General; Servicing A New Motorcycle; Safe Operating Maintenance; Shop Practices - Buell XB 2010 Service Manual

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GENERAL

SERVICING A NEW MOTORCYCLE

Perform the service and maintenance operations as
indicated in the regular service interval table. Lack of
regular maintenance at the recommended intervals can
affect the safe operation of your motorcycle, which could
result in death or serious injury. (00010a)
Service operations to be performed before customer delivery
are specified in the applicable model year predelivery and set-
up instructions.
The performance of new motorcycle initial service is required
to keep warranty in force and to verify proper emissions sys-
tems operation. See 1.5 MAINTENANCE

SAFE OPERATING MAINTENANCE

NOTES
Do not attempt to tighten engine head bolts or engine
damage may result.
During the initial break-in period, use only Harley-Davidson
20W50 engine oil. Failure to use the recommended oil will
result in improper break-in of the engine cylinders and
piston rings.
A careful check of certain equipment is necessary after periods
of storage, and frequently between regular service intervals,
to determine if additional maintenance is required.
Check:
1. Tires for abrasions, cuts and correct pressure.
2. Drive belt tension and condition.
3. Brakes, steering and throttle for responsiveness.
4. Brake fluid level and condition. Hydraulic lines and fittings
for leaks. Also, check brake pads and discs for wear.
5. Cables for fraying, crimping and free operation.
6. Engine oil and transmission fluid levels.
7. Headlamp, auxiliary lamp, tail lamp, brake lamp, horn and
turn signal operation.

SHOP PRACTICES

Repair Notes

General maintenance practices are given in this section.
NOTES
Repair = Disassembly/Assembly.
Replacement = Substitute a new part for existing com-
ponent.
All special tools and torque values are noted at the point of
use.
All required parts or materials can be found in the appropriate
parts catalog.

Safety

Safety is always the most important consideration when per-
forming any job. Be sure you have a complete understanding
of the task to be performed. Use common sense. Use the
proper tools. Protect yourself and bystanders with approved
eye protection. Don't just do the job - do the job safely.

Removing Parts

Always consider the weight of a part when lifting. Use a hoist
whenever necessary. Do not lift heavy parts by hand. A hoist
and adjustable lifting beam or sling are needed to remove some
parts. The lengths of chains or cables from the hoist to the part
should be equal and parallel and should be positioned directly
over the center of the part. Be sure that no obstructions will
interfere with the lifting operation. Never leave a part suspended
SCHEDULE.
in mid-air.
Be sure to check capacity rating and condition of hoists,
slings, chains and cables before use. Exceeding capacity
ratings or using lifting devices that are in poor condition
can lead to an accident, which could result in death or
serious injury. (00466c)
Always use blocking or proper stands to support the part that
has been hoisted. If a part cannot be removed, verify that all
bolts and attaching hardware have been removed. Check to
see if any parts are in the way of the part being removed.
When removing hoses, wiring or tubes, always tag each part
to verify proper installation.

Cleaning

If you intend to reuse parts, follow good shop practice and
thoroughly clean the parts before assembly. Keep all dirt out
of parts; the unit will perform better and last longer. Seals, filters
and covers are used in this vehicle to keep out environmental
dirt and dust. These items must be kept in good condition to
verify satisfactory operation.
When you are instructed in a step to clean fastener threads or
threaded holes, proceed as follows: Clean all LOCTITE material
from fastener threads and threaded holes. Use a wire brush
to clean fastener threads. Use a thread chaser or other suitable
tool to clean threaded holes. Use PJ-1 cleaner or equivalent
to remove all traces of oil and contaminants from threads. Blow
out all threaded holes with low pressure compressed air.
Clean and inspect all parts as they are removed. Be sure all
holes and passages are clean and open. After cleaning, cover
all parts with clean lint-free cloth, paper or other material. Be
sure the part is clean when it is installed.
Always clean around lines or covers before they are removed.
Plug, tape or cap holes and openings to keep out dirt, dust and
debris.
Always verify cleanliness of blind holes before assembly.
Tightening a screw with dirt, water or oil in the hole can cause
castings to crack or break.
2010 XB Service: Maintenance 1-3
1.2