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2009 XB Series
Buell 2009 XB Series Manuals
Manuals and User Guides for Buell 2009 XB Series. We have
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Buell 2009 XB Series manual available for free PDF download: Service Manual
Buell 2009 XB Series Service Manual (712 pages)
Brand:
Buell
| Category:
Motorcycle
| Size: 110.53 MB
Table of Contents
Maintenance 1.6 Engine Oil and Filter
9
Important Notice
2
About this Manual
7
Table of Contents
9
Appendix A Connector Repair
18
Fastener Torque Values
23
Fastener Torque Values in this Chapter
23
General
25
Safe Operating Maintenance
25
Servicing a New Motorcycle
25
Shop Practices
25
Cleaning
25
Removing Parts
25
Repair Notes
25
Safety
25
Checking Torques on Fasteners with Lock Patches
26
Disassembly and Assembly
26
Magnetic Parts Trays
26
Repair and Replacement Procedures
26
Bearings
26
Bushings
26
Hardware and Threaded Parts
26
Instruments and Gauges
26
Threadlocking Agents
26
Wiring, Hoses and Lines
26
Exhaust System Leakage
27
Gears
27
O-Rings (Preformed Packings)
27
Part Replacement
27
Shafts
27
Cleaning
27
Bearings
27
Cleaning Process
27
Part Protection
27
Rust or Corrosion Removal
27
Hammers
28
Punches/Chisels
28
Ratchets and Handles
28
Screwdrivers
28
Sockets
28
Storage Units
28
Engine Lubrication
29
Fuel
29
Fuel and Oil
29
Gasoline Blends: Buell Models
29
Winter Lubrication
30
General
31
Maintenance Schedule
31
Battery Maintenance
33
General
33
Battery Disconnection and Removal
34
Charging Battery
34
Safety Precautions
34
Using a Battery Charger
34
Cleaning and Inspection
34
Battery Installation and Connection
35
Storage
36
Change Engine Oil and Filter
37
Drain Oil
37
Change Filter
38
Clear Oil Cooler
38
Fill Engine with Oil
38
Return to Service
39
Engine Oil and Filter
37
Engine Oil Level Check
37
General
37
Bleeding Brakes
40
Bleeding Front Brake
41
Bleeding Rear Brake
42
Brake System Maintenance
40
General
40
Brake Pedal Adjustment
42
Brake Pad Thickness
43
Brake Pad Replacement
44
Front Pad Installation
44
Front Pad Removal
44
Rear Pad Installation
45
Rear Pad Removal
45
Brake Rotor Thickness
44
Tire Inflation
47
Tire Wear
47
Tires and Wheels
47
Wheel Bearings
48
Clutch/Transmission/Primary Fluid
49
Inspection
49
Transmission Fluid
49
Adjustment
50
Cleaning
52
Drive Belt Maintenance
52
General
52
Inspection
52
Drive Belt
52
Idler Pulley
52
Rear Sprocket
52
Adjustment
55
Inspection
55
Primary Chain
55
Determining Proper Resistance
57
General
57
Inspection
57
Steering Head Bearings
57
Inspection
58
Spark Plugs
58
Air Cleaner and Exhaust System
60
Removal
60
Cleaning and Inspection
61
Installation
61
Exhaust System Leak Check
62
Table of Contents
77
6.17 Interactive Exhaust System 6.27 Main Wire Harness
227
Table of Contents
227
Throttle Cable
63
Throttle Cable Adjustment
63
Interactive Exhaust Cable
64
Headlamp
66
Windshield Maintenance
69
Storage
70
Troubleshooting
71
Low Oil Pressure
72
Lubrication System
72
Electrical System
73
Fastener Torque Values
79
Specifications
89
Suspension Settings
93
Vehicle Identification Number (Vin)
97
Wheels
99
Front Wheel
101
Bearing Installation
104
Rear Wheel
109
Tires
113
Wheel Balancing
116
Checking Cast Rim Runout
117
Front Brake Hand Lever
118
Front Brake: Eight Piston Caliper
118
Front Brake: Six Piston Caliper
126
Brake Pedal
134
Rear Brake Master Cylinder
135
Rear Brake Line
141
Removal: Lightning
142
Installation: Lightning
143
Removal: Ulysses
143
Installation: Ulysses
144
Rear Brake Caliper
146
Fenders
149
Front Forks: All Models
151
Fork Clamps: Upper and Lower
158
Steering Head Bearings
161
Swingarm and Brace
164
Front and Rear Isolators
168
Frame Pucks
169
Frame
170
Rear Shock Absorber
171
Assembly and Installation
177
Cleaning and Inspection
177
Removal and Disassembly
177
Throttle Control
177
Installation
178
Removal
178
Throttle Cable Replacement
178
Clutch Cable
180
Clutch Control
180
General
180
Removal and Disassembly
180
Assembly and Installation
182
Clutch Cable
182
Assembly: Firebolt
184
Disassembly: Firebolt
184
Headlamp Assembly and Support Bracket
184
Removal: Firebolt
184
Installation: Firebolt
185
Removal: Lightning/Ulysses
186
Assembly: Lightning/Ulysses
188
Disassembly: Lightning/Ulysses
188
Installation: Lightning/Ulysses
189
Fairing Support Bracket: Firebolt
190
Installation
190
Removal
190
Assembly and Installation
192
Deflectors: Xb9Sx/Xb12X/Xb12Xt/Xb12Xp
192
Removal and Disassembly
192
General
193
Grille: Xb9Sx/Xb12X/Xb12Xp
193
Removal and Installation
193
Front Modules: Lightning/Ulysses
194
Removal
194
Installation
195
General
196
Handlebars: Firebolt
196
Installation
196
Left Clip-On
196
Removal
196
Right Clip-On
196
Handlebars: Lightning/Ulysses
197
Installation
197
Removal
197
Installation
199
Mirrors
199
Removal
199
Footpeg, Heel Guard and Mount: Firebolt/Lightning
200
Installation
200
Passenger
200
Removal
200
Rider
200
Installation
201
Footpeg Installation
202
Footpeg Removal
202
Heel Guard and Footpeg Mounts: Ulysses Models
202
Mount Installation
202
Mount Removal
202
Passenger Footpegs
202
Rider Footpegs
202
Heel Guard Replacement
203
Installation
204
Removal
204
Sprocket Cover
204
Belt Guards
205
Installation
205
Removal
205
Installation
206
Intake Cover
206
Removal
206
Disassembly
208
Subframe Tail Assembly and Body Work: Firebolt
208
Cleaning
211
Left Tail Section and Battery Pan: Lightning
213
Center Tail Section: Lightning
217
Right Tail Section: Lightning
218
Left Tail Section and Battery Pan: Ulysses Models
219
Center Tail Loop: Ulysses Models
223
Right Tail Section: Ulysses Models
225
General
227
Removal
227
Sidestand
227
Installation
228
Front Fairing, Windshield, and Mirrors: Firebolt
229
Installation
229
Removal
229
Windshield and Windscreen: Lightning and Ulysses
230
Air Scoops
234
Chin Fairing
236
Installation
236
Removal
236
Rider Seat
237
Seat
237
Ulysses
239
Seat Locks
241
Removal
245
Triple Tail: Ulysses
245
Installation
246
Luggage: Xb12Xt
247
Luggage: Xb12Xp
251
6.18 Headlight
229
Table of Contents
253
Fastener Torque Values
255
Specifications
257
Engine
261
Diagnosing Smoking Engine or High Oil Consumption
262
Engine Rotation for Service
263
Engine Removal
268
Engine Installation
278
6.20 License Plate Lamp Assembly
286
Lightning
286
Removal
289
Cylinder Head
289
Valve Guides
295
Cylinder Head Installation
301
Cylinder and Piston
305
Deglazing Cylinder
308
Oiling System
314
Oil Pump
315
Oil Reservoir and Oil Hose Routing
321
Installation
323
Oil Line Fittings
323
General
325
Oil Cooler
325
General
326
Oil Pressure Indicator Switch
326
Crankcase Breathing System
328
General
328
General
330
Hydraulic Lifters
330
Gearcase and Cam Gears
332
Crankcase
336
6.21 Main Fuse and Fuses
325
6.22 Neutral Indicator Switch
326
(Ckp)
328
6.23 Sidestand Switch (Hdi)
328
6.24 Crankshaft Position Sensor
328
Table of Contents
351
Fastener Torque Values
353
Specifications
355
Air Cleaner Assembly
356
Electronic Control Module (Ecm)
359
Throttle Position Sensor (Tps)
362
Ignition Coil
363
Installation
364
Oxygen Sensor
364
Removal
365
Engine Temperature Sensor (Et)
365
Installation
366
Removal
367
6.19 Tail Lamp
366
Bank Angle Sensor (Bas)
367
Installation
368
Ulysses
369
Installation
370
Removal
370
General
370
Intake Air Temperature Sensor (Iat)
370
Cooling Fan
371
Assembly
372
General
372
General
371
Fuel Tank Vent Valve
372
Fuel Cap Retaining Ring
373
Fuel Pump
374
General
381
Throttle Body
381
Fuel Pressure Test
386
Intake Leak Test
388
Exhaust System
390
Evaporative Emissions Control (Ca Models)
394
6.25 Vehicle Speed Sensor (Vss)
381
Table of Contents
397
Fastener Torque Values
399
Specifications
401
Primary Cover
402
Clutch Release Mechanism
406
Clutch
408
Primary Chain
415
Drive Belt and Idler Pulley
421
Transmission
425
Case Disassembly for Transmission Removal
426
Transmission Disassembly
429
Transmission Assembly
436
Main Drive Gear and Bearing
438
Transmission Right Case Bearings
445
Transmission Left Case Bearings
447
Transmission Installation
449
Shifter Shaft
453
Transmission Sprocket
455
Table of Contents
459
Fastener Torque Values
461
Specifications
464
Ignition System
466
Ignition/Headlamp Key Switch
468
Spark Plug Cables
476
Charging System
478
Battery Cables
481
Starter
484
Starter Solenoid
488
Voltage Regulator
491
Alternator
493
Heated Hand Grips: Ulysses Models
495
Horn
498
Turn Signal Flasher
500
Front Turn Signals
502
Rear Turn Signals
504
Interactive Exhaust System
510
Headlight
514
Tail Lamp
519
License Plate Lamp Assembly
521
Main Fuse and Fuses
523
Neutral Indicator Switch
526
Sidestand Switch (Hdi)
527
Crankshaft Position Sensor (Ckp)
528
Vehicle Speed Sensor (Vss)
530
Instrument Module
531
Main Wire Harness
534
Auxiliary Harness: Xb12Xp
550
Sprocket Cover Wiring
558
Auxiliary Power Outlets: Ulysses Models
559
Table of Contents
561
Amp Multilock Connectors
563
Autofuse Electrical Connectors
567
Delphi Connectors
568
Deutsch Electrical Connectors
570
Deutsch Standard Terminal Repair
574
Deutsch Solid Barrel Mini Terminal Repair
575
Deutsch Mini Terminal Repair
577
Molex Connectors
578
Packard 150 Metri-Pack Connectors
582
Packard 280 Metri-Pack Relay and Fuse Block Connectors
584
Packard 480 Metri-Pack Connectors
585
Packard 630 Metri-Pack Connectors
586
Packard Metri-Pack Terminals
587
Packard Ecm Connector
589
Packard Micro-64 Connectors
591
Sealed Splice Connectors
594
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