Installation: Firebolt - Buell XB 2008 Series Service Manual

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5
4
3
2
1
1. Body fastener (2)
2. Body
3. Fastener (2)
4. Ignition switch
5. Housing
6. Connector [33]
Figure 7-6. Ignition Switch Assembly: Firebolt

INSTALLATION: FIREBOLT

1. See Figure 7-4. From beneath upper triple clamp (4), insert
ignition switch assembly into hole. The word "OFF"
stamped on the switch housing should face front of vehicle.
2. See Figure 7-6. Attach ignition switch assembly to upper
triple clamp using ignition switch fasteners (3). USE
LOCTITE 271 (red) on fasteners. Tighten to 18-20 ft-
lbs (24.4-27.1 Nm).
3. See Figure 7-4. Install steering stem cap (3). Tighten but
do not tighten.
4. Install upper clamp on fork assembly.
a. Apply LOCTITE 271 to upper fork clamp pinch
fasteners (1).
b. Tighten but do not torque upper fork clamp pinch
fasteners.
c. Tighten steering stem cap to 38-42 ft-lbs (52-57 Nm).
d. Install steering stem pinch fastener (2) applying
LOCTITE 271 and tightening to 20-22 ft-lbs (27-30
Nm).
e. Tighten upper fork clamp fasteners to 23-25 ft-lbs (31-
34 Nm).
f. Repeat torque sequence in steps d and e.
5. See Figure 7-5. Connect ignition key switch connector (3)
to wiring harness. Install cable strap (2) around ignition
switch, fuse block and right handlebar switch wires.
6. Install intake cover assembly. See
7.
8.
6
The automatic-on headlamp feature provides increased
visibility of the rider to other motorists. Be sure headlamp
is on at all times. Poor visibility of rider to other motorists
can result in death or serious injury. (00030b)
9.
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)
10. Install seat.
REMOVAL: LIGHTNING
PART NUMBER
FTXR45E
1.
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect negative (-) battery
cable before proceeding. (00048a)
2.
3.
4.
5.
6.
2.40 INTAKE COVER.
See Figure 7-3. Attach cable straps to upper fork clamp.
a. Install cable strap to the right of ignition switch
securing right hand switch and brake line wires to
upper fork clamp.
b. Install cable strap to the left of ignition switch securing
left hand switch and clutch cable wires to upper fork
clamp.
Install negative battery cable to battery terminal. Tighten
fastener to 72-96 in-lbs (8-11 Nm).
Check ignition key switch for proper operation. If operation
fails, reread procedure and verify that all steps were per-
formed.
SNAP-ON TAMPER RESISTANT T45
TORX DRIVER
Remove seat.
Disconnect negative battery cable.
Remove windscreen.
See Figure 7-7. Disconnect:
a. Turn signal flasher connector [30] (1)
b. Turn signals connector [31] (5)
c. Left [24] (4) and right [22] (3) handlebar wiring har-
nesses connectors
d. Instrument cluster connector [39] (2)
e. Horn connector [122] (10)
Remove horn (11) from horn mount (9).
Cut cable strap that loosely holds main wiring harness (7)
to the ignition switch (6) and disconnect ignition switch
connector [33].
2008 XB Service: Electrical 7-7
TOOL NAME