Handlebars: Lightning/Ulysses; Removal; Installation - Buell 2009 XB Series Service Manual

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HANDLEBARS: LIGHTNING/ULYSSES

REMOVAL

1. Remove seat.
NOTE
On Ulysses Models, it will be necessary to disconnect and
remove the heated handgrips. See
GRIPS: ULYSSES MODELS.
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
2. Disconnect battery cables from battery: negative cable
(black) first.
3. XB9SX, XB12X, XB12XT and XB12XP: Remove
deflectors. See
XB9SX/XB12X/XB12XT/XB12XP.
4. Remove left handlebar switch housing.
5. Detach clutch hand control from handlebars. See
2.25 CLUTCH CONTROL.
6. Remove front brake master cylinder. See
BRAKE: SIX PISTON CALIPER.
7. Loosen screws on right handlebar switch housing, but do
not detach throttle grip assembly from handlebar. See
2.24 THROTTLE CONTROL.
8. Ulysses Models: Remove four harness retainers securing
switch housing harnesses to handlebars.
9. Remove clutch lever assembly. See
TROL.
10. See Figure 2-153. Remove the four screws holding upper
handlebar clamp.
NOTE
Remove right hand control assembly from detached handlebar.
11. Remove handlebars without stretching throttle cables.
12. Remove end caps.

INSTALLATION

1. Slide handlebars into throttle grip assembly. Fasten right
handlebar switch housing
2.24 THROTTLE CONTROL.
2. See Figure 2-153. Attach handlebars.
a. Position handlebar on lower clamp.
b. Place the upper handlebar clamp in position and
thread the four screws in place after applying LOC-
TITE 271 (red).
c. Tighten both front screws to 10-12 ft-lbs (14-16 Nm).
d. Then tighten both rear screws 10-12 ft-lbs (14-16
Nm).
6.12 HEATED HAND
2.28 DEFLECTORS:
2.10 FRONT
2.25 CLUTCH CON-
to handlebar. See
3. Install clutch hand control. Tighten but do not torque. See
2.25 CLUTCH CONTROL.
4. Install left switch housing.
5. Check control wire routings. See
AND WIRE ROUTING.
a. Route right hand control wires between the lower
clamp and fork tube and on the outside of the clutch
cable.
b. Route left hand control wires between the lower clamp
and fork tube.
c. Ulysses Models: Install harness retainers.
NOTE
On Ulysses models, with heated hand grips, it will be necessary
to install the original hand grip from the removal process.
6. Install a new left hand grip.
7. Position clutch hand lever to rider preferences and tighten
fastener to 60-84 in-lbs (7-9.5 Nm). See
CONTROL.
8. Install front brake master cylinder. See
BRAKE: SIX PISTON CALIPER.
9. XB9SX, XB12X, XB12XT and XB12XP: Install end caps
and deflectors. See
XB9SX/XB12X/XB12XT/XB12XP.
10. Check steering motion range to both fork stops.
Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)
11. Connect battery cables to battery: positive cable (red) first.
Tighten to 72-96 in-lbs (8-11 Nm). See
MAINTENANCE.
After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)
12. Install seat.
2009 XB Service: Chassis 2-119
2.32
D.1 APPENDIX D: HOSE
2.25 CLUTCH
2.10 FRONT
2.28 DEFLECTORS:
1.5 BATTERY