User Manuals: Buell 2009 XB Series Motorcycle

User Manuals: Buell 2009 XB Series Motorcycle

Manuals and User Guides for Buell 2009 XB Series Motorcycle. We have 1 Buell 2009 XB Series Motorcycle manual available for free PDF download: Service Manual

Buell 2009 XB Series Service Manual

Buell 2009 XB Series Service Manual (712 pages)

Brand: Buell | Category: Motorcycle | Size: 110 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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