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SPECIFICATIONS
Table 2-1. Dimensions
DIMENSIONS
Wheel base
Seat height (XB9R/XB12R)
Ground clearance
Trail
Rake
Table 2-2. Weight Specifications (XB12R)
WEIGHT-U.S. MODELS
Wet weight
GVWR
GAWR - front
GAWR - rear
Load capacity
Table 2-3. Weight Specifications (XB9R)
WEIGHT-U.S. MODELS
Wet weight
GVWR
GAWR - front
GAWR - rear
Load capacity
NOTE
Gross Vehicle Weight Rating (GVWR) (maximum allowable
loaded vehicle weight) and corresponding Gross Axle Weight
Ratings (GAWR) are given on an information decal located
on the steering head.
IN.
MM
52.0
1320.8
31.9
810.3
4.35
110.0
3.3
83.8
21 Degrees
LBS.
KG
460
204
850
386
325
147
525
238
400
181
LBS.
KG
450
204
850
386
325
147
525
238
400
181
Table 2-4. Capacities
CAPACITIES
Fuel tank (inc. reserve)
Reserve/Low fuel light at
Oil tank
(wet - for normal oil change)
Fork oil
Transmission
Table 2-5. Tire and Positions
TIRE AND POSITION
Front
Dunlop Sportmax Radial II
120/70 ZR 17 D207FY
Rear
Dunlop Sportmax Radial II
180/55 ZR 17 D207U
Table 2-6. Brake Rotor Runout
RUNOUT
Front radial
Front lateral
Rear radial
Rear lateral
11
1
WARNING
Do not inflate any tire beyond its maximum inflation pres-
sure as specified on tire sidewall. Overinflation may
cause tire to suddenly deflate which could result in death
or serious injury.
2004 Buell Firebolt: Chassis
2.1
U.S.
LITERS
3.7 gallons
14.0
0.7 gallons
2.6
2.5 quarts
2.4
14 ounces
0.41
1.0 quart
0.95
SOLO
GVWR
RIDING
36 PSI
(248 kPa)
Same as
Solo
38 PSI
(262 kPa)
IN.
MM
0.0177
0.45
0.0248
0.63
0.0177
0.45
0.0154
0.39
WARNING
2-1
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Table of Contents
Related Manuals for Buell Firebolt XB12R 2004
Summary of Contents for Buell Firebolt XB12R 2004
- Page 1 Do not inflate any tire beyond its maximum inflation pres- Ratings (GAWR) are given on an information decal located sure as specified on tire sidewall. Overinflation may on the steering head. cause tire to suddenly deflate which could result in death or serious injury. 2004 Buell Firebolt: Chassis...
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Page 2: Torque Values
17-19 ft-lbs 23-26 Nm LOCTITE 272 (red), page 2-52 Fork damper locknut 22-30 ft-lbs 30-40 Nm page 2-48 Front fender fasteners 12-36 in-lbs 1-4 Nm page 2-77 Front isolator bolt 49-51 ft-lbs 66-69 Nm page 2-59 2004 Buell Firebolt: Chassis... - Page 3 Sidestand pivot bolt 18-20 ft-lbs 24-27 Nm page 2-91 Sidestand switch fastener 36-60 in-lbs 4-7 Nm page 2-91 Sprocket cover fastener 12-36 in-lbs 1-4 Nm page 2-76 Sprocket fasteners 35-37 ft-lbs 48-50 Nm Replace with new, page 2-17 2004 Buell Firebolt: Chassis...
- Page 4 Tail frame to frame 21-23 ft-lbs 28-31 Nm LOCTITE 272 (red), page 2-85 Torca clamp 40-45 ft-lbs 54-61 Nm page 2-73 Valve stem nut 40-44 in-lbs 4-5 Nm page 2-21 Wear Peg, rider 36-48 in-lbs 4.1-5.4 m page 2-74 2004 Buell Firebolt: Chassis...
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Page 5: Tire Specifications
& POSITION RIM SIZE HOLE DIAMETER TIRE SIZE 17 in. – Front MT 3.5 x 17.0 DOT 0.33 in. 120/70 ZR17 D207FY 17 in. – Rear MT 5.5 x 17.0 DOT 0.33 in. 180/55 ZR17 D207U 2004 Buell Firebolt: Chassis... -
Page 6: Vehicle Identification Number
An abbreviated V.I.N. is stamped on the front left side of the crankcase. NOTE Figure 2-3. Always give the V.I.N. or abbreviated V.I.N. when ordering parts or making inquiries about your Buell motorcycle. Figure 2-2. Abbreviated V.I.N. Location 4 = Domestic 5 = International... -
Page 7: Troubleshooting
Figure 2-4. Checking Tire Inflation Pressure Figure 2-4. Check tire inflation pressure at least once each week. At the same time, inspect tire tread for punctures, cuts, breaks and other damage. Repeat the inspection before long trips. 2004 Buell Firebolt: Chassis... - Page 8 Always locate and eliminate the cause of the original your Buell dealer. Speed should not exceed 50 mph (80 tire failure. km/h) for the first 24 hours after repair and the repaired Do not patch or vulcanize a tire casing.
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Page 9: Front Wheel
Figure 2-6. Raise the wheel up until the rotor clears the caliper and rotate the fork leg counterclockwise allowing wheel clearance for removal. Remove wheel. Figure 2-6. Front Wheel Removal and Installation 2004 Buell Firebolt: Chassis... -
Page 10: Bearing Removal
Forcing screw Figure 2-9. Expand the Collet Figure 2-10. Place the bridge (1) against the wheel hub. Hold the forcing screw (2), and turn the nut (3) clockwise until the bearing is free of the hub. 2-10 2004 Buell Firebolt: Chassis... -
Page 11: Front Rotor Removal
Always replace brake pads in complete sets for correct brake operation. Never replace just one brake pad. Fail- ure to install brake pads as a set could result in death or serious injury. Inspect brake rotor and pads. See 1.7 BRAKE SYSTEM MAINTENANCE. 2004 Buell Firebolt: Chassis 2-11... -
Page 12: Bearing Installation
Insert the forcing Remove the nut, bearing, washer, FRONT BEARING screw and backing plate into the wheel hub. INSTALLER (Part No. B-43993-9) and forcing screw. 2-12 2004 Buell Firebolt: Chassis... - Page 13 15. Remove the nut, bearing, washer, FRONT BEARING INSTALLER (Part No. B-43993-10) and forcing screw. 16. Install the wheel. See INSTALLATION under 2.5 FRONT Forcing screw WHEEL. Spacer Figure 2-16. Install the Spacer 10. See Figure 2-16. Install the spacer. 2004 Buell Firebolt: Chassis 2-13...
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Page 14: Front Rotor Installation
fitted into rotor properly. Failure to comply may affect braking ability and Align reference dot on front rotor with the valve stem. lead to brake failure which could result in death or seri- ous injury. 2-14 2004 Buell Firebolt: Chassis... -
Page 15: Installation
Tighten the front axle pinch fasteners (2) to 20-22 ft-lbs (27-30 Nm). 8419 Install right side fender fasteners. See 2.31 FENDERS. Axle (left handed thread) Front axle pinch fasteners (2) (metric) Figure 2-20. Front Wheel Mounting 2004 Buell Firebolt: Chassis 2-15... -
Page 16: Rear Wheel
See IDLER PULLEY REMOVAL 6.6 DRIVE For wheel bearing removal follow identical procedure as used BELT SYSTEM. for front wheel. Remove rear axle. Slide drive belt out of the way and remove rear wheel. 2-16 2004 Buell Firebolt: Chassis... - Page 17 HOME b0936x2x Rotor mounting fastener (6) Brake rotor Wheel bearing Wheel spacer Wheel Sprocket Sprocket fastener Axle Figure 2-23. Rear Wheel Assembly 2004 Buell Firebolt: Chassis 2-17...
- Page 18 (1) and tighten to 25-27 ft-lbs (34-37 Nm). INSTALLATION Center rear wheel in the swingarm at the same time slid- ing the drive belt onto the rear sprocket. With wheel centered in swingarm, lower bike to align swingarm and wheel hub. 2-18 2004 Buell Firebolt: Chassis...
- Page 19 Always test motorcycle brakes at low speed after servic- ing or bleeding system. To prevent death or serious injury, Buell recommends that all brake repairs be per- formed by a Buell dealer or other qualified mechanic. 2004 Buell Firebolt: Chassis...
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Page 20: Checking Cast Rim Runout
Wheel Truing and Balancing Stand (HD-99500-80) Table 2-9. Wheel Rim Runout b0758x2x RUNOUT Maximum lateral 0.040 1.02 Maximum radial 0.030 0.76 Gauge rod Figure 2-29. Checking Cast Rim Radial Runout Using Wheel Truing and Balancing Stand (HD-99500-80) 2-20 2004 Buell Firebolt: Chassis... - Page 21 Installing a tire with the wrong rotation could result in death or serious injury. Dunlop front and rear tires for Buell motorcycles are not the same. They are not interchangeable. Use Figure 2-30. Loosening Beads from Rim Flange front tire ONLY for a front tire.
- Page 22 Apply air to stem to seat beads on rim. It may be neces- sary to use a TIRE BEAD EXPANDER (Part No. HD- 28700) on the tire until beads seal on rim. 2-22 2004 Buell Firebolt: Chassis...
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Page 23: Checking Tire Lateral Runout
Figure 2-33. Checking Tire Lateral Runout RUNOUT. Replace rims not meeting specifications. Install tire and check tire tread radial runout again. b0088x2x Gauge Figure 2-34. Checking Tire Radial Runout Table 2-10. Tire Runout RUNOUT Radial 0.060 1.52 Lateral 0.080 2.03 2004 Buell Firebolt: Chassis 2-23... -
Page 24: Wheel Balancing
Allow eight hours for adhesive to cure completely before using wheel. NOTE If wheel assembly is out of specification (1 oz. front, 2 oz. rear) rotate tire on rim and rebalance until wheel is within specification. 2-24 2004 Buell Firebolt: Chassis... -
Page 25: Brake Pedal
(5) to 22-24 ft-lbs (30-33 Nm). Install clevis pin (2). Rear master cylinder body Install new cotter pin (7). Clevis pin Pedal bushings (2) Shift brake pedal sleeve Brake pedal fastener Brake pedal Cotter pin Figure 2-36. Brake Pedal Assembly 2004 Buell Firebolt: Chassis 2-25... -
Page 26: Front Brake Master Cylinder And Hand Lever
Pivot bolt nut (metric) 10. Brake switch fastener 11. Brake switch 12. Brake switch terminal 13. Banjo bolt (metric) 14. Brake line 15. Copper washers 16. Pivot bolt Figure 2-37. Front Brake Hand Lever Assembly 2-26 2004 Buell Firebolt: Chassis... -
Page 27: Brake Hand Lever
Circlip Figure 2-38. Piston Assembly in Master Cylinder Figure 2-38. Depress piston assembly (1) and remove internal circlip (2) and discard. Figure 2-37. Remove piston assembly (6) from front master cylinder reservoir (4) and discard. 2004 Buell Firebolt: Chassis 2-27... - Page 28 Figure 2-39. Front Master Cylinder Piston Assembly Figure 2-39. Assemble new piston components placing small end of spring (5) behind primary seal of piston (4). Lubricate master cylinder body and piston seals with special lubricant found in the service parts kit. 2-28 2004 Buell Firebolt: Chassis...
- Page 29 To prevent death or serious Install brake lamp switch (11) with switch fastener injury, Buell recommends that all brake repairs be per- (10) and tighten to 7-10 in-lbs (0.8-1.0 Nm). formed by a Buell dealer or other qualified technician.
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Page 30: Front Brake Line
Carefully inspect the brake line for dents, cuts, chaffing or other defects. Replace the brake line if any damage is noted. P-clamp Brake line Wire form Bleeder valve Banjo bolt Figure 2-42. Front Brake Line 2-30 2004 Buell Firebolt: Chassis... - Page 31 Always test motorcycle brakes at low speed after servic- ing or bleeding system. To prevent death or serious injury, Buell recommends that all brake repairs be per- formed by a Buell dealer or other qualified mechanic. 2004 Buell Firebolt: Chassis...
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Page 32: Front Brake Caliper
Figure 2-44. Disconnect brake line at caliper. See 2.11 FRONT BRAKE LINE. Remove caliper mounting fasteners (5). Slide caliper down the rotor to clear fork lower and then remove off rotor. Figure 2-46. Removing Pistons (B-42887) 2-32 2004 Buell Firebolt: Chassis... - Page 33 Install two new o-rings (6) in grooves of each piston bore. Install pistons (5) in each piston bore. Install new o-rings (8) between caliper halves. Clamp caliper together with caliper fasteners (11) and tighten to 15-19 ft-lbs (20-26 Nm). 2004 Buell Firebolt: Chassis 2-33...
- Page 34 HOME b0976x2x Pin hanger set Brake bleeder Bleeder cap Caliper Piston Piston o-rings Pad spring Small o-ring Caliper mounting fasteners 10. Brake pads 11. Caliper fasteners Figure 2-47. Front Caliper Assembly 2-34 2004 Buell Firebolt: Chassis...
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Page 35: Rear Brake Master Cylinder
Remote reservoir hose bled. Prevent damage to seating surfaces by carefully removing brake line components. Figure 2-49. Rear Master Cylinder On Vehicle Figure 2-49. Remove brake reservoir hose at master cylinder. Remove seat. See 2.38 SEAT. 2004 Buell Firebolt: Chassis 2-35... - Page 36 Rear brake light switch assembly Brake line Copper washer Rear master cylinder body Clevis pin Pedal bearing Sleeve Brake pedal fastener Brake pedal 10. Cotter pin 11. Rear master cylinder mount screw Figure 2-51. Rear Master Cylinder Assembly 2-36 2004 Buell Firebolt: Chassis...
- Page 37 Circlip must be snapped into the groove of the master cylinder body. If the circlip is not properly installed, improper brake operation could result in death or serious injury. Tuck rubber boot on rod assembly (3) into master cylin- der body (1). 2004 Buell Firebolt: Chassis 2-37...
- Page 38 2.29 FOOTPEG, ing or bleeding system. To prevent death or serious HEEL GUARD AND MOUNT. injury, Buell recommends that all brake repairs be per- formed by a Buell dealer or other qualified mechanic. WARNING WARNING 10. Add brake fluid and bleed brake system. See 1.7 BRAKE...
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Page 39: Rear Brake Line
Pump brake foot pedal to drain brake fluid. Tighten bleeder valve to 36-60 in-lbs (4-7 Nm). Figure 2-56. Rear Brake Line Switch/Banjo Bolt Figure 2-56. Remove brake line switch/banjo bolt from rear master cylinder. Discard copper washer. Remove brake line from motorcycle. 2004 Buell Firebolt: Chassis 2-39... - Page 40 If brakes are not operating properly or braking efficiency is poor, testing at high speeds could result in death or serious injury. 10. Test ride motorcycle and check for proper brake opera- tion. 2-40 2004 Buell Firebolt: Chassis...
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Page 41: Rear Brake Caliper
Figure 2-59. Removing Rear Brake Caliper Piston Figure 2-59. Remove piston (3) using BRAKE CALI- PER PISTON REMOVER (1) (Part No. B-42887) with adaptor (2). Remove two o-rings from groove in caliper bore and dis- card. 2004 Buell Firebolt: Chassis 2-41... - Page 42 Inspect brake pads for damage or excessive wear. tighten to 36-60 in-lbs (4-7 Nm). Replace both pads as a set if the friction material of either pad is worn to 0.04 in. (1.0 mm) or less. 2-42 2004 Buell Firebolt: Chassis...
- Page 43 Always test motorcycle brakes at low speed after servic- ing or bleeding system. To prevent death or serious CAUTION injury, Buell recommends that all brake repairs be per- formed by a Buell dealer or other qualified mechanic. To avoid leakage, verify that gaskets, banjo bolt, hydrau- lic brake line and caliper bore are completely clean.
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Page 44: Front Fork
Remove fork from lower fork clamp (4). Repeat 4 through 6 on opposite side. Upper pinch fasteners Upper fork clamp Lower pinch fasteners Lower fork clamp Figure 2-62. Upper and Lower Fork Clamp Pinch Fasteners 2-44 2004 Buell Firebolt: Chassis... - Page 45 TOOL (1) (Part No. HD-41177) in a vise and install the upper part of the front fork in the holding tool. Remove snap ring (2). Figure 2-66. Removing Fork Cap From Outer Tube Figure 2-66. Remove fork cap from outer tube. 2004 Buell Firebolt: Chassis 2-45...
- Page 46 (1). PRESING TOOL. CAUTION Careful not to damage preload pins while holding damper rod assembly. Remove preload washer (4) and slider piston (5). Figure 2-67. Uncompress fork and remove from FORK SPRING COMPRESING TOOL. 2-46 2004 Buell Firebolt: Chassis...
- Page 47 24. Oil seal Inner slider piston o-ring 16. Spring 25. Oil seal stopper ring Snap ring 17. Spring joint 26. Dust seal Rebound adjuster assembly 18. Outer tube 27. Slider fork Figure 2-69. Front Fork Assembly 2004 Buell Firebolt: Chassis 2-47...
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Page 48: Damper Rod Disassembly
(9) counter clockwise till it stops. Holding the damper locknut (10), unscrew the rebound adjuster assembly (9) and remove from damper rod assembly (11). Remove damper locknut (10) from damper rod assembly (11). 2-48 2004 Buell Firebolt: Chassis... -
Page 49: Fork Assembly
Tighten the damper locknut (10) to 22- 11. Replace the sealing washer (13) and center bolt (14) 30 ft-lbs (30-40 Nm). (metric). Tighten the center bolt to 22-30 ft-lbs (30- Repeat for other fork assembly. 40 Nm). 2004 Buell Firebolt: Chassis 2-49... - Page 50 (3). Fork oil level 22. Apply fork oil or light grease to o-rings on preload adjuster and install preload adjuster (3). Figure 2-73. Measuring Fork Oil Level 23. Install snap ring (2). 2-50 2004 Buell Firebolt: Chassis...
- Page 51 11. Install front wheel. See 2.5 FRONT WHEEL. 12. Install front fender. See 2.31 FENDERS. 13. Check headlamp alignment. See 1.19 HEADLIGHTS. 14. Adjust front forks suspension to rider preferences. See 1.12 SUSPENSION DAMPING ADJUSTMENTS\. 2004 Buell Firebolt: Chassis 2-51...
- Page 52 HOME NOTES 2-52 2004 Buell Firebolt: Chassis...