Remote Reservoir Clamp Nut - Buell XB9R 2003 Service Manual

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17. See Figure 2-111. Remove rear brake reservoir clamp
nut.
8359
Figure 2-111. Remote Reservoir Clamp Nut
18. Disconnect fuel pump connection and remove case from
tail frame. See 4.38 FUEL
19. Remove shock reservoir fasteners and feed the reservoir
out of tail frame. See 2.22 REAR SHOCK
20. See Figure 2-112. Remove tail frame fasteners (7) and
remove tail frame (8) from frame.
CLEANING
CAUTION
Do not use wheel care products or other compounds
developed specifically for cleaning and polishing pow-
dercoat. These cleaners could potentially damage the tail
section finish.
The cast aluminum tail section has a black powdercoat.
Because the surface is not bare polished aluminum, it must
be cleaned using only mild soap and warm water. After wash-
ing, always dry the surface using a clean, soft cloth.
ASSEMBLY
1. Install tail frame (8) to frame and tighten tail frame fas-
teners (7) to 21-23 ft-lbs (28-31 Nm) using LOCTITE
272.
2. Connect fuel pump connection and install connection
case onto tail frame. See
3. See Figure 2-110. Feed rear brake light connector (5)
into tail frame and connect.
4. Install main fuse case (3) onto tail frame.
5. Install main battery ground (1) and ground to wire har-
ness (2) to tail frame. Tightening fastener to 72-96 in-lbs
(8-11 Nm).
6. See Figure 2-109. Feed the rear shock reservoir (4)
through second tail frame support.
7. Install rear shock reservoir into shock reservoir clamp
and install clamp on to tail frame. Do not tighten. See
2.22 REAR SHOCK ABSORBER.
2-78 2003 Buell XB9R: Chassis
PUMP.
ABSORBER.
4.38 FUEL PUMP.
8. Check rear shock reservoir suspension screw alignment
with upper body work.
a. Install upper body work without tightening any fas-
teners.
b. Move the rear shock canister in position to see the
suspension screw through the upper body work.
c. Remove upper body work and tighten rear shock
reservoir clamp to 120-144 in-lbs (14-16 Nm).
9. See Figure 2-109. Feed fuel vent hose (1) through tail
section, keeping the hose on top of rear shock reservoir
hose. See D.1 HOSE AND WIRE ROUTING
wire routing.
10. Install cable strap (3) holding shock reservoir hose, wire
harness and fuel vent hose to tail frame.
11. See Figure 2-111. Feed rear brake reservoir hose under-
neath tail frame and install rear brake reservoir tightening
fastener to 48-72 in-lbs (5.4-8.1 Nm).
12. See Figure 2-110. Install cable strap holding brake light
switch and rear reservoir hose.
13. See Figure 2-112. Install lower body work (9) and trunk
(11) onto tail frame (8).
a. Install trunk (11).
b. Install lower body work (9) underneath tail frame by
tightening fasteners (10) to 36-48 in-lbs (4-5 Nm).
14. Install passenger footpeg mounts. tightening footpeg
mount fasteners to 15-18 ft-lbs (20-24 Nm). See
FOOTPEG, HEEL GUARD AND
15. See Figure 2-109. Connect rear power harness to tail
light harness (5).
16. Install christmas tree tie down that holds the turn signals
and tail light wire harness to tail frame. See
SIGNALS.
11 1
WARNING
Check for proper turn signal operation before riding
motorcycle. Visibility is a major concern for motorcy-
clists. Failure to have proper turn signal operation could
result in death or serious injury.
17. See Figure 2-112. Install license plate (13) to lower tail
body work (9) and tighten fasteners (12) to 36-48 in-lbs
(4-5 Nm).
18. Install turn signals and reflectors onto lower body work
and tighten to 25-28 in-lbs (2-3 Nm). See
SIGNALS.
19. Connect turn signal bullet connections and tail light con-
nections. See 7.13 TURN SIGNALS
LAMP.
20. Install passenger seat latch (14) from rear of tail frame
and tighten to 60-96 in-lbs (7-11 Nm).
for hose and
MOUNT.
7.13 TURN
WARNING
7.13 TURN
and 7.12 TAIL
2.29