Buell 2005 FIREBOLT Manuals

Buell 2005 FIREBOLT Manuals

Manuals and User Guides for Buell 2005 FIREBOLT. We have 1 Buell 2005 FIREBOLT manual available for free PDF download: Service Manual

Buell 2005 FIREBOLT Service Manual

Buell 2005 FIREBOLT Service Manual (621 pages)

Brand: Buell | Category: Motorcycle | Size: 24.32 MB

Table of Contents

Maintenance 1

2
- Table of Contents
  2
- General
  4
  - Repair and Replacement Procedures
    5
  - Hardware and Threaded Parts
    5
  - Lip Type Seals
    5
  - Instruments and Gauges
    5
  - Part Replacement
    5
  - Part Protection
    6
  - Cleaning Process
    6
  - Rust or Corrosion Removal
    6
  - Tool Safety
    6
  - Air Tools
    6
  - Ratchets and Handles
    6
  - Storage Units
    7
- Fuel and Oil
  8
- Maintenance Schedule
  9
- Care of Molded-In-Color Body Panels
  12
- Battery Maintenance
  13
  - Cleaning and Inspection
    14
- Engine Lubrication System
  16
- Brake System Maintenance
  19
  - Bleeding Front Brake
    21
  - Bleeding Rear Brake
    22
  - Brake Pad Replacement
    25
- Tires and Wheels
  27
- Clutch
  28
- Drive Belt System
  31
- Primary Chain
  34
- Suspension Damping Adjustments
  36
- Steering Head Bearings
  41
- Spark Plugs
  42
- Air Cleaner Filter
  44
- Throttle Cable and Idle Speed Adjustment
  46
- Interactive Exhaust Cable (XB12R)
  48
- Ignition Timing
  49
- Headlights
  51
- Throttle Position Sensor (TPS)
  53
- Storage
  54
- Troubleshooting
  55
  - Electrical System
    56
Chassis 2

60
- Specifications
  62
  - Torque Values
    63
- Tire Specifications
  66
- Buell Vehicle Identification Number (V.I.N.)
  67
- Wheels
  68
- Front Wheel
  70
  - Bearing Installation
    73
- Rear Wheel
  77
- Checking Cast Rim Runout
  81
- Tires
  82
  - Wheel Balancing
    85
- Brake Pedal
  86
- Front Brake Master Cylinder
  88
  - Front Master Cylinder
    89
- Front Brake Line
  91
- Front Brake Caliper
  93
- Rear Brake Master Cylinder
  96
- Rear Brake Line
  100
- Rear Brake Caliper
  102
- Front Fork
  105
  - Fork Assembly
    110
- Fork Clamps, Upper and Lower
  114
- Steering Head Bearings
  116
- Swingarm and Brace
  119
- Front and Rear Isolator
  123
- Frame
  124
- Rear Shock Absorber
  125
- Throttle Control
  127
- Clutch Control
  128
  - Clutch Cable
    130
- Headlight Assembly and Support Bracket
  132
- Fairing Support Bracket
  135
- Handlebars
  137
- Exhaust System
  139
- Footpeg, Heel Guard and Mount
  142
- Sprocket Cover
  144
- Fenders
  145
  - Front Fender
    145
- Belt Guards
  146
- Chin Fairing
  148
- Intake Cover Assembly
  149
- Air Scoops
  150
- Subframe Tail Assembly and Body Work
  151
- Front Fairing, Windshield, and Mirrors
  155
- Seat
  156
  - Rider Seat
    156
  - Pillion Seat
    156
- Passenger Seat Lock
  157
- Sidestand
  158
Engine 3

160
- Specifications
  162
- Engine
  167
  - Diagnosing Smoking Engine or High Oil Consumption
    168
- Engine Rotation for Service
  169
- Stripping Motorcycle for Engine Service
  180
- Engine Installation
  190
- Cylinder Head
  206
  - Valve Guides
    212
  - Valve Springs
    212
- Cylinder and Piston
  224
  - Deglazing Cylinder
    227
- Lubrication System
  234
- Oil Hose Routing and Oil Reservoir
  235
- Oil Cooler
  236
- Oil Pressure Indicator Switch
  238
- Crankcase Breathing System
  239
- Oiling System
  241
- Oil Pump
  242
- Oil Filter Mount
  245
- Hydraulic Lifters
  246
- Gearcase Cover and Cam Gears
  248
- Crankcase
  253
Fuel System 4

268
- Fuel System
  270
- Specifications
  270
- Dynamic Digital Fuel Injection
  272
- Diagnostic Introduction
  274
- Checking for Trouble Codes
  275
- Check Engine Lamp Diagnostics
  277
- Breakout Box
  279
- Wiggle Test
  280
  - General Information
    281
- Initial Diagnostic Check
  281
- Check Engine Lamp Not Illuminated at Key on 4.9
  286
- Check Engine Lamp on Continuously
  289
- Engine Cranks but will Not Start
  292
- No ECM Power
  298
- Fuel Pressure Test
  301
- Idle Speed Control
  306
- Misfire
  307
- Trouble Code 11
  312
- Trouble Code 13
  316
- Trouble Code 14
  321
- Trouble Code 15
  325
- Trouble Code 16
  329
- Trouble Code 21
  333
- Trouble Codes 23 and 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23 Trouble Codes 24 and
  336
- Trouble Code 33
  343
- Trouble Code 35
  346
- Trouble Code 36
  349
- Trouble Code 44
  353
- Trouble Codes 52, 53, 54 and 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29 Trouble Code 56
  357
- Electronic Control Module
  362
- Cam Position Sensor and Rotor
  364
- Ignition Coil
  368
- Oxygen Sensor
  370
- Engine Temperature Sensor
  371
- Bank Angle Sensor
  372
- Intake Air Temperature Sensor
  373
- Throttle Position Sensor
  374
- Cooling Fan
  375
- Fuel Pump/Early Model Year
  376
- Fuel Pump/Late Model Year
  382
- Fuel Tank Vent Valve
  390
- Fuel Cap Retaining Ring
  391
- Throttle Body
  392
- Manifold
  394
  - Fuel Injectors
    394
- Intake Leak Test
  397
- Airbox
  399
Electric Starter 5

406
- Specifications
  408
- Electric Starter System
  409
  - Wiring Diagrams
    409
  - Starter Relay
    409
- Starting System Diagnosis
  411
- Starter Activation Circuits
  415
- Diagnostics/Troubleshooting
  416
- Starter System Testing
  418
- Starter
  419
  - Testing Assembled Starter
    420
- Starter Solenoid
  428
Drive/Transmission 6

430
- Specifications
  432
- Primary Cover
  434
- Clutch Release Mechanism
  438
- Clutch
  440
  - Assembly and Installation
    445
- Primary Chain
  447
- Drive Belt System
  452
  - Drive Belt Installation
    454
- Transmission
  456
- Case Disassembly for Transmission Removal
  457
- Transmission Disassembly
  460
- Transmission Assembly
  467
- Main Drive Gear
  469
- Transmission Right Case Bearings
  472
- Transmission Left Case Bearings
  474
- Transmission Installation
  475
- Shifter Shaft Installation
  479
- Transmission Sprocket
  480
Electrical 7

484
- Ignition System
  488
- Ignition/Headlight Key Switch
  490
- Spark Plug Cables
  494
  - Main Fuse
    501
- Charging System
  508
- Voltage Regulator
  517
- Battery Cables
  518
  - Battery Testing
    521
  - Voltmeter Test
    521
  - Disconnection and Removal
    522
  - Battery Charging
    523
  - Safety Precautions
    523
- Tail Lamp
  529
- Turn Signals
  530
- Turn Signal Flasher
  533
- Handlebar Switches
  534
  - Bulb Replacement
    538
- Speedometer Performance Check
  540
- Neutral Indicator Switch
  547
- Main Fuse and Fuses
  548
- Main Wire Harness
  549
- Sprocket Cover Wiring
  556
Appendices

558
- Appendix A-Tools
  560
  - Amp Multilock Electrical Connectors
    568
  - Deutsch Electrical Connectors
    572
  - Electrical Connectors
    581
- Appendix B-Wiring
  583
- Appendix C-Metric Conversions
  598
- Appendix D-Hose and Wire Routing
  600
- Appendix E-Active Intake System (Japan Only
  614

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