Buell 2008 XB SERIES Electrical Diagnostics Manual
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Buell 2008 XB SERIES Electrical Diagnostics Manual

Buell 2008 XB SERIES Electrical Diagnostics Manual

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2008 Buell XB Models Electrical Diagnostics Manual
99493-08Y
©2007 Buell Motorcycle Company

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Summary of Contents for Buell 2008 XB SERIES

  • Page 1 2008 Buell XB Models Electrical Diagnostics Manual 99493-08Y ©2007 Buell Motorcycle Company...

  • Page 2: Important Notice

    IMPORTANT NOTICE Buell motorcycles conform to all applicable U.S.A. Federal Motor Vehicle Safety Standards and U.S.A. Environmental Protection Agency regulations effective on the date of manufacture. To maintain the safety, dependability, and emission and noise control performance, it is essential that the procedures, specifications and service instructions in this manual are followed.
  • Page 3 2008 Buell XB Models Electrical Diagnostics Manual ©2007 Buell Motorcycle Company ALL RIGHTS RESERVED 99493-08Y Printed in the U.S.A. VISIT THE BUELL WEB SITE http://www.buell.com...
  • Page 4 Blank Text Here...
  • Page 5 READER COMMENTS Blank Text Here The Buell Motorcycle Company maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we need user feedback - your critical evaluation of this manual. Please comment on the completeness, accuracy, organization, usability, and readability of this manual.
  • Page 6 NOTES...

  • Page 7: Starting / Charging

    First, it will acquaint the user with the construction of the Buell product and assist in the perform- In figure legends, the number which follows the name of ance of repair.
  • Page 8 Accordingly, anyone who uses a service H-D MICHIGAN, INC. TRADEMARK procedure or tool which is not recommended by Buell Motor- INFORMATION cycle Company must first thoroughly satisfy himself that neither his nor the operator's safety will be jeopardized as a result.

  • Page 9: Table Of Contents

    STARTING / CHARGING ENGINE MANAGEMENT 1.1 SPECIFICATIONS 2.1 SPECIFICATIONS General................1-1 Specifications..............2-1 1.2 ELECTRIC STARTER SYSTEM 2.2 DYNAMIC DIGITAL FUEL INJECTION (DDFI) General................1-2 Wiring Diagrams............1-2 Introduction.................2-2 Start Relay..............1-2 General................2-2 Starter Interlock............1-2 For More Information............2-2 Operation................1-2 Troubleshooting............2-2 1.3 STARTING SYSTEM DIAGNOSIS 2.3 DIAGNOSTIC INTRODUCTION Diagnostics.................1-4 System Problems...............2-5 Diagnostic Notes............1-4...
  • Page 10 TABLE OF CONTENTS 2.11 CHECK ENGINE LAMP ON 2.21 DTC P0261 (23), P0262 (23), P0264 (32), CONTINUOUSLY P0265 (32) General................2-27 General................2-70 Diagnostics...............2-27 Front and Rear Fuel Injectors........2-70 Diagnostic Notes............2-27 Diagnostics...............2-70 Diagnostic Notes............2-70 2.12 ENGINE CRANKS BUT WILL NOT 2.22 DTC P0339 (56) START General................2-74 General................2-31...
  • Page 11 TABLE OF CONTENTS Active Intake System (Japanese Models Only)..2-109 APPENDIX A CONNECTOR REPAIR Diagnostics..............2-109 Diagnostic Notes.............2-109 A.1 AMP MULTILOCK CONNECTORS Verify Settings..............2-109 Removal.................2-109 AMP Multilock Connector Repair........A-1 Installation..............2-110 General...............A-1 Separating Pin and Socket Housings......A-1 2.31 DTC P1151 (44), P1152 (44) Mating Pin and Socket Housings........A-1 Removing Terminals from Housing......A-1 General................2-115...
  • Page 12 TABLE OF CONTENTS Installing Socket Terminals........A-16 Wire Color Codes............B-3 Crimping Terminals...........A-16 Wiring Diagram Symbols..........B-3 2008 Buell Wiring Diagrams..........B-4 A.8 480 METRI-PACK CONNECTORS Wire Routing..............B-27 480 Metri-Pack Connector Repair........A-18 APPENDIX C CONVERSIONS General..............A-18 Separating Pin and Socket Housings.......A-18 C.1 METRIC CONVERSION Mating Pin and Socket Housings......A-18...
  • Page 13 SUBJECT..........................PAGE NO. 1.1 SPECIFICATIONS........................1-1 1.2 ELECTRIC STARTER SYSTEM....................1-2 1.3 STARTING SYSTEM DIAGNOSIS....................1-4 1.4 STARTER ACTIVATION CIRCUITS..................1-14 1.5 DIAGNOSTICS/TROUBLESHOOTING...................1-15 1.6 STARTER TROUBLESHOOTING....................1-16 1.7 TESTING STARTER ON MOTORCYCLE................1-18 1.8 TESTING STARTER ON BENCH....................1-22 1.9 CHARGING SYSTEM......................1-25 1.10 BATTERY TESTING......................1-33...
  • Page 14 NOTES...

  • Page 15: Specifications

    8.1 ft-lbs (11 Nm) (min) @ 2.4 V Table 1-3. Torque Values ITEM TORQUE Battery terminal fasteners 72-96 in-lbs 8-11 Nm Starter battery positive cable nut 60-85 in-lbs 7-10 Nm Starter mounting bolts 13-20 ft-lbs 18-27 Nm 2008 Buell XB Diagnostics: Starting / Charging 1-1...

  • Page 16: Electric Starter System

    (7) is returned to its original position by the return spring, which causes the pinion gear (1) to disengage from the See Section 2, Engine Management, for operation and clutch ring gear (13). troubleshooting information. 1-2 2008 Buell XB Diagnostics: Starting / Charging...
  • Page 17 Overrunning clutch Starter during cranking Solenoid plunger Clutch ring gear Pinion gear Main solenoid contacts Starting circuit (see wiring Idler gear Battery diagram) Field winding Pull-in winding 6. Armature Figure 1-1. Starter Operation 2008 Buell XB Diagnostics: Starting / Charging 1-3...

  • Page 18: Starting System Diagnosis

    STARTER ON BENCH. 3. Solenoid terminal Job/Time Code Values Figure 1-2. Starter Terminals Dealership technicians filing warranty claims should use the job/time code values printed in bold text underneath the appropriate repair. 1-4 2008 Buell XB Diagnostics: Starting / Charging...
  • Page 19 Right handlebar switch 4-place Multilock Behind windscreen [95] Clutch switch 2-place Multilock Underside of clutch lever assembly [128] Starter solenoid Spade terminal Top of starter [131] Neutral switch 1-place bullet Under sprocket cover 2008 Buell XB Diagnostics: Starting / Charging 1-5...
  • Page 20 Right handlebar switch 4-place Multilock Behind windscreen [95] Clutch switch 2-place Multilock Underside of clutch lever assembly [128] Starter solenoid Spade terminal Top of starter [131] Neutral switch 1-place bullet Under sprocket cover 1-6 2008 Buell XB Diagnostics: Starting / Charging...
  • Page 21 Depending on relay used, relay socket terminal could be shown as “1” or “U”. Replace Replace Nothing clicks. See Starter Start Switch. Start Relay. Test: Nothing Clicks (Part 1 of 2). 5818 5832 fc01584_en 2008 Buell XB Diagnostics: Starting / Charging 1-7...
  • Page 22 Clean ground Repair connection between Repair or replace STOP connections. Battery and Starter. solenoid (contacts). 5824 5824 5845 Go to Starter Test: Relay Clicks. Begin with box marked with bold asterisk. Fc01585_en 1-8 2008 Buell XB Diagnostics: Starting / Charging...
  • Page 23 Depending on relay used, relay socket terminal could be shown as “5” or “K”. 5827 Repair open or poor connections on (GN) wire Replace between Start Relay and Starter Solenoid. Start Relay. 5827 5832 fc01586_en 2008 Buell XB Diagnostics: Starting / Charging 1-9...
  • Page 24 Repair terminal “1”. open. 5831 5831 Is voltage present? 7004 Repair open in circuits between Replace Ignition Ignition Switch and Fuse Block. Switch. 7021 7002 fc01587_en 1-10 2008 Buell XB Diagnostics: Starting / Charging...
  • Page 25 [95B] terminal 1711 Switch. (BK/R) circuit “1” to connector [11B] terminal “1”. terminal “2”. 5832 Replace ECM. Repair Is there continuity? 5831 open. 1722 1721 fc01588_en Replace ECM. Repair open. 1722 1711 2008 Buell XB Diagnostics: Starting / Charging 1-11...
  • Page 26 Remove Starter. Disassemble Drive Housing assembly. Inspect for damage to Armature Gear or Idler Gear. Is damage present? Replace damaged Idler Starter Clutch failure. Gear and Armature. Replace Starter Clutch. 5825 5837 fc01589_en 1-12 2008 Buell XB Diagnostics: Starting / Charging...
  • Page 27 Are test results within range? Remove spark plugs while in Test Starter Motor 5th gear. Rotate rear wheel. for opens, short or Check for engine, primary Grounds. and/or crankshaft bind. 5817 Use appropriate code fc01590_en 2008 Buell XB Diagnostics: Starting / Charging 1-13...

  • Page 28: Starter Activation Circuits

    Lightning); 30 Amp J-Fuse purposes only) 11. Solenoid (Firebolt) Ignition fuse Starter Key switch fuse Key switch relay 4. Key switch Figure 1-5. Typical Circuitry. Refer to wiring diagrams for more information. 1-14 2008 Buell XB Diagnostics: Starting / Charging...

  • Page 29: Diagnostics/Troubleshooting

    Open circuits on the ground side will read zero. by the powdered paint will cause a voltage drop or potential difference in the ground circuit. 2008 Buell XB Diagnostics: Starting / Charging 1-15...

  • Page 30: Starter Troubleshooting

    Table 1-7. Pinion Does Not Engage With Ring Gear While Starter is Cranked or Engine Cannot Be Cranked SOURCE OF PROBLEM PROBABLE CAUSE SOLUTION Battery Voltage drop due to discharged battery. Charge battery. Short-circuited or open between electrodes. Replace battery. Poor contact condition of battery terminal(s). Clean and retighten. 1-16 2008 Buell XB Diagnostics: Starting / Charging...
  • Page 31 Replace start switch or start relay. Gear teeth on clutch shell Excessively worn teeth. Replace clutch shell. Solenoid Return spring worn. Replace spring. Coil layer shorted. Replace solenoid. Contact plate melted and stuck. Replace solenoid. 2008 Buell XB Diagnostics: Starting / Charging 1-17...

  • Page 32: Testing Starter On Motorcycle

    "5". A good relay shows continuity (continuity tester lamp "on" or a zero ohm reading on the ohmmeter). A malfunctioning relay will not show continuity and must be replaced. ed01238 Figure 1-7. Fuses and Relays (Ulysses) 1-18 2008 Buell XB Diagnostics: Starting / Charging...
  • Page 33 Figure 1-8. Fuses and Relays (Lightning) 2008 Buell XB Diagnostics: Starting / Charging 1-19...

  • Page 34: Starter Current Draw Test

    Remove starter for further tests. See the 1.8 TESTING STARTER ON BENCH, Free Running Current Draw Test. NOTE A DC current probe may be used if an induction ammeter is not available. 1-20 2008 Buell XB Diagnostics: Starting / Charging...
  • Page 35 1. Starter 2. Induction ammeter 3. Battery Figure 1-11. Starter Current Draw Test 2008 Buell XB Diagnostics: Starting / Charging 1-21...

  • Page 36: Testing Starter On Bench

    Solenoid motor terminal to negative battery post. Solenoid relay terminal to positive battery post. Observe starter shaft. If starter shaft extends strongly, solenoid is working properly. If starter shaft does not extend strongly, replace the solenoid. 1-22 2008 Buell XB Diagnostics: Starting / Charging...

  • Page 37: Solenoid Hold-In Test

    If starter shaft retracts, solenoid is working properly. If starter shaft remains extended, solenoid is working If starter shaft does not retract, replace the solenoid. properly. If starter shaft retracts, replace the solenoid. 2008 Buell XB Diagnostics: Starting / Charging 1-23...

  • Page 38: Post Test

    Reattach starter cable to starter solenoid. Reinstall starter assembly to motorcycle engine in accordance with the procedures in the Service Manual. 1. Motor terminal 2. Battery 3. Relay terminal Figure 1-15. Test 3: Return Test 1-24 2008 Buell XB Diagnostics: Starting / Charging...

  • Page 39: Charging System

    Check for corroded or loose connections in the charging circuit. Figure 1-18. Job/Time Code Values Dealership technicians filing warranty claims should use the job/time code values printed in bold text underneath the appropriate repair. 2008 Buell XB Diagnostics: Starting / Charging 1-25...
  • Page 40 Figure 1-18. Charging System Circuit (Ulysses, Lightning) Table 1-9. Wire Harness Connectors DESCRIPTION TYPE LOCATION [46] Stator 2-place Packard Under ram air scoop [77] Voltage regulator 2-place Packard Under ram air scoop 1-26 2008 Buell XB Diagnostics: Starting / Charging...
  • Page 41 Figure 1-19. Charging System Circuit (Firebolt) Table 1-10. Wire Harness Connectors DESCRIPTION TYPE LOCATION J-Fuse Spade terminals Under seat [46] Stator 2-place Packard Under ram air scoop [77] Voltage regulator 2-place Packard Under ram air scoop 2008 Buell XB Diagnostics: Starting / Charging 1-27...
  • Page 42 STOP replaced, re-test the system to 5310 be sure the problem has been corrected. Go to Charging System Test (Part 2 of 2). fc01591_en 1-28 2008 Buell XB Diagnostics: Starting / Charging...
  • Page 43 Regulator. been corrected. Inspect Rotor. Perform Current and Voltage Output Test. 5315 PASS FAIL PASS FAIL System Damaged or Replace Replace slipping Rotor. Stator. Rotor. 5319 5314 5319 fc01592_en 2008 Buell XB Diagnostics: Starting / Charging 1-29...

  • Page 44: Testing

    If battery runs down during use, the current draw of the motorcycle components and accessories may exceed output Connect the ADVANCED BATTERY CONDUCTANCE of the charging system. AND ELECTRICAL SYSTEM ANALYZER (Part No. HD- 1-30 2008 Buell XB Diagnostics: Starting / Charging...

  • Page 45: Current And Voltage Output Test: Using Load Tester

    The current output should be 28-34 amps. Make note of Figure 1-23. Test for Grounded Stator (Typical) measurement for use in 1.9 CHARGING SYSTEM, Testing. NOTE Rider's habits may require output test at lower RPM. 2008 Buell XB Diagnostics: Starting / Charging 1-31...

  • Page 46: Ac Output Check

    1 and 2. Figure 1-25. Check Stator AC Voltage Output (Typical) Run the engine at 2000 RPM. The AC output should be 40-56 volts AC (approximately 20-28 volts per 1000 RPM). 1-32 2008 Buell XB Diagnostics: Starting / Charging...

  • Page 47: Battery Testing

    Voltage reading after 15 REPLACE BATTERY - Replace the battery and retest. seconds should be 9.6V or more at 70°F (21°C). BAD CELL-REPLACE - Replace the battery and retest. 2008 Buell XB Diagnostics: Starting / Charging 1-33...
  • Page 48 Install the battery on the motorcycle. 1. Load Tester 2. Induction Pick-Up 3. Battery Figure 1-27. Load Test Battery Table 1-12. Battery Load Test COLD CRANKING 100% AMPERAGE (CCA) All Buell models 1-34 2008 Buell XB Diagnostics: Starting / Charging...

  • Page 49: Dtc P0112 (15),

    SUBJECT..........................PAGE NO. 2.1 SPECIFICATIONS........................2-1 2.2 DYNAMIC DIGITAL FUEL INJECTION (DDFI)................2-2 2.3 DIAGNOSTIC INTRODUCTION....................2-5 2.4 CHECKING FOR TROUBLE CODES..................2-6 2.5 CHECK ENGINE LAMP DIAGNOSTICS...................2-9 2.6 BREAKOUT BOX........................2-11 2.7 WIGGLE TEST........................2-13 2.8 INITIAL DIAGNOSTIC CHECK....................2-14 2.9 INTAKE LEAK TEST........................2-21 2.10 CHECK ENGINE LAMP NOT ILLUMINATED AT KEY ON............2-23 2.11 CHECK ENGINE LAMP ON CONTINUOUSLY..............2-27 2.12 ENGINE CRANKS BUT WILL NOT START................2-31 2.13 NO ECM POWER........................2-36...
  • Page 50 NOTES...

  • Page 51: Specifications

    10R12X Table 2-8. Ignition Coil Specifications 0.035 in. 0.9 mm IGNITION COIL RESISTANCE Torque 12-18 ft-lbs 16-24 Nm Primary winding 0.5-0.7 ohms Cable resistance 1,350-3,465 ohms Secondary winding 5500-7500 ohms (front and rear) 2008 Buell XB Diagnostics: Engine Management 2-1...

  • Page 52: Introduction

    Independently mapped spark and fuel control. GENERAL Engine and air temperature compensated fuel delivery. The Buell DDFI operates both as an open and closed loop Engine load measurement through throttle position. system which allows it to adjust for all possible operating con- ditions.
  • Page 53 LGN/Y Sensor Sensor ground #1 BK/W BK/W Sensor ground #2 28 BK/W [89B] [89A] BK/W Oxygen sensor V/GY Sensor [88B] [88A] [11A] [11B] [137B] [137A] Figure 2-1. Dynamic Digital Fuel Injection (DDFI) System 2008 Buell XB Diagnostics: Engine Management 2-3...
  • Page 54 Table 2-9. Wire Harness Connectors DESCRIPTION MODEL TYPE LOCATION [10] ECM (BK) Firebolt 34-place Amp (Tyco) In fairing Ulysses, Lightning Under seat [11] ECM (GY) Firebolt 34-place Amp (Tyco) In fairing Ulysses, Lightning Under seat 2-4 2008 Buell XB Diagnostics: Engine Management...

  • Page 55: System Problems

    This involves clearing the trouble codes and confirming proper vehicle operation as indicated by the behavior of the check engine lamp. 1. Low fuel lamp 2. Check engine lamp Figure 2-2. Check Engine Lamp (Typical) 2008 Buell XB Diagnostics: Engine Management 2-5...

  • Page 56: Check Engine Lamp

    2.4 CHECKING FOR TROUBLE CODES, Code Types for a complete description of trouble code formats. 1. OFF position 2. RUN position Figure 2-4. Engine Stop Switch 2-6 2008 Buell XB Diagnostics: Engine Management...

  • Page 57: Code Types

    Historic trouble codes are stored for a length of time to assist ECM will reduce engine power to assist in cooling the engine in the diagnosis of intermittent faults. The check engine lamp 2008 Buell XB Diagnostics: Engine Management 2-7...
  • Page 58 The check engine lamp will ature. This will not set a trouble code. flash until the engine has cooled to a safe operating temper- 2-8 2008 Buell XB Diagnostics: Engine Management...

  • Page 59: Check Engine Lamp Diagnostics

    After the pause comes the intermission, which is fol- lowed by transmission of the next recorded trouble code. All subsequent codes are sent in the same manner each separated from the next by he intermission. 2008 Buell XB Diagnostics: Engine Management 2-9...

  • Page 60: Clearing Codes

    Turn the engine off. HD-44750 DIGITAL TECHNICIAN After correcting system problems, clear trouble codes. If the DIGITAL TECHNICIAN (Part No. HD-44750) is not available, perform 50 start and run cycles. To execute one run cycle: 2-10 2008 Buell XB Diagnostics: Engine Management...

  • Page 61: Breakout Box

    3. ECM gray connector REMOVAL 4. ECM black connector Figure 2-9, Figure 2-10 Figure 2-11. Depress Figure 2-9. ECM and Breakout Box with Connections latches on each side of connectors [10] (black) and [11] (Ulysses) (gray). 2008 Buell XB Diagnostics: Engine Management 2-11...
  • Page 62 Detach Breakout Box connectors from ECM connectors. Reconnect harness to ECM. Detach Breakout Box connectors from wiring harness. 2-12 2008 Buell XB Diagnostics: Engine Management...

  • Page 63: Wiggle Test

    Electronic Control Module (ECM) connections, a BREAKOUT BOX (Part No. B-48115) may be used to simplify the procedure. See 2.6 BREAKOUT BOX. Figure 2-12. Fluke 78 Multimeter (DVOM) (Part No. HD-39978) Set DVOM to read voltage changes. 2008 Buell XB Diagnostics: Engine Management 2-13...

  • Page 64: Initial Diagnostic Check

    2.22 DTC P0339 (56) Manifold leak 2.9 INTAKE LEAK TEST Ignition coil 2.16 MISFIRE Leaky injectors Test fuel injectors. 2.18 DTC P0117 (14), P0118 (14). Valve sticking Perform compression test. See appropriate Buell Service Manual. 2-14 2008 Buell XB Diagnostics: Engine Management...
  • Page 65 A low IAC may also indicate an air intake leak. almost 0 and code P0506 will set. Throttle plates not opening fully Perform throttle cable adjustment. See appropriate Buell Service Manual EVAP hose (California models only) disconnected from induction Connect.
  • Page 66 2.20 DTC P0151 (13), P0152 (11), P0154 (13) P0151 Oxygen Sensor Circuit Low/Engine 2.20 DTC P0151 (13), P0152 (11), P0154 (13) Lean P0511 Idle Air Control Circuit 2.24 DTC P0506 (34), P0507 (34), P0511 (34) 2-16 2008 Buell XB Diagnostics: Engine Management...
  • Page 67 System ground #3 System ground #2 System ground #1 [91A] [10A] (BK) LGN/R LGN/R Serial data receive Data Link Connector Serial data transmit BK/W BK/W Sensor ground #3 [11A] [11B] Figure 2-13. Diagnostic Check 2008 Buell XB Diagnostics: Engine Management 2-17...
  • Page 68 Under seat [11] ECM (GY) Firebolt 34-place Amp (Tyco) In fairing Ulysses, Lightning Under seat [91A] Data link con- Firebolt 4-place Deutsch Under fairing nector Ulysses Behind left airflow guide Lightning Under seat 2-18 2008 Buell XB Diagnostics: Engine Management...
  • Page 69 Refer to applicable trouble code flow chart. tips in related trouble Start with highest priority trouble code. All code chart (even if DTCs are listed in Table 2-13. no DTC codes are set). fc00368_en 2008 Buell XB Diagnostics: Engine Management 2-19...
  • Page 70 NOTE: After replacing ECM or TPS, the TPS zero set procedure must be performed. Refer to THROTTLE POSITION SENSOR in the appropriate BUELL SERVICE MANUAL. 2-20 2008 Buell XB Diagnostics: Engine Management...

  • Page 71: Intake Leak Test

    Fuel Injectors and intake tract. Figure 2-15. Push valve (4) to release propane. Tone of engine will change when propane enters source of leak. Note which components fail the intake leak test, for further servicing. 2008 Buell XB Diagnostics: Engine Management 2-21...
  • Page 72 Figure 2-16. Checking for Leaks 2-22 2008 Buell XB Diagnostics: Engine Management...

  • Page 73: Check Engine Lamp Not Illuminated At Key On

    [10] (black) for contamination or corrosion. If con- nection is good, replace ECM. See 2.13 NO ECM POWER. Figure 2-19. Electronic Control Module (Lightning) Check continuity between instrument module connector [39] terminal "7" and ECM connector [10] (black), terminal "23". 2008 Buell XB Diagnostics: Engine Management 2-23...
  • Page 74 (GY) (BK) Figure 2-21. Check Engine Lamp Circuit (Ulysses, Lightning) Table 2-15. Wire Harness Connectors DESCRIPTION TYPE LOCATION [10] ECM (BK) 34-place Amp (Tyco) Under seat [39] Instrument module 20-place Multilock Behind windscreen 2-24 2008 Buell XB Diagnostics: Engine Management...
  • Page 75 Figure 2-22. Check Engine Lamp Circuit (Firebolt) Table 2-16. Wire Harness Connectors DESCRIPTION TYPE LOCATION J-Fuse Spade terminals Under seat [10] ECM (BK) 34-place Amp (Tyco) In fairing [39] Instrument module 20-place Multilock In fairing 2008 Buell XB Diagnostics: Engine Management 2-25...
  • Page 76 [39] lamp bulb. THROTTLE POSITION SENSOR in the and connector [10B] Bulb failed? appropriate BUELL SERVICE MANUAL. (Black). Replace Replace Instrument bulb. Module. See INSTRUMENT MODULE in the appropriate Buell Service Manual. fc00370_en 2-26 2008 Buell XB Diagnostics: Engine Management...

  • Page 77: Check Engine Lamp On Continuously

    2-25. If the check engine lamp turns off when the black Electronic Control Module (ECM) connector [10] is unplugged, the (BK/Y) wire is not shorted to ground. Figure 2-25. Electronic Control Module (Lightning) 2008 Buell XB Diagnostics: Engine Management 2-27...
  • Page 78 (GY) (BK) Figure 2-27. Check Engine Lamp Circuit (Ulysses, Lightning) Table 2-17. Wire Harness Connectors DESCRIPTION TYPE LOCATION [10] ECM (BK) 34-place Amp (Tyco) Under seat [39] Instrument module 20-place Multilock Behind windscreen 2-28 2008 Buell XB Diagnostics: Engine Management...
  • Page 79 Figure 2-28. Check Engine Lamp Circuit (Firebolt) Table 2-18. Wire Harness Connectors DESCRIPTION TYPE LOCATION J-Fuse Spade terminals Under seat [10] ECM (BK) 34-place Amp (Tyco) In fairing [39] Instrument module 20-place Multilock In fairing 2008 Buell XB Diagnostics: Engine Management 2-29...
  • Page 80 CHECKING FOR connector [10] TROUBLE CODES. (Black). NOTE: After replacing ECM or TPS, the TPS zero set procedure must be performed. Refer to fc00371_en THROTTLE POSITION SENSOR in the appropriate BUELL SERVICE MANUAL. 2-30 2008 Buell XB Diagnostics: Engine Management...

  • Page 81: Engine Cranks But Will Not Start

    (00275a) Purge fuel line of high pressure gasoline. See appropriate Buell Service Manual. Access fuel injectors. Remove right side air scoop. See appropriate Buell Service Manual. Remove airbox to access fuel injectors. See appro- priate Buell Service Manual.
  • Page 82 Beneath airbox base [85] Rear injector 2-place Packard Beneath airbox base [133] Side stand sensor 3-place Amp Below left ram air scoop [134] Bank angle sensor Firebolt 6-place Sumitomo In fairing Ulysses, Lightning Under seat 2-32 2008 Buell XB Diagnostics: Engine Management...
  • Page 83 Incorrect pressure. STOP engine lamp. See 2.10 CHECK See 2.15 FUEL ENGINE LAMP NOT PRESSURE TEST. ILLUMINATED AT KEY ON. Go to Engine fc00372_en Cranks but Will Not Start Test (Part 2 of 3). 2008 Buell XB Diagnostics: Engine Management 2-33...
  • Page 84 Are plugs good? or open in harness between coil and Go to Engine ECM. Repair open. Cranks but Will Not Start Test (Part 3 of 3). fc00373_en Replace Replace Ignition Coil. Spark Plugs. 2-34 2008 Buell XB Diagnostics: Engine Management...
  • Page 85 Is voltage at least 1.0 VAC ? Replace Crankshaft Replace NOTE: Position ECM. After replacing ECM or TPS, the TPS zero Sensor. set procedure must be performed. Refer to THROTTLE POSITION SENSOR in the appropriate BUELL SERVICE MANUAL. fc00374_en 2008 Buell XB Diagnostics: Engine Management 2-35...

  • Page 86: No Ecm Power

    Table 2-20. Wire Harness Connectors DESCRIPTION TYPE LOCATION [10] ECM (BK) 34-place Amp (Tyco) Under seat [11] ECM (GY) 34-place Amp (Tyco) Under seat [22] Right handlebar switch 4-place Multilock To the right of windscreen 2-36 2008 Buell XB Diagnostics: Engine Management...
  • Page 87 LOCATION J-Fuse Spade terminals Under seat [10] ECM (BK) 34-place Amp (Tyco) In fairing [11] ECM (GY) 34-place Amp (Tyco) In fairing [22] Right handlebar switch 4-place Multilock To the right of windscreen 2008 Buell XB Diagnostics: Engine Management 2-37...
  • Page 88 “4” (R/BK) wire. [22] and Ignition Relay. Is voltage present? Repair open on (R/BK) wire between Replace right handlebar right handlebar switch connector [22] fc00375_en and Ignition Switch. switch assembly. 2-38 2008 Buell XB Diagnostics: Engine Management...

  • Page 89: Starts, Then Stalls

    Table 2-22. Wire Harness Connectors DESCRIPTION MODEL TYPE LOCATION [10] ECM (BK) Firebolt 34-place Amp (Tyco) In fairing Ulysses, Lightning Under seat [11] ECM (GY) Firebolt 34-place Amp (Tyco) In fairing Ulysses, Lightning Under seat 2008 Buell XB Diagnostics: Engine Management 2-39...
  • Page 90 Beneath airbox base [131] Neutral switch 1-place Under sprocket cover [133] Side stand sensor 3-place Amp Below left ram air scoop [134] Bank angle sensor Firebolt 6-place Sumitomo In fairing Ulysses, Lightning Under seat 2-40 2008 Buell XB Diagnostics: Engine Management...
  • Page 91 Problem still exist? problem. See flow operation PRESSURE TEST. chart under 2.34 normal. DTC P1501 (45), P1502 (45), P1503 (45). System Replace Fuel Injectors. Problem still exist? System Replace Electronic Control Module (ECM). fc01618_en 2008 Buell XB Diagnostics: Engine Management 2-41...

  • Page 92: Fuel Pressure Test

    An open spark around gasoline could cause a result in death or serious injury. (00275a) fire or explosion, resulting in death or serious injury. (00518b) Remove airbox. See the appropriate Buell Service Manual. 10. See Figure 2-40. Turn engine off. Detach pressure gauge Purge the fuel supply line of high pressure gasoline.
  • Page 93 Figure 2-38. Fuel Line ed01538 ed01470 1. Throttle body inlet 2. Fuel pressure gauge adapter 3. Fuel line Figure 2-39. Fuel Pressure Gauge Adapter Figure 2-37. Fuel Pump Connector [86] (Firebolt - swingarm removed for illustration) 2008 Buell XB Diagnostics: Engine Management 2-43...

  • Page 94: Diagnostics

    System ground # 2 24 24 Fuel pump output 27 27 BN/Y Fuel pump output 27 27 BN/Y System ground # 1 33 33 [10A] [10B] Figure 2-41. Fuel Pump Circuit (Ulysses, Lightning) 2-44 2008 Buell XB Diagnostics: Engine Management...
  • Page 95 Table 2-23. Wire Harness Connectors DESCRIPTION TYPE LOCATION [10] ECM (BK) 34-place Amp (Tyco) Under seat [39] Instrument module 20-place Multilock Behind windscreen [86] Fuel pump 4-place Multilock Left side of frame 2008 Buell XB Diagnostics: Engine Management 2-45...
  • Page 96 Instrument Module [39A] [39B] Low fuel lamp [11B] [10B] 27 28 8 16 24 33 27 28 8 16 24 33 [11A] [10A] [11A] [10A] (GY) (BK) Figure 2-42. Fuel Pump Circuit (Firebolt) 2-46 2008 Buell XB Diagnostics: Engine Management...
  • Page 97 Table 2-24. Wire Harness Connectors DESCRIPTION TYPE LOCATION J-Fuse Spade terminals Under seat [10] ECM (BK) 34-place Amp (Tyco) In fairing [39] Instrument module 20-place Multilock In fairing [86] Fuel pump 4-place Multilock Left side of frame 2008 Buell XB Diagnostics: Engine Management 2-47...
  • Page 98 Ignition seconds after Ignition Switch Relay and Fuel is ON. Pump. Is voltage greater than 1.0V? Locate and repair Replace poor connection Ignition fc01619_en between Battery Relay. and Ignition Relay. 2-48 2008 Buell XB Diagnostics: Engine Management...
  • Page 99 (BN/Y) wire. PUMP in appropriate Buell Service Manual. NOTE: After replacing ECM or TPS, the TPS zero set procedure must be performed. Refer to THROTTLE POSITION SENSOR in the appropriate BUELL SERVICE MANUAL. fc00377_en 2008 Buell XB Diagnostics: Engine Management 2-49...

  • Page 100: Misfire

    Using an ohmmeter, touch probes to terminals on each end of plug wire. Compare resistance values to Table 2-25. Replace cables not meeting specifications. Reinstall and repeat procedure on other spark plug cable. 2-50 2008 Buell XB Diagnostics: Engine Management...
  • Page 101 Beneath airbox base [85] Rear injector 2-place Packard Beneath airbox base [133] Side stand sensor 3-place Amp Below left ram air scoop [134] Bank angle sensor Firebolt 6-place Sumitomo In fairing Ulysses, Lightning Under seat 2008 Buell XB Diagnostics: Engine Management 2-51...
  • Page 102 Perform spark test. Did spark jump gap during engine cranking? Original Ignition Coil STOP is faulty. Replace. Go to Misfire at fc00378_en Idle or Under Load (Part 2 of 2). 2-52 2008 Buell XB Diagnostics: Engine Management...
  • Page 103 NOTE: Is voltage greater than 1.0V? After replacing ECM or TPS, the TPS zero set procedure must be performed. Refer to THROTTLE POSITION SENSOR in the appropriate BUELL SERVICE MANUAL. fc00379_en Replace Replace Crankshaft ECM. Position Sensor.

  • Page 104: General

    P0112 Intake air temperature sensor on the flow chart(s). voltage low Connect BREAKOUT BOX (Part No. B-48115) to EFI P0113 Intake air temperature sensor harness only (leave disconnected). voltage high/open 2.6 BREAKOUT BOX. 2-54 2008 Buell XB Diagnostics: Engine Management...
  • Page 105 Table 2-29. Wire Harness Connectors DESCRIPTION MODEL TYPE LOCATION [11] ECM (GY) Firebolt 34-place Amp (Tyco) In fairing Ulysses, Lightning Under seat [89] Intake Air Temperature 2-place Amp In air cleaner baseplate (IAT) sensor 2008 Buell XB Diagnostics: Engine Management 2-55...
  • Page 106 After replacing Electronic Control Module (ECM) or chart brings you to this location. TPS, TPS zero set procedure must be performed. Refer to THROTTLE POSITION SENSOR in the fc000397_en appropriate Buell Service Manual. 2-56 2008 Buell XB Diagnostics: Engine Management...
  • Page 107 Disregard the asterisk (but not Codes can be cleared using DIGITAL the instruction box) if your normal progression TECHNICIAN (Part No. HD-44750). through the chart brings you to this location. 2008 Buell XB Diagnostics: Engine Management 2-57...

  • Page 108: Diagnostic Tips

    Figure 2-47. Location of Engine Temperature Sensor in Connect BREAKOUT BOX (Part No. B-48115) to ECM. Rear Cylinder Head 2.6 BREAKOUT BOX. Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404-B), purple socket probes and patch cord. 2-58 2008 Buell XB Diagnostics: Engine Management...
  • Page 109 Table 2-32. Wire Harness Connectors DESCRIPTION MODEL TYPE LOCATION [11] ECM (GY) Firebolt 34-place Amp (Tyco) In fairing Ulysses, Lightning Under seat [90] Engine Temperature (ET) 1-place bullet Beneath air cleaner base- sensor plate 2008 Buell XB Diagnostics: Engine Management 2-59...
  • Page 110 Disregard lamp. Codes can be cleared the asterisk (but not the instruction using DIGITAL TECHNICIAN box) if your normal progression through (Part No. HD-44750). the chart brings you to this location. fc00395_en 2-60 2008 Buell XB Diagnostics: Engine Management...
  • Page 111 After replacing Electronic Control Module (ECM) or chart brings you to this location. TPS, TPS zero set procedure must be performed. Refer to THROTTLE POSITION SENSOR in the appropriate Buell Service Manual. fc000396_en 2008 Buell XB Diagnostics: Engine Management 2-61...

  • Page 112: General

    (when throttle is held wide open). As the throttle is slowly Figure 2-49. TPS Assembly moved, the voltage should change gradually without spikes or low voltage being observed. Diagnostic Notes Each reference number below correlates to a circled number on the flow chart(s). 2-62 2008 Buell XB Diagnostics: Engine Management...
  • Page 113 2-place Deutsch Below left ram air scoop sensor [88] Throttle Position Sensor 3-place Amp Beneath air cleaner base- (TPS) plate [134] Bank angle sensor Firebolt 6-place Sumitomo In fairing Ulysses, Lightning Under seat 2008 Buell XB Diagnostics: Engine Management 2-63...
  • Page 114 After replacing ECM or TPS, TPS zero set procedure progression through the chart brings must be performed. Refer to THROTTLE POSITION you to this location. SENSOR in the appropriate Buell Service Manual. fc00390_en 2-64 2008 Buell XB Diagnostics: Engine Management...
  • Page 115 DIGITAL TECHNICIAN (Part Replace ECM. between connector [88] terminal “1” No. HD-44750). and terminal “3”. Is resistance greater than 1 megohm? Locate and repair short Replace BAS. between (R/W) and (BK/W) wires. fc00391_en 2008 Buell XB Diagnostics: Engine Management 2-65...

  • Page 116: General

    Loose/Leaking Exhaust: This can cause poor ground connection for sensor or allow fresh air into the exhaust system. If fresh air enters exhaust system, the oxygen sensor will read a lean condition, causing the system to go rich. 2-66 2008 Buell XB Diagnostics: Engine Management...

  • Page 117: Diagnostic Notes

    Table 2-36. Wire Harness Connectors DESCRIPTION MODEL TYPE LOCATION [11] ECM (GY) Firebolt 34-place Amp (Tyco) In fairing Ulysses, Lightning Under seat [137] Oxygen (O ) sensor 1-place Packard Above rear cylinder head 2008 Buell XB Diagnostics: Engine Management 2-67...
  • Page 118 Replace ECM. Replace ECM. zero set procedure must be performed. ground on (V/ to voltage and Refer to THROTTLE POSITION GY) wire. repair. SENSOR in the appropriate Buell Service Manual. fc00392_en 2-68 2008 Buell XB Diagnostics: Engine Management...
  • Page 119 ECM. Road test again to verify. After replacing ECM or TPS, TPS zero set procedure must be performed. Refer to THROTTLE POSITION Fuel injectors SENSOR in the appropriate Buell Service Manual. Repair. may be dirty. See Fuel Injectors under THROTTLE...

  • Page 120: General

    Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (00257a) Purge fuel line. See FUEL PUMP in the appropriate Buell Service Manual. Use HARNESS CONNECTOR TEST KIT (Part No. HD- 41404-B), purple pin probes and patch cord.
  • Page 121 Under seat [79] Crankshaft Position (CKP) 2-place Mini-Deutsch Below left ram air scoop sensor [84] Front injector 2-place Packard Beneath air cleaner base plate [85] Rear injector 2-place Packard Beneath air cleaner base plate 2008 Buell XB Diagnostics: Engine Management 2-71...
  • Page 122 DIGITAL TECHNICIAN (Part No. HD-44750). After replacing ECM or TPS, TPS zero set procedure must be performed. Refer to THROTTLE POSITION SENSOR in the appropriate Buell Service Manual. Using Breakout Box, check with test lamp Repair open or between ECM [10] terminal “29” (DTC poor connection.
  • Page 123 See 2.7 WIGGLE TEST open wire. to locate intermittents. Repair as necessary. NOTE: Clear DTCs and confirm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). fc00403_en 2008 Buell XB Diagnostics: Engine Management 2-73...

  • Page 124: General

    41404-B), brown socket probes and patch cords. ed01303 For testing purposes, install sensor without running wiring along normal path. Disconnect and route wiring properly if system is now OK. Figure 2-57. CKP Sensor Location 2-74 2008 Buell XB Diagnostics: Engine Management...
  • Page 125 Table 2-40. Wire Harness Connectors DESCRIPTION MODEL TYPE LOCATION [11] ECM (GY) Firebolt 34-place Amp (Tyco) In fairing Ulysses, Lightning Under seat [79] Crankshaft Position (CKP) 2-place Mini-Deutsch Below left ram air scoop sensor 2008 Buell XB Diagnostics: Engine Management 2-75...
  • Page 126 “2” of fc01609_en wire between terminal CKP sensor. appropriate connector [79B] and “1” of connector [79B] Replace ECM. BUELL terminal “26” of connector and terminal “18” of SERVICE [11B] (Gray). connector [11B] (Gray). MANUAL. 2-76 2008 Buell XB Diagnostics: Engine Management...

  • Page 127: General

    Use SPEEDOMETER TESTER (Part No. HD-41354) and INPUT/OUTPUT CABLE (Part No. HD-41354-1) to provide Figure 2-59. Vehicle Speed Sensor a signal to the speed indication system. Connect BREAKOUT BOX (Part No. B-48115) between wire harness and ECM. 2008 Buell XB Diagnostics: Engine Management 2-77...
  • Page 128 Figure 2-61. Speedometer Tester (Part No. HD-41354) 2-78 2008 Buell XB Diagnostics: Engine Management...
  • Page 129 ECM (GY) 34-place Amp (Tyco) Under seat [33] Ignition switch 4-place Augat Behind windscreen [39] Instrument module 20-place Multilock Behind windscreen [65] Vehicle Speed Sensor (VSS) 3-place Deutsch Right rear top of crankcase 2008 Buell XB Diagnostics: Engine Management 2-79...
  • Page 130 ECM (GY) 34-place Amp (Tyco) In fairing [33] Ignition switch 4-place Augat Beneath fairing [39] Instrument module 20-place Multilock In fairing [65] Vehicle Speed Sensor (VSS) 3-place Deutsch Right rear top of crankcase 2-80 2008 Buell XB Diagnostics: Engine Management...
  • Page 131 Clear DTCs and confirm proper terminal “12” (R/BK) operation with no check engine lamp. and ignition switch DTCs can also be cleared with a Digital connector [39B] Technician (Part No. HD-44750). terminal “3” (R/BK). fc01629_en 2008 Buell XB Diagnostics: Engine Management 2-81...
  • Page 132 DTCs can also be cleared with a Digital Technician (Part No. HD-44750). STOP System OK. Go to Vehicle Speed Sensor Test, DTC P0502 fc01630_en (43); P0503 (43); P0608 (37) (Part 3 of 3) 2-82 2008 Buell XB Diagnostics: Engine Management...
  • Page 133 Locate and repair open on THROTTLE POSITION SENSOR in the Replace Vehicle (W) wire between connector [78B] appropriate BUELL SERVICE MANUAL. Speed Sensor. terminal “13” and connector [65B] terminal “2”. If wiring is OK, replace ECM. fc01631_en 2008 Buell XB Diagnostics: Engine Management 2-83...

  • Page 134: General

    RPM higher than expected P0507 Idle Air Control (IAC) system RPM lower than expected P0511 Idle Air Control (IAC) circuit ed02020 Figure 2-66. IAC Motor Pintle Air Inlet Figure 2-64. IAC Test Lamp (Part No. HD-41199-3) 2-84 2008 Buell XB Diagnostics: Engine Management...

  • Page 135: Diagnostics

    To during ignition switch ON/OFF cycle. check for leaky injectors , first remove the air cleaner. See Air Cleaner in the appropriate Buell Service Manual. Turn NOTE key ON for 2 seconds five consecutive times. Replace the There is a remote possibility that one of the circuits is shorted fuel injector if there is any evidence of raw fuel in bores.
  • Page 136 [11B] or repair open wire Is voltage present? in harness. Repair short STOP to voltage. Go to Idle Air Control Test DTC P0506 (34); P0507 (34); P0511 (34) (Part 2 of 2). fc01612_en 2-86 2008 Buell XB Diagnostics: Engine Management...
  • Page 137 Connections OK? After replacing Electronic Control Module (ECM) or TPS, TPS zero set procedure must be performed. Refer to THROTTLE POSITION SENSOR in the appropriate BUELL SERVICE MANUAL. Replace Repair ECM ECM. connections. fc01613_en 2008 Buell XB Diagnostics: Engine Management 2-87...

  • Page 138: General

    This checks for voltage drops in the ECM power circuit. If a significant voltage drop is not present, condition may be caused by excessive starter current draw. ed01571 Figure 2-70. Battery Location (Firebolt) Figure 2-68. Battery Location (Ulysses) 2-88 2008 Buell XB Diagnostics: Engine Management...
  • Page 139 [11] ECM (GY) 34-place Amp (Tyco) Under seat [22] Right hand controls 4-place Multilock Behind windscreen [33] Ignition switch 4-place Augat Behind windscreen [91] Data link connector 4-place Deutsch Behind left airflow guide 2008 Buell XB Diagnostics: Engine Management 2-89...
  • Page 140 ECM (GY) 34-place Amp (Tyco) In fairing [22] Right handlebar switch 4-place Multilock To the right of windscreen [33] Ignition switch 4-place Augat Beneath fairing [91] Data link connector 4-place Deutsch Beneath fairing 2-90 2008 Buell XB Diagnostics: Engine Management...
  • Page 141 Test DTC P0562 (16); P0563 (16) (Part 1 of 2). NOTE: Clear DTCs and confirm proper operation with no check engine lamp. Codes can be cleared using fc00399_en DIGITAL TECHNICIAN (Part No. HD-44750). 2008 Buell XB Diagnostics: Engine Management 2-91...
  • Page 142 Replace (R/Y) wire between battery fuse Replace J-Fuse. and battery. NOTE: Clear DTCs and confirm proper operation with no check engine lamp. Codes can be cleared using fc00400_en DIGITAL TECHNICIAN (Part No. HD-44750). 2-92 2008 Buell XB Diagnostics: Engine Management...

  • Page 143: General

    ECM Failure All of the following codes indicate a failure which requires replacement of the Electronic Control Module (ECM). Refer to ELECTRONIC CONTROL MODULE in the appropriate Buell Service Manual. Code 52 - RAM failure Code 53 - ROM failure...

  • Page 144: General

    4. Ignition 2. Auxiliary Figure 2-77. Start Relay (Lightning) 3. Key switch 4. Ignition Figure 2-76. Start Relay (Ulysses) ed01336 1. Start 2. Auxiliary 3. Key switch 4. Ignition Figure 2-78. Start Relay (Firebolt) 2-94 2008 Buell XB Diagnostics: Engine Management...

  • Page 145: Diagnostics

    Right handlebar switch 4-place Multilock Behind windscreen [95] Clutch switch 2-place Multilock Underside of clutch lever assembly [128] Starter solenoid Spade terminal Top of starter [131] Neutral switch 1-place bullet Under sprocket cover 2008 Buell XB Diagnostics: Engine Management 2-95...
  • Page 146 Right handlebar switch 4-place Multilock Behind windscreen [95] Clutch switch 2-place Multilock Underside of clutch lever assembly [128] Starter solenoid Spade terminal Top of starter [131] Neutral switch 1-place bullet Under sprocket cover 2-96 2008 Buell XB Diagnostics: Engine Management...
  • Page 147 Is continuity present? Is continuity present? Locate and repair Replace Key Locate and repair Replace Key open wire (R/BK). Switch Relay. open wire (BK). Switch. fc01635_en Headlamp Illuminated? Replace Start Problem solved. Relay. 2008 Buell XB Diagnostics: Engine Management 2-97...
  • Page 148 Is connector [131] mated properly? connector [10B] (Black) terminal “8” to ground. Is voltage 0.6V or less? Replace Mate connectors neutral switch. Replace Start and retest. Replace ECM. Relay. fc01636_en 2-98 2008 Buell XB Diagnostics: Engine Management...

  • Page 149: General

    If resistance greater than 1 ohm is found between ECM connector [10] terminal "27" OR "28" and fuel pump con- nector [86A] terminal "4", but not both, the open must be repaired but this repair will not correct the concern. 2008 Buell XB Diagnostics: Engine Management 2-99...
  • Page 150 Under seat [22] Right hand controls 4-place Multilock Behind windscreen [33] Ignition switch 4-place Augat Behind windscreen [39] Instrument module 20-place Multilock Behind windscreen [86] Fuel pump 4-place Multilock Left side of frame 2-100 2008 Buell XB Diagnostics: Engine Management...
  • Page 151 Instrument Module [39A] [39B] Low fuel lamp [11B] [10B] 27 28 8 16 24 33 27 28 8 16 24 33 [11A] [10A] [11A] [10A] (GY) (BK) Figure 2-83. Fuel Pump Circuit (Firebolt) 2008 Buell XB Diagnostics: Engine Management 2-101...
  • Page 152 In fairing [22] Right hand controls 4-place Multilock Beneath fairing [33] Ignition switch 4-place Augat Beneath fairing [39] Instrument module 20-place Multilock In fairing [86] Fuel pump 4-place Multilock Left side of frame 2-102 2008 Buell XB Diagnostics: Engine Management...
  • Page 153 After replacing ECM or TPS, TPS zero set connector [86A] terminal “4”. procedure must be performed. Refer to Is continuity present? THROTTLE POSITION SENSOR in the appropriate Buell Service Manual. Repair open. fc00405_en 2008 Buell XB Diagnostics: Engine Management 2-103...

  • Page 154: General

    If resistance greater than 1 ohm is found between Elec- tronic Control Module (ECM) connector [10] terminal "27" OR "28" and fuel pump [86A] terminal "4", but not both, the open must be repaired but this repair will not correct the concern. 2-104 2008 Buell XB Diagnostics: Engine Management...
  • Page 155 (GY) (BK) Figure 2-85. Cooling Fan Circuit (Ulysses, Lightning) Table 2-57. Wire Harness Connectors DESCRIPTION TYPE LOCATION [10] ECM (BK) 34-place Amp (Tyco) Under seat [97] Cooling fan 2-place Multilock Behind rear cylinder 2008 Buell XB Diagnostics: Engine Management 2-105...
  • Page 156 Figure 2-86. Cooling Fan Circuit (Firebolt) Table 2-58. Wire Harness Connectors DESCRIPTION TYPE LOCATION J-Fuse Spade terminals Under seat [10] ECM (BK) 34-place Amp (Tyco) In fairing [97] Cooling fan 2-place Multilock Behind rear cylinder 2-106 2008 Buell XB Diagnostics: Engine Management...
  • Page 157 At some point in the flow chart you may be instructed to jump directly to a box with the bold asterisk. Disregard the asterisk (but not the instruction box) if your normal progression through the chart brings you to this location. fc00407_en 2008 Buell XB Diagnostics: Engine Management 2-107...
  • Page 158 Place a jumper wire between (Y/ Cooling Fan. BN) wire and battery positive (+). Place Fan. a jumper between cooling fan (BK) wire and ground. Does the Cooling Fan run at full speed? System Replace Cooling Fan. fc00408_en 2-108 2008 Buell XB Diagnostics: Engine Management...

  • Page 159: Active Intake System (Japanese Models Only)

    Active Intake System (Japanese Models throttle position sensor (TPS) zero set procedure. See Only) Throttle Position Sensor (TPS) in the appropriate Buell The active intake system utilizes a solenoid in the airbox which Service Manual. is connected to the throttle valve via a cable. The throttle valve Leave Digital Technician attached to vehicle.

  • Page 160: Installation

    If the cable comes out the cable See Cable Adjustment in the appropriate Buell Service will not work properly and will not be able to be adjusted.
  • Page 161 [22] Right hand controls 4-place Multilock Behind windscreen [33] Ignition switch 4-place Augat Behind windscreen [178] Active intake solenoid 2-place Deutsch Under airbox cover [179] Active intake system sub-harness 2-place Deutsch Under seat 2008 Buell XB Diagnostics: Engine Management 2-111...
  • Page 162 [22] Right hand controls 4-place Multilock In fairing [33] Ignition switch 4-place Augat In fairing [178] Active intake solenoid 2-place Deutsch Under airbox cover [179] Active intake system sub-harness 2-place Deutsch Under seat 2-112 2008 Buell XB Diagnostics: Engine Management...
  • Page 163 Go to Active Intake System Test (Japanese Models Only), DTC (Japanese Models Only), DTC P1110 (22); P1111 (22); P1112 P1110 (22); P1111 (22); P1112 (22) (Part 2 of 2). (22) (Part 2 of 2). fc01607_en 2008 Buell XB Diagnostics: Engine Management 2-113...
  • Page 164 Control Module in the appropriate BUELL (ECM). SERVICE MANUAL. NOTE: After replacing ECM or TPS, TPS zero set procedure must be performed. Refer to THROTTLE POSITION SENSOR in the appropriate BUELL SERVICE MANUAL. fc01608_en 2-114 2008 Buell XB Diagnostics: Engine Management...

  • Page 165: General

    Bank angle sensor shorted low P1152 Bank angle sensor shorted high or failed sensor ed01535 Table 2-63. Bank Angle Sensor Voltage MODE VOLTS Run mode 0.24-3.4 Disable mode 3.5-4.79 Figure 2-91. Bank Angle Sensor (Connector End) 2008 Buell XB Diagnostics: Engine Management 2-115...

  • Page 166: Diagnostics

    Figure 2-92. Bank Angle Sensor Circuit Table 2-64. Wire Harness Connectors DESCRIPTION MODEL TYPE LOCATION [11] ECM (GY) Firebolt 34-place Amp (Tyco) In fairing Ulysses, Lightning Under seat [134] Bank angle sensor 6-place Sumitomo In fairing 2-116 2008 Buell XB Diagnostics: Engine Management...
  • Page 167 Replace Bank Angle Sensor. See BANK configuration. ANGLE SENSOR in the appropriate Buell Service Manual. NOTE: Clear DTCs and confirm proper operation with no check engine lamp. Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). fc00409_en 2008 Buell XB Diagnostics: Engine Management 2-117...
  • Page 168 Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). After replacing ECM or TPS, TPS zero set procedure must be performed. Refer to THROTTLE POSITION SENSOR in the appropriate BUELL SERVICE MANUAL. fc00410_en 2-118 2008 Buell XB Diagnostics: Engine Management...

  • Page 169: General

    Connect BREAKOUT BOX (Part No. B-48115) to ECM. 2.6 BREAKOUT BOX. If DTC is current (lamp on continuously, clear codes return during operation), replace ECM. If DTC is historic, check for intermittents. 2008 Buell XB Diagnostics: Engine Management 2-119...
  • Page 170 Ignition switch 4-place Augat Behind windscreen [39] Instrument module 20-place Multilock In front modules behind windscreen [95] Clutch switch 2-place Multilock Underside of clutch lever assembly [131] Neutral switch 1-place Bullet Under sprocket cover 2-120 2008 Buell XB Diagnostics: Engine Management...
  • Page 171 In fairing [33] Ignition switch 4-place Augat Beneath fairing [39] Instrument module 20-place Multilock In fairing [95] Clutch switch 2-place Multilock Underside of clutch lever assembly [131] Neutral switch 1-place bullet Under sprocket cover 2008 Buell XB Diagnostics: Engine Management 2-121...
  • Page 172 NOTES: harness between [11B] After replacing Electronic Control Module and [95B). (ECM) or TPS, TPS zero set procedure must be performed. Refer to THROTTLE POSITION SENSOR in the appropriate BUELL SERVICE MANUAL. fc01614_en 2-122 2008 Buell XB Diagnostics: Engine Management...
  • Page 173 Neutral Switch. main wiring harness. NOTES: After replacing Electronic Control Module (ECM) or TPS, TPS zero set procedure must be performed. Refer to THROTTLE POSITION SENSOR in the appropriate BUELL SERVICE MANUAL. fc01615_en 2008 Buell XB Diagnostics: Engine Management 2-123...

  • Page 174: Interactive Muffler Control Actuator

    Interactive muffler control actuator stuck closed P1477 Interactive muffler control actuator low/open ed01339 P1478 Interactive muffler control actuator high ed01318 Figure 2-99. Active Muffler Control Actuator Motor Figure 2-97. Active Muffler Control Actuator (Open) 2-124 2008 Buell XB Diagnostics: Engine Management...

  • Page 175: Diagnostics

    Horn Y/BK [122A] [122B] [121A] [121B] [24A] Brake/Horn/Muffler Left Handlebar From key Switch R/BK switch relay [165B] [165A] [11B] [10B] [11A] [10A] [11A] [10A] (GY) (BK) Figure 2-100. Interactive Exhaust Circuit (Ulysses, Lightning) 2008 Buell XB Diagnostics: Engine Management 2-125...
  • Page 176 Front brake switch 2-place Multilock Underside of front master cylinder assembly [122] Horn switch Spade lugs Behind windscreen [161] Muffler valve actuator 4-place Deutsch Beneath intake cover assembly [165] Sub-harness 3-place Packard Under seat 2-126 2008 Buell XB Diagnostics: Engine Management...
  • Page 177 Rear Brake Switch Horn [122A] [122B] [121A] [121B] [24A] Brake/Horn/Muffler Left Handlebar From key Switch R/BK switch relay [165B] [165A] [11B] [10B] [11A] [10A] [11A] [10A] (BK) (GY) Figure 2-101. Interactive Exhaust Circuit (Firebolt) 2008 Buell XB Diagnostics: Engine Management 2-127...
  • Page 178 Front brake switch 2-place Multilock Underside of front master cylinder assembly [122] Horn switch Spade lugs In fairing [161] Muffler valve actuator 4-place Deutsch Beneath intake cover assembly [165] Sub-harness 3-place Packard Under seat 2-128 2008 Buell XB Diagnostics: Engine Management...
  • Page 179 Codes can be cleared using DIGITAL TECHNICIAN (Part No. HD-44750). After replacing ECM or TPS, PTS zero set procedure must be performed. Refer to THROTTLE POSITION Replace Replace Interactive SENSOR in the appropriate Buell Service Manual. muffler Muffler Control Actuator cable. assembly. fc00401_en...

  • Page 180: General

    Diagnostic Notes Each reference number below correlates to a circled number on the flow chart(s). See the appropriate Buell Service Manual for ECM replacement. Unplug the neutral switch connector [131]. Using a DVOM (Part No. HD-39978), test continuity to ground.
  • Page 181 Table 2-72. Wire Harness Connectors DESCRIPTION MODEL TYPE LOCATION [11] ECM (GY) Firebolt 34-place Amp (Tyco) In fairing Ulysses, Lightning Under seat [133] Side stand sensor 3-place Amp Behind left ram air scoop 2008 Buell XB Diagnostics: Engine Management 2-131...
  • Page 182 DTC? Replace Disconnect connector [11] (Gray) Side Stand Electronic Control Module (ECM). Sensor. Test for continuity between terminal “34” (Gray) to ground. Is continuity present? Repair short Replace to ground. ECM. fc01616_en 2-132 2008 Buell XB Diagnostics: Engine Management...
  • Page 183 After replacing Electronic Control Module (ECM) or TPS, TPS zero set procedure must be performed. Refer to THROTTLE POSITION SENSOR in the appropriate BUELL SERVICE MANUAL. Replace Replace Side ECM. fc01617_en Stand Sensor. 2008 Buell XB Diagnostics: Engine Management 2-133...
  • Page 184 [133B] terminal “1” and ECM tension. Sensor. appropriate Buell Service connector [11B] (Gray) terminal “25". Does spring have correct Manual. tension? Is continuity present? Replace Repair Replace spring. Operation normal. ECM. open wire. fc01632_en 2-134 2008 Buell XB Diagnostics: Engine Management...

  • Page 185: Dtc P1601 (47)

    Figure 2-105. Front 12 Volt Auxiliary Power Outlet (Ulysses on the flow chart(s). Shown) Remove the seat to access the rear 12-volt auxiliary power outlet electrical connector. Remove the windscreen to access the front 12-volt auxil- iary power outlet electrical connector. 2008 Buell XB Diagnostics: Engine Management 2-135...
  • Page 186 4-place Multilock Behind windscreen [33] Ignition switch 4-place Augat Behind windscreen [160] Front 12-volt auxiliary power 2-place Sumitomo Behind windscreen outlet [180] Rear 12-volt auxiliary power Ulysses only 2-place Sumitomo Under seat outlet 2-136 2008 Buell XB Diagnostics: Engine Management...
  • Page 187 [10] ECM (BK) 34-place Amp (Tyco) In fairing [22] Right handlebar switch 4-place Multilock Beneath fairing [33] Ignition switch 4-place Augat Beneath fairing [160] Front 12-volt auxiliary power outlet 2-place Sumitomo Beneath fairing 2008 Buell XB Diagnostics: Engine Management 2-137...
  • Page 188 Ignition Relay. Locate and repair open wire between relay Replace ECM. assembly connector [62B] terminal “16” (R/BK) and fuse block assembly [62B] terminal “15” (R). If wiring is OK, replace Auxiliary Relay. fc01639_en 2-138 2008 Buell XB Diagnostics: Engine Management...

  • Page 189: General

    Connect BREAKOUT BOX (Part No. B-48115) to ECM. 2.6 BREAKOUT BOX. Replace instrument module. See Instrument Module in the appropriate Buell Service Manual. Figure 2-110. Instrument Module Connector [39] (Disconnected) 2008 Buell XB Diagnostics: Engine Management 2-139...
  • Page 190 Switch R/GY R/BK R/BK Instrument Module Battery Switch R/BK Ignition Fuse Ground TACH [11B] [10B] [39A] [39B] [11A] [10A] J-Fuse From battery [5A] [5B] [11A] [10A] (BK) (GY) Figure 2-112. Tachometer Circuit (Firebolt) 2-140 2008 Buell XB Diagnostics: Engine Management...
  • Page 191 Table 2-78. Wire Harness Connectors DESCRIPTION TYPE LOCATION J-Fuse Spade terminals Under seat [10] ECM (BK) 34-place Amp (Tyco) In fairing [33] Ignition switch 4-place Augat Beneath fairing [39] Instrument module 20-place Multilock In fairing 2008 Buell XB Diagnostics: Engine Management 2-141...
  • Page 192 4.0-6.0 volts? Reconnect connector [39]. Locate intermittents using Replace wiggle test. See 2.7 WIGGLE ECM. TEST. Intermittents found? Replace Instrument Module. See INSTRUMENT Repair. MODULE in the appropriate Buell Service Manual. fc00406_en 2-142 2008 Buell XB Diagnostics: Engine Management...

  • Page 193: General

    1. Front cylinder post 2. Coil Pin A (rear cylinder) 3. Coil Pin B (12 VDC) 4. Coil Pin C (front cylinder) 5. Rear cylinder post Figure 2-113. Ignition Coil Figure 2-114. Ignition Coil Circuit Test 2008 Buell XB Diagnostics: Engine Management 2-143...
  • Page 194 ECM (GY) Firebolt 34-place Amp (Tyco) In fairing Ulysses, Lightning Under seat [79] Crankshaft Position (CKP) 2-place Mini-Deutsch Below left ram air scoop sensor [83] Ignition coil 3-place Delphi Beneath air cleaner base plate 2-144 2008 Buell XB Diagnostics: Engine Management...
  • Page 195 After replacing ECM or TPS, TPS zero set Intermittents found? procedure must be performed. Refer to THROTTLE POSITION SENSOR in the appropriate Buell Service Manual. Repair as Replace necessary. ECM. fc00404_en 2008 Buell XB Diagnostics: Engine Management 2-145...

  • Page 196: Heated Handlebar Grips

    Remove windscreen to access the connectors for the Heated Handlebar Grips. 1. High heat position 2. Low heat position 3. Control switch Figure 2-116. Heated Handlebar Grips Control Switch 2-146 2008 Buell XB Diagnostics: Engine Management...
  • Page 197 2. Right hand controls [22] 3. Heated handlebar grip subharness [206] 4. Auxiliary power [160] 5. Left heated handlebar grip [189L] 6. Left hand controls [24] Figure 2-117. Heated Handlebar Grips Connector Locations 2008 Buell XB Diagnostics: Engine Management 2-147...
  • Page 198 Auxiliary power 2-place Sumitomo Inside windscreen [189L] Left heated handlebar grip 3-place Deutsch Inside windscreen [189R] Right heated handlebar grip 3-place Deutsch Inside windscreen [260B] Heated handlebar grip subharness 2-place Sumitomo Inside windscreen 2-148 2008 Buell XB Diagnostics: Engine Management...
  • Page 199 (BN) and then terminal “3” (BE). Repeat for connector [189RB]. Is continuity present? Replace Heated Locate and repair open wire Handlebar Grip between connector [206B] switch. terminal “1” (O/R) and Heated Handlebar Grip switch. fc01655_en 2008 Buell XB Diagnostics: Engine Management 2-149...
  • Page 200 HIGH, check for continuity from connector [206B] terminal “1” (O/R) and ground. Is continuity present? Locate and repair Perform 2.7 WIGGLE shorted wire(s) as TEST. If no intermittents applicable. found, repeat test. fc01656_en 2-150 2008 Buell XB Diagnostics: Engine Management...
  • Page 201 SUBJECT..........................PAGE NO. A.1 AMP MULTILOCK CONNECTORS..................A-1 A.2 DELPHI CONNECTORS......................A-5 A.3 DEUTSCH ELECTRICAL CONNECTORS................A-7 A.4 DEUTSCH STANDARD TERMINALS..................A-11 A.5 METRI-PACK TERMINALS.....................A-12 A.6 150 METRI-PACK CONNECTORS..................A-14 A.7 280 METRI-PACK CONNECTORS..................A-16 A.8 480 METRI-PACK CONNECTORS..................A-18 A.9 630 METRI-PACK CONNECTORS..................A-19 A.10 SEALED SPLICE CONNECTORS..................A-20...
  • Page 202 NOTES...

  • Page 203: Amp Multilock Connectors

    Socket: Lift the socket tang (8) up. Pin: Press the pin tang (7) down. NOTE A "click" is heard if the tang is released. Gently tug on wire to pull wire and terminal from cavity. 2008 Buell XB Diagnostics: Appendix A Connector Repair A-1...

  • Page 204: Inserting Terminals Into Housing

    Hold the terminal so the catch faces the tang in the chamber. Insert the terminal into its numbered cavity until Strip 5/32 in. (4.0 mm) of insulation from the wire lead. it snaps in place. A-2 2008 Buell XB Diagnostics: Appendix A Connector Repair...

  • Page 205: Crimping Terminals To Leads

    Figure A-5. AMP Multilock Connector: Socket Terminal Crimping Terminals to Leads NOTE Crimping with an Amp Multilock tool is a one step operation. One squeeze crimps both the wire core and the insulation tails. 2008 Buell XB Diagnostics: Appendix A Connector Repair A-3...

  • Page 206: Inspecting Crimped Terminals

    2. Locking bar flange 3. Insert contact 4. Release locking bar 5. Insert lead 6. Squeeze 7. Raise locking bar 8. Remove crimped terminal Figure A-6. AMP Multilock Connector: Terminal Crimping Procedure A-4 2008 Buell XB Diagnostics: Appendix A Connector Repair...

  • Page 207: Delphi Connectors

    If present, seat wires in separate channels of wire lock and then push channels inside chambers at wire end of socket housing. Fully installed, slot on each side of wire lock engages ear on socket housing. 2008 Buell XB Diagnostics: Appendix A Connector Repair A-5...
  • Page 208 1. Remove wire lock 2. Remove terminal lock 3. Pry tang outward Figure A-9. Delphi Connector: Removing Socket Terminals A-6 2008 Buell XB Diagnostics: Appendix A Connector Repair...

  • Page 209: Deutsch Electrical Connectors

    If necessary, fit the attachment clip to the pin housing. Seal plugs (6) are installed through the wire seals of unused chambers. If removed, seal plugs must be replaced to seal the connector. 2008 Buell XB Diagnostics: Appendix A Connector Repair A-7...
  • Page 210 1. Arrow on socket locking wedge 2. Arrow on pin locking wedge Figure A-12. Deutsch Connector: 3-Place Locking Wedges Figure A-11. Deutsch Connector: Remove Secondary Locking Wedge A-8 2008 Buell XB Diagnostics: Appendix A Connector Repair...

  • Page 211: Removing Pin Terminals

    8-place and 12-place gray installed position. and black connectors are not interchangeable. Since loc- ation of the alignment tabs differ between the black and 2008 Buell XB Diagnostics: Appendix A Connector Repair A-9...

  • Page 212: Crimping Terminals

    4. Locking wedge Figure A-15. Deutsch Connector: 2, 3, 4 and 12-Place Pin Housings Table A-2. Deutsch Connector: Terminal Crimping Instructions TYPE CRIMPING INSTRUCTIONS Standard (with crimp tails) A.4 DEUTSCH STANDARD TERMINALS A-10 2008 Buell XB Diagnostics: Appendix A Connector Repair...

  • Page 213: Deutsch Standard Terminals

    Insert stripped lead Insert terminal in locking bar Squeeze crimper Release locking bar to lock terminal in die Raise locking bar and remove terminal Figure A-16. Crimping a Deutsch Standard Terminal 2008 Buell XB Diagnostics: Appendix A Connector Repair A-11...

  • Page 214: Metri-Pack Terminals

    3. HD-38125-8 non-sealed terminals Figure A-17. Metri-Pack Terminal Crimp Tools Crimping Insulation/Seal NOTE Always perform Crimping Wire Core before Crimping Insu- lation/Seal. Figure A-18. Identify the correct die for the insula- tion/seal crimp (2). A-12 2008 Buell XB Diagnostics: Appendix A Connector Repair...

  • Page 215: Inspecting Crimps

    Inspect the insulation (2) or seal (3) crimp. The tails of the terminal should be wrapped around the insulation without distortion. 1. Wire core crimp 2. Insulation crimp 3. Seal crimp Figure A-18. Metri-Pack Connector: Inspect Core and Insulation/Seal Crimps 2008 Buell XB Diagnostics: Appendix A Connector Repair A-13...

  • Page 216: Metri-Pack Connector Repair

    For pull-to-seat: Push on the lead to extract the ter- minal from the mating end of the connector. For push-to-seat: Pull on the lead to draw the ter- minal out the wire end. A-14 2008 Buell XB Diagnostics: Appendix A Connector Repair...
  • Page 217 2. Pivot pin to depress tang 3. Pull to remove 3. Push to remove 4. Raise tang to install 4. Raise tang to install Figure A-20. 150 Metri-Pack Connector: Push-to-Seat Figure A-19. 150 Metri-Pack Connector: Pull-to-Seat 2008 Buell XB Diagnostics: Appendix A Connector Repair A-15...

  • Page 218: Metri-Pack Connector Repair

    Push on lead to verify that terminal is locked in place. Fit rubber wire seal back into wire end of connector. Crimping Terminals If necessary, crimp new terminals on the wire leads. Refer to A.5 METRI-PACK TERMINALS, Metri-Pack Terminal Crimps. A-16 2008 Buell XB Diagnostics: Appendix A Connector Repair...
  • Page 219 2. Insert safety pin to depress tang 3. Push on lead to remove terminal 4. Raise tang with X-Acto knife 5. Pull on lead to draw terminal into chamber Figure A-22. 280 Metri-Pack Connector: Remove/Install Socket Terminal 2008 Buell XB Diagnostics: Appendix A Connector Repair A-17...

  • Page 220: Metri-Pack Connector Repair

    Figure A-23. 480 Metri-Pack Connector: Remove Socket Verify that terminal will not back out of the chamber. A Terminal slight tug on the cable will confirm that it is locked. A-18 2008 Buell XB Diagnostics: Appendix A Connector Repair...

  • Page 221: Metri-Pack Connector Repair

    The Rotate the hinged secondary lock inward until tabs fully locking tang is on the side opposite the crimp tails and engage latches on both sides of connector. 2008 Buell XB Diagnostics: Appendix A Connector Repair A-19...

  • Page 222: Sealed Splice Connectors

    3. Yellow connector die Squeeze the handles tightly closed to crimp the lead in the insert (2). The tool automatically opens when the Figure A-24. Packard Crimping Tool (HD-38125-8) crimping is complete. A-20 2008 Buell XB Diagnostics: Appendix A Connector Repair...
  • Page 223 1. Wire lead in metal insert 2. Crimp metal insert 3. Center of crimp 4. Melted sealant Figure A-25. Sealed Splice Connector 2008 Buell XB Diagnostics: Appendix A Connector Repair A-21...
  • Page 224 NOTES A-22 2008 Buell XB Diagnostics: Appendix A Connector Repair...
  • Page 225 SUBJECT..........................PAGE NO. B.1 CONNECTORS........................B-1 B.2 WIRING DIAGRAMS.........................B-3...
  • Page 226 NOTES...

  • Page 227: Connector Locations

    Below left ram air scoop [83] Ignition coil 3-place Packard Beneath aircleaner baseplate [84] Front fuel injector 2-place Packard Beneath aircleaner baseplate [85] Rear fuel injector 2-place Packard Beneath aircleaner baseplate 2008 Buell XB Diagnostics: Appendix B Wiring Diagrams B-1...
  • Page 228 [189L] Left heated grip 3-place Deutsch Behind windscreen (Ulysses only) [189R] Right heated grip 3-place Deutsch Behind windscreen (Ulysses only) [206] Heated grip subharness connector 3-place Sumitomo Behind windscreen (Ulysses only) B-2 2008 Buell XB Diagnostics: Appendix B Wiring Diagrams...

  • Page 229: Wiring Diagram Information

    9. No connection 10. Twisted pair Figure B-1. Connector/Wiring Diagram Symbols (typical) Table B-2. Wire Color Codes ALPHA CODE WIRE COLOR Blue Black Brown Green Grey Light Green Orange Pink Violet White Yellow 2008 Buell XB Diagnostics: Appendix B Wiring Diagrams B-3...

  • Page 230: Buell Wiring Diagrams

    Horn and Instruments Circuit, All Models Figure B-8 Starting Circuit, Ulysses and Lightning Figure B-9 Starting Circuit, Firebolt Figure B-10 Charging Circuits, All Models Figure B-11 Heated Handlebar Grips (Ulysses only) Figure B-12 B-4 2008 Buell XB Diagnostics: Appendix B Wiring Diagrams...
  • Page 231 Exhaust [11B] [11A] et00001 Valve Crank Voltage (Japan only) Vehicle Neutral LH CONTROLS WIRING DIAGRAM Pressure Foot Brake Starter TN/LGN Clutch switch Actuator Position Cooling Active Intake Regulator Speed [11A] Throttle position sensor Battery Switch Switch Solenoid PINS Fuel Pump Sub-harness Sensor TN/Y...
  • Page 232 Figure B-2. Figure B-2. Main Harness, Ulysses and Lightning Main Harness, Ulysses and Lightning...
  • Page 233 Key Switch Ignition Horn Headlight Relay Right Turn Signal Fuel Pump Fuse Assembly et00008 IGNITION SW WIRING DIAGRAM Left Turn Signal [38B] Center O/GY KEY POSITION Auxiliary [122A] Brake/Horn/EVA PARK [62B] R/BK LOCK R/BK Cooling Fan 14 15 [31B] [31B] [122B] Y/BN Lights...
  • Page 234 Figure B-3. Figure B-3. Main Harness, Firebolt Main Harness, Firebolt...
  • Page 235 Active et00007 Japan only Ignition Intake [33A] [33B] Switch Solenoid [88B] [88A] [83B] [83A] Throttle Ignition BK/W IGNITION SWITCH WIRING DIAGRAM Y/BE Engine Temp Sensor Position [178] Coil R/GY KEY POSITION Sensor [90B] [90A] BE/O R/BK R/BK PARK PK/Y LOCK Oxygen Sensor [137B] [137A]...
  • Page 236 Figure B-4. Figure B-4. Engine Management Circuit, All Models Engine Management Circuit, All Models...
  • Page 237 RH Turn Signal et00002 Brake SW IGNITION SWITCH WIRING DIAGRAM KEY POSITION PARK [31B] LOCK [170B] WIRE COLOR R/BK R/GY WIRE SECT MM Ignition CONNECTING Switch BATTERY USER + BATTERY USER + Flasher [30B] [GRD2] GRD 2 GRD 4 [33A] [33B] LIC.
  • Page 238 Figure B-5. Figure B-5. Lighting Circuit, Ulysses and Lightning Lighting Circuit, Ulysses and Lightning...
  • Page 239 RH Turn Signal et00055 Brake SW IGNITION SWITCH WIRING DIAGRAM KEY POSITION PARK [31B] LOCK [121B] WIRE COLOR R/BK R/GY WIRE SECT MM Ignition Switch CONNECTING BATTERY USER + BATTERY USER + Flasher [30B] [121A] [121B] Foot Brake Switch GRD 2 [33A] GRD 4 [33B]...
  • Page 240 Figure B-6. Figure B-6. Lighting Circuit, Firebolt Lighting Circuit, Firebolt...
  • Page 241 et00085 Tail Lamp/Rear Turning Lights (Firebolt) Tail Sub Front Turn Signals Harness [7A] LH Turn Signals 2 3 4 5 [7B] Brake SW. [31A] [31B] Main Harness [121A] RH Turn Signals [19B] [18B] RH Controls [93B] [45B] [31A] [31B] BK/R Horn [22B] W/BK...
  • Page 242 Figure B-7. Figure B-7. Component Circuits, All Models Component Circuits, All Models...
  • Page 243 et00003 IGNITION SWITCH WIRING DIAGRAM Ignition KEY POSITION Switch PARK [GRD2] LOCK WIRE COLOR R/BK R/GY [11A] [11B] [33A] WIRE SECT MM [33B] 5V sensor power 24 24 [11A] CONNECTING (GY) BATTERY USER + BATTERY USER + TN/W Sidestand switch 34 34 BK/W Sensor ground...
  • Page 244 Figure B-8. Figure B-8. Horn and Instruments Circuit, All Models Horn and Instruments Circuit, All Models...
  • Page 245 Ignition et00004 Switch IGNITION SWITCH WIRING DIAGRAM KEY POSITION PARK RH Controls LOCK 1 2 3 [22A] WIRE COLOR R/BK R/GY WIRE SECT MM Starter [33A] Solenoid [33B] CONNECTING GRD 2 BATTERY USER + BATTERY USER + [11A] [11B] Exhaust Valve [128A] Actuator Sub-Harness...
  • Page 246 Figure B-9. Figure B-9. Starting Circuit, Ulysses and Lightning Starting Circuit, Ulysses and Lightning...
  • Page 247 et00057 Ignition Switch IGNITION SWITCH WIRING DIAGRAM KEY POSITION PARK RH Controls LOCK 1 2 3 [22A] WIRE COLOR R/BK R/GY WIRE SECT MM [11A] [11B] [33A] CONNECTING [33B] BATTERY USER + BATTERY USER + [11A] Starter (GY) Solenoid GRD 2 Exhaust Valve Actuator Sub-Harness...
  • Page 248 Figure B-10. Figure B-10. Starting Circuit, Firebolt Starting Circuit, Firebolt...
  • Page 249 et00005 Battery Cable Starter Solenoid [128A] Battery Starter Motor [GRD2] Ulysses/Lightning Firebolt Fuse/Relay Assembly Fuse/Relay Assembly Battery, 30 Amp Battery, 30 Amp [61B] J-FUSE To Voltage Regulator [77B] [77A] Voltage Regulator Stator [46A] [46B] Figure B-11. Charging Circuits, All Models...
  • Page 250 Figure B-11. Figure B-11. Charging Circuits, All Models Charging Circuits, All Models...
  • Page 251 et00087 Left Side Right Side 1 2 3 Left Hand 2 3 4 5 6 7 8 [24B] [189LA] 1 2 3 [189RA] R Heat L Heat Controls Grip Grip [189LB] [189RB] 1 2 3 1 2 3 [160A] Right Hand [22B] 1 2 3 Auxiliary...
  • Page 252 Figure B-12. Figure B-12. Heated Handlebar Grips (Ulysses only) Heated Handlebar Grips (Ulysses only)

  • Page 253: Wire Routing

    Wiring Harness, Right Side View (Firebolt) Figure B-21 Exhaust Valve Actuator, Right Side View (Ulysses) Figure B-22 Exhaust Valve Actuator, Right Side View (Lightning) Figure B-23 Exhaust Valve Actuator, Right Side View (Firebolt) Figure B-24 2008 Buell XB Diagnostics: Appendix B Wiring Diagrams B-27...
  • Page 254 1. Active intake solenoid (Japan only) 2. Ignition coil 3. Fuel pump 4. Crank Position (CKP) sensor Figure B-13. Wiring Harness, Left Side View (Ulysses) B-28 2008 Buell XB Diagnostics: Appendix B Wiring Diagrams...
  • Page 255 1. Active Intake Solenoid (Japan only) 2. Ignition coil 3. Fuel pump 4. Crank Position (CKP) sensor Figure B-14. Wiring Harness, Left Side View (Lightning) 2008 Buell XB Diagnostics: Appendix B Wiring Diagrams B-29...
  • Page 256 1. Active intake solenoid (Japan only) 2. Ignition coil 3. Fuel pump 4. Crankshaft Position (CKP) sensor 5. To ECM Figure B-15. Wiring Harness, Left Side View (Firebolt) B-30 2008 Buell XB Diagnostics: Appendix B Wiring Diagrams...
  • Page 257 1. Fuel injector (2) 2. Idle Air Control (IAC) 3. Throttle Position Sensor (TPS) 4. Intake Air Temperature (IAT) sensor 5. Oxygen (O2) sensor Figure B-16. Wiring Harness, Top View (Ulysses) 2008 Buell XB Diagnostics: Appendix B Wiring Diagrams B-31...
  • Page 258 1. Fuel injector (2) 2. Idle Air Control (IAC) 3. Throttle Position Sensor (TPS) 4. Intake Air Temperature (IAT) sensor 5. Oxygen (O2) sensor Figure B-17. Wiring Harness, Top View (Lightning) B-32 2008 Buell XB Diagnostics: Appendix B Wiring Diagrams...
  • Page 259 2. Idle Air Control (IAC) 3. Throttle Position Sensor (TPS) 4. Intake Air Temperature (IAT) sensor 5. Oxygen (O2) sensor 6. Engine Temperature (ET) sensor Figure B-18. Wiring Harness, Top View (Firebolt) 2008 Buell XB Diagnostics: Appendix B Wiring Diagrams B-33...
  • Page 260 1. Vehicle Speed Sensor (VSS) 2. Cable, starter to battery positive 3. Solenoid 4. Oil pressure switch 5. Neutral switch 6. Relay terminal Figure B-19. Wiring Harness, Right Side View (Ulysses) B-34 2008 Buell XB Diagnostics: Appendix B Wiring Diagrams...
  • Page 261 1. Vehicle Speed Sensor (VSS) 2. Cable, starter to battery positive 3. Solenoid 4. Voltage regulator 5. Oil pressure switch 6. Neutral switch 7. Relay terminal Figure B-20. Wiring Harness, Right Side View (Lightning) 2008 Buell XB Diagnostics: Appendix B Wiring Diagrams B-35...
  • Page 262 1. Vehicle Speed Sensor (VSS) 2. Cable, starter to battery positive 3. Solenoid 4. Voltage regulator 5. Oil pressure switch 6. Neutral switch 7. Relay terminal Figure B-21. Wiring Harness, Right Side View (Firebolt) B-36 2008 Buell XB Diagnostics: Appendix B Wiring Diagrams...
  • Page 263 1. Exhaust valve actuator 2. Muffler valve Figure B-22. Exhaust Valve Actuator, Right Side View (Ulysses) 2008 Buell XB Diagnostics: Appendix B Wiring Diagrams B-37...
  • Page 264 1. Exhaust valve actuator 2. Muffler valve Figure B-23. Exhaust Valve Actuator, Right Side View (Lightning) B-38 2008 Buell XB Diagnostics: Appendix B Wiring Diagrams...
  • Page 265 1. Exhaust valve actuator 2. Muffler valve Figure B-24. Exhaust Valve Actuator, Right Side View (Firebolt) 2008 Buell XB Diagnostics: Appendix B Wiring Diagrams B-39...
  • Page 266 NOTES B-40 2008 Buell XB Diagnostics: Appendix B Wiring Diagrams...
  • Page 267 SUBJECT..........................PAGE NO. C.1 METRIC CONVERSION......................C-1 C.2 FLUID CONVERSIONS......................C-2 C.3 TORQUE CONVERSIONS.......................C-3...
  • Page 268 NOTES...

  • Page 269: Conversion Table

    115.89 .8661 2.165 3.464 4.764 7/16 11.112 1-13/16 46.04 81.28 116.84 .9055 2.205 3.504 4.803 12.700 1-7/8 47.62 3-1/4 82.55 4-5/8 117.47 .9449 2.244 3.543 4.842 9/16 14.288 48.26 83.82 4-11/16 119.06 2008 Buell XB Diagnostics: Appendix C Conversions C-1...

  • Page 270: United States System

    (Imp.) x 1.201 = pints (U.S.) liters x 1.057 = quarts (U.S.) quarts (Imp.) x 1.201 = quarts (U.S.) liters x 0.264 = gallons (U.S.) gallons (Imp.) x 1.201 = gallons (U.S.) C-2 2008 Buell XB Diagnostics: Appendix C Conversions...

  • Page 271: United States System

    (in-lbs) X 0.08333 = foot pounds (ft-lbs). Newton meters (Nm) X 8.85085 = inch pounds (in-lbs). foot pounds (ft-lbs) X 1.35582 = Newton meters (Nm). inch pounds (in-lbs) X 0.112985 = Newton meters (Nm). 2008 Buell XB Diagnostics: Appendix C Conversions C-3...
  • Page 272 NOTES C-4 2008 Buell XB Diagnostics: Appendix C Conversions...
  • Page 273 SUBJECT..........................PAGE NO. D.1 GLOSSARY..........................D-1...
  • Page 274 NOTES...

  • Page 275: Acronyms And Abbreviations

    Fluid Ounce Gram Gallon GAWR Gross Axle Weight Rating Ground (electrical) GVWR Gross Vehicle Weight Rating Harley-Davidson International H-DSSS Harley-Davidson Smart Security System HFSM Hands Free Security Module Mercury Idle Air Control 2008 Buell XB Diagnostics: Appendix D Glossary D-1...
  • Page 276 Throttle Control Actuator Top Dead Center Twist Grip Sensor Throttle Position TMAP Intake Air Temperature/Manifold Absolute Pressure Turn Signal Module TSSM Turn Signal/Security Module Volt Volts of Alternating Current Volts of Direct Current D-2 2008 Buell XB Diagnostics: Appendix D Glossary...
  • Page 277 Table D-1. Acronyms and Abbreviations ACRONYM OR ABBREVIATION DESCRIPTION Vehicle Identification Number Vehicle Speed Sensor 2008 Buell XB Diagnostics: Appendix D Glossary D-3...
  • Page 278 NOTES D-4 2008 Buell XB Diagnostics: Appendix D Glossary...
  • Page 279 Tools Used in This Manual PART NUMBER TOOL NAME NOTES B-45522 FUEL PRESSURE GAUGE ADAPTER 2.15 FUEL PRESSURE TEST, Inspection B-48115 BREAKOUT BOX 1.3 STARTING SYSTEM DIAGNOSIS, Diagnostics B-48115 BREAKOUT BOX 2.6 BREAKOUT BOX, General B-48115 BREAKOUT BOX 2.7 WIGGLE TEST, Procedure B-48115 BREAKOUT BOX 2.8 INITIAL DIAGNOSTIC CHECK, Initial Diagnostics...
  • Page 280 Tools Used in This Manual PART NUMBER TOOL NAME NOTES HD-39978 DVOM 2.6 BREAKOUT BOX, General HD-39978 DVOM 2.7 WIGGLE TEST, Procedure HD-39978 DVOM 2.8 INITIAL DIAGNOSTIC CHECK, General HD-39978 DVOM 2.20 DTC P0151 (13), P0152 (11), P0154 (13), Dia- gnostics HD-39978 DVOM...
  • Page 281 Tools Used in This Manual PART NUMBER TOOL NAME NOTES HD-44750 DIGITAL TECHNICIAN 2.2 DYNAMIC DIGITAL FUEL INJECTION (DDFI), Intro- duction HD-44750 DIGITAL TECHNICIAN 2.7 WIGGLE TEST, General HD-44750 DIGITAL TECHNICIAN 2.24 DTC P0506 (34), P0507 (34), P0511 (34), General HD-48053 ADVANCED BATTERY CONDUCTANCE 1.9 CHARGING SYSTEM, Troubleshooting...
  • Page 282 NOTES IV TOOLS...
  • Page 283 2008 Buell XB Models Electrical Diagnostics Manual FASTENER TORQUE VALUE NOTES Cable connector 20-24 in-lbs 2.3-2.7 Nm 2.30 DTC P1110 (22), P1111 (22), P1112 (22) (JAPANESE MODELS ONLY), Installation Jam nuts 48-60 in-lbs 5.4-6.7 Nm 2.30 DTC P1110 (22), P1111 (22), P1112 (22)
  • Page 284 NOTES VI TORQUE VALUES...
  • Page 285 Diagnostics....... 2-119 Conversions 150 Metri-Pack Connector Fluid........C-2 Repair.
  • Page 286 Loctite......... I-II Buell........I-II Referenced Products.
  • Page 287 INSIDE BACK COVER GOES HERE...
  • Page 288 OUTSIDE BACK COVER GOES HERE...

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