Repair; Throttle Position Sensor; Fuel Injectors; Installation - Buell XB 2008 Series Service Manual

REPAIR

Throttle Position Sensor

See 4.4 THROTTLE POSITION SENSOR (TPS)
installation and calibration information.

Fuel Injectors

1. Remove throttle body. See
Removal in this section.
2. See Figure 4-41. Separate fuel rail assembly from throttle
body.
a. Remove IAC fasteners (7) and remove IAC (18).
b. Remove fuel rail fastener (15) that holds the fuel rail
to the throttle body and manifold.
c. Separate fuel rail (14) from injectors (12) by gently
rocking the fuel rail and pulling it away from the
injectors.
3. Remove fuel injectors (12) from manifold by gently rocking
and pulling it away from the manifold.
Injectors with damaged o-rings can leak fuel. Gasoline is
extremely flammable and highly explosive which could
result in death or serious injury. (00520b)
4. Inspect injector o-rings (11, 13) for cuts, tears or general
deterioration. Replace injector o-rings if they have been
damaged or have taken a definite set.
NOTE
Front and rear fuel injectors are not interchangeable.
5. See Figure 4-41. Coat new o-rings with thin film of clean
engine oil and install both fuel injectors (12) into the throttle
body.
6. Using a new idle air control gasket (16), press the fuel rail
assembly (14) onto the top of the injectors.
7. Apply LOCTITE 272 (red) to the fasteners (15) for the fuel
rail assembly.
8. While holding the fuel rail assembly against the throttle
body (10), install the fasteners and tighten to 24-28 in-
lbs (2.8-3.2 Nm).
9. Coat new o-ring (17) with thin film of clean engine oil and
install on IAC actuator (18).
10. Place the actuator (18) onto the fuel rail assembly (14).
11. Install fasteners (7) and tighten to 25-30 in-lbs (2.9-3.5
Nm).

INSTALLATION

NOTES
The intake flanges have been extended to improve clamp
load distribution.
Intake flanges are interchangeable.
1. See Figure 4-41. Install flanges onto throttle body with the
counterbore (2) facing out.
4-30 2008 XB Service: Fuel System
for removal,
4.14 THROTTLE BODY,
2. Place a new seal in each intake flange with the beveled
side against the counterbore.
3. Install throttle body/intake manifold assembly.
a. See Figure 4-43. Slide the assembly toward the
installed position. Manifold should engage fasteners
(2) on primary cover side of engine.
b. Align holes in opposite side or intake flanges with
those in cylinder heads and start screws.
c. Make sure throttle body is centered between cylinders
and tighten all intake flange screws to 96-120 in-
lbs (10.8-13.6 Nm).
4. Install manifold to cylinder brace fastener (1) and tighten
to 90-120 in-lbs (10-13.6 Nm).
5. Attach throttle cables. See
6. Attach wiring.
a. Injector cables are tagged (Front) and (Rear) for ease
of assembly. Push connector halves together until
latches click.
b. Connect throttle position sensor connector.
c. Connect IAC connector.
7. See Figure 4-40. Connect fuel line and EVAP hose to port
at bottom of throttle body (California models only).
8. Calibrate throttle position sensor if replaced. See
4.4 THROTTLE POSITION SENSOR
9. Install coil. See 4.5 IGNITION
10. Check throttle cable adjustment. See
CONTROL.
NOTE
When installing the left side air scoop, it is necessary to ensure
that the voltage regulator and alternator wiring harnesses are
not trapped between the air scoop and cylinder head.
11. Install air scoops. See 2.52 AIR
sm00892
Figure 4-42. Extended Intake Flanges
2.26 THROTTLE CONTROL.
(TPS).
COIL.
2.26 THROTTLE
SCOOPS.