Buell 2007 FIREBOLT Service Manual

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2007 BUELL FIREBOLT MODELS

SERVICE MANUAL

Part Number 99493-07Y

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

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Buell 2007 FIREBOLT

Page 1 2007 BUELL FIREBOLT MODELS SERVICE MANUAL Part Number 99493-07Y Section 1: Maintenance Section 2: Chassis Section 3: Engine Section 4: Fuel System Section 5: Starter Section 6: Drive/Transmission Section 7: Electrical Appendices...
Page 2 Part No. HD-33416 Universal Driver Handle HD-28431B h33418 HD-28431-6 Fluorescent Additive 6 1-oz. bottles HD-28431-22 Fluorescent Additive 1 22-oz. container Part No. HD-28431-B Black Light Fluorescent Additive Part No. HD-33418 Universal Puller Forcing Screw (Use with HD-) 2007 Buell Firebolt: Appendix A...
Page 3 Part No. HD34736-B Valve Spring Compressor Part No. HD-35316-C Main Drive Gear Remover/Installer and Main Drive Gear Bearing Installer h35457 h34751 Part No. HD-35457 Black Part No. HD-34751 Nylon Valve Guide Brush Light Leak Detector 2007 Buell Firebolt: Appendix A...
Page 4 Part No. HD-35758-B Neway Valve Seat Cutter Set Part No. HD-38515-A Clutch Spring Compressor HD-38125-6 h39302 Part No. HD-38125-6 Packard Terminal Crimp Tool Part No. HD-39302 Steering Head Bearing Race Installer (Sealed) (Used with B-45521) 2007 Buell Firebolt: Appendix A...
Page 5 Part No. HD-39965 Deutsch Terminal Crimp Tool HD-39969 h39782 Part No. HD-39969 Ultra-Torch UT-100 Part No. HD-39782-A Cylinder Head Support Stand HD39978 h39786 Part No. HD-39978 Fluke 78 Multimeter (DVOM)F Part No. HD-39786 Cylinder Head Holding Fixture 2007 Buell Firebolt: Appendix A...
Page 6 Part No. HD-41137 Two-Way Hose Clamp Pliers h41354 HD41155-2 Part No. HD-41354 Speedometer Tester Part No. HD-41155 VHS Tape Storage Rack b41177-94 HD41404 Part No. HD-41177 Fork Tube Holder Part No. HD-41404 Harness Connector Test Kit 2007 Buell Firebolt: Appendix A...
Page 7 Part No. B-41623-B Oil Line Remover HD41675 h41475-100 Part No. HD-41475-100 Deutsch Connector Pick Tool Part No. HD-41675 Oil Pressure Sending Unit Wrench HD41496 h42310a Part No. HD-41496 Main Drive Gear Seal Installer Part No. HD-42310 Engine Transmission Stand 2007 Buell Firebolt: Appendix A...
Page 8 Part No. HD-42376 Battery Load Tester h42320a b42887 Part No. HD-42320-A Piston Pin Extractor Part No. B-42887 Brake Caliper Piston Remover h42322 h43646a Part No. HD-42322 Piston Support Plate Part No HD-43646-A Rolling Engine Stand 2007 Buell Firebolt: Appendix A...
Page 9 Part No. B-43721 Front Fork Seal Driver Part No. B-43993 Wheel Bearing Collets b-43982 hd44060 Part No. B43982 Transmission Locking Tool Part No. HD-44060 Wheel Bearing Remover/Installer hd43984 hd44067b Part No. HD-43984 Crankshaft Locking Tool Part No. HD-44067-A Oil Filter Wrench 2007 Buell Firebolt: Appendix A...
Page 10 Part No. HD-44567 7" Universal Driver Handle h44687 b45521 Part No HD-44687 Ignition Coil Test Adapter Part No. B-45521 Steering Head Bearing Remover/Installer HD44720a B-45522a Part No. HD-44720 TSSM Adapter Cable Part No. B-45522 Fuel Pressure Gauge Adapter 2007 Buell Firebolt: Appendix A...
Page 11 Part No. B-45524 Valve Guide Installer Part No. HD-45830 Techlink Kit HD45835a B-45525 Part No. B-45525 Valve Guide Hone Part No. HD-45835 Road Test Kit b45657 B43983 Part No. B-45657 Fuel Pump Puller Part No. B-45847 Cross Plate A-10 2007 Buell Firebolt: Appendix A...
Page 12 Part No. B-45926 Clutch Shell Bearing Remover Part No. B-46279 7/8" Axle Wrench (Hex) HD45928 HD-46283 Part No. HD-45928 Terminal Crimper Part No. HD-46283 Primary Drive Locking Tool HD4529 HD-46285 Part No. HD-45929 Terminal Remover Part No.HD-46285 Transmission Assembly Fixture 2007 Buell Firebolt: Appendix A A-11...
Page 13 Part No. HD-47248 Rocker Housing Wrench HD-47184 HD-47250 Part No. HD-47184 Leak Detector Flashlight Part No. HD-47250 Intake Manifold Wrench HD-47258 HD-47187 Part No. HD-47258 Rocker Cover Wrench Part No. HD-47187 Technician Pen Light A-12 2007 Buell Firebolt: Appendix A...
Page 14 Part No. HD-48053 Advanced Battery Conductance Part No. HD-94804-57 Rocker Arm Bushing Reamer and Electrical System Analyzer HD-95635-46 J-5586A Part No. HD-95635-46 All-Purpose Claw Puller Part No. J-5586 Transmission Shaft (use with HD-95637-46A) Retaining Ring Pliers 2007 Buell Firebolt: Appendix A A-13...
Page 15 (HD-95770-69) and 8 (HD-95771-69) are optional. 96796-47 h95952-33C Part No. HD-95952-33C Connecting Rod Clamping Tool Part No. HD-96796 Valve Spring Test Fixture h96921-52C h95920-32D Part No. HD-95970-32D Piston Pin Bushing Tool Part No. HD-96921-52B A-14 2007 Buell Firebolt: Appendix A...
Page 16 HOME h97081a Part No. HD97097-65B Hose Clamp Pliers HD99500-80a Part No. HD-99500-80 Wheel Truing & Balancing Stand 2007 Buell Firebolt: Appendix A A-15...
Page 17 HOME NOTES A-16 2007 Buell Firebolt: Appendix A...
Page 18: 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 2007 Buell Firebolt: Appendix B...
Page 19 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. 2007 Buell Firebolt: Appendix B...
Page 20 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 2007 Buell Firebolt: Appendix B...
Page 21 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 2007 Buell Firebolt: Appendix B...
Page 22 “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. 2007 Buell Firebolt: Appendix B...
Page 23 (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. 2007 Buell Firebolt: Appendix B...
Page 24 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. 2007 Buell Firebolt: Appendix B...
Page 25 When correctly positioned, the locking bar ﬁts snugly in the space between the contact band and the core crimp tails. 2007 Buell Firebolt: Appendix B...
Page 26 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 2007 Buell Firebolt: Appendix B...
Page 27 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 2007 Buell Firebolt: Appendix B...
Page 28 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. 2007 Buell Firebolt: Appendix B B-11...
Page 29 HOME PUSH-TO-SEAT TERMINALS Installing Push-to-Seat Terminals NOTE The Packard push-to-seat terminal connectors are Buell Fire- For wire location purposes, alpha characters are stamped bolts. onto the secondary locks or onto the wire end of the connec- tor housing. Removing Push-to-Seat Terminals...
Page 30 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 2007 Buell Firebolt: Appendix B B-13...
Page 31: Electrical Connectors
[90] engine temperature sensor 1-place bullet beneath air cleaner baseplate [91A] data link 4-place Deutsch beneath left side fairing 2-place spade [93] tail light back of tail light 1-place spade (ground) B-14 2007 Buell Firebolt: Appendix B...
Page 32 Interactive exhaust subharness to [165] 3-place Deutsch under seat main harness [178] Active intake system to solenoid 2-place Deutsch under air cleaner cover [179] Active intake system to ECM 2-place Deutsch in fairing 2007 Buell Firebolt: Appendix B B-15...
Page 33 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 Starting and charging circuits B-27 Component circuits B-29 B-16 2007 Buell Firebolt: Appendix B...
Page 34 DATA LINK SPEEDOMETER BK/R LT.GN/R TN/LT.GN [91A] [77B] R/BK LH TURN SIGNAL [39A] GN/Y OIL PRESSURE SW R/BK [31B] [120B] [95B] R/BK CLUTCH SW GN/Y R/BK [120A] MALE R/BK FEMALE 2007 XB Firebolt Main Harness 2007 Buell Firebolt: Electrical B-17...
Page 35 HOME 2007 XB Firebolt Main Harness 2007 XB Firebolt Main Harness B-18 2007 Buell Firebolt: Electrical...
Page 36 BK/W GN/W GN/W W/BK BK/W BK/W BANK ANGLE SENSOR GY/O [14B] [14A] [134B] GY/O [38A] DATA LINK SPEEDOMETER LT.GN/R [39A] [95B] CLUTCH SW [91A] R/BK R/BK MALE R/BK FEMALE 2007 XB Firebolt Engine Management Circuit 2007 Buell Firebolt: Electrical B-19...
Page 37 HOME 2007 XB Firebolt Engine Management Circuit 2007 XB Firebolt Engine Management Circuit B-20 2007 Buell Firebolt: Electrical...
Page 38 KEY SWITCH 15 AMP [39B] 1 2 3 4 5 6 7 8 9 10 HEADLAMP [24A] LH CONTROLS [62B] RELAY CENTER [38A] SPEEDOMETER LH TURN SIGNAL [39A] [31B] R/BK R/BK 2007 XB Firebolt Lighting Circuit 2007 Buell Firebolt: Electrical B-21...
Page 39 HOME 2007 XB Firebolt Lighting Circuit 2007 XB Firebolt Lighting Circuit B-22 2007 Buell Firebolt: Electrical...
Page 40 1 2 3 4 5 6 7 8 9 10 [24A] RELAY CENTER 1 2 3 4 5 6 7 8 [62B] LH CONTROLS SPEEDOMETER TN/LT.GN [39A] GN/Y [120B] R/BK GN/Y OIL PRESSURE SW MALE [120A] FEMALE 2007 XB Firebolt Horn & Instruments Circuit 2007 Buell Firebolt: Electrical B-23...
Page 41 HOME 2007 XB Firebolt Horn & Instruments Circuit 2007 XB Firebolt Horn & Instruments Circuit B-24 2007 Buell Firebolt: Electrical...
Page 42 TN/LT.GN IGNITION 15AMP GY/O R/BK KEY SWITCH 15AMP 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 2007 XB Firebolt Starting Circuit 2007 Buell Firebolt: Electrical B-25...
Page 43 HOME 2007 XB Firebolt Starting Circuit 2007 XB Firebolt Starting Circuit B-26 2007 Buell Firebolt: Electrical...
Page 44 HOME bd0018xx Battery Cable [128A] Battery Starter Motor [GRD2] To J-Fuse Assembly Maxifuse [5A] To Voltage Regulator [77B] [77A] Voltage Regulator Stator H-D 3-Phase Male Female [46A] [46B] 2007 XB Firebolt Starting & Charging Circuit 2007 Buell Firebolt: Electrical B-27...
Page 45 HOME 2007 XB Firebolt Starting & Charging Circuit 2007 XB Firebolt Starting & Charging Circuit B-28 2007 Buell Firebolt: Electrical...
Page 46 [85B] FUEL PUMP [84B] ENGINE TEMP SENSOR PK/Y [90B] [90A] MAIN HARNESS BN/Y [86B] [89A] BANK ANGLE SENSOR FUEL INTAKE AIR TEMP SENSOR LT.GN/GY [89B] BK/W MALE [134B] [134A] FEMALE 2007 XB Firebolt Component Circuits 2007 Buell Firebolt: Electrical B-29...
Page 47 HOME 2007 XB Firebolt Component Circuits 2007 XB Firebolt Component Circuits B-30 2007 Buell Firebolt: Electrical...
Page 48 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 2007 Buell Firebolt: Appendix C...
Page 49 2.113 = pints (U.S.) pints (Imp.) x 1.201 = pints (U.S.) liters x 1.057 = quarts (U.S.) quarts (Imp.) x 1.201 = quarts (U.S.) liters x 0.264 = gallons (U.S.) gallons (Imp.) x 1.201 = gallons (U.S.) 2007 Buell Firebolt: Appendix C...
Page 50 HOME HOSE AND WIRE ROUTING b1114xaxf Figure D-1. Front and Rear Brake Systems, Right Side View...
Page 51 HOME b1115abxf Figure D-2. Rear Brake Systems, Top View...
Page 52 HOME b1116acxf Figure D-3. Rear Brake Systems, Left Side View...
Page 53 HOME b1117aaxf Carbon canister Figure D-4. Evaporative Emissions Control, California Models, Top View...
Page 54 HOME b1118abxf 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 55 HOME b1119xcxf To ECM Active intake solenoid (Japan only) Fuel pump Intake air temperature sensor (IAT) Figure D-6. Wiring Harness, Left Side View...
Page 56 HOME b1120abxf Fuel injector (2) Intake air temperature (IAT) sensor Throttle position sensor (TPS) Oxygen (O2) sensor Figure D-7. Wiring Harness, Top View...
Page 57 HOME b1121xdsxu 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 58 HOME b1122xbsxf 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 59 HOME b1123xcsxf Vent line Feed oil line Return oil line Figure D-10. Oil Lines, Bottom View...
Page 60 HOME b1124xbxf Exhaust valve actuator Mufﬂer valve Figure D-11. Clutch, Throttle Cables and Interactive Exhaust System (1200 Only), Right Side View...
Page 61 HOME b1125xcxaf Exhaust valve actuator Cable, seat lock Mufﬂer valve Figure D-12. Clutch, Throttle Seat Release Cables and Interactive Exhaust System (1200 Only), Left Side View...
Page 62 HOME b1126xdxaf TPS adjuster Cable, seat lock Clip to functional air cleaner cover. Exhaust valve actuator mounted functional air cleaner cover. Figure D-13. Clutch, Throttle Seat Release Cables and Active Intake System with Exhaust Valve Actuator (1200 Only), Top View...
Page 64 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. 2007 Buell Firebolt: Appendix E...
Page 65 (1) inward to the fully retracted position. 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 2007 Buell Firebolt: Appendix E...
Page 66 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 2007 Buell Firebolt: Appendix E...
Page 67 Adjust stop screw, while reading the TPS on Digital 1.15 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 2007 Buell Firebolt: Appendix E...
Page 68 HOME b1171xex Active Intake Solenoid [178A] [178B] Figure E-4. Active Intake System 2007 Buell Firebolt: Appendix E...
Page 69 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. 2007 Buell Firebolt: Appendix E...
Page 70 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. 2007 Buell Firebolt: Appendix E...
Page 71 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 2007 Buell Firebolt: Appendix E...
Page 72: Table Of Contents
MAINTENANCE Table Of Contents SUBJECT PAGE NO. 1.1 General ............1.2 Fuel and Oil .
Page 74: General
Operate the vehicle to perform any ﬁnal check or adjust- All required parts or materials can be found in the appropriate ments. If all is correct, the vehicle is ready to go back to the PARTS CATALOG. customer. 2007 Buell Firebolt: Maintenance...
Page 75: 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. 2007 Buell Firebolt: Maintenance...
Page 76: 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. 2007 Buell Firebolt: Maintenance...
Page 77: 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. 2007 Buell Firebolt: Maintenance...
Page 78: Fuel And Oil
If the engine is run long enough for the crankcase to age and/or equipment malfunction. (00148a) become thoroughly heated, the water returns to vapor and is Buell motorcycles are designed to give the best performance then exhausted. using unleaded gasoline. Some fuel suppliers sell gasoline/ alcohol blends as a fuel.
Page 79: 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. Every two years. 2007 Buell Firebolt: Maintenance...
Page 80 1/8 in. (3.2 mm) from the top Master cylinder reservoir cover torque 9-13 in-lbs (1.0-1.5 Nm) Brake pad linings and Minimum brake pad thickness 0.040 in. (1.0 mm) or less discs Minimum brake disc thickness 0.18 in. (4.5 mm) or less 2007 Buell Firebolt: Maintenance...
Page 81 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) 2007 Buell Firebolt: Maintenance...
Page 82: Windshield Maintenance
WINDSHIELD MAINTENANCE GENERAL HARLEY-DAVIDSON SUNWASH (PART No. 94659-98). NOVUS 1 CLEANER/PROTECTANT (Part No. 99837- Buell recommends using Harley Softcloths with the following 94T). products to clean your windscreen. To minimize swirl marks, NOVUS 2 SCRATCH REMOVER (Part No. 99836-94T). cleaning should be done when motorcycle is cool and parked in the shade.
Page 83: Battery Maintenance
HOME BATTERY MAINTENANCE GENERAL BATTERY TESTING Voltmeter Test Buell motorcycle batteries are permanently sealed, mainte- nance-free, valve-regulated, lead/calcium and sulfuric acid Table 1-4. 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 84: Cleaning And Inspection
Inspect the battery case for cracks or leaks. 100 % at 77 ° F 75 % at 105 ° F 50 % M O N T H S O F S T A N D Figure 1-3. Battery Self-Discharge Rate 2007 Buell Firebolt: Maintenance 1-11...
Page 85 (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) 1-12 2007 Buell Firebolt: Maintenance...
Page 86: Engine Lubrication System
The motorcycle must be on level ground, on the side- stand, with the engine off. Figure 1-4. Unscrew and remove dipstick from oil tank/swingarm ﬁller hole. Wipe dipstick clean. Insert dipstick into oil tank ﬁller hole, screwing dipstick in completely. DO NOT OVER TIGHTEN. 2007 Buell Firebolt: Maintenance 1-13...
Page 87: Engine Oil And Filter Change
Check that no lubricant gets on tires, wheels or brakes when changing ﬂuid. Traction can be adversely affected, which could result in loss of control of the motorcycle and death or serious injury. (00047b) Figure 1-6. Dipstick Location 8418 Figure 1-7. Oil Filter 1-14 2007 Buell Firebolt: Maintenance...
Page 88 ° 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 2007 Buell Firebolt: Maintenance 1-15...
Page 89: Brake System Maintenance
5). Use only D.O.T. 4 brake ﬂuid in motorcycles that spec- 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. 1-16 2007 Buell Firebolt: Maintenance...
Page 90 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. 2007 Buell Firebolt: Maintenance 1-17...
Page 91: 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. 1-18 2007 Buell Firebolt: Maintenance...
Page 92: Bleeding Rear Brake
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) 11. Install seat. See 2.38 SEAT. 2007 Buell Firebolt: Maintenance 1-19...
Page 93 Figure 1-12. Critical Measurements with Typical clevis and tighten to 130-173.5 in-lbs (14.7-19.6 Brake Pedal Nm). NOTE Brake pedal has no free play adjustment. 8349 Bottom of master cylinder Rod adjuster Locknut Clevis Clevis pin Figure 1-13. Pushrod Adjustment 1-20 2007 Buell Firebolt: Maintenance...
Page 94 0.18 in. (4.5 mm). NOTE 2.12 FRONT BRAKE CALIPER 2.15 REAR BRAKE CALIPER for rotor replacement procedure. Whenever rotor is replaced, replace rotor drive bushings, fasteners, washers and springs. Figure 1-15. Front Brake Rotor 2007 Buell Firebolt: Maintenance 1-21...
Page 95: Brake Pad Replacement
9-13 in-lbs (1.0- 1.5 Nm). NOTE Avoid making hard stops for the ﬁrst 100 miles (160 km) to allow new brake pads to “wear in” properly with the rotor. 1-22 2007 Buell Firebolt: Maintenance...
Page 96 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 1-18. Rear Brake Pad Spring 2007 Buell Firebolt: Maintenance 1-23...
Page 97: Tires And Wheels
TIRES AND WHEELS TIRE INFLATION 12379 WARNING WARNING Use only Buell approved tires. See a Buell dealer. Using non-approved tires can adversely affect stabil- ity, which could result in death or serious injury. (00133a) Do not inﬂate tire beyond maximum pressure as speciﬁed on sidewall.
Page 98: Clutch
Install clutch inspection cover tighten- Primary cover ing three fasteners and washers to 84-108 in-lbs (10- Correct chaincase lubricant level 12 Nm). Figure 1-22. Fluid Level Clean up any ﬂuid that may have spilled on mufﬂer. 2007 Buell Firebolt: Maintenance 1-25...
Page 99 Jam nut adjusting screw clockwise until it aligns. Adjuster NOTE Figure 1-23. Clutch Cable Adjuster Mechanism Spring installs on outboard side of hex lockplate. 8405 Diaphragm spring Lockplate Adjusting screw Figure 1-24. Clutch Adjustment 1-26 2007 Buell Firebolt: Maintenance...
Page 100 Slide boot (1) over cable adjuster mechanism. Change or add transmission ﬂuid if necessary. Figure 1-20. Install clutch inspection cover and new gasket using three fasteners and washers and tighten to 84-108 in-lbs (10-12 Nm). Figure 1-25. Adjusting Clutch Free Play 2007 Buell Firebolt: Maintenance 1-27...
Page 101: Drive Belt System
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. 1-28 2007 Buell Firebolt: Maintenance...
Page 102 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 2007 Buell Firebolt: Maintenance 1-29...
Page 103 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 1-30 2007 Buell Firebolt: Maintenance...
Page 104: Primary Chain
Tighten fasteners to 84-108 in-lbs (10-12 Nm). Table 1-9. Primary Chain Tension ENGINE FREE PLAY TEMPERATURE Cold 3/8-1/2 in. 9.5-12.7 mm Hot (normal running 1/4-3/8 in. 6.4-9.5 mm temperature) 2007 Buell Firebolt: Maintenance 1-31...
Page 105 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 (Typical) 1-32 2007 Buell Firebolt: Maintenance...
Page 106: 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 107 1.50 1.25 180-200 82-91 1.50 1.50 1.25 1.25 200-220 91-100 1.25 1.25 1.25 220-240 100-109 1.25 1.25 0.75 240-GVWR 109-GVWR 0.75 * Note all compression and rebound settings are # of turns out from maximum. 1-34 2007 Buell Firebolt: Maintenance...
Page 108 Using a screwdriver, turn the slotted dial Figure 1-31. Front Fork Compression Damping Adjuster clockwise until it stops. This is the maximum compression damping setting. Then turn the dial counterclockwise the recommended amount specified in Table 1-10. 2007 Buell Firebolt: Maintenance 1-35...
Page 109 This is the maximum rebound Figure 1-32. Rear Shock Preload Adjuster damping setting. Then turn the dial counterclockwise the recommended amount speciﬁed in Table 1-10. 8416a Figure 1-33. Rear Shock Rebound Adjustment 1-36 2007 Buell Firebolt: Maintenance...
Page 110 This is the maximum com- pression damping setting. Then turn the dial counterclockwise the recommended amount specified in Table 1-10. Figure 1-34. Accessing Rear Shock Compression Adjuster 8976 Figure 1-35. Rear Shock Compression Adjustment 2007 Buell Firebolt: Maintenance 1-37...
Page 111: Steering Head Bearings
Do not operate motorcycle with loose, worn 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 112: 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. 2007 Buell Firebolt: Maintenance 1-39...
Page 113 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 2.38 SEAT. 1-40 2007 Buell Firebolt: Maintenance...
Page 114: Air Cleaner Filter
Remove four fasteners, nylon washers and intake cover assembly. See 2.34 INTAKE COVER ASSEMBLY. Air cleaner cover Air cleaner cover latch tabs Figure 1-41. Air Cleaner Cover (XB9R) Figure 1-41. Unlatch six latching tabs and remove air cleaner cover from base plate. 2007 Buell Firebolt: Maintenance 1-41...
Page 115 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 2.38 SEAT. 1-42 2007 Buell Firebolt: Maintenance...
Page 116: Throttle Cable And Idle Speed Adjustment
10. Install left air scoop. See 2.35 AIR SCOOPS. 11. Recheck engine slow idle speed; adjust if required. 12. Install air cleaner assembly baseplate, ﬁlter, air cleaner cover and intake cover assembly. See 4.44 AIR CLEANER ASSEMBLY. 2007 Buell Firebolt: Maintenance 1-43...
Page 117: Interactive Exhaust Cable
This ensures the system is working prop- For the next step in the procedure it will be necessary to erly. If you do not see the mark, verify previous cable adjust- obtain a permanent marker. ment. 1-44 2007 Buell Firebolt: Maintenance...
Page 118 If cable is routed in front of the frame lug it will cause the mufﬂer valve to stay open not allowing it to work prop- erly. 12. Install air intake cover. See 2.34 INTAKE COVER ASSEMBLY. 2007 Buell Firebolt: Maintenance 1-45...
Page 119: Ignition Timing
Listen for fuel pump cycling to conﬁrm igni- tion is active. Turn or gently bump the ﬂywheel in a forward direction using the rear wheel. Position the ﬂywheel TDC mark at the very left edge of the inspection hole. 1-46 2007 Buell Firebolt: Maintenance...
Page 120 Tighten sensor assembly fasteners to 15-30 in-lbs (1.7- 3.4 Nm). Recheck timing. 12136a Figure 1-54. Retard Timing Figure 1-51. Timer Cover 8391a Figure 1-52. Cam Position Sensor (Timing Plate) 2007 Buell Firebolt: Maintenance 1-47...
Page 121: 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 1-55. Figure 1-56. Headlamp Switch Adjust headlamp alignment. See ADJUSTMENT section. 1-48 2007 Buell Firebolt: Maintenance...
Page 122 If headlamp requires adjustment, perform the following as required: To lower beam: Turn adjuster clockwise. To raise beam: Turn adjuster counterclockwise. High beam adjuster (left) Low beam adjuster (right) Figure 1-57. Headlamp Height Adjustment 2007 Buell Firebolt: Maintenance 1-49...
Page 123: Throttle Position Sensor (Tps)
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 1-58. Back off idle adjustment until TP volts stop decreasing and then continue to back out one full turn.
Page 124: Storage
Wash and polish molded-in-color, painted and chrome- plated surfaces. 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. 2007 Buell Firebolt: Maintenance 1-51...
Page 125: Troubleshooting
18. TP Sensor/fast idle screw not set properly. See dealer. 21. Obstructed fuel tank vent valve or pinched vent tube. 19. No output from CMP sensor. See dealer. See dealer. 20. Inoperative fuel pump. See dealer. 22. Air intake screen covered or restricted. 1-52 2007 Buell Firebolt: Maintenance...
Page 126: 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. 2007 Buell Firebolt: Maintenance 1-53...
Page 127 Shock absorber or front forks not functioning normally. 1.12 SUSPENSION DAMPING ADJUSTMENTS. 10. Heavy front end loading. Non-standard equipment on the front end (such as heavy radio receivers, extra lighting equipment or luggage) tends to cause unstable handling. 1-54 2007 Buell Firebolt: Maintenance...
Page 128 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. 2007 Buell Firebolt: Maintenance 1-55...
Page 129 HOME NOTES 1-56 2007 Buell Firebolt: Maintenance...
Page 130 2.2 Tire Specifications ..........2.3 Buell Vehicle Identification Number (V.I.N.) ......
Page 132: Specifications
ﬁed on sidewall. Over inﬂated tires can blow out, which Transmission 1.0 quart could result in death or serious injury. (00027a) Table 2-4. Brake Rotor Runout RUNOUT Front radial 0.0177 0.45 Front lateral 0.0248 0.63 Rear radial 0.0177 0.45 Rear lateral 0.0154 0.39 2007 Buell Firebolt: Chassis...
Page 133: Torque Values
Electronic control module fas- 72-96 in-lbs 8-11 Nm page 2-73 teners Engine shift lever pinch screw 48-60 in-lbs 5.4-6.8 Nm LOCTITE 271 (red), Page 2-69 Engine shroud air scoop 12-36 in-lbs 1-4 Nm page 2-88 2007 Buell Firebolt: Chassis...
Page 134 22-27 Nm page 2-32 front Master cylinder cover fasten- 9-13 in-lbs 1.0-1.5 Nm page 2-30 ers, front Master cylinder mounting fas- 72-96 in-lbs 8-11 Nm page 2-39 teners, rear Mirror fasteners 72-96 in-lbs 8-11 Nm page 2-93 2007 Buell Firebolt: Chassis...
Page 135 3-4 Nm page 2-66 right Tail body work, upper 12-36 in-lbs 1-4 Nm page 2-92 Tail frame to frame 21-23 ft-lbs 28-31 Nm LOCTITE 271 (red), page 2-91 Torca clamp 28-30 ft-lbs 38-40.6 Nm page 2-80 2007 Buell Firebolt: Chassis...
Page 136 HOME ITEM TORQUE NOTES Valve stem nut 40-44 in-lbs 4.5-4.9 Nm page 2-23 Wear peg, rider 36-48 in-lbs 4.1-5.4 m LOCTITE 271 (red), page 2-81 2007 Buell Firebolt: Chassis...
Page 137: 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 138: Buell Vehicle Identification Number (V.i.n.)
A Motor Identiﬁcation Number is stamped on the left 4MZ KP 01 D 3 7 3 0 00456 Figure 2-2. Typical 2007 Buell Vehicle Identiﬁcation Number Table 2-7. Buell 2007 XB Models V.I.N. Description ITEM...
Page 139: Wheels
Figure 2-3. Checking Tire Inﬂation Pressure Figure 2-3. 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. 2007 Buell Firebolt: Chassis...
Page 140 WARNING WARNING To prevent death or serious injury, use the following Use only Buell approved tires. See a Buell dealer. Using guidelines when installing a new tire or repairing a ﬂat: non-approved tires can adversely affect stability, which could result in death or serious injury. (00133a)At regular...
Page 141: Front Wheel
Figure 2-5. 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 2-5. Front Wheel Removal 2-10 2007 Buell Firebolt: Chassis...
Page 142 Forcing screw Figure 2-8. Expand the Collet Figure 2-9. 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. 2007 Buell Firebolt: Chassis 2-11...
Page 143 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 1.7 BRAKE SYSTEM MAINTENANCE 2.12 FRONT BRAKE CALIPER. 2-12 2007 Buell Firebolt: Chassis...
Page 144: Bearing Installation
Backing plate Remove the nut, bearing, washer, FRONT BEARING Forcing screw INSTALLER (Part No. B-43993-9) and forcing screw. Figure 2-12. Install the Backing Plate (B-43993-11) and Forcing Screw 2007 Buell Firebolt: Chassis 2-13...
Page 145 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 2-15. Install the Spacer 10. See Figure 2-15. Install the spacer. 2-14 2007 Buell Firebolt: Chassis...
Page 146 (8) toward center of wheel. Align reference dot on front rotor with the valve stem. CAUTION Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. (00319b) 2007 Buell Firebolt: Chassis 2-15...
Page 147 Tighten the front axle pinch fasteners (2) to 20-22 ft-lbs (27-30 Nm). 8419 Install right side fender fasteners. See 2.31 FENDERS. Axle (left handed thread) Front axle pinch fasteners (2) (metric) Figure 2-19. Front Wheel Mounting 2-16 2007 Buell Firebolt: Chassis...
Page 148: Rear Wheel
Remove idler pulley assembly by removing nuts and washers. See IDLER PULLEY REMOVAL 6.6 DRIVE BELT SYSTEM. Remove lower belt guard. See 2.32 BELT GUARDS. Remove rear axle. 2007 Buell Firebolt: Chassis 2-17...
Page 149 Be sure that brake ﬂuid or other lubricants do not con- tact brake pads or discs. Such contact can adversely affect braking ability, which could cause loss of control, resulting in death or serious injury. (00290a) 2-18 2007 Buell Firebolt: Chassis...
Page 150 40-45 ft-lbs (54-61 Nm). Position rear brake rotor (2) on wheel (5). Install lower belt guard. See 2.32 BELT GUARDS. Install brake rotor (2) with new rotor mounting fas- teners (1) and tighten to 25-27 ft-lbs (34-37 Nm). 2007 Buell Firebolt: Chassis 2-19...
Page 151 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) 2-20 2007 Buell Firebolt: Chassis...
Page 152: Checking Cast Rim Runout
Wheel Truing and Balancing Stand (HD-99500-80) Table 2-9. Wheel Rim Runout b0758x2x RUNOUT Maximum lateral 0.040 1.02 Maximum radial 0.030 0.76 Gauge rod Figure 2-28. Checking Cast Rim Radial Runout Using Wheel Truing and Balancing Stand (HD-99500-80) 2007 Buell Firebolt: Chassis 2-21...
Page 153: 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 154 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 2-32. Starting Bead on Rim (Typical) changing front and rear tires can cause tire failure, which could result in death or serious injury.
Page 155 Figure 2-33. Checking Tire Lateral Runout RUNOUT. Replace rims not meeting speciﬁcations. Install tire and check tire tread radial runout again. b0088x2x Gauge Figure 2-34. Checking Tire Radial Runout Table 2-10. Tire Runout RUNOUT Radial 0.060 1.52 Lateral 0.080 2.03 2-24 2007 Buell Firebolt: Chassis...
Page 156: 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. 2007 Buell Firebolt: Chassis 2-25...
Page 157: Brake Pedal
(5) to 22-24 ft-lbs (30-33 Nm). Install clevis pin (2). Rear master cylinder body Install new cotter pin (7). Clevis pin Pedal bushings (2) Shift brake pedal sleeve Brake pedal fastener Brake pedal Cotter pin Figure 2-36. Brake Pedal Assembly 2-26 2007 Buell Firebolt: Chassis...
Page 158 Pivot bolt nut (metric) 10. Brake switch fastener 11. Brake switch 12. Brake switch terminal 13. Banjo bolt (metric) 14. Brake line 15. Copper washers 16. Pivot bolt Figure 2-37. Front Brake Hand Lever Assembly 2007 Buell Firebolt: Chassis 2-27...
Page 159: Front Brake Master Cylinder
Circlip Figure 2-38. Piston Assembly in Master Cylinder Figure 2-38. Depress piston assembly (1) and remove internal circlip (2) and discard. Figure 2-37. Remove piston assembly (6) from front master cylinder reservoir (4) and discard. 2-28 2007 Buell Firebolt: Chassis...
Page 160: Front Master Cylinder
Figure 2-39. Front Master Cylinder Piston Assembly Figure 2-39. Assemble new piston components placing small end of spring (5) behind primary seal of piston (4). Lubricate master cylinder body and piston seals with special lubricant found in the service parts kit. 2007 Buell Firebolt: Chassis 2-29...
Page 161 Bleed brake system. See 1.7 BRAKE SYSTEM MAINTE- NANCE. 10. See Figure 2-37. Attach master cylinder cover (2) and cover gasket (3). Tighten two cover fasteners (1) to 9- 13 in-lbs (1.0-1.5 Nm). 2-30 2007 Buell Firebolt: Chassis...
Page 162: Front Brake Line
Carefully inspect the brake line for dents, cuts, chafﬁng or other defects. Replace the brake line if any damage is noted. P-clamp Brake line Wire form Bleeder valve Banjo bolt Figure 2-42. Front Brake Line 2007 Buell Firebolt: Chassis 2-31...
Page 163 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) 2-32 2007 Buell Firebolt: Chassis...
Page 164: Front Brake Caliper
Figure 2-44. Disconnect brake line at caliper. See 2.11 FRONT BRAKE LINE. Remove caliper mounting fasteners (5). Slide caliper down the rotor to clear fork lower and then remove off rotor. Figure 2-46. Removing Pistons (B-42887) 2007 Buell Firebolt: Chassis 2-33...
Page 165 Install two new o-rings (6) in grooves of each piston bore. Install pistons (5) in each piston bore. Install new o-rings (8) between caliper halves. Clamp caliper together with caliper fasteners (11) and tighten to 15-19 ft-lbs (20-26 Nm). 2-34 2007 Buell Firebolt: Chassis...
Page 166 HOME b0976x2x Pin hanger set Brake bleeder Bleeder cap Caliper Piston Piston o-rings Pad spring Small o-ring Caliper mounting fasteners 10. Brake pads 11. Caliper fasteners Figure 2-47. Front Caliper Assembly 2007 Buell Firebolt: Chassis 2-35...
Page 167: Rear Brake Master Cylinder
Prevent damage to seating surfaces by carefully Remote reservoir hose removing brake line components. Figure 2-49. Rear Master Cylinder On Vehicle Figure 2-49. Remove brake reservoir hose at master cylinder. Remove seat. See 2.38 SEAT. 2-36 2007 Buell Firebolt: Chassis...
Page 168 Rear brake light switch assembly Brake line Copper washer Rear master cylinder body Clevis pin Pedal bearing Sleeve Brake pedal fastener Brake pedal 10. Cotter pin 11. Rear master cylinder mount screw Figure 2-51. Rear Master Cylinder Assembly 2007 Buell Firebolt: Chassis 2-37...
Page 169 Circlip must be snapped into the groove of the master cylinder body. If the circlip is not properly installed, improper brake operation could result in death or serious injury. Tuck rubber boot on rod assembly (3) into master cylin- der body (1). 2-38 2007 Buell Firebolt: Chassis...
Page 170 (2). Tighten to 48-72 in-lbs (5.4-8.1 Nm). Attach hose (3) to rear brake reservoir using clamp. Figure 2-50. Connect brake line switch connector under seat. Install heel guard. See 2.29 FOOTPEG, HEEL GUARD AND MOUNT. 2007 Buell Firebolt: Chassis 2-39...
Page 171: Rear Brake Line
Tighten bleeder valve to 36-60 in-lbs (4-7 Nm). Figure 2-56. Rear Brake Line Switch/Banjo Bolt Figure 2-56. Remove brake light switch/banjo bolt from rear master cylinder. Discard copper washer. 10. Remove brake line from motorcycle. 2-40 2007 Buell Firebolt: Chassis...
Page 172 Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) 10. Turn ignition key ON, depress rear brake pedal and check for proper brake light operation. 2007 Buell Firebolt: Chassis 2-41...
Page 173: Rear Brake Caliper
Figure 2-59. Removing Rear Brake Caliper Piston Figure 2-59. Remove piston (3) using BRAKE CALI- PER PISTON REMOVER (1) (Part No. B-42887) with adaptor (2). Remove two o-rings from groove in caliper bore and dis- card. 2-42 2007 Buell Firebolt: Chassis...
Page 174 Install pin plug. Tighten to 24 in-lbs (3 Nm). either pad is worn to 0.04 in. (1.0 mm) or less. Install a new bleeder valve (metric) if necessary and tighten to 36-60 in-lbs (4-7 Nm). 2007 Buell Firebolt: Chassis 2-43...
Page 175 Low visibility of rider can result in death or serious injury. (00316a) NOTE Avoid making hard stops for the ﬁrst 100 miles (160 km) to allow new brake pads to “wear in” properly with the brake rotor. 2-44 2007 Buell Firebolt: Chassis...
Page 176: Front Fork
Remove fork from lower fork clamp (4). Repeat 4 through 6 on opposite side. Upper pinch fasteners Upper fork clamp Lower pinch fasteners Lower fork clamp Figure 2-62. Upper and Lower Fork Clamp Pinch Fasteners 2007 Buell Firebolt: Chassis 2-45...
Page 177 TOOL (1) (Part No. B-41177) in a vise and install the upper part of the front fork in the holding tool. Remove snap ring (2). Figure 2-66. Removing Fork Cap From Outer Tube Figure 2-66. Remove fork cap from outer tube. 2-46 2007 Buell Firebolt: Chassis...
Page 178 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). When using the FORK SPRING COMPRESSING TOOL Figure 2-67.
Page 179 24. Oil seal 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 2-69. Front Fork Assembly 2-48 2007 Buell Firebolt: Chassis...
Page 180 (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). 2007 Buell Firebolt: Chassis 2-49...
Page 181: 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). 2-50 2007 Buell Firebolt: Chassis...
Page 182 Thread fork cap (3) into fork tube (18) and tighten to 22-30 ft-lbs (29.8-40.6 Nm). 24. Apply fork oil or light grease to o-rings on preload adjuster and install preload adjuster (3). 25. Install snap ring (2). 2007 Buell Firebolt: Chassis 2-51...
Page 183 11. Install front wheel. See 2.5 FRONT WHEEL. 12. Install front fender. See 2.31 FENDERS. 13. Check headlamp alignment. See 1.19 HEADLIGHTS. 14. Adjust front forks suspension to rider preferences. See 1.12 SUSPENSION DAMPING ADJUSTMENTS. 2-52 2007 Buell Firebolt: Chassis...
Page 184: Fork Clamps, Upper And Lower
See 7.3 IGNITION/HEADLIGHT KEY SWITCH. b0937x2x Stem capnut Stem pinch fastener Upper fork clamp pinch fastener Upper fork clamp Head bearing Stem Lower fork clamp pinch fastener Lower fork clamp Figure 2-75. Steering Stem Assembly 2007 Buell Firebolt: Chassis 2-53...
Page 185 Repeat previous two steps on second fork assembly. Connect ignition switch and install cable strap. Tighten steering stem cap nut to 38-42 ft-lbs (52-57 Nm). Install steering stem pinch bolt applying LOCTITE 271 and tightening to 20-22 ft-lbs (27-30 Nm). 2-54 2007 Buell Firebolt: Chassis...
Page 186: Steering Head Bearings
(upper bearing removed for clarity) b1172x2x NOTE Discard steering head bearings and replace with new. Steer- ing head bearings are not reusable. Wheel Bearing Backing Plate (Part No. B-43993-12) Figure 2-77. Steering Head Bearings Installation Tools 2007 Buell Firebolt: Chassis 2-55...
Page 187 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. 2-56 2007 Buell Firebolt: Chassis...
Page 188 20-22 ft-lbs (27-30 Nm). 13. Apply LOCTITE 271 to the upper clamp fasteners and tighten to 23-25 ft-lbs (31-34 Nm) 14. Install brake lever housing. See 2.10 FRONT BRAKE MASTER CYLINDER AND HAND LEVER. Figure 2-80. Install Bearings 2007 Buell Firebolt: Chassis 2-57...
Page 189: Swingarm And Brace
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 2-82. Belt Guard Assembly 2-58 2007 Buell Firebolt: Chassis...
Page 190 12. Remove pivot shaft (9) with a special 7/8 in. hex tool from swingarm. See 1.6 ENGINE LUBRICATION SYS- located in tool kit. TEM. Remove rear wheel. See 2.6 REAR WHEEL. 13. Remove swingarm from vehicle. 2007 Buell Firebolt: Chassis 2-59...
Page 191 Figure 2-84. Install oil line ﬁttings on swingarm. Tighten to 108-156 in-lbs (12-17.6 Nm). See 3.10 OIL LINE FITTINGS. Figure 2-83. Install drain plug (8). Tighten to 26- 29 ft-lbs (35-39 Nm). 2-60 2007 Buell Firebolt: Chassis...
Page 192 (00070a) Install seat. See 2.38 SEAT. Final Swingarm Inspection Check oil level after starting motorcycle and allowing it to reach operating temperature. Check rear brake operation. 2007 Buell Firebolt: Chassis 2-61...
Page 193: Front And Rear Isolator
Tighten front isolator bolt (6) to 49-51 ft-lbs (66-69 Nm). NOTE Hold wire form while tightening to prevent it from twisting. Figure 2-85. Install clutch cable wire form. Tighten fastener to 84-92 in-lbs (9.4-10.3 Nm). 2-62 2007 Buell Firebolt: Chassis...
Page 194: Frame
Install rear shock. See 2.22 REAR SHOCK ABSORBER. Install subframe tail assembly. See 2.36 SUBFRAME TAIL ASSEMBLY AND BODY WORK. Install exhaust header. See 2.28 EXHAUST SYSTEM. Rotate engine. See 3.3 ENGINE ROTATION FOR SER- VICE. 2007 Buell Firebolt: Chassis 2-63...
Page 195: Rear Shock Absorber
Lower shock mount fastener and washer Shock reservoir body 10. Shock spring retainer kit Upper shock mount fastener 11. Rear shock spring Lower shock mount nut and washer 12. Washers Figure 2-88. Rear Shock Absorber Assembly 2-64 2007 Buell Firebolt: Chassis...
Page 196 (00070a) (13.5-16.2 Nm). Install seat. See 2.38 SEAT. Figure 2-89. Install cable strap. NOTE Figure 2-88. Verify compression adjuster screw is facing Install upper body work. See 2.36 SUBFRAME TAIL ASSEMBLY AND BODY WORK. 2007 Buell Firebolt: Chassis 2-65...
Page 197: Throttle Control
Attach housings with two fasteners, installing longer fastener on bottom. Tighten to 25-33 in-lbs (3-4 Nm). Adjust cables. See 1.16 THROTTLE CABLE AND IDLE SPEED ADJUSTMENT. Install air cleaner assembly. See 4.44 AIR CLEANER ASSEMBLY. 2-66 2007 Buell Firebolt: Chassis...
Page 198: Clutch Control
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 2-95. Clutch Hand Control Assembly 2007 Buell Firebolt: Chassis 2-67...
Page 199 Figure 2-97. Clutch Release Mechanism 15. See Figure 2-97. 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. 2-68 2007 Buell Firebolt: Chassis...
Page 200 Loctite 271 to fasteners and tighten to 36-60 in-lbs (4-6.8 Nm). Adjust to rider comfort. NOTE D.1 HOSE AND WIRE ROUTING in Appendix D. Route clutch cable through clutch cable wire form and upper triple clamp. 2007 Buell Firebolt: Chassis 2-69...
Page 201 13. Install new clutch cover gasket. 14. See Figure 2-96. 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). 2-70 2007 Buell Firebolt: Chassis...
Page 202: Headlight Assembly And Support Bracket
Loosen headlamp pivot fasteners (1). Rotate headlight bracket (2) down. 8470 Figure 2-102. Disconnect headlight connection. Disconnect and remove electronic control module. See 4.30 ELECTRONIC CONTROL MODULE. Figure 2-103. Remove headlight support bracket (2). Figure 2-102. Headlight Connector 2007 Buell Firebolt: Chassis 2-71...
Page 203 Headlight pivot fasteners Headlight support bracket Electronic control module fasteners Black rubber cover Low beam headlight Headlight fastener High beam headlight Headlight bulb Bank angle sensor 10. Bank angle sensor fastener Figure 2-103. Headlight Support Bracket Assembly 2-72 2007 Buell Firebolt: Chassis...
Page 204 (2) and tighten pivot fasteners (1) to 72-96 in-lbs (8- 11 Nm). Figure 2-101. Install electric control module. Figure 2-103. Align electronic control module and headlight support bracket with fairing support bracket. Tighten electronic control module fasteners (3) to 72-96 in-lbs (8-11 Nm). 2007 Buell Firebolt: Chassis 2-73...
Page 205: Fairing Support Bracket
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 2.38 SEAT. 2-74 2007 Buell Firebolt: Chassis...
Page 206 HOME b0958x2x Jam nut Washer Rubber grommet Fairing support bracket fasteners and washers Fairing support bracket Instrument cluster P-clamp P-clamp fastener and washers Figure 2-105. Fairing Support Bracket Assembly 2007 Buell Firebolt: Chassis 2-75...
Page 207: Handlebars
Remove clip-on endcap (1). Figure 2-94. Position clutch hand lever to rider pref- erences and tighten fastener (1) to 60-84 in-lbs (6.8- 9.5 Nm). See 2.24 CLUTCH CONTROL. 8355 Figure 2-106. Handlebar Clip-on Mounting Fasteners (right clip-on shown) 2-76 2007 Buell Firebolt: Chassis...
Page 208 HOME b0945x2x Endcap Clip-on Upper fork clamp Clip-on fastener Figure 2-107. Handlebar Clip-on Assembly (left clip-on shown) 2007 Buell Firebolt: Chassis 2-77...
Page 209: Exhaust System
Remove exhaust header (2) by Remove mufﬂer. removing mounting fasteners (3). NOTE Remove exhaust ring (4), retaining ring (5) and port gas- The mufﬂer may be removed for replacement without remov- ket (6). ing the exhaust header. 2-78 2007 Buell Firebolt: Chassis...
Page 210 10. Interactive exhaust cable Mufﬂer (XB9R) 11. Rear mufﬂer bracket Front mufﬂer strap 12. Rear mufﬂer bracket fasteners (2) Front mufﬂer strap fastener 13. Jacking point on mufﬂer Front mufﬂer mount Figure 2-108. Mufﬂer Assembly 2007 Buell Firebolt: Chassis 2-79...
Page 211 Torca mufﬂer clamps have eliminated the need for silicone or graphite tape during assembly. To ensure sealing integrity of mufﬂer clamps and prevent the possibility of leakage, Buell recommends that mufﬂer clamp assemblies be discarded and replaced each time they are removed.
Page 212: Footpeg, Heel Guard And Mount
36-48 in-lbs (4-5 Nm). Figure 2-110. Position footpeg mount (1). b0934a2x Footpeg mount Spring Footpeg mount fasteners Wear peg Heel guard Footpeg Heel guard fasteners Clip, footpeg Figure 2-110. Rider Footpeg, Mount and Heel Guard Assembly 2007 Buell Firebolt: Chassis 2-81...
Page 213 Check that footpeg clicks in the up and down position. Remove footpeg mount (3). Heel guard fasteners b0933x2x Heel guard Footpeg mount Spring Ball Detent plate Clip Footpeg 10. Footpeg mount fastener Figure 2-111. Passenger Footpeg, Mount and Heel Guard Assembly 2-82 2007 Buell Firebolt: Chassis...
Page 214: Sprocket Cover
36 in-lbs (1-4 Nm). Install chin fairing. See 2.33 CHIN FAIRING. Figure 2-112. Chin Fairing Assembly, Right Rear Fasteners b1187x2x Long fastener and washer Sprocket cover Short fastener and washer (2) Figure 2-113. Sprocket Cover 2007 Buell Firebolt: Chassis 2-83...
Page 215: Fenders
Install rear fender (3) with fasteners and washers (4), Tighten to 12-36 in-lbs (1-4 Nm). Front fender Front fender fastener and washer Rear fender Rear fender fastener and washer Figure 2-114. Front and Rear Fender 2-84 2007 Buell Firebolt: Chassis...
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 2-115. Belt Guard Assembly 2007 Buell Firebolt: Chassis 2-85...
Page 217: Chin Fairing
Turn wheel full right or left for easier access to center fasten- ers. Align left section (3) and loosely install left side fasteners and washers (4). Apply LOCTITE 271 (red) and tighten all fasteners to 36- 48 in-lbs (4-5 Nm). “‘ 2-86 2007 Buell Firebolt: Chassis...
Page 218: Intake Cover Assembly
Install seat. See 2.38 SEAT. Figure 2-117. Start the front two fasteners (2) with nylon washers. b1222x2x b0981x2x Intake cover assembly Intake cover fasteners and washers Intake air inlet Figure 2-117. Intake Cover Assembly 2007 Buell Firebolt: Chassis 2-87...
Page 219: Air Scoops
Oil cooler air scoop fastener and washer (2) Ram air scoop Oil cooler air scoop Engine shroud scoop fastener and washer (3) Ram air scoop fastener and washer Engine shroud scoop Figure 2-118. Ram Air Scoop, Engine Shroud, Oil Cooler 2-88 2007 Buell Firebolt: Chassis...
Page 220: Subframe Tail Assembly And Body Work
Passenger seat lock plate 11. Trunk Passenger seat lock retainer 12. Fastener Passenger seat lock cable 13. License plate bracket Subframe tail assembly 14. Passenger seat latch and fastener Figure 2-119. Subframe Tail Assembly and Body Work Assembly 2007 Buell Firebolt: Chassis 2-89...
Page 221 15. See Figure 2-121. Cut cable strap (4) holding rear brake reservoir hose (5) and rear brake light wire (6). 16. Disconnect rear brake light connection (6). 2-90 2007 Buell Firebolt: Chassis...
Page 222 Figure 2-121. Install cable strap holding brake light powdercoat must be cleaned using only mild soap and warm connector and rear reservoir hose. water. After washing, always dry the surface using a clean, soft cloth. 2007 Buell Firebolt: Chassis 2-91...
Page 223 See 7.14 TURN SIGNALS 7.13 TAIL LAMP. 23. Install seat and pillion. See 2.38 SEAT. 20. Install passenger seat latch (14) from rear of subframe tail assembly and tighten to 60-96 in-lbs (7-11 Nm). 2-92 2007 Buell Firebolt: Chassis...
Page 224: Front Fairing, Windshield And Mirrors
(5). fasteners (3) and tighten to 10-12 in-lbs (1-1.4 Nm). b0967x2x Windshield Mirrors Side windshield fastener Center windshield fastener Front fairing Turn signal Turn signal fastener Well nut Figure 2-123. Front Fairing and Windscreen 2007 Buell Firebolt: Chassis 2-93...
Page 225: Seat
Align rear tab with latch slot at rear of motorcycle. Press down firmly on rear of pillion seat to engage seat latch. Pull up on rear of pillion seat to make sure latch is engaged. Turn ignition key counterclockwise and remove from seat lock. 2-94 2007 Buell Firebolt: Chassis...
Page 226: Passenger Seat Lock
11. Install the seat lock cable (9) into the seat lock plate (6). 12. Install upper body work on tail section. See 2.36 SUB- FRAME TAIL ASSEMBLY AND BODY WORK. 13. Install rider and pillion seat. See 2.38 SEAT. 2007 Buell Firebolt: Chassis 2-95...
Page 227: Sidestand
Retract sidestand leg (1). Remove sidestand spring (2) and spring extension plate (4) using SNAP-ON SPRING TOOL (Part No. HE-52B). Remove sidestand pivot pin circlip (7) and remove sidestand pivot pin (3). Extend sidestand leg (1) and remove. 2-96 2007 Buell Firebolt: Chassis...
Page 228 Install mufﬂer. See Mufﬂer and Straps 2.28 EXHAUST SYSTEM. Install chin fairing fasteners. See 2.33 CHIN FAIRING. Extend and retract sidestand leg to check for proper operation Figure 2-131. Lubricating Points (Shaded Areas) 2007 Buell Firebolt: Chassis 2-97...
Page 229 HOME NOTES 2-98 2007 Buell Firebolt: Chassis...
Page 230 ENGINE Table Of Contents SUBJECT PAGE NO. 3.1 Specifications ..........3.2 Engine .
Page 232: Specifications
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 2007 Buell Firebolt: Engine...
Page 233 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 2007 Buell Firebolt: Engine...
Page 234 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 2007 Buell Firebolt: Engine...
Page 235 3-76 Oil ﬁlter adapter 96-144 in-lbs 11-16 Nm LOCTITE 243 (blue), page 3-86 Oil line clamp at starter motor 40-50 in-lbs 5-5.5 Nm page 3-35 Oil line ﬁttings at swingarm 108-156 in-lbs 12-17.6 Nm page 3-74 2007 Buell Firebolt: Engine...
Page 236 LOCTITE 271 (red), page 3-30 bolt Swingarm pivot shaft 24-26 ft-lbs 32.5-35.2 Nm page 3-30 V bracket to main frame 120-144 in-lbs 13.6-16.3 Nm page 3-14 Vent oil line at gearcase cover 12-13 ft-lbs 16.3-17.6 Nm page 3-35 2007 Buell Firebolt: Engine...
Page 237: Engine
“oxygenate” the gas. Your sion, it indicates the piston rings need replacing. Low motorcycle will run normally using this type of gas. Buell compression by itself, however, may indicate improperly recommends you use it when possible, as an aid to seated valves, in addition to or in lieu of worn piston rings.
Page 238: Diagnosing Smoking Engine Or High Oil Consumption
Valve guide seals. The following are some general instructions that apply to Buell motorcycle engines: Valve guide-to-valve stem clearance. Run engine until it reaches normal operating tempera- ture. Gasket surface of both head and cylinder. 2007 Buell Firebolt: Engine...
Page 239: Engine Rotation For Service
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) 2007 Buell Firebolt: Engine...
Page 240 Figure 3-2. Electrical Connections and Throttle Cables (Typical) 10. See Figure 3-2. Disconnect the ignition coil connector (2) [83] and remove ignition coil (1). 11. Disconnect the following sensors: Temperature sensor (3) [90] Oxygen sensor (4) [137]. 2007 Buell Firebolt: Engine...
Page 241 Figure 3-3. Remove mufﬂer. See 2.28 EXHAUST 2.35 AIR SCOOPS. SYSTEM. 13. Remove idler pulley. See 6.6 DRIVE BELT SYSTEM. NOTE 7.6 INTERACTIVE EXHAUST SYSTEM (XB12 MODEL) for speciﬁc details on removal of interactive components. 3-10 2007 Buell Firebolt: Engine...
Page 242 Loosen clutch adjuster to release tension from hand lever. Remove clutch cable ferrule from hand lever. Wire form retainer Clutch cable adjuster boot Figure 3-4. Clutch Cable Wire Form Retainer and Adjuster Boot 2007 Buell Firebolt: Engine 3-11...
Page 243 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 2007 Buell Firebolt: Engine...
Page 244 Figure 3-7. Front Isolator and Tie Bar Assemblies 21. Loosen rear isolator bolt. DO NOT REMOVE. 22. See Figure 3-7. Remove front isolator bolt (1). 23. Remove front isolator mount (2) from engine. 24. Rotate engine down. 2007 Buell Firebolt: Engine 3-13...
Page 245 120-144 in-lbs (13.6-16.3 Nm). See 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 2007 Buell Firebolt: Engine...
Page 246 Install wire form and tighten fastener to 84-92 in-lbs (9.5-10.4 Nm). Figure 3-9. Clutch Cable Wire Form Retainer 10501a Figure 3-10. Oil Cooler Feed and Return Oil Line 1/8-1/4 in. (3.175-6.35 mm) Clearance to Clutch Cable 2007 Buell Firebolt: Engine 3-15...
Page 247 Figure 3-11. Electrical Connections and Throttle Cables (Typical) 11. Connect the following sensors: Temperature sensor [90]. Oxygen sensor [137]. 12. See Figure 3-11. Install the ignition coil (1) and connect (2) [83] and tighten fasteners to 120-144 in-lbs (13.6- 16.3 Nm). 3-16 2007 Buell Firebolt: Engine...
Page 248 22. Install sprocket cover. See 2.30 SPROCKET COVER. 23. Install chin fairing. See 2.33 CHIN FAIRING. 24. Install air scoops, right and left sides. See 2.35 AIR SCOOPS. 25. Connect fuel pump. See 4.39 FUEL PUMP. 2007 Buell Firebolt: Engine 3-17...
Page 249: Stripping Motorcycle For Engine Service
(-) battery cable before proceeding. (00048a). 10646a Fuel line connection Connection for throttle position sensor [88] Connections for fuel injectors [84 & 85] Figure 3-13. Fuel Line and DDFI Electrical Connections (Typical) 3-18 2007 Buell Firebolt: Engine...
Page 250 Figure 3-14. Disconnect the ignition coil connector (2) and remove the ignition coil (1). 10. Disconnect the following sensors: Temperature sensor [90] (3). Oxygen sensor [137] (4). 11. Disconnect throttle cables from induction module/throttle body. 2007 Buell Firebolt: Engine 3-19...
Page 251 13. Remove chin fairing. See 2.33 CHIN FAIRING. 16. See Figure 3-15. Remove mufﬂer. See 2.28 EXHAUST 14. Remove rear belt and idler pulley. See 6.6 DRIVE BELT SYSTEM. SYSTEM. 15. Remove transmission sprocket. See 6.16 TRANSMIS- SION SPROCKET. 3-20 2007 Buell Firebolt: Engine...
Page 252 Figure 3-16. Remove oil ﬁlter (8). NOTE Remove the right side footrest mount and secure towards 18. Remove left and right side rider footrest mounts. See rear of vehicle. 2.29 FOOTPEG, HEEL GUARD AND MOUNT. 2007 Buell Firebolt: Engine 3-21...
Page 253 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 3-17. Engine Mounting System 3-22 2007 Buell Firebolt: Engine...
Page 254 (1) [77]. Disconnect oil cooler lines at oil cooler. Remove front tie-bar (7) from “V” bracket. Remove front tie-bar (7) from engine. Unbolt “V” bracket from main frame and remove “V” bracket. 2007 Buell Firebolt: Engine 3-23...
Page 255 Remove p-clamp (12) at swingarm/oil reservoir (1). Disconnect oil return line (4) at swingarm/oil reser- voir (1). See 3.10 OIL LINE FITTINGS. Disconnect oil return line (4) at oil pump (14) and remove. 28. Remove front and rear mufﬂer brackets. 3-24 2007 Buell Firebolt: Engine...
Page 256 Figure 3-21. Remove two fasteners (5) and remove sidestand assembly. Sidestand assembly 31. Support engine with wide scissors jack. Bracket fasteners (2) b0946c2x Figure 3-21. Sidestand Assembly (Extended) 32. See Figure 3-21. Remove sidestand assembly. 2007 Buell Firebolt: Engine 3-25...
Page 257 37. Lower engine with scissors lift all the way down. 38. Move the engine assembly from under the main frame to the right side of the lift. 39. Remove engine. Figure 3-23. Supporting the Swingarm (Typical) 3-26 2007 Buell Firebolt: Engine...
Page 258 Aluminum bushings from front exhaust mount. Figure 3-28. Front Exhaust Mount Bushings (2 piece) Timer cover. Figure 3-29. Wire guard located under the sprocket cover. 12367 8724 12369a 8729 Figure 3-29. Wire Guard Figure 3-27. Removing Threaded Insert 2007 Buell Firebolt: Engine 3-27...
Page 259 NOTE Figure 3-32. This allows the vehicle to remain together as a rolling chassis and to be removed from the lift and stored if necessary. 3-28 2007 Buell Firebolt: Engine...
Page 260: Engine Installation
Remove pivot shaft after installing the Right Side threaded insert. Figure 3-35. Apply LOCTITE 242 (blue) to swin- garm pivot shaft pinch bolt threaded insert and install. Figure 3-36. Front Exhaust Mount Bushings (2 piece) 2007 Buell Firebolt: Engine 3-29...
Page 261 Using the overhead hoist to align the Apply LOCTITE 271 (red) and tighten swingarm pivot frame to the rear isolator, install rear isolator bolt and shaft pinch bolt to 17-19 ft-lbs (23-25.8 Nm). leave loose at this time. 3-30 2007 Buell Firebolt: Engine...
Page 262 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 3-42. Engine Mounting System 2007 Buell Firebolt: Engine 3-31...
Page 263 (33.9-36.6 Nm). Attach remote idle adjustment cable “V” to bracket using nylon cable straps. Attach regulator wiring harness to clutch cable below clutch cable lower retaining clamp using a nylon cable strap. 18. Remove scissors jack. 3-32 2007 Buell Firebolt: Engine...
Page 264 ﬁtting with a wrench to maintain proper orientation NOTE and prevent damage to the oil line ﬁtting. DO NOT install mufﬂer at this time. It is necessary to install mufﬂer mounts ﬁrst in order to properly install feed oil line. 2007 Buell Firebolt: Engine 3-33...
Page 265 The feed oil line (3) is routed through the right side of the rear vehicle. Leave all oil line ﬁttings loose at the engine at mufﬂer bracket (10). this time. See 3.10 OIL LINE FITTINGS. 3-34 2007 Buell Firebolt: Engine...
Page 266 24. Install oil line clamp (13) attaching vent oil line (2) to 13 ft-lbs (16.3-17.6 Nm). return oil line (4) in front of starter motor and tighten to 40-50 in-lbs (5-5.5 Nm). 28. Install vent oil line protective cover. 2007 Buell Firebolt: Engine 3-35...
Page 267 ﬁtting with a wrench to maintain proper orientation 1/4 (3.175-6.35 mm) clearance speciﬁed between the and prevent damage to the oil line ﬁtting. feed oil line and the clutch cable at the front of the crank- case. 3-36 2007 Buell Firebolt: Engine...
Page 268 (1-4 Nm). b1031x3x Oil cooler feed line should be centered after line is torqued. Orientation of return line should be approximately 6 o’clock Figure 3-49. Oil Cooler Feed and Return Oil Lines Location and Orientation 2007 Buell Firebolt: Engine 3-37...
Page 269 7.25 SPROCKET COVER WIRING before connect- ing the following electrical components: Neutral switch [131]. Speedometer sensor [65]. Cam position sensor [14]. Alternator [46]. Voltage regulator [77]. Positive battery cable at starter. Starter solenoid [128]. Oil pressure switch [120]. 3-38 2007 Buell Firebolt: Engine...
Page 270 Connect clutch cable to handlebars and adjust to speciﬁcations. See CLUTCH. Install wire form retainer and tighten fastener to 84- 92 in-lbs (9.5-10.4 Nm). 35. Install sidestand assembly. See 2.40 SIDESTAND. Figure 3-51. Correct Routing of Wiring Harnesses and Interactive Mufﬂer Cable 2007 Buell Firebolt: Engine 3-39...
Page 271 HOME b0986x3c Clamp, Torca Mufﬂer Mufﬂer strap, front Front mufﬂer strap fastener Front mufﬂer mount Rear mufﬂer bracket Rear mufﬂer strap fastener Mufﬂer strap, rear (2) Figure 3-53. Mufﬂer and Mounting System 3-40 2007 Buell Firebolt: Engine...
Page 272 [83] (2). Tighten ignition coil fas- teners 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 3-54. Electrical Connections and Throttle Cables (Typical) 2007 Buell Firebolt: Engine 3-41...
Page 273 (00070a) 48. Install rear belt and idler pulley. See 6.6 DRIVE BELT SYSTEM. 54. Install seat. See 2.38 SEAT. 3-42 2007 Buell Firebolt: Engine...
Page 274: 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) b1266x3x Figure 3-56. Rocker Arm and Pushrod Cover Assemblies 2007 Buell Firebolt: Engine 3-43...
Page 275 Remove rocker arms and mark them for reassembly in their original locations. 10. Mark the location and orientation (top/bottom) of each push rod. Remove push rods. Figure 3-58. Removing Rocker Arm Shafts 3-44 2007 Buell Firebolt: Engine...
Page 276 No special tools are required to remove valve stem seal and lower collar assembly. Repeat the above procedure for the other valves. Figure 3-59. Head Screw Loosening/Tightening Sequence 8684 Figure 3-60. Valve Spring Compressor (Part No. HD-34736B) 2007 Buell Firebolt: Engine 3-45...
Page 277 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 3-61. Cylinder Head, Cylinder and Piston Assembly 3-46 2007 Buell Firebolt: Engine...
Page 278 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. 2007 Buell Firebolt: Engine 3-47...
Page 279 Figure 3-64. Measure where rocker arm bush- Check end play of rocker arm with feeler gauge. ings ride. Replace rocker arm or lower cover or both if end play exceeds 0.025 in. (0.635 mm). 3-48 2007 Buell Firebolt: Engine...
Page 280: 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. 2007 Buell Firebolt: Engine 3-49...
Page 281 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 3-69. Replacing Rocker Arm Bushings 3-50 2007 Buell Firebolt: Engine...
Page 282 60°. Figure 3-71. Cleaning Valve Guides Figure 3-71. Thoroughly clean valve guide bores using VALVE GUIDE BRUSH (Part No. HD-34751) and hot soapy water. 2007 Buell Firebolt: Engine 3-51...
Page 283 Clamp tool in vise and further tighten cylinder head onto the ﬁxture to prevent any movement during operation. Place cylinder head at a 45° angle or one that offers a comfortable working position. 3-52 2007 Buell Firebolt: Engine...
Page 284 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 3-73. Valve and Seat Dimensions 2007 Buell Firebolt: Engine 3-53...
Page 285 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 3-74. Cylinder Head, Cylinder and Piston Assembly 3-54 2007 Buell Firebolt: Engine...
Page 286 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. 2007 Buell Firebolt: Engine 3-55...
Page 287 10. Insert valve keepers into upper collar, making sure they engage grooves in valve stem. 11. Release and remove from VALVE SPRING COMPRES- SOR. 12. Repeat steps 4-11 for the remaining valve. 3-56 2007 Buell Firebolt: Engine...
Page 288 1 Band-Orange 17909-02 (271.948 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. 2007 Buell Firebolt: Engine 3-57...
Page 289: Cylinder Head Installation
Tighten each screw to 13-15 ft-lbs (18-20 Nm). Figure 3-82. Tightening Head Screws Figure 3-82. Mark cylinder head and head screw shoulder with a line as shown (View A). ° ° Turn all screws an additional 85 -95 . 3-58 2007 Buell Firebolt: Engine...
Page 290 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) b1266x3x Figure 3-83. Rocker Arm and Push Rod Cover Assemblies 2007 Buell Firebolt: Engine 3-59...
Page 291 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 120-168 in- lbs (13.6-18.9 Nm). 3-60 2007 Buell Firebolt: Engine...
Page 292: Cylinder And Piston
Ring set Piston Piston pin Retaining ring (2) Dowel and o-ring Cylinder Base gasket Cylinder stud (4) Connecting rod 10. Piston pin bushing Figure 3-85. Cylinder and Piston 2007 Buell Firebolt: Engine 3-61...
Page 293 Figure 3-88. Removing Piston Rings Remove circlip from claw and discard. Figure 3-88. To remove piston rings spread outward until they clear grooves in piston and lift off. 3-62 2007 Buell Firebolt: Engine...
Page 294 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. 2007 Buell Firebolt: Engine 3-63...
Page 295 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. 3-64 2007 Buell Firebolt: Engine...
Page 296 If re-using pis- ton, replace piston rings and hone the cylinder walls with a No. 240 grit ﬂexible hone to facilitate ring seating. Piston ring sets must be properly ﬁtted to piston and cyl- inder: 2007 Buell Firebolt: Engine 3-65...
Page 297 Figure 3-94. Ring End Gap Position Figure 3-94. Install rings so end gaps of adjacent rings are a minimum of 90° apart. Ring gaps are not to be within 10° of the thrust face centerline. 3-66 2007 Buell Firebolt: Engine...
Page 298 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. 2007 Buell Firebolt: Engine 3-67...
Page 299 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. 3-68 2007 Buell Firebolt: Engine...
Page 300 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. 2007 Buell Firebolt: Engine 3-69...
Page 301 HOME NOTES 3-70 2007 Buell Firebolt: Engine...
Page 302: Lubrication System
2500 mile (4000 km) intervals. Reﬁll with fresh oil. Always change oil ﬁlter when changing engine oil. NOTE 1.6 ENGINE LUBRICATION SYSTEM for more informa- tion on checking oil level and changing oil and ﬁlter. 2007 Buell Firebolt: Engine 3-71...
Page 303: Oil Hose Routing And Oil Reservoir
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 3-106. Oil Lines and Connections 3-72 2007 Buell Firebolt: Engine...
Page 304: Oil Line Fittings
Repeat to remove the remaining oil lines. Remove oil line ﬁttings and plug the holes until they can Figure 3-107. Oil Line Remover (B-41623-B) be replaced. 10369 Figure 3-108. Oil Line Fitting with Spring Clip 2007 Buell Firebolt: Engine 3-73...
Page 305 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 3-109. Flanged Oil Line 3-74 2007 Buell Firebolt: Engine...
Page 306: Oil Cooler
Oil cooler feed line Screws with washers (2) Oil cooler return line Stabilizer bracket Clamp, oil line Screw with washer (1) Screw with nut Oil cooler scoop Oil cooler 10. Screws with washers (2) Figure 3-110. Oil Cooler 2007 Buell Firebolt: Engine 3-75...
Page 307 The oil cooler should be checked for dirt and debris. Figure 3-111. Verify that the clutch cable and feed line have a clearance of 1/8-1/4 in. (3.175-6.35 mm) between them. Install oil line clamp and tighten to 12-36 in-lbs (1.3-4 Nm). 3-76 2007 Buell Firebolt: Engine...
Page 308 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 3-111. Oil Cooler Feed Oil Line Orientation (Approximately 2 O’Clock) and Oil LIne Clearances 2007 Buell Firebolt: Engine 3-77...
Page 309: Oil Pressure Indicator Switch
Burned-out signal bulb. (prior to oper- crankcase. Dead battery (see NOTE). ating engine). See Install OIL PRESSURE GAUGE ADAPTER (Part No. HD-96925-58) (2) in oil pressure indicator lamp switch mounting hole. Tighten adapter snugly. DO NOT OVERTIGHTEN. 3-78 2007 Buell Firebolt: Engine...
Page 310 10. Check oil level in oil tank. See 1.6 ENGINE LUBRICA- TION SYSTEM. 11. Start engine and test oil pressure switch for proper oper- ation. Check oil pressure switch for leaks. 2007 Buell Firebolt: Engine 3-79...
Page 311: Crankcase Breathing System
8661 Base plate, air box Breather hose, rear Breather hose, front PCV Valves (2) Figure 3-114. Reed Valve Assembly in Gearcase Grommet Rocker cover (2) Figure 3-115. Crankcase Breathing System 3-80 2007 Buell Firebolt: Engine...
Page 312 (3). b1033x3x Reed valve fastener Reed valve Reed valve stop 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 2007 Buell Firebolt: Engine 3-81...
Page 313: 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. 3-82 2007 Buell Firebolt: Engine...
Page 314: 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 2007 Buell Firebolt: Engine 3-83...
Page 315 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 3-84 2007 Buell Firebolt: Engine...
Page 316 ﬁtting. 1.6 ENGINE LUBRICATION SYSTEM. Liberally coat all moving parts with clean engine oil to ensure easy assembly and smooth operation at start-up. 15. Install chin fairing. See 2.33 CHIN FAIRING. 2007 Buell Firebolt: Engine 3-85...
Page 317: 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. 3-86 2007 Buell Firebolt: Engine...
Page 318: 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. 2007 Buell Firebolt: Engine 3-87...
Page 319 Install push rods, cylinder head, lower and upper rocker covers. See 3.6 CYLINDER HEAD. Repeat process for remaining cylinder head. Pushrod (exhaust) O-ring Pushrod cover Screws (4) Pushrod cover Pushrod cover gasket Hydraulic lifter (tappet) Anti- rotation screw Figure 3-125. Valve Lifter Service 3-88 2007 Buell Firebolt: Engine...
Page 320: Gearcase Cover And Cam Gears
Gear cover gasket 13. Oil pump drive gear Bushing, outer, intake camshaft gear 14. Pinion gear “E” Cam gear set 15. Nut Right crankcase half 16. Bushing, gear shaft- pinion Figure 3-126. Gearcase Cover & Cam Assembly 2007 Buell Firebolt: Engine 3-89...
Page 321 8662a Front exhaust cam gear Front intake cam gear Rear intake cam gear Rear exhaust cam gear Pinion gear Pinion nut Timing V marks Figure 3-127. Cam and Pinion Gear Location and Timing Mark Indexing 3-90 2007 Buell Firebolt: Engine...
Page 322 Table 3-25. Cam Location Numbers STAMP LOCATION 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. 2007 Buell Firebolt: Engine 3-91...
Page 323 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) 3-92 2007 Buell Firebolt: Engine...
Page 324 Install cam position sensor and rotor in gearcase cover. 8654 4.31 CAM POSITION SENSOR AND ROTOR sec- tion. 10. Install any components removed to gain access to gear- case. Figure 3-132. Checking Cam Gear End Play 2007 Buell Firebolt: Engine 3-93...
Page 325: Crankcase
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. 3-94 2007 Buell Firebolt: Engine...
Page 326 Placing wrench on ﬁrst (lower) nut installed, unscrew piston jet assembly to free piston jets from right crank- stud from cylinder deck. case. Remove piston jet gaskets from right crankcase. Loosen nuts and remove from cylinder base stud. 2007 Buell Firebolt: Engine 3-95...
Page 327 11. Inner race Thrust washer 12. Gear shaft bearing Crankcase half 13. Retaining ring Bearing 14. Outer bearing race Bearing retaining ring 15. Crankshaft case Inner race, sprocket shaft bearing Figure 3-137. Crankcase and Flywheel Assembly 3-96 2007 Buell Firebolt: Engine...
Page 328 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). 2007 Buell Firebolt: Engine 3-97...
Page 329 (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. 3-98 2007 Buell Firebolt: Engine...
Page 330 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. 2007 Buell Firebolt: Engine 3-99...
Page 331 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 3-100 2007 Buell Firebolt: Engine...
Page 332 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. 2007 Buell Firebolt: Engine 3-101...
Page 333 1.2499 in. (31.747 mm) OD inner race, a blue bear- Table 3-34. Pinion Inner Race ing is required. Speciﬁcations Roundness within 0.0002 in. (0.0051 mm) Taper within 0.0002 in. (0.0051 mm) Surface ﬁnish 16 RMS 3-102 2007 Buell Firebolt: Engine...
Page 334 Check connecting rod side play with a thickness gauge as shown. If side play measurement is greater than the service wear limit, 0.036 in. (0.8 mm), replace the ﬂywheel/con- necting rod assembly. Figure 3-149. Checking Connecting Rod Side Play 2007 Buell Firebolt: Engine 3-103...
Page 335 LATION. Figure 3-151. Using CRANKCASE BEARING REMOVER/INSTALLER (Part No. B-45655, HD-42720-2 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 3-104 2007 Buell Firebolt: Engine...
Page 336 Figure 3-152. Installing Flywheel Assembly with CRANKSHAFT GUIDE (Part No. HD-42326) 8789 a0120x3x Figure 3-153. Pinion Shaft Bearing 8762 Shoulder Crankcase bearing remover/installer tool (Part No. B-45655, HD-42720-2 and HD-46663) Retaining ring Figure 3-151. Sprocket Shaft Bearing Installation 2007 Buell Firebolt: Engine 3-105...
Page 337 Slide outer race in right crankcase over pinion shaft and bearing assembly. Apply LOCTITE 271 to the last few threads and 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. 3-106 2007 Buell Firebolt: Engine...
Page 338 Install the stud in the crankcase with the shoulder end down. Use an air gun to drive the stud until the shoulder reaches the crankcase. Remove air gun. Use a torque wrench to tighten stud to 10-20 ft-lbs (14-27 Nm). 2007 Buell Firebolt: Engine 3-107...
Page 339 HOME NOTES 3-108 2007 Buell Firebolt: Engine...
Page 340 Table Of Contents FUEL SYSTEM SUBJECT PAGE NO. 4.1 Specifications ..........4.2 Dynamic Digital Fuel Injection .
Page 341 4.38 Cooling Fan ..........4-106 4.39 Fuel Pump .
Page 342: Fuel System
Low fuel level sensor retaining 18-22 in-lbs 2.0-2.5 Nm page 4-110 screw Manifold to engine mount fas- 90-120 in-lbs 10-13.6 Nm page 4-121 tener Oxygen sensor 40-45 ft-lbs 54-61 Nm LOCTITE ANTI-SEIZE, page 4-101 2007 Buell Firebolt: Fuel System...
Page 343 4-129 clamp rear Throttle position sensor LOCTITE THREADLOCKER 222 (purple), page 12-15 in-lbs 1.4-1.7 Nm 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 2007 Buell Firebolt: Fuel System...
Page 344: Dynamic Digital Fuel Injection
DYNAMIC DIGITAL FUEL INJECTION (DDFI) INTRODUCTION GENERAL The Buell DDFII operates both as an open and closed loop The Buell Dynamic Digital Fuel Injection (DDFII) System pro- system which allows it to adjust for all possible operating con- vides microprocessor-based electronic engine management ditions.
Page 345 BE/O IGN Coil Throttle To cooling Position Cooling BK/O fan fuse Sensor BK/W TN/V BE/O BK/W LT GN/Y Sensor [165] Ground Interactive mufﬂer control To Brake/horn/ mufﬂer fuse Figure 4-1. Buell Dynamic Digital Fuel Injection 2007 Buell Firebolt: Fuel System...
Page 346: 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. 2007 Buell Firebolt: Fuel System...
Page 347: 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 2007 Buell Firebolt: Fuel System...
Page 348 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. 2007 Buell Firebolt: Fuel System...
Page 349: 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. 2007 Buell Firebolt: Fuel System...
Page 350 50 start and run cycles. To execute one run cycle: Remove diagnostic test wire and install protective cover Start the vehicle. over data link connector. Return data link to original posi- tion. Let it run for at least 30 seconds. Turn the engine off. 2007 Buell Firebolt: Fuel System...
Page 351: Breakout Box
[10] (black) and [11] (gray). Detach Breakout Box connectors from ECM connectors. Detach Breakout Box connectors from wiring harness. Breakout Box Install ECM. See 4.30 ELECTRONIC CONTROL MOD- ULE. Figure 4-10. Installed Breakout Box 4-10 2007 Buell Firebolt: Fuel System...
Page 352: 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. 2007 Buell Firebolt: Fuel System 4-11...
Page 353: Initial Diagnostic Check
Starts hard. See Table 4-4. ADJUSTMENT. Hesitates, stumbles, surges, misﬁres and/or slug- EVAP hose disconnected Connect. gish performance. See Table 4-5. from induction module Engine exhaust emits black smoke or fouls plugs. (CA) Table 4-6. 4-12 2007 Buell Firebolt: Fuel System...
Page 354 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 2007 Buell Firebolt: Fuel System 4-13...
Page 355 Table 4-8. Wire Harness Connectors in Figure 4-12. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing [11] ECM (gray) 12-place Deutsch in fairing [91A] data link 4-place Deutsch beneath left side fairing 4-14 2007 Buell Firebolt: Fuel System...
Page 356 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). 2007 Buell Firebolt: Fuel System 4-15...
Page 357 DATA LINK TERMINAL 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. 4-16 2007 Buell Firebolt: Fuel System...
Page 358: Check Engine Lamp Not Illuminated At Key On 4.9
If connection is good, replace ECM. See 4.30 ELECTRONIC CONTROL MODULE. Check continuity between instrument connector [39] Pin 7 and ECM connector [10] (black), Pin 4. Headlights Figure 4-14. Electronic Control Module 2007 Buell Firebolt: Fuel System 4-17...
Page 359 Electronic Control Module (ECM) Figure 4-15. Check Engine Lamp Circuit Table 4-9. Wire Harness Connectors in Figure 4-15. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing [39] instrument module 20-place Multilock in fairing 4-18 2007 Buell Firebolt: Fuel System...
Page 360 Repair open or Disassemble instrument short to voltage on module. Inspect check BK/Y wire between engine lamp bulb. connector [39] and Bulb failed? connector [10B]. Replace Instrument module. See 7.18 INSTRUMENT MODULE Replace bulb. 2007 Buell Firebolt: Fuel System 4-19...
Page 361: Check Engine Lamp On Continuously
Test 4.10 ﬂow chart. Figure 4-17. If the lamp goes off when the black ECM connector [10] is unplugged, the BK/Y wire is not 8428 shorted to ground. Headlights Figure 4-17. Electronic Control Module 4-20 2007 Buell Firebolt: Fuel System...
Page 362 Electronic Control Module (ECM) Figure 4-18. Check Engine Lamp Circuit Table 4-10. Wire Harness Connectors in Figure 4-18. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing [39] instrument module 20-place Multilock in fairing 2007 Buell Firebolt: Fuel System 4-21...
Page 363 Replace ECM. See Replace Instrument Repair short to ground function OK. Check for 4.30 ELECTRONIC Module on BK/Y wire between trouble codes. See CONTROL MODULE. connector [39] and CHECKING FOR connector [10]. TROUBLE CODES. 4-22 2007 Buell Firebolt: Fuel System...
Page 364: 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. 2007 Buell Firebolt: Fuel System 4-23...
Page 365 DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing [11] ECM (gray) 12-place Deutsch in fairing [14] cam position sensor 3-place Deutsch under sprocket cover [83] ignition coil 3-place Packard beneath airbox base 4-24 2007 Buell Firebolt: Fuel System...
Page 366 Sensor [14] Rear Front Injector Injector [85] [84] [85A] [14A] [84A] To Ignition Relay A B C [84B] [85B] [14B] Dyno Loop Connector [11] Connector [10] Electronic Control Module (ECM) Figure 4-21. Ignition Circuit 2007 Buell Firebolt: Fuel System 4-25...
Page 367 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. 4-26 2007 Buell Firebolt: Fuel System...
Page 368 PART 3 of 3. Check for continuity between Ter- minal A connector [14B] and ground. Continuity present? Replace Replace ignition coil. spark plugs Repair open circuit. Repair short Replace ECM. See to ground. 4.30 ELECTRONIC CONTROL MODULE. 2007 Buell Firebolt: Fuel System 4-27...
Page 369 Replace cam Replace cam position Mechanical failure. position sensor. See 4.31 sensor. See 4.31 Inspect for loose CAM POSITION SENSOR CAM POSITION SEN- rotor cup and ROTOR. SOR AND ROTOR. sheared pinion gear key. 4-28 2007 Buell Firebolt: Fuel System...
Page 370: 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 can also disable the Connect BREAKOUT BOX (Part No. HD-42682) to ECM. ECM. 4.6 BREAKOUT BOX. 2007 Buell Firebolt: Fuel System 4-29...
Page 371 Table 4-12. Wire Harness Connectors in Figure 4-22. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing [22] right hand controls 4-place Multilock beneath right side of fairing [95] clutch switch 2-place Multilock beneath fairing 4-30 2007 Buell Firebolt: Fuel System...
Page 372 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. 2007 Buell Firebolt: Fuel System 4-31...
Page 373: Fuel Pressure Test
Figure 4-24. Fuel Line NOTE Figure 4-26. 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 2007 Buell Firebolt: Fuel System...
Page 374 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 4-26. Fuel Pressure Gauge (Part No. HD-41182) 2007 Buell Firebolt: Fuel System 4-33...
Page 375 Table 4-13. Wire Harness Connectors in Figure 4-27. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing [39] instrument module 20-place Multilock in fairing [86] fuel pump 4-place Multilock left side of rear shock absorber 4-34 2007 Buell Firebolt: Fuel System...
Page 376 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. 2007 Buell Firebolt: Fuel System 4-35...
Page 377 [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 2007 Buell Firebolt: Fuel System...
Page 378: Idle Speed Control
An idle speed too low can cause poor throttle response. An idle speed too high can cause a slow return to idle. 1.16 THROTTLE CABLE AND IDLE SPEED ADJUST- MENT for more information on idle speed adjustment. 2007 Buell Firebolt: Fuel System 4-37...
Page 379: Misfire
7.4 SPARK PLUG CABLES. Using an ohmmeter, touch probes to terminals on each end plug wire. Compare resistance values to Table 4-15. Replace cables not meeting speciﬁcations. Reinstall and repeat procedure on other spark plug cable. 4-38 2007 Buell Firebolt: Fuel System...
Page 380 Table 4-16. Wire Harness Connectors in Figure 4-30. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing [22] right hand controls 4-place Multilock beneath right side of fairing [83] ignition coil 3-place Packard beneath airbox base 2007 Buell Firebolt: Fuel System 4-39...
Page 381 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 2007 Buell Firebolt: Fuel System...
Page 382 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. 2007 Buell Firebolt: Fuel System 4-41...
Page 383 HOME NOTES 4-42 2007 Buell Firebolt: Fuel System...
Page 384: Trouble Code 11
Diagnostic Notes The reference numbers below correlate with the circled num- bers on the Code 11 ﬂow charts. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. 2007 Buell Firebolt: Fuel System 4-43...
Page 385 [11] ECM (gray) 12-place Deutsch in fairing [14] cam position sensor 3-place Deutsch beneath sprocket cover [88] throttle position sensor 3-place Packard beneath air cleaner baseplate [134] bank angle sensor 6-place Sumitomo in fairing 4-44 2007 Buell Firebolt: Fuel System...
Page 386 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2007 Buell Firebolt: Fuel System 4-45...
Page 387 [14]. Measure resistance Replace BAS. between connector [88] Terminal A and Terminal C. Is resistance greater than 1 megaohm? Locate and repair short between R/W and BK/W Replace cam position wires. Reconnect [14]. sensor. 4-46 2007 Buell Firebolt: Fuel System...
Page 388: Trouble Code 13
If fresh air enters exhaust system, the oxygen 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. 2007 Buell Firebolt: Fuel System 4-47...
Page 389 Electronic Control Module (ECM) Figure 4-36. Oxygen Sensor Circuit Table 4-18. Wire Harness Connectors in Figure 4-36. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch in fairing [137] oxygen sensor 1-place Packard behind rear cylinder head 4-48 2007 Buell Firebolt: Fuel System...
Page 390 4.30 ELECTRONIC 4.30 ELECTRONIC voltage and repair. V/GY wire. CONTROL MODULE. CONTROL MODULE. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2007 Buell Firebolt: Fuel System 4-49...
Page 391 Repair. Fuel injectors may be dirty. See Fuel Injectors 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 2007 Buell Firebolt: Fuel System...
Page 392 ECM (4.30 now OK. ELECTRONIC CONTROL MODULE). Road test again to verify. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2007 Buell Firebolt: Fuel System 4-51...
Page 393: Trouble Code 14
[10]). bers on the Code 14 ﬂow charts. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404), gray pin probes and patch cord. 4-52 2007 Buell Firebolt: Fuel System...
Page 394 Figure 4-38. Engine Temperature Sensor Circuit Table 4-20. Wire Harness Connectors in Figure 4-38. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch in fairing [90] engine temperature sensor 1-place bullet beneath air cleaner baseplate 2007 Buell Firebolt: Fuel System 4-53...
Page 395 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 2007 Buell Firebolt: Fuel System...
Page 396 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2007 Buell Firebolt: Fuel System 4-55...
Page 397: Trouble Code 15
Shifted sensor. The temperature-to-resistance values table may be used to test the IAT sensor at various tem- perature levels in order to evaluate the possibility of a shifted (out-of-calibration) sensor which may result in driveability problems. 4-56 2007 Buell Firebolt: Fuel System...
Page 398 Figure 4-39. Intake Air Temperature Sensor Circuit Table 4-22. Wire Harness Connectors in Figure 4-39. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch in fairing [89] intake air temperature sensor 2-place Amp in air cleaner baseplate 2007 Buell Firebolt: Fuel System 4-57...
Page 399 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 2007 Buell Firebolt: Fuel System...
Page 400 Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2007 Buell Firebolt: Fuel System 4-59...
Page 401: Trouble Code 16
Figure 4-41. Fuse Block bd0016ax Empty Spare Diode Spare Empty Bk/Hn/Mflr Lights Acces. Key Sw Figure 4-42. Fuses and Diode 4-60 2007 Buell Firebolt: Fuel System...
Page 402 Connector [10] Connector [11] Electronic Control Module (ECM) Figure 4-43. Battery Voltage Circuit Table 4-23. Wire Harness Connectors in Figure 4-43. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing 2007 Buell Firebolt: Fuel System 4-61...
Page 403 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 2007 Buell Firebolt: Fuel System...
Page 404 Is voltage drop greater than 0.5 volt? Replace R/Y wire between main 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). 2007 Buell Firebolt: Fuel System 4-63...
Page 405: Trouble Code 21
Figure 4-44. Fuses and Diode Using TEST CONNECTOR KIT (Part No. HD-41404), attach red probe and patch cord to [164B] (1, 2). Using TEST CONNECTOR KIT (Part No. HD-41404), use gray male pin probe and patch cord. 4-64 2007 Buell Firebolt: Fuel System...
Page 406 Figure 4-45. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing [161] Interactive mufﬂer actuator 4-place Amp beneath air cleaner [164] 1-place Amp in fairing [165] sub-harness 3-place Deutsch beneath air cleaner baseplate 2007 Buell Firebolt: Fuel System 4-65...
Page 407 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 2007 Buell Firebolt: Fuel System...
Page 408: 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 4-47. 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). 2007 Buell Firebolt: Fuel System 4-67...
Page 409 ECM (black) 12-place Deutsch in fairing [14] cam position sensor 3-place Deutsch beneath sprocket cover [84] front fuel injector 2-place Packard beneath air cleaner baseplate [85] rear fuel injector 2-place Packard beneath air cleaner baseplate 4-68 2007 Buell Firebolt: Fuel System...
Page 410 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). 2007 Buell Firebolt: Fuel System 4-69...
Page 411 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 2007 Buell Firebolt: Fuel System...
Page 412 24 or 25. This condition is normal and does not by itself indicate a malfunction. Codes must be cleared if his condition occurs. Figure 4-50. Testing Ignition Coil Connectors 2007 Buell Firebolt: Fuel System 4-71...
Page 413 Electronic Control Module (ECM) Figure 4-51. Ignition Coil Circuit Table 4-26. Wire Harness Connectors in Figure 4-51. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch beneath fairing [83] ignition coil 3-place Packard beneath air cleaner baseplate 4-72 2007 Buell Firebolt: Fuel System...
Page 414 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). 2007 Buell Firebolt: Fuel System 4-73...
Page 415: 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 2007 Buell Firebolt: Fuel System...
Page 416 Table 4-27. Wire Harness Connectors in Figure 4-53. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing [39] instrument module 20-place Multilock in fairing [86] fuel pump 4-place Multilock left side of rear shock absorber 2007 Buell Firebolt: Fuel System 4-75...
Page 417 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 2007 Buell Firebolt: Fuel System...
Page 418: Trouble Code 35
Code 35 ﬂow chart. Breakout box Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Figure 4-54. Installed Breakout Box Replace instrument module. See 7.18 INSTRUMENT MODULE. 8426 Figure 4-55. Instrument Module Connector [39] 2007 Buell Firebolt: Fuel System 4-77...
Page 419 Connector [11] Electronic Control Module (ECM) Figure 4-56. Tachometer Circuit Table 4-28. Wire Harness Connectors in Figure 4-56. DESCRIPTION TYPE LOCATION [10] ECM (black) 12-place Deutsch in fairing [39] instrument module 20-place Multilock in fairing 4-78 2007 Buell Firebolt: Fuel System...
Page 420 TEST. Intermit- TROL MODULE. tents found? Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). Repair. Replace instrument module. 7.18 INSTRUMENT MODULE 2007 Buell Firebolt: Fuel System 4-79...
Page 421: 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 2007 Buell Firebolt: Fuel System...
Page 422 Electronic Control Module (ECM) Figure 4-58. Cooling Fan Circuit Table 4-30. Wire Harness Connectors in Figure 4-58. DESCRIPTION TYPE LOCATION [11] ECM (gray) 12-place Deutsch in fairing [97] cooling fan 2-place Multilock behind rear cylinder 2007 Buell Firebolt: Fuel System 4-81...
Page 423 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 2007 Buell Firebolt: Fuel System...
Page 424 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? System ok. Replace fan. 2007 Buell Firebolt: Fuel System 4-83...
Page 425: Trouble Code 44
41404), gray pin probes and patch cord. Connect BREAKOUT BOX (Part No. HD-42682) to ECM. 4.6 BREAKOUT BOX. Bank angle sensor Headlights Figure 4-60. Bank Angle Sensor Table 4-31. Bank Angle Sensor Voltage MODE VOLTS 0.24-3.4 Disable 3.5-4.79 4-84 2007 Buell Firebolt: Fuel System...
Page 426 [11] ECM (gray) 12-place Deutsch in fairing [14] cam position sensor 3-place Deutsch beneath sprocket cover [88] throttle position sensor 3-place Packard beneath air cleaner baseplate [134] bank angle sensor 6-place Sumitomo in fairing 2007 Buell Firebolt: Fuel System 4-85...
Page 427 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 2007 Buell Firebolt: Fuel System...
Page 428 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). 2007 Buell Firebolt: Fuel System 4-87...
Page 429: Trouble Codes 52, 53, 54 And 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29 Trouble Code 56
ECM. See 4.30 ELECTRONIC CONTROL MODULE. Code 52 - RAM failure. Code 53 - ROM failure. Code 54 - EE PROM failure. Code 55 - Microprocessor failure. Figure 4-62. Mounting Location of ECM 4-88 2007 Buell Firebolt: Fuel System...
Page 430 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 4-63. Cam Position Sensor 2007 Buell Firebolt: Fuel System 4-89...
Page 431 [11] ECM (gray) 12-place Deutsch in fairing [14] cam position sensor 3-place Deutsch beneath sprocket cover [88] throttle position sensor 3-place Packard beneath air cleaner baseplate [134] bank angle sensor 6-place Sumitomo in fairing 4-90 2007 Buell Firebolt: Fuel System...
Page 432 [11] and connectors [11] and to ground. to voltage. TROL MODULE. [14]. [14]. Clear codes and conﬁrm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). 2007 Buell Firebolt: Fuel System 4-91...
Page 433 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 2007 Buell Firebolt: Fuel System...
Page 434: Electronic Control Module
SEAT. NOTE If the ECM was replaced with a new component, it will be necessary to recalibrate Throttle Position Sensor. Throttle position sensor can only be calibrated using DIGITAL TECH- NICIAN (Part No. HD-44750). 2007 Buell Firebolt: Fuel System 4-93...
Page 435 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 2007 Buell Firebolt: Fuel System...
Page 436: Cam Position Sensor And Rotor
Remove bolt (17) and trig- ger rotor (16). 10. Carefully remove camshaft oil seal (15) if damaged or if there is any evidence of oil leakage past the seal.Figure 4-74. 2007 Buell Firebolt: Fuel System 4-95...
Page 437 11. Mounting fastener 12. Ignition coil 13. Front spark plug cable 14. Cylinder brace 15. Seal 16. Trigger rotor 17. Trigger rotor bolt 18. Cam position sensor 19. Inner cover b1164a4x Figure 4-69. Ignition Components 4-96 2007 Buell Firebolt: Fuel System...
Page 438 HOME bd0022bf Figure 4-70. Ignition System Circuit 2007 Buell Firebolt: Fuel System 4-97...
Page 439 10. Secure timer cover (2) to inner cover using new rivets (1). 11. Install sprocket cover. See 2.30 SPROCKET COVER. 12. Connect negative battery cable. 4-98 2007 Buell Firebolt: Fuel System...
Page 440: Ignition Coil
Install intake cover assembly. See 2.34 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 4-73. Ignition Coil 2007 Buell Firebolt: Fuel System 4-99...
Page 441 This is most noticeable in wet weather or after NORMAL 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 4-100 2007 Buell Firebolt: Fuel System...
Page 442: Oxygen Sensor
Connect 1-place connector [137] (1) to wiring harness. Install cable straps (2). Install air cleaner cover assembly. See 4.44 AIR CLEANER ASSEMBLY. Install intake cover assembly. See 2.34 INTAKE COVER ASSEMBLY. Connect negative battery cable. 2007 Buell Firebolt: Fuel System 4-101...
Page 443: Engine Temperature Sensor
While riding, a loose seat can shift causing loss of control, which could result in death Figure 4-77. Engine Temperature Sensor Location (rear or serious injury. (00070a) cylinder) Install seat. See 2.38 SEAT. 4-102 2007 Buell Firebolt: Fuel System...
Page 444: Bank Angle Sensor
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 2.38 SEAT. 2007 Buell Firebolt: Fuel System 4-103...
Page 445: Intake Air Temperature Sensor
INSTALLATION Connect IAT sensor connector [89] to wiring harness. Install IAT sensor into grommet on air cleaner base from beneath. Install air cleaner cover. See 4.44 AIR CLEANER ASSEMBLY. Install negative battery cable. 4-104 2007 Buell Firebolt: Fuel System...
Page 446: Throttle Position Sensor
Throttle position sensor can only be calibrated using DIGITAL TECHNICIAN (Part No. HD-44750). Calibrate throttle position sensor. 12501 Figure 4-82. Throttle Position Sensor Figure 4-81. Throttle Position Sensor Connector Location b0651x4x Figure 4-83. Tabs on TP Sensor Connector [88A] 2007 Buell Firebolt: Fuel System 4-105...
Page 447: Cooling Fan
Install fan and rotate counter-clockwise 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 2007 Buell Firebolt: Fuel System...
Page 448: 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). 2007 Buell Firebolt: Fuel System 4-107...
Page 449 10. Place wrench onto nut and another wrench onto the bolt. Hold the bolt stationary and turn nut clockwise until fuel pump is pulled free from frame. 4-108 2007 Buell Firebolt: Fuel System...
Page 450 (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 4-89. Fuel Pressure Regulator 2007 Buell Firebolt: Fuel System 4-109...
Page 451 10935a Fuel supply stud Fuel pump connectors Fuel pump assembly Low fuel pressure sensor O-rings Fastener Fuel screen Fuel pressure regulator Fuel pump 10. Low fuel level sensor connector Figure 4-90. Fuel Pump Assembly 4-110 2007 Buell Firebolt: Fuel System...
Page 452 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 4-91. Fuel Pump Assembly (Left and Right Sides) 2007 Buell Firebolt: Fuel System 4-111...
Page 453 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 4-92. Fuel Pump Assembly 4-112 2007 Buell Firebolt: Fuel System...
Page 454 11. Connect fuel pump connectors (8). Connectors are two different sizes. 12. Install fuel pump assembly. See INSTALLATION in this section. Safety pin Fuel pump connector Clips Figure 4-94. Fuel Pump Connector Disassembly 8780 Figure 4-95. Wire Harness Removal Direction 2007 Buell Firebolt: Fuel System 4-113...
Page 455 Connect fuel pump connector [86] (1) and push cable strap tab into hole in frame. Install swingarm. See 2.19 SWINGARM AND BRACE. 10. Install rider footpeg mounts. See 2.29 FOOTPEG, HEEL GUARD AND MOUNT. 4-114 2007 Buell Firebolt: Fuel System...
Page 456: 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) 10. Install seat. See 2.38 SEAT. 2007 Buell Firebolt: Fuel System 4-115...
Page 457: 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 4-98. Fuel Cap Retaining Ring 4-116 2007 Buell Firebolt: Fuel System...
Page 458: Throttle Body
Remove fuel rail fastener (1) that holds the fuel rail to the throttle body and manifold. 10. Remove fastener connecting thottle body to cylinder brace 11. Disconnect TPS connector [88] and injector connectors [84] and [85]. 2007 Buell Firebolt: Fuel System 4-117...
Page 459 10. Throttle position sensor 21. Bolt (2) 11. Clamp, wire spring 22. Mounting ﬂange, intake (1 front, 1 rear) 12. Velocity stack 23. Seal, intake manifold (2) Figure 4-101. One Piece Throttle Body/Intake Manifold Assembly (XB9/12 Models) 4-118 2007 Buell Firebolt: Fuel System...
Page 460: Fuel Injectors
8750a Fuel rail fastener to throttle body Intake ﬂange fastener (2) Figure 4-104. Intake Manifold Fasteners (gearcase cover side) Manifold to cylinder brace fastener Intake ﬂange fastener (2) Figure 4-102. Intake Manifold (Primary Side) 2007 Buell Firebolt: Fuel System 4-119...
Page 461 Snap the injector clips (4) over the ﬂange on the fuel rail outlet and into the top grove in the injector. Fuel rail fastener Rear fuel injector Fuel rail assembly Clip (2) Front fuel injector Figure 4-106. Fuel Injectors 4-120 2007 Buell Firebolt: Fuel System...
Page 462 11. Install air cleaner cover. See 4.44 AIR CLEANER ASSEMBLY. 12. Check throttle cable adjustment. See 2.23 THROTTLE CONTROL. 13. Install air scoops. See 2.35 AIR SCOOPS. 14. Verify engine speed. See 1.20 THROTTLE POSITION SENSOR (TPS). 2007 Buell Firebolt: Fuel System 4-121...
Page 463 Install air cleaner cover. See 4.44 AIR CLEANER ASSEMBLY. Install intake cover assembly. See 2.34 INTAKE COVER ASSEMBLY. Fuel rail fastener Rear fuel injector Fuel rail assembly Clip (2) Front fuel injector Figure 4-109. Fuel Injectors 4-122 2007 Buell Firebolt: Fuel System...
Page 464: Intake Leak Test
Nozzle Figure 4-110. 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 4-111. Leak Tester 2007 Buell Firebolt: Fuel System 4-123...
Page 465 Aim nozzle toward possible sources of leak such as fuel injectors and intake tract. Push valve (4) to release propane. Tone of engine will change when propane enters source of leak. 4-124 2007 Buell Firebolt: Fuel System...
Page 466: Air Cleaner Assembly
INTAKE AIR TEMPERATURE SENSOR Fuel vapor vent valve Inspect breather hoses, intake air temperature sensor grommet and baseplate gasket. Replace as necessary. Figure 4-114. Air Cleaner Cover, Fuel Vent Tube and Fuel Tank Vent (XB12R) 2007 Buell Firebolt: Fuel System 4-125...
Page 467 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) 12. Install seat. See 2.38 SEAT. 4-126 2007 Buell Firebolt: Fuel System...
Page 468 Interactive exhaust cable Mounting fasteners, actuator Cover, air cleaner Filter element Air cleaner seal Shoulder screw (4) 10. Base plate assembly 11. Breather hoses, front and rear Figure 4-116. Air Cleaner Assembly with Interactive Exhaust (XB12R) 2007 Buell Firebolt: Fuel System 4-127...
Page 469 4.45 GENERAL 8817a 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 470 Make sure to push hoses all the way on to carbon canis- Adjuster screw alignment hole ter ﬁttings. Figure 4-120. Adjuster Screw Alignment Install upper tail body work. See 2.36 SUBFRAME TAIL ASSEMBLY AND BODY WORK. 2007 Buell Firebolt: Fuel System 4-129...
Page 471 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 4-121. Emissions Hose Attachment, California Models Only 4-130 2007 Buell Firebolt: Fuel System...
Page 472 ELECTRIC STARTER Table Of Contents SUBJECT PAGE NO. 5.1 Specifications ..........5.2 Electric Starter System .
Page 474: Specifications
8 ft-lbs (11 Nm) (min.) @ 2.4 V TORQUE VALUES ITEM TORQUE NOTES Battery terminal fasteners 72-96 in-lbs 8-11 Nm page 5-19 Starter battery positive cable 60-85 in-lbs 7-10 Nm page 5-19 Starter mounting bolts 13-20 ft-lbs 18-27 Nm page 5-19 2007 Buell Firebolt: Starter...
Page 475: 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). 2007 Buell Firebolt: Starter...
Page 476 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 2007 Buell Firebolt: Starter...
Page 477: Starting System Diagnosis
Is 12V present on starter relay Replace Starter Test 3: Relay Clicks. Terminal 86 with starter button solenoid. not pressed? 5845 Nothing clicks. See Starter Replace Replace Test 4: Nothing Clicks. right handlebar starter relay. switchgear. 5832 5818 2007 Buell Firebolt: Starter...
Page 478 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 2007 Buell Firebolt: Starter...
Page 479 (W/BK wire at connector [22]). Interlock Circuit relay. button to relay. Battery voltage present? or Correct Relay Ground. 5832 5831 5828 Replace right han- Repair wiring to dlebar switchgear. starter button. 5816 5831 2007 Buell Firebolt: Starter...
Page 480 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 2007 Buell Firebolt: Starter...
Page 481: 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. 2007 Buell Firebolt: Starter...
Page 482: Diagnostics/Troubleshooting
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. 2007 Buell Firebolt: Starter...
Page 483 5-10 2007 Buell Firebolt: Starter...
Page 484: 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 2007 Buell Firebolt: Starter 5-11...
Page 485: Starter
Remove positive battery cable ring terminal (2). Detach solenoid wire (3). Remove starter and gasket from the gearcase cover side. Fastener with washer (metric) Positive battery cable Solenoid wire Figure 5-9. Starter Wires (protective boot not shown) 5-12 2007 Buell Firebolt: Starter...
Page 486 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. 2007 Buell Firebolt: Starter 5-13...
Page 487 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 2007 Buell Firebolt: Starter...
Page 488 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 2007 Buell Firebolt: Starter 5-15...
Page 489 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 2007 Buell Firebolt: Starter...
Page 490 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 2007 Buell Firebolt: Starter 5-17...
Page 491 16. Remove drive (1), idler gear (2), idler gear bearing (3), and o-ring (4) from drive housing (o-ring is located in Figure 5-22. Open Field Test drive housing groove). s0164x5x Figure 5-23. Brush Holder Insulation Test 5-18 2007 Buell Firebolt: Starter...
Page 492 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 2.38 SEAT. 2007 Buell Firebolt: Starter 5-19...
Page 493 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 2007 Buell Firebolt: Starter...
Page 494: Starter Solenoid
Replace wire connection hardware as necessary. Figure 5-28. Starter Solenoid 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). 2007 Buell Firebolt: Starter 5-21...
Page 495 HOME NOTES 5-22 2007 Buell Firebolt: Starter...
Page 496 Table Of Contents DRIVE/TRANSMISSION 6 SUBJECT PAGE NO. 6.1 Specifications ..........6.2 Primary Cover .
Page 498: Specifications
Table 6-4. Wet Clutch Multiple Disc-Clutch Plate Thickness ITEM NEW COMPONENTS SERVICE WEAR LIMITS Friction plate (ﬁber) 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) 2007 Buell Firebolt: Drive/Transmission...
Page 499 LOCTITE 271 (red), page 6-6 LOCTITE 271 (red), left hand threads, special Special proce- Transmission sprocket nut dure 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 2007 Buell Firebolt: Drive/Transmission...
Page 500: Primary Cover
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). 2007 Buell Firebolt: Drive/Transmission...
Page 501 17. Bolt 18. Shifter lever 19. Oil seal 20. Sems screw, 21. Adjuster assembly 22. Chain adjustment nut 23. O-ring 24. Drain plug 25. Rubber washer Figure 6-3. Primary Cover, Primary Chain Adjuster and Shifter Assembly 2007 Buell Firebolt: Drive/Transmission...
Page 502 1.9 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 1.11 PRIMARY to hold it while threading lock nut. CHAIN. 2007 Buell Firebolt: Drive/Transmission...
Page 503 13. After applying LOCTITE 271, install ﬂange bolt (5) and shift pedal to primary cover, and tighten to 22-24 ft-lbs (30-32.5Nm). 14. After applying LOCTITE 271 (red), tighten engine shift lever pinch screw to 48-60 in-lbs (5.4-6.8 Nm). 2007 Buell Firebolt: Drive/Transmission...
Page 504: Clutch Release Mechanism
As the adjusting screw is turned, ramp 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 2007 Buell Firebolt: Drive/Transmission...
Page 505 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 2.38 SEAT. 2007 Buell Firebolt: Drive/Transmission...
Page 506: Clutch
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. 2007 Buell Firebolt: Drive/Transmission...
Page 507 29. Clutch shell and sprocket Retaining ring 19. Steel plate (7) 30. Outer thrust washer Retaining ring 20. Friction plate, narrow 10. Spring seat 21. Damper spring 11. Diaphragm spring 22. Damper spring seat Figure 6-12. Clutch Assembly 6-10 2007 Buell Firebolt: Drive/Transmission...
Page 508 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. 2007 Buell Firebolt: Drive/Transmission 6-11...
Page 509 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 2007 Buell Firebolt: Drive/Transmission...
Page 510 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. 2007 Buell Firebolt: Drive/Transmission 6-13...
Page 511 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 2007 Buell Firebolt: Drive/Transmission...
Page 512 Diaphragm spring 11. Install seat. See 2.38 SEAT. 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 2007 Buell Firebolt: Drive/Transmission 6-15...
Page 513: Primary Chain
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 2007 Buell Firebolt: Drive/Transmission...
Page 514 If the inner race shows any of these signs the complete hub assembly must be replaced. 11. Replace damaged parts as necessary. Figure 6-28. Clutch Hub Bearing Race 2007 Buell Firebolt: Drive/Transmission 6-17...
Page 515 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 2007 Buell Firebolt: Drive/Transmission...
Page 516 NOTE Clutch hub New mainshaft nut comes with a chemical lock patch making Needle bearing it unnecessary to use Loctite with new fastener. Clutch shell Thrust washer, outer Figure 6-33. Clutch Hub and Shell Assembly 2007 Buell Firebolt: Drive/Transmission 6-19...
Page 517 (00070a) 14. Install seat. See 2.38 SEAT. Adjusting screw assembly Retaining ring Tab recesses Figure 6-37. Clutch Adjusting Screw Assembly and Retaining Ring 6-20 2007 Buell Firebolt: Drive/Transmission...
Page 518: Drive Belt System
GENERAL INSPECTION & CLEANING 1.10 DRIVE BELT. There is no drive belt adjustment required for the Buell Fire- bolt. The system utilizes a ﬁxed idler pulley that maintains the desired tension throughout suspension travel and life of the belt. Forward bend must not be less than 5 in. (127 mm).
Page 519 Right section Right section fastener and washer (3) Figure 6-39. Chin Fairing Assembly Remove right rear chin fairing fasteners. See 2.33 CHIN FAIRING. b0943a2x Sprocket cover fastener and washers Sprocket cover Figure 6-40. Sprocket Cover 6-22 2007 Buell Firebolt: Drive/Transmission...
Page 520: Drive Belt Installation
11. 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 2007 Buell Firebolt: Drive/Transmission 6-23...
Page 521 61 Nm). 11810 b1106x6x 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 2007 Buell Firebolt: Drive/Transmission...
Page 522: Transmission
1st Gear Neutral Countershaft Countershaft Mainshaft Mainshaft 2nd Gear 3rd Gear Countershaft Countershaft Mainshaft Mainshaft 4th Gear 5th Gear Countershaft Countershaft - IN - SLIDING MEMBER - POWER FLOW - OUT Figure 6-45. Transmission Power Flow 2007 Buell Firebolt: Drive/Transmission 6-25...
Page 523: Case Disassembly For Transmission Removal
Figure 6-48. With transmission still in neutral, scribe a line on the end of the shifter drum at the 12 o’clock Figure 6-46. Place transmission in 1st gear. Remove position for later reference. hex fastener. 6-26 2007 Buell Firebolt: Drive/Transmission...
Page 524 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). 2007 Buell Firebolt: Drive/Transmission 6-27...
Page 525 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 2007 Buell Firebolt: Drive/Transmission...
Page 526: Transmission Disassembly
Slots for removing the shifter fork shafts Figure 6-56. Removing Shifter Fork Shafts Mainshaft 11349 Left Right Shifter drum Shifter fork (3) Mainshaft Mainshaft 2nd gear Countershaft Countershaft Figure 6-55. Shifter Forks, Drum and Shafts Figure 6-57. Transmission Assembly 2007 Buell Firebolt: Drive/Transmission 6-29...
Page 527 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 2007 Buell Firebolt: Drive/Transmission...
Page 528 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 2007 Buell Firebolt: Drive/Transmission 6-31...
Page 529 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 2007 Buell Firebolt: Drive/Transmission...
Page 530 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 2007 Buell Firebolt: Drive/Transmission 6-33...
Page 531 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 2007 Buell Firebolt: Drive/Transmission...
Page 532: 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 2007 Buell Firebolt: Drive/Transmission 6-35...
Page 533 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 2007 Buell Firebolt: Drive/Transmission...
Page 534: Main Drive Gear And Bearing
Right crankcase half Bearing (Inner) Ball bearing with spacer Fifth gear mainshaft Retaining ring Bearing (Outer) 10. Oil seal O-ring 11. Bearing, (closed end) countershaft Oil seal 12. Bushing, shifter drum Figure 6-66. Transmission Assembly-Right Crankcase Half 2007 Buell Firebolt: Drive/Transmission 6-37...
Page 535 7) (4), NICE BEARING (5), FLAT WASHER (6) and NUT Figure 6-67. Main Drive Gear Assembly (7) over end of bolt. Tighten nut until main drive gear is free. 8681 Figure 6-68. Bearing Remover Cross Plate Mounting (Part No. B-45847) 6-38 2007 Buell Firebolt: Drive/Transmission...
Page 536 Figure 6-70. Removing Main Drive Gear Bearing (Typical) Main drive gear 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 2007 Buell Firebolt: Drive/Transmission 6-39...
Page 537 0.285 in. (7.2 mm) from the 11477 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 2007 Buell Firebolt: Drive/Transmission...
Page 538 AND PRIMARY CHAINCASE LUBRICANT. Cross plate (Part No. B-45847) 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 2007 Buell Firebolt: Drive/Transmission 6-41...
Page 539: Main Drive Gear
0.060-0.030 in. (1.524- 0.762 mm). 11510 8 in. bolt (Part No. HD-35316-4A) Washer (Part No. HD-35316-7) Main drive gear Installer cup (Part No. HD-35316-12) Nice bearing Flat washer Figure 6-77. Installing Main Drive Gear (Typical) 6-42 2007 Buell Firebolt: Drive/Transmission...
Page 540 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. 2007 Buell Firebolt: Drive/Transmission 6-43...
Page 541 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 2007 Buell Firebolt: Drive/Transmission...
Page 542: Transmission Right Case Bearings
Right crankcase half Bearing (Inner) Ball bearing with spacer Fifth gear mainshaft Retaining ring Bearing (Outer) 10. Oil seal O-ring 11. Bearing, (closed end) countershaft Oil seal 12. Bushing, shifter drum Figure 6-84. Transmission Assembly-Right Crankcase Half 2007 Buell Firebolt: Drive/Transmission 6-45...
Page 543: 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 2007 Buell Firebolt: Drive/Transmission...
Page 544: 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) 2007 Buell Firebolt: Drive/Transmission 6-47...
Page 545 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 2007 Buell Firebolt: Drive/Transmission...
Page 546 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). 2007 Buell Firebolt: Drive/Transmission 6-49...
Page 547 HOME b1016x3x One Behind Shifter Mechanism Indicates Bolt Pattern Location Figure 6-94. Crankcase Fasteners 6-50 2007 Buell Firebolt: Drive/Transmission...
Page 548: 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) 2007 Buell Firebolt: Drive/Transmission 6-51...
Page 549 3.19 CRANKCASE/ ASSEMBLY 3.6 CYLINDER HEAD/3.7 CYLINDER AND PISTON/ ASSEMBLY/ INSTALLATION. 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 2007 Buell Firebolt: Drive/Transmission...
Page 550: Transmission Sprocket
Replace with new pulley wheel (1). Transmission sprocket holding tool Mainshaft locknut wrench NOTE Breaker bar The pulley wheel bearings can not be replaced separately. A new pulley wheel must be installed. Figure 6-102. Removing Transmission Sprocket Locknut 2007 Buell Firebolt: Drive/Transmission 6-53...
Page 551 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 2007 Buell Firebolt: Drive/Transmission...
Page 552 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). 2007 Buell Firebolt: Drive/Transmission 6-55...
Page 553 HOME NOTES 6-56 2007 Buell Firebolt: Drive/Transmission...
Page 554 Table Of Contents SUBJECT PAGE NO. 7.1 Specifications ..........7.2 Ignition System .
Page 556: Specifications
Check engine 1.12 0.08 Y0163.02A8 High beam 0.05 Y0162.02A8 Oil indicator 1.12 0.08 Y0163.02A8 Instruments Neutral 1.12 0.08 Y0163.02A8 1.12 0.08 Y0163.02A8 Backlight 0.05 Y0162.02A8 Low fuel Replace instrument cluster if low fuel warning lamp fails. 2007 Buell Firebolt: Electrical...
Page 557 25-28 in-lbs 2.8-3.2 Nm page 7-47 Turn signal fasteners (front) 25-28 in-lbs 2.8-3.2 Nm page 7-47 Turn signal ﬂasher fastener 36-60 in-lbs 4-6.7 Nm page 7-48 Voltage regulator mounting 36-60 in-lbs 6.7-8 Nm page 7-32 fasteners 2007 Buell Firebolt: Electrical...
Page 558: 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. 2007 Buell Firebolt: Electrical...
Page 559 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 2007 Buell Firebolt: Electrical...
Page 560: Ignition/Headlight Key Switch
Front and rear turn signals can be activated 8345 cannot be Horn can be activated activated ON position OFF position PUSH DETENT LOCK position PARKING LIGHT position Upper triple clamp Figure 7-2. Ignition/Headlight Key Switch 2007 Buell Firebolt: Electrical...
Page 561 (3) securing ignition switch (4) to upper fork clamp. Slide ignition switch out of upper fork clamp. Upper fork clamp pinch fastener (2) Stem pinch fastener Stem capnut Upper fork clamp Figure 7-4. Upper Fork Clamp 2007 Buell Firebolt: Electrical...
Page 562 Install ignition switch body fasteners (1). Tighten to 12-36 Ignition switch in-lbs (1.4-4.0 Nm). Housing Connector [33] Figure 7-5. Ignition Switch Assembly b1023b8x Headlights (2) Cable strap Ignition switch connector [33] Figure 7-6. Ignition Switch Connector (viewed from beneath fairing) 2007 Buell Firebolt: Electrical...
Page 563 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) 10. Install seat. See 2.38 SEAT. 2007 Buell Firebolt: Electrical...
Page 564: Spark Plug Cables
Remove air cleaner assembly. See 4.44 AIR CLEANER ASSEMBLY. Remove left side air scoop. Figure 7-8. Disconnect spark plug cables from igni- tion coil and spark plug terminals. Inspect cables for damage. 2007 Buell Firebolt: Electrical...
Page 565 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) 7-10 2007 Buell Firebolt: Electrical...
Page 566: Starter Interlock
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. 2007 Buell Firebolt: Electrical 7-11...
Page 567 Figure 7-11. Diode Polarity b1107e7x RELAY CENTER [95A] [95B] TN/LTGN Clutch Switch Empty Spare Spare Diode Diode Empty Bk/Hn/Mflr TN/Y Lights [131B] Acces. Key Sw [131A] TN/LTGN Neutral Start Switch Relay Figure 7-13. Diode Wiring 7-12 2007 Buell Firebolt: Electrical...
Page 568 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 2007 Buell Firebolt: Electrical 7-13...
Page 569 Repair open on TN/ wire of connector [95]. LT. GN wire Ground present? between connector [95] and starter relay. 5073 Replace clutch Repair open on switch. BK wire between connector [95] and 5074 ground. 5075 7-14 2007 Buell Firebolt: Electrical...
Page 570 Replace the assembly with a new switch if necessary and tighten switch fasteners to 7-10 in-lbs (0.8-1.12 Clutch engaged (switch open) Nm). See 2.24 CLUTCH CONTROL. Clutch disengaged (switch closed) Connector [95] Figure 7-14. Clutch Switch 2007 Buell Firebolt: Electrical 7-15...
Page 571: Main Fuse
A 30 Amp main fuse links the ignition key switch and the bat- tery. The 30 Amp main fuse is located under the rider’s seat. 7.22 MAIN FUSE AND FUSES for more information. Figure 7-16. Starter Relay Test 7-16 2007 Buell Firebolt: Electrical...
Page 572 Replace the diode by pulling it straight out. Ensure it is installed in the correct direction. Figure 7-17. Fuse Block (contains diode) b1165x4x Empty Spare Spare Diode Empty Bk/Hn/Mflr Lights Key Sw Acces. Figure 7-18. Fuse Block 2007 Buell Firebolt: Electrical 7-17...
Page 573: Interactive Exhaust System (Xb12 Model)
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 7-19. Interactive Exhaust System Mufﬂer 7-18 2007 Buell Firebolt: Electrical...
Page 574 HOME b0064b Interactive exhaust cable Harness with connector [161B] Interactive exhaust cable bracket Actuator Air cleaner cover Figure 7-20. Interactive Control System (XB12R) 2007 Buell Firebolt: Electrical 7-19...
Page 575 13. Remove mufﬂer. See 2.28 EXHAUST SYSTEM. 14. Loosen jam nut and remove interactive exhaust cable from bracket on mufﬂer. 15. Remove interactive exhaust cable from cable wheel on mufﬂer. 7-20 2007 Buell Firebolt: Electrical...
Page 576 Figure 7-22. Interactive Exhaust Cable Behind Wire Harness Strap and Guide Install actuator. Tighten fasteners to 36-40 in-lbs (4.1- 4.5 Nm). Attach interactive exhaust cable to cable wheel on actua- tor. Connect interactive exhaust harness to actuator [161B]. 2007 Buell Firebolt: Electrical 7-21...
Page 577 HOME NOTES 7-22 2007 Buell Firebolt: Electrical...
Page 578: Charging System
Wiring Check for corroded or loose connections in the charging cir- cuit. See Figure 7-25. Figure 7-24. Stator Connector [46] Voltage Regulator Inspection Figure 7-24. The plug connector to stator must be clean and tight. 2007 Buell Firebolt: Electrical 7-23...
Page 579 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 2007 Buell Firebolt: Electrical...
Page 580 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. 2007 Buell Firebolt: Electrical 7-25...
Page 581 HOME bd0018xx Battery Cable Starter Solenoid [128A] Battery Starter Motor [GRD2] To J-Fuse Assembly Maxifuse [5A] To Voltage Regulator [77B] [77A] Voltage Regulator Stator H-D 3-Phase Male Female [46A] [46B] Figure 7-25. Charging System Circuit 7-26 2007 Buell Firebolt: Electrical...
Page 582 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. 2007 Buell Firebolt: Electrical 7-27...
Page 583 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 2007 Buell Firebolt: Electrical...
Page 584 If output is good, charging problem might be faulty regulator/rectiﬁer. Replace as required. Check the output again as described under CURRENT AND VOLTAGE OUTPUT TEST page 7-28. b0997x7x Figure 7-30. Check for Stator Resistance b0998x7x Figure 7-31. Check Stator AC Voltage Output 2007 Buell Firebolt: Electrical 7-29...
Page 585: Alternator
Remove retainer plate fasteners. Stator Grommet Remove stator wiring grommet (3) from left crankcase Stator wiring half. Connector [46] Withdraw stator wiring (4) from grommet hole in left Figure 7-34. Stator Assembly crankcase half. Remove stator 7-30 2007 Buell Firebolt: Electrical...
Page 586 Install connector (5) [46] onto the stator wiring (4) using cavities 1, 2, 3 of connector (5) [446]. See DEUTSCH ELECTRICAL CONNECTORS for addi- tional information. NOTE 7.25 SPROCKET COVER WIRING for remaining wire routing information. 2007 Buell Firebolt: Electrical 7-31...
Page 587: Voltage Regulator
Stator connector [46] or serious injury. (00070a) Voltage regulator connector [77] Install seat. See 2.38 SEAT. Voltage regulator mount bracket Voltage regulator Test charging system. See 7.7 CHARGING SYSTEM. Fastener (3) Figure 7-37. Voltage Regulator 7-32 2007 Buell Firebolt: Electrical...
Page 588: Battery Cables
60-85 in-lbs (7-10 Nm). Figure 7-39. Negative Battery Cable Figure 7-39. Attach negative cable to frame. Tighten to 48-72 in-lbs (5.4-8.1 Nm). Apply light coat of petroleum jelly or corrosion-retardant material to both battery terminals. 2007 Buell Firebolt: Electrical 7-33...
Page 589 Connect negative cable to negative (-) battery termi- nal using fastener. Tighten terminal fasteners to 72-96 in-lbs (8-11 Nm). Fastener with washer Positive battery cable Figure 7-40. Positive Battery Cable (Protective Boot Not Shown) 7-34 2007 Buell Firebolt: Electrical...
Page 590: Battery
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 591: 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 7-43. Battery Test Results–Printout 7-36 2007 Buell Firebolt: Electrical...
Page 592: Disconnection And Removal
Load battery at 50% of CCA rating using battery has been frozen, overheated or overcharged. the load tester. Voltage reading after 15 seconds should be 9.6V or more at 70° F. (21° C). Inspect the battery case for cracks or leaks. 2007 Buell Firebolt: Electrical 7-37...
Page 593 Overheating may result in plate distortion, internal shorting, dryout or other damage. Perform a voltmeter test to determine the state of charge. BATTERY TESTING. If battery needs to be charged, proceed to step 2. 7-38 2007 Buell Firebolt: Electrical...
Page 594 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. 2007 Buell Firebolt: Electrical 7-39...
Page 595 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 2.38 SEAT. 7-40 2007 Buell Firebolt: Electrical...
Page 596 (not freezing), dry place. See Fig- ure 7-47. 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). 2007 Buell Firebolt: Electrical 7-41...
Page 597: Headlight
Failure to do so could result in bulb damage. (00210a) Figure 7-48. Disconnect headlight connection (1). Remove rubber boot from headlight housing. Release wire retaining latch (5) from headlight housing clips. Pull bulb housing from headlight housing. 7-42 2007 Buell Firebolt: Electrical...
Page 598 HIGH beam (2) settings. Set headlight to LOW beam. Press passing lamp switch (1). Headlight should ﬂash HIGH beam for as long as the switch is pressed. Turn ignition key switch to OFF. Align headlight. See 1.19 HEADLIGHTS. 2007 Buell Firebolt: Electrical 7-43...
Page 599: Tail Lamp
Squeeze front brake hand lever. Check for brake lamp illumination. Release front brake hand lever. Press rear brake pedal. Check for brake lamp illumi- nation. Release rear brake pedal. Turn ignition key switch to OFF. 7-44 2007 Buell Firebolt: Electrical...
Page 600: Turn Signals
In next step, reﬂector bracket (3) will be removed with turn signal (1). Remove turn signal from tail section (7) and license plate bracket (4). Turn signal (2) Lockwasher (2) Fastener (2) Fairing support bracket Fairing Bulb Figure 7-52. Front Turn Signals 2007 Buell Firebolt: Electrical 7-45...
Page 601 HOME b1008a7x Turn signal Turn signal bulb Reﬂector bracket License plate bracket Lockwasher (2) Fastener (2) Tail section Figure 7-53. Rear Turn Signals 7-46 2007 Buell Firebolt: Electrical...
Page 602 While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070a) Install tail frame upper bodywork. See 2.36 SUBFRAME TAIL ASSEMBLY AND BODY WORK. Install seat. See 2.38 SEAT. 2007 Buell Firebolt: Electrical 7-47...
Page 603: Turn Signal Flasher
Front and rear left turn sig- Figure 7-56. Turn Signal Controls nals must ﬂash. Activate right turn signals using switch on left han- dlebar. Front and rear right turn signals must ﬂash. Turn ignition key switch to OFF. 7-48 2007 Buell Firebolt: Electrical...
Page 604: Handlebar Switches
Remove cable straps. Detach connector [24] from To Ign. relay wiring harness. GY/O From Ign. relay W/BK W/BK From Ign. relay W/BK W/BK To starter relay BK/R BK/R Fused power To stoplight Brake Switch [121] Figure 7-57. Right Handlebar Switch Connection 2007 Buell Firebolt: Electrical 7-49...
Page 605 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. Activate horn by pressing horn switch. Turn ignition key switch to OFF. 7-50 2007 Buell Firebolt: Electrical...
Page 606: Speedometer Sensor
Fuse Key Sw Acces. [5A] Vehicle Speed Sensor Connector Vehicle Speed [39A] [39B] Sensor BK/W Instrument Module [65A] [65B] [10B] [11B] Connector Connector Electronic Control Module [10A] [11B] (ECM) Figure 7-60. Vehicle Speed Sensor Wiring 2007 Buell Firebolt: Electrical 7-51...
Page 607: Instrument Module
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. 7-52 2007 Buell Firebolt: Electrical...
Page 608 (00070a) Headlight support bracket Install seat. See 2.38 SEAT. Instrument module Grommet (3) Washer (3) Fastener (3) 8426 Instrument module connector [39] Figure 7-65. Instrument Module Figure 7-64. Instrument Module Connector [39] 2007 Buell Firebolt: Electrical 7-53...
Page 609: Speedometer Performance Check
CLEAR to cancel and enter the new fre- ENG, AUS, EUR, quency. Press ENTER to begin and reverify. 60 KPH CAN, JPN 80 KPH 1320 NOTE The speedometer should be accurate within 0-5 MPH (0-8 100 KPH 1650 KPH). 7-54 2007 Buell Firebolt: Electrical...
Page 610 OK. If reading does not change, vehicle speed sensor is suspect. Install a known, good vehicle speed sensor and test again. Deutsch socket housing (2) Deutsch pin housing b0779x7x Figure 7-68. Test Harness 2007 Buell Firebolt: Electrical 7-55...
Page 611 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. Go to 6020 Speedometer Test: Chart 7-56 2007 Buell Firebolt: Electrical...
Page 612 If necessary, remove vehicle speed sensor and check for accumulation of debris. If Go to Speedometer Test: debris is not present, replace sensor. If Chart debris is present, clean sensor and repeat test. Replace if necessary. 2007 Buell Firebolt: Electrical 7-57...
Page 613 Does voltage fluctuate? instrument module Replace vehicle speed sensor. 6022 6010 Repair as necessary. Check speedometer speed sensor. Clean or replace sen- 6008 sor as required. Retest. Problem solved? System OK. Replace instrument module. 6029 6024 7-58 2007 Buell Firebolt: Electrical...
Page 614: Horn
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 2.38 SEAT. 2007 Buell Firebolt: Electrical 7-59...
Page 615 If horn is faulty, replace unit as an assembly. The horn is not repairable. If battery voltage is not present, either horn switch or wiring to horn is faulty. If horn switch is faulty, replace left handlebar switch. See 7.16 HANDLE- SWITCHES. 7-60 2007 Buell Firebolt: Electrical...
Page 616: Neutral Indicator Switch
243 (blue) to new neutral indicator switch (1) threads. Install washer (3) over neutral indicator switch (2) threads. Install switch in crankcase. Tighten switch to 60-84 in-lbs (6.7-9.5 Nm). Connect wire lead (1) to switch. Install sprocket cover. See 2.30 SPROCKET COVER. 2007 Buell Firebolt: Electrical 7-61...
Page 617: Main Fuse And Fuses
HOME MAIN FUSE AND FUSES 7.22 GENERAL 10960 Buell motorcycles feature two components which protect the electrical system. Fuses Figure 7-74.The covered fuse block is behind the fairing on the right hand side of the motorcycle. Figure 7-75. The lights, key switch and ignition fuses are rated at 15 Amps.
Page 618: Main Wire Harness
11. Disconnect foot brake light switch connector [121] (5). Foot brake light switch connector [121] 12. Remove the rear shock absorber assembly and reser- voir. See 2.22 REAR SHOCK ABSORBER. Figure 7-78. Battery Tray Wiring 13. Remove fan. See 4.38 COOLING FAN. 2007 Buell Firebolt: Electrical 7-63...
Page 619 21. Remove fuse block and relay block from their brackets. 22. Remove any remaining cable straps and clamps secur- ing wire harness and remove harness from front of vehi- cle. 23. Remove all tree fasteners from frame. 7-64 2007 Buell Firebolt: Electrical...
Page 620 13. Install intake assembly. See 2.34 INTAKE COVER Left switch housing connector [24] and right switch ASSEMBLY. housing connector [22]. Ignition switch [33]. Ground terminals on front of steering head. Horn connectors [122]. Instrument module connector [39]. 2007 Buell Firebolt: Electrical 7-65...
Page 621 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) 30. Install seat. See 2.38 SEAT. 7-66 2007 Buell Firebolt: Electrical...
Page 622 Left switch housing connector [24] Cable strap Headlight connector [38] Right turn signal connectors Cable strap Right switch housing connector [22] 10. Ignition switch connector [33] 11. Cable strap Figure 7-83. Fairing Wiring (viewed from beneath fairing) 2007 Buell Firebolt: Electrical 7-67...
Page 623: Interactive Exhaust Harness (Xb12 Models)
7.6 INTER- ACTIVE EXHAUST SYSTEM (XB12 MODEL). Figure 7-84. Left Side Subframe Hose and Wire Routing 8478 Main battery ground Wire harness ground Main fuse case Figure 2-85. Battery and Harness Ground (battery removed for clarity) 7-68 2007 Buell Firebolt: Electrical...
Page 624 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) 10. Install seat and pillion. See 2.38 SEAT. 2007 Buell Firebolt: Electrical 7-69...
Page 625: Sprocket Cover Wiring
Neutral switch connector Cam position sensor connector [14] Sprocket cover boss Stator connector [46] Vehicle speed sensor connector [65] Oil pressure switch wiring Main harness 10. Interactive exhaust cable Figure 7-87. Sprocket Cover Wiring and Connections 7-70 2007 Buell Firebolt: Electrical...
Page 626 (3-pin black). 11. Using a cable strap, secure the loop of the neutral safety wire to the cam position connector (13) under the attach- ment clip on the connector. 2007 Buell Firebolt: Electrical 7-71...
Page 627 13. Cable strap securing neutral connector to cam Cable wrap securing Interactive exhaust cable and position sensor connector [14] main harness to oil return line 14. Position of forward cable straps to secure wiring Figure 7-89. Sprocket Cover Wiring and Connections 7-72 2007 Buell Firebolt: Electrical...
Page 628 Figure 7-90. Cable Strap Wire Bundle to Return Oil Line Main harness Cable strap securing main harness wiring to Return Oil Line, Upper Part of Sprocket Cover 12369 Figure 7-92. Correct Location for Sprocket Cover Wiring Figure 7-91. Vehicle Speed Sensor 2007 Buell Firebolt: Electrical 7-73...
Page 629 HOME NOTES 7-74 2007 Buell Firebolt: Electrical...
Page 630: Index To Wiring Diagrams
Table Of Contents SUBJECT PAGE NO. A.1 Tools ............B.1 Amp Multilock Electrical Connectors .

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Buell 2007 FIREBOLT Service Manual

Maintenance 1

Chassis 2

Engine 3

Fuel System 4

Electric Starter 5

Drive/Transmission 6

Electrical 7

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