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1125 2009 Series
Buell 1125 2009 Series Motorcycle Manuals
Manuals and User Guides for Buell 1125 2009 Series Motorcycle. We have
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Buell 1125 2009 Series Motorcycle manuals available for free PDF download: Service Manual, Electrical Diagnostics Manual
Buell 1125 2009 Series Service Manual (557 pages)
Brand:
Buell
| Category:
Motorcycle
| Size: 86 MB
Table of Contents
About this Manual
7
Table of Contents
9
Fastener Torque Values
23
Safe Operating Maintenance
25
Shop Practices
25
Removing Parts
25
Cleaning
25
Repair and Replacement Procedures
26
Hardware and Threaded Parts
26
Bushings
26
Gaskets
26
Tool Safety
27
Gears
27
Shafts
27
Exhaust System Leakage
27
Punches/Chisels
28
Screwdrivers
28
Ratchets and Handles
28
Sockets
28
Maintenance Schedule
29
Quick Reference Maintenance Chart
29
Fuel and Oil
31
Gasoline Blends
31
Engine Lubrication
31
Recommended Engine Oils
31
Engine Oil and Filter
32
Checking Oil Level
32
Oil Level Cold Check
32
Oil Level Hot Check
32
Engine Oil Change
33
Air Filter Element Removal and Installation
35
Intake Cover Removal and Installation
35
Air Filter Element Cleaning and Inspection
36
Throttle Cable Adjustment
37
Tires and Wheels
38
Tire Replacement
38
Wheel Bearings
38
Bleeding Clutch Fluid Line
39
Hydraulic Clutch
39
Checking Fluid Level (Clutch)
39
Reservoir Banjo Bolt
39
Bleeder Valve
40
Drive Belt Maintenance
41
Rear Sprocket Inspection
41
Drive Belt Inspection
41
Drive Belt Wear Patterns
41
Potential Limits to Belt Drive Service Life
42
Idler Pulley Inspection
43
Brake System Maintenance
44
Brake Troubleshooting
44
Checking Brake Fluid Level
44
Front Brake Fluid Reservoir
44
Bleeding Brakes
45
Rear Brake Fluid Reservoir
45
Brake Pedal Adjustment
47
Brake Pad Thickness
48
Pedal Adjustment
48
Brake Rotor Thickness
49
Brake Pad Replacement
49
Front Pad Removal
49
Front Pad Installation
50
Rear Pad Removal
50
Rear Pad Installation
51
Rear Brake Pad Retaining Spring
51
Rear Caliper Piston Lug for Pad Retaining Spring
52
Rear Master Cylinder Reservoir
52
Bottom View of Rear Caliper and Brake Pads
52
Spark Plug Clean
53
Plug Deposits
53
Spark Plug Replacement
53
Spark Plug Gap Specification
54
Spark Plug Cleaning
55
Headlamp Alignment
56
Headlamp Adjustment
56
Battery Maintenance
58
Battery Cleaning and Inspection
59
Voltmeter Test
59
Charging Battery
59
Using a Battery Charger
59
Battery Disconnection and Removal
60
Battery Charging Rates/Times
60
Battery Storage
61
Battery Installation and Connection
61
Battery Terminals View
61
Battery Component Clearance View
61
Engine Coolant Level
63
Coolant Type
63
Checking and Adding Coolant in Expansion Tank
63
Bleeding Coolant
64
Valve Clearance
65
Valve Lash
65
Steering Head Bearings Inspection
68
Steering Head Bearings Resistance Test
68
Vehicle Storage
69
Troubleshooting
70
Engine Troubles
70
Lubrication System Troubles
71
Electrical System Troubles
71
Transmission Troubles
71
Clutch Troubles
72
Chassis Troubles
72
Cooling System Troubles
72
Suspension Troubles
72
Chassis
74
Fastener Torque Values (Chassis)
76
Chassis Specifications
81
Recommended Suspension Settings
82
Vehicle Identification Number (VIN)
83
Covers, Guards and Guides
87
Tires Repair
89
Tire and Wheel Troubleshooting
89
Tires Specifications
90
Tire Size
90
Rim Size
90
Tire Fitment-Tubeless Cast Wheels
90
Tire Dismounting
91
Tire Cleaning and Inspection
91
Tire Mounting
91
Using the Tire Machine
91
Direction of Rotation Arrow
92
Tire Bead at Bottom of Rim Well
92
Runout
93
Inflate Tire
93
Tire Balancing
94
Wheels Troubleshooting
95
Wheels Installation
96
Wheels Inspection
97
Rear Wheel Removal
97
Rear Wheel Installation
99
Wheels Repair
100
Wheel Rim Runout
102
Wheel Bearings Removal
103
Installation: Rotor Side Bearing
104
Installation: Opposite Side Bearing
105
Front Brake Hand Lever
107
Master Cylinder/Reservoir: Removal
107
Master Cylinder/Reservoir: Repair
108
Brake System Components Cleaning and Inspection
108
Master Cylinder/Reservoir: Assembly
109
Master Cylinder/Reservoir: Installation
110
Front Brake Fluid Line Removal and Installation
111
Caliper Removal and Installation
113
Caliper Repair
113
Caliper Cleaning and Inspection
114
Caliper Assembly
114
Front Caliper Assembly View
115
Rear Brake Pedal Removal and Installation
116
Master Cylinder/Reservoir Removal
116
Master Cylinder/Reservoir Installation
118
Brake Fluid Line Removal
119
Brake Fluid Line Installation
120
Front Fork Removal
122
Front Fork Disassembly
122
Drain the Fork Oil
122
Fork Disassembly
123
Front Fork Assembly View
125
Front Fork Cleaning and Inspection
126
Front Fork Assembly
126
Fill with Fork Oil
126
Front Fork Final Assembly
127
Fork Clamps Removal and Installation
128
Steering Head Bearing Removal and Installation
131
Shock Absorber Replacement
134
Rear Shock Assembly View
135
Swingarm and Brace
136
Axle Sliders
136
Swingarm Removal
136
Swingarm Repair
137
Swingarm Installation
138
Swingarm Assembly View
138
Frame Service
139
K-Brackets
140
Motor Mounts
140
Subframe Tail Section
141
Subframe Pan Removal
141
Subframe Pan Installation
142
Subframe Removal
143
Subframe Installation
143
Fairing and Headlamp Assembly
145
Windshield
145
Fairing Removal and Installation
145
Headlamp Assembly Removal and Installation
146
Support Bracket Removal
147
Support Bracket Installation
148
Headlamp/Fairing Support Bracket Removal and Installation
149
Windscreen and Headlamp Assembly
150
Handlebars
152
Left Clip-On Removal and Installation
152
Left Hand Grip
152
Right Clip-On Removal and Installation
153
Handlebars Removal and Installation
155
Footpegs, Heel Guards and Mounts
157
Rider Seat Removal and Installation
160
Pillion
160
Pillion Lock Removal
161
Pillion Lock Installation
162
Sidestand Removal and Disassembly
164
Sidestand Assembly and Installation
165
Sidestand Stop Bracket
165
Engine
166
Fastener Torque Values (Engine)
168
Engine Specifications
171
Engine Troubleshooting
174
Compression Test
174
Diagnosis Smoking Engine or High Oil Consumption
174
Oil Pressure Test
174
Engine Rotation
180
Down Rotation
180
Upper Engine
181
Muffler
183
Rotate Engine
184
Up Rotation
185
Engine Replacement
187
Engine Removal
187
Drain the Fluids/Oil Cooler
190
Engine Disassembly
194
Engine Assembly
195
Engine Installation
195
Final Tighten Exhaust System
197
Return to Service (Engine)
199
Rebuild Timing Instructions
200
Front Cylincder TDC
200
270 Degree Rotation
200
Rear Cylinder TDC
200
Engine Rebuild Sequence by Component
201
Top Dead Center (TDC)
202
Locking Crankshaft
202
Camshaft Assembly
203
Valve Covers Removal and Installation
203
Camshaft Assembly View
206
Camshaft Cleaning and Inspection
207
Camshaft Installation
208
Cylinder Head Removal
212
Cylinder Head Disassembly
212
Cylinder Head Cleaning and Inspection
214
Spark Plug Threads
214
Cutting Valve Seats
215
Neway Valve Seat Cutter
216
Cylinder Head Assembly
217
Cylinder Head Installation
217
Cylinders and Pistons Removal and Disassembly
219
Cylinders and Pistons Cleaning and Inspection
220
Checking Piston Pin
220
Deglazing Cylinder
222
Installing Piston Rings
223
Installing Piston
224
Installing Cylinder
225
Clutch Case Vent Tube Removal and Installation
227
Clutch Cover Removal and Installation
228
P-Clamp
230
Balancer: Water Pump Shaft
230
Balancer: Bottom
230
Oil Pump Removal
232
Oil Pump Inspection
234
Oil Pump Installation
234
Oil Strainer
235
Alternator Side
237
Oil Filter
237
Pressure Retaining Valve
238
Sealing Sleeve
238
Ignition Cover Removal
239
Ignition Cover Installation
240
Balancer: Top - Removal
241
Bearing and Oil Seal
242
Balancer: Top - Installation
243
Starter Friction Clutch Removal
244
Starter Friction Clutch Installation
245
Crankcase Breather Replacement
246
Valve Train Drive
248
Front Cylinder Removal and Installation
248
Rear Cylinder Removal and Installation
248
Split Crankcase
250
Clutch Side Components Removal
250
Alternator Side Components Removal
250
Crankcase Disassembly
251
Oil Sump Removal and Installation
252
Oil Nozzles
253
Oil Passage Plugs
253
Water Pump Shaft Bearing Removal and Installation
254
Main Bearings Removal and Installation
255
Join Crankcase Halves
256
Clutch Side Components Installation
258
Alternator Side Components Installation
259
Crankshaft Removal
260
Crankshaft Disassembly
260
Crankshaft Assembly
261
Crankshaft Installation
261
Fuel System
262
Fastener Torque Values (Fuel System)
264
Air Cleaner Assembly
266
Ram Air Intake Snorkel
266
Baseplate Removal
266
Baseplate Installation
267
Throttle Mount Gasket Removal and Installation
268
Sensors
269
Bank Angle Sensor (BAS) Replacement
269
Barometric Pressure Sensor (BARO)
269
Fuel Pressure Sensor
270
Intake Air Temperature Sensor (IAT) Removal
270
Intake Air Temperature Sensor (IAT) Installation
271
Manifold Absolute Pressure Sensor (MAP) Removal and Installation
271
Oxygen Sensors (O2)
271
Throttle Position Sensor (TPS) Replacement
273
Manual TPS Reset
273
Throttle Control Removal and Disassembly
274
Throttle Control Cleaning and Inspection
274
Throttle Control Assembly and Installation
274
Throttle Cable Replacement
275
Idle Air Control (IAC) Removal and Installation
276
Throttle Body - Intake Leak Test
277
Injector Leak Test
278
Fuel Rail Removal and Installation
278
Fuel Injectors Removal
279
Throttle Body Removal
280
Fuel Injectors Installation
280
Throttle Body Inspection and Disassembly
281
Intake Flanges
281
Throttle Body Installation
281
Active Intake - Cable Adjustment
284
Active Intake Removal and Installation
285
Exhaust System
286
Muffler Removal
286
Headers Removal and Installation
287
Muffler Installation
287
Draining the Fuel Tank
289
Fuel Cap Retaining Ring Removal and Installation
289
Vent Valve Removal and Installation
290
Vent House Routing
291
Tank Set Screws
292
Fuel Pump
293
Fuel Pressure Test
293
Wire Guide/Fuel Pump Cover Removal
294
Wire Guide/Fuel Pump Cover Installation
295
Fuel Pump Removal
296
Fuel Pump Installation
297
Evaporative Emissions Control (EVAP): CA Models
299
Vent Hose Routing
299
Canister Removal and Installation
299
Cooling System
300
Cooling System - Fastener Torque Values
302
Cooling System Specifications
303
Coolant Flow
304
Operating Temperature and the Radiators
304
Cooling Fans
304
Pressure Cap
304
Engine Coolant Temperature (ECT) Sensor
305
Skip Spark
305
Cooling Fans Troubleshooting
305
Pressure Cap Test
306
System Pressure Test
306
Leak Detection Dye Test
307
Tests for Blown Gasket
308
Engine Coolant - Freeze Point Test
309
Replacing Coolant
309
To Drain Coolant
309
Fill with Coolant
311
Thermostat Removal
312
Thermostat Installation
313
Water Pump Removal
314
Water Pump Installation
315
Coolant Pipes and Hoses Removal
319
Coolant Pipes and Hoses Installation
320
Radiators Removal
322
Overflow Tank
324
Oil Cooler Removal and Installation
326
Oil Line Fittings
327
Drive/Transmission
328
Drive/Transmission - Fastener Torque Values
330
Drive/Transmission Specifications
332
Drive/Transmission Troubleshooting
334
Clutch Actuator
336
Clutch Lever Removal and Installation
336
Clutch Master Cylinder/Reservoir Removal
336
Clutch Master Cylinder/Reservoir Repair
337
Clutch Master Cylinder/Reservoir Cleaning and Inspection
338
Clutch Master Cylinder/Reservoir Assembly
338
Clutch Master Cylinder/Reservoir Installation
339
Clutch Fluid Line Removal
340
Clutch Fluid Line Installation
341
Secondary Clutch Actuator Removal and Installation
341
Secondary Actuator Repair
344
Clutch
347
Vacuum Assist Hose
347
Vacuum Assist Diaphragm Removal and Installation
348
Inner Diaphragm Cover Oil Seal
350
Oil Jet
351
Clutch Pack Removal
351
Clutch Springs
351
Friction Plates
352
Steel Plates
352
Pressure Plate Bearing
354
Clutch Basket Removal
355
Clutch Basket Installation
356
Primary Drive
357
Primary Drive Engine Sprocket
360
Shift Linkage
361
Shift Lever
361
Shift Shaft
361
Detent Wheel
362
Index Shim
362
Transmission
364
VSS Trigger Wheel
364
Transmission Removal
365
Mainshaft Disassembly
365
Clutch Shaft Disassembly
366
Mainshaft Assembly
366
Shift Drum and Forks
367
Clutch Shaft Assembly
367
Transmission Installation
368
Transmission Assembly
368
Transmission Case Bearings and Seals
370
Fork Drum
371
Mainshaft
372
Mainshaft Seal
373
Clutch Shaft
374
Final Drive Sprocket
376
Pulley Assembly Removal and Installation
376
Rubber Compensator Dampers
378
Drive Belt and Idler Pulley
379
Drive Belt Tension/Handling
379
Drive Belt Removal
380
Drive Belt Installation
381
Idler Removal and Installation
381
Idler Assembly View
382
Electrical
384
Electrical - Fastener Torque Values
386
Electrical - Specifications
388
Ignition Switch/Fork Lock Replacement
389
Ignition Switch/Fork Lock Repair
390
Electronic Control Module (ECM) Replacement
392
Ignition Coils
393
Battery Cables
394
Negative Battery Cable Removal and Installation
394
Positive Battery Cable Removal and Installation
395
Starter
397
Solenoid Removal and Installation
397
Starter Removal
399
Starter Installation
400
Voltage Regulator Removal and Installation
401
Alternator Removal and Disassembly
402
Alternator Assembly and Installation
403
Stator
405
Horn Removal and Installation
406
Turn Signals
407
Front Turn Signals/Mirrors Removal and Installation
407
Rear Turn Signals Removal and Installation
409
Headlamp
410
Bulbs - Marker Lamp
410
Wire Harness Removal
411
Wire Harness Installation
412
High Beam
413
Marker Lamp
413
Low Beam
413
High and Low Beam Horizontal Alignment
414
Tail and License Plate Lamp
416
License Plate Bracket Removal
417
License Plate Bracket Installation
418
License Plate Bracket Assembly View
419
Fuse Block
420
Fuses
420
Battery (Main) Fuse
420
Relays
421
Switches and Connectors
422
Auxiliary Connector
422
Brake Light Switch: Front/Rear
422
Can Bus Connector
423
Clutch Interlock Switch
423
Neutral Indicator Switch
424
Oil Pressure Switch
425
Sidestand Sensor (HDI)
425
Crankshaft Position Sensor (CKP) Removal and Installation
427
Vehicle Speed Sensor (VSS) Removal and Installation
429
Handlebar Switch Housings
430
Instrument Cluster Replacement
433
Engine Harness Removal
435
Wire Harness Support
435
Engine Harness Disassembly
435
Engine Harness Assembly
436
Engine Harness Installation
437
Main Wire Harness Removal
439
Main Harness Connectors and Connections
440
Wire Harness Front Bracket
442
Main Wire Harness Installation
442
Cooling Fans Removal
445
Fuel Pump Components View
446
Connector Repair
450
AMP Multilock Connectors Repair
452
Inserting Terminals into Housing
453
Preparing Wire Leads for Crimping
453
Crimping Terminals to Leads
454
Inspecting Crimped Terminals
455
Autofuse Connector Repair
456
Delphi Connector Repair
457
Delphi Main Fuse Housing Repair
459
Deutsch Electrical Connectors Repair
461
Deutsch Standard Terminal Repair
465
Deutsch Solid Barrel Miniterminal Repair
466
Deutsch Miniterminal Repair
468
Molex Connectors Repair
469
Packard 150 Metri-Pack Connectors Repair
473
Packard 280 Metri-Pack Relay and Fuse Block Connectors
475
Packard 480 Metri-Pack Connectors
476
Packard 630 Metri-Pack Connectors
477
Packard Metri-Pack Terminals
478
Packard ECM Connector
480
Packard 100W Connector Repair
480
Packard Micro-64 Connector Repair
482
Sealed Splice Connector Repair
485
Connector Locations
490
Wiring Diagrams
492
Wiring Diagram List
493
Component Wiring Diagrams
505
Valve Tappet Shims Tables
510
Valve Lash Calculation Worksheets
511
Length Conversion Table
518
Fluid Conversion
519
Torque Conversion
520
Acronyms and Abbreviations
524
Tools Used in this Manual
528
Index
548
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Buell 1125 2009 Series Electrical Diagnostics Manual (306 pages)
Brand:
Buell
| Category:
Motorcycle
| Size: 36 MB
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