrument Module BK/W [65A] [65B] [10B] [11B] Connector Connector [10A] Electronic Control Module [11B] (ECM) Figure 7-70. Vehicle Speed Sensor Wiring 7-54 2006 Buell Lightning: Electrical...
Page 611 Remove the nine fasteners securing the back of the module housing to the display and remove back cover. NOTE Do not turn display over. Speedometer and tachometer will fall out possibly causing damage to instruments. 2006 Buell Lightning: Electrical 7-55...
Page 612 (00070a) Install seat. See 2.43 SEAT. 12155a Front support module, left and right Instrument module Grommet (3) Washer (2) Fastener (3) Instrument module connector [39] Figure 7-75. Instrument Module Figure 7-74. Instrument Module Connector [39] 7-56 2006 Buell Lightning: Electrical...
Page 613: Speedometer Performance Check
CLEAR to cancel and enter the new fre- quency. Press ENTER to begin and reverify. 40 MPH 1062 NOTE 60 MPH 1593 The speedometer should be accurate within 0-5 MPH (0-8 80 MPH 2124 KPH). 2006 Buell Lightning: Electrical 7-57...
Page 614 If testing LO range, press 1 or 3. If testing CEN range, press 4 or 6. If testing HI range, press 7 or 9. Deutsch socket housing (2) Deutsch pin housing Figure 7-78. Test Harness 7-58 2006 Buell Lightning: Electrical...
Page 615 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 2006 Buell Lightning: Electrical 7-59...
Page 616 Go to If necessary, remove vehicle speed sensor Speedometer Test: and check for accumulation of debris. If Chart debris is not present, replace sensor. If debris is present, clean sensor and repeat test. Replace if necessary. 7-60 2006 Buell Lightning: Electrical...
Page 617 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 2006 Buell Lightning: Electrical 7-61...
Page 618 To ground or serious injury. (00070a) [95A] [95B] Install seat. See 2.43 SEAT. Clutch Switch [122A] [122B] Horn Left Handlebar Switch Figure 7-80. Horn Wiring 7-62 2006 Buell Lightning: Electrical...
Page 619 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. 2006 Buell Lightning: Electrical 7-63...
Page 620: Neutral Indicator Switch
Neutral indicator switch wire lead threads. Neutral indicator switch Install switch in crankcase. Tighten switch to 36-60 Washer in-lbs (4-6.8 Nm). Figure 7-83. Neutral Indicator Switch Connect wire lead (1) to switch. Install sprocket cover. See 2.33 SPROCKET COVER. 7-64 2006 Buell Lightning: Electrical...
Page 621 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. Acces. Diode Figure 7-84. The lights, key switch and ignition fuses are rated at 15 amps.
Page 622: Main Wire Harness
[165B], (under main wiring harness) (1200 models 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 4.38 COOLING FAN. 7-66 2006 Buell Lightning: Electrical...
Page 623 13. Tail light connectors [93] Ground terminals (low voltage ground wires) 14. Interactive exhaust connector [165B], (1200 models ECM connectors [10] & [11] only) Fuse block and relay center Figure 7-87. Main Harness and Electrical Connectors Under Seat (Typical) 2006 Buell Lightning: Electrical 7-67...
Page 624 Fuse block and relay center Battery positive cable BAS (bank angle sensor) connector [134] Rear brake light switch connector [121] 10. Interactive exhaust connector [165B] Figure 7-88. Main Harness and Electrical Connectors Under Seat (XB12Ss) 7-68 2006 Buell Lightning: Electrical...
Page 625 16. Disconnect wiring located under sprocket cover. See 7.26 SPROCKET COVER WIRING. 17. Remove connector from oil pressure switch [120]. Oil pressure switch is located on front of engine. See 3.12 OIL PRESSURE INDICATOR SWITCH. 2006 Buell Lightning: Electrical 7-69...
Page 626 (1) at rear of frame. Install new plastic tree fasteners. Figure 7-90. Wire Harness Clip Figure 7-90. Install clamp over portion of harness that leads to engine connectors. Install clamp as shown using new plastic tree fastener. 7-70 2006 Buell Lightning: Electrical...
Page 627 Rear brake light switch connector [121]. 14. Install sprocket cover wiring. See 7.26 SPROCKET Wire harness ground [GRD 2]. COVER WIRING. 15. Connect fan connector [97]. 21. Install starter side of positive battery cable to starter. 2006 Buell Lightning: Electrical 7-71...
Page 628 12. License plate lamp connector [45] Ground terminals (low voltage ground wires) 13. Tail light connectors [93] ECM connectors [10] [11] & [164] (1200 models only) Figure 7-93. Main Harness and Electrical Connectors Under Seat (Typical) 7-72 2006 Buell Lightning: Electrical...
Page 629 Fuse block and relay center Battery positive cable BAS (bank angle sensor) connector [134] Rear brake light switch connector [121] 10. Interactive exhaust connector [165B] Figure 7-94. Main Harness and Electrical Connectors Under Seat (XB12Ss) 2006 Buell Lightning: Electrical 7-73...
Page 630 Rear cable strap (1) secures conduit to voltage reg- ulator wiring. 23. Verify that front forks can be turned from full left to full right lock without wire harness binding or pinching. 7-74 2006 Buell Lightning: Electrical...
Page 631: Interactive Exhaust Actuator Harness
Remove actuator. Battery and actuator ground Active mufﬂer connector [164] Figure 7-96. Harness and Cable Routing (XB12 Models) 12049 Interactive exhaust cable Actuator connector [161B] Interactive exhaust cable wheel Figure 7-97. Exhaust Actuator (XB12 Models) 2006 Buell Lightning: Electrical 7-75...
Page 632 While riding, a loose seat can Cable shift causing loss of control, which could result in death or serious injury. (00070a) Figure 7-99. Correct Cable Routing Behind Frame Lug 10. Install seat. 7-76 2006 Buell Lightning: Electrical...
Page 633: Sprocket Cover Wiring
Neutral switch connector [131] Cam position sensor connector [14] Neutral switch location Stator connector [46] Vehicle speed sensor connector [65] Oil pressure switch wiring Main harness 10. Interactive exhaust cable Figure 7-100. Sprocket Cover Wiring and Connections 2006 Buell Lightning: Electrical 7-77...
Page 634 (2-pin) voltage regulator (1). 12010 Reﬂective convolute covering with seam Covering in place on bottom of return line Covering in place on top of return line Sprocket cover boss Figure 7-101. Convoluted Covering for Oil Return Line 7-78 2006 Buell Lightning: Electrical...
Page 635 Using a cable strap, secure the loop the neutral safety wire makes to the cam position con- nector under the attachment clip on the connector. Figure 7-103. Cable Strap Locations 12013 Figure 7-104. Cam Position Sensor Connector with Cable Strap 2006 Buell Lightning: Electrical 7-79...
Page 636 12014 Sprocket cover boss Main harness Cable strap securing main harness wiring Figure 7-108. Correct Location for Sprocket Cover Wiring Figure 7-106. Cable Strap Wire Bundle to Return Oil Line, Upper Part of Sprocket Cover 7-80 2006 Buell Lightning: Electrical...
Page 637 Table Of Contents SUBJECT PAGE NO. APPENDIX A-TOOLS ..........APPENDIX B-WIRING .

Buell 2006LIGHTNING MODELS Service Manual

Index to Wiring Diagrams B.5

Maintenance 1

Chassis 2

Fuel System 4

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