O-Rings (Preformed Packings); Gears; Shafts; Part Replacement - Buell XB 2008 Series Service Manual

Always discard seals after removal. Do not use the same seal
twice.

O-Rings (Preformed Packings)

Always discard o-rings after removal. Replace with new o-rings.
To prevent leaks, lubricate the o-rings before installation. Apply
the same type of lubricant as that being sealed. Be sure that
all gasket, o-ring and seal mating surfaces are thoroughly clean
before installation.

Gears

Always check gears for damaged or worn teeth.
Remove burrs and rough spots with a honing stone or crocus
cloth before installation.
Lubricate mating surfaces before pressing gears on shafts.

Shafts

If a shaft does not come out easily, check that all nuts, bolts
or retaining rings have been removed. Check to see if other
parts are in the way before using force.
Shafts fitted to tapered splines should be very tight. If shafts
are not tight, disassemble and inspect tapered splines. Discard
parts that are worn. Be sure tapered splines are clean, dry and
free of burrs before putting them in place. Press mating parts
together tightly.
Clean all rust from the machined surfaces of new parts.

Part Replacement

Always replace worn or damaged parts with new parts.

Exhaust System Leakage

In the event of an exhaust system leak at a muffler or header
pipe connection location, disassemble and clean all mating
surfaces. Replace any damaged components. If leak still exists,
disassemble and repair the leak by applying a bead of Harley-
Davidson High-Performance Sealant (Part No. 99650-02) (or
an equivalent 02 Sensor/Catalyst-safe alternative). Reassemble
components, wipe off any excess sealant and allow adequate
curing time following sealant product instructions before oper-
ating vehicle.

CLEANING

Part Protection

Before cleaning, protect rubber parts (such as hoses, boots
and electrical insulation) from cleaning solutions. Use a grease-
proof barrier material. Remove the rubber part if it cannot be
properly protected.

Cleaning Process

Any cleaning method may be used as long as it does not result
in parts damage. Thorough cleaning is necessary for proper
parts inspection. Strip rusted paint areas to bare metal before
priming and repainting.

Rust or Corrosion Removal

Remove rust and corrosion with a wire brush, abrasive cloth,
sand blasting, vapor blasting or rust remover. Use buffing
crocus cloth on highly polished parts that are rusted.

Bearings

Remove shields and seals from bearings before cleaning.
Clean bearings with permanent shields and seals in solution.
Using compressed air to "spin dry" bearings can cause
bearing to fly apart, which could result in death or serious
injury. (00505b)
Clean open bearings by soaking them in a petroleum cleaning
solution. Never use a solution that contains chlorine.
Let bearings stand and dry. Do not dry with compressed air.
Do not spin bearings while they are drying.

TOOL SAFETY

Air Tools

Always use approved eye protection equipment when
performing any task using air-operated tools.
On all power tools, use only recommended accessories
with proper capacity ratings.
Do not exceed air pressure ratings of any power tools.
Bits should be placed against work surface before air
hammers are operated.
Disconnect the air supply line to an air hammer before
attaching a bit.
Never point an air tool at yourself or another person.
Protect bystanders with approved eye protection.

Wrenches

Never use an extension on a wrench handle.
If possible, always pull on a wrench handle and adjust
your stance to prevent a fall if something lets go.
Never cock a wrench.
Never use a hammer on any wrench other than a
STRIKING FACE wrench.
Discard any wrench with broken or battered points.
Never use a pipe wrench to bend, raise or lift a pipe.

Pliers/Cutters/Pry bars

Plastic- or vinyl-covered pliers handles are not intended
to act as insulation. Do not use on live electrical circuits.
Do not use pliers or cutters for cutting hardened wire
unless they were designed for that purpose.
Always cut at right angles.
Do not use any pry bar as a chisel, punch or hammer.
2008 XB Service: Maintenance 1-3