Assembly - Buell XB 2008 Series Service Manual

ASSEMBLY

NOTE
See Figure 2-170. There are two threaded plastic lugs (14) on
the trunk pan that are used for manufacturing purposes only.
1. Install trunk pan assembly (11) from left side of vehicle.
2. Install fastener (8) securing right front trunk pan to right
side tail section and tighten to 12-36 in-lbs (1.3-4 Nm).
3. Install right side passenger footrest support assembly.
See 2.36 FOOTPEG, HEEL GUARD AND MOUNT:
FIREBOLT/LIGHTNING.
4. Install two fasteners (12) securing trunk pan to center tail
section and leave loose.
5. Install left tail section (5) onto vehicle.
a. Install fastener (8) attaching left front trunk pan to left
side tail section and tighten to 72-96 in-lbs (8-10.8
Nm).
b. Apply LOCTITE 271 (red) and install fasteners (4)
attaching left rear tail section to center tail section and
tighten to 102-114 in-lbs (11.5-12.8 Nm).
c. Apply LOCTITE 271 (red) and install fasteners (1)
attaching left tail section to main frame/fuel tank
assembly and tighten to 21-23 ft-lbs (28.5-31.2 Nm).
d. Apply LOCTITE 271 (red) and install fasteners
securing battery tray to side castings and tighten to
48-72 in-lbs (5.4-8 Nm).
6. Tighten fasteners (12) securing trunk pan to center tail
section to 48-72 in-lbs (5.4-8 Nm).
7. Install left side passenger footrest support assembly. See
2.36 FOOTPEG, HEEL
FIREBOLT/LIGHTNING.
8. Move rear main harness and shock absorber reservoir
back to left side of vehicle.
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
2-122 2008 XB Service: Chassis
GUARD AND MOUNT:
9. See Figure 2-169. Connect:
a. Wire harness ground (2) [GRD 2].
b. Rear brake light switch connector (5) [121].
c. ECM connectors (7) [10, 11] and [164] (on XB12
models).
d. BAS (bank angle sensor) connector (9) [134].
e. Right turn signal connector (11) [18].
f. Left turn signal connector (10) [19].
g. License plate lamp connector (12) [45]
h. Tail light connectors (13) [93].
i. Ground terminals on right side tail section (6) [GRD
1] & [GRD 3].
10. Attach cable strap loosely securing the BAS harness to
the seat latch cable.
11. Install the rear shock absorber reservoir into bracket and
tighten fastener. See 2.25 REAR SHOCK
Connect positive (+) battery cable first. If positive (+) cable
should contact ground with negative (-) cable connected,
the resulting sparks can cause a battery explosion, which
could result in death or serious injury. (00068a)
12. Install battery cables to battery: positive cable (red) first.
Tighten to 72-96 in-lbs (8-10.8 Nm). See
MAINTENANCE.
After installing seat, pull upward on seat to be sure it is
locked in position. While riding, a loose seat can shift
causing loss of control, which could result in death or
serious injury. (00070b)
13. Install seat.
ABSORBER.
1.4 BATTERY