Buell Firebolt Series Manuals

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

Buell Firebolt Series Service Manual

Buell Firebolt Series Service Manual (631 pages)

Brand: Buell | Category: Motorcycle | Size: 18.11 MB

Table of Contents

Maintenance 1

72
- Amp Multilock Electrical Connectors
  18
- Electrical Connectors
  31
- Table of Contents
  72
- General
  74
  - Repair and Replacement Procedures
    75
  - Hardware and Threaded Parts
    75
  - Threadlocking Agents
    75
  - Lip Type Seals
    75
  - Instruments and Gauges
    75
  - Part Replacement
    75
  - Part Protection
    76
  - Cleaning Process
    76
  - Rust or Corrosion Removal
    76
  - Tool Safety
    76
  - Air Tools
    76
  - Ratchets and Handles
    76
  - Storage Units
    77
- Fuel and Oil
  78
- Maintenance Schedule
  79
- Windshield Maintenance
  82
- Battery Maintenance
  83
  - Cleaning and Inspection
    84
- Engine Lubrication System
  86
  - Engine Oil and Filter Change
    87
- Brake System Maintenance
  89
  - Bleeding Front Brake
    91
  - Bleeding Rear Brake
    92
  - Brake Pad Replacement
    95
- Tires and Wheels
  97
- Clutch
  98
- Drive Belt System
  101
- Primary Chain
  104
- Suspension Damping Adjustments
  106
- Steering Head Bearings
  111
- Spark Plugs
  112
- Air Cleaner Filter
  114
- Throttle Cable and Idle Speed Adjustment
  116
- Interactive Exhaust Cable
  117
- Ignition Timing
  119
- Headlights
  121
- Throttle Position Sensor (TPS)
  123
- Storage
  124
- Troubleshooting
  125
  - Electrical System
    126
Chassis 2

130
- Specifications
  132
  - Torque Values
    133
- Tire Specifications
  137
- Buell Vehicle Identification Number (V.I.N.)
  138
- Wheels
  139
- Front Wheel
  141
  - Bearing Installation
    144
- Rear Wheel
  148
- Checking Cast Rim Runout
  152
- Tires
  153
  - Wheel Balancing
    156
- Brake Pedal
  157
- Front Brake Master Cylinder
  159
  - Front Master Cylinder
    160
- Front Brake Line
  162
- Front Brake Caliper
  164
- Rear Brake Master Cylinder
  167
- Rear Brake Line
  171
- Rear Brake Caliper
  173
- Front Fork
  176
  - Fork Assembly
    181
- Fork Clamps, Upper and Lower
  184
- Steering Head Bearings
  186
- Swingarm and Brace
  189
- Front and Rear Isolator
  193
- Frame
  194
- Rear Shock Absorber
  195
- Throttle Control
  197
- Clutch Control
  198
  - Clutch Cable
    198
- Headlight Assembly and Support Bracket
  202
- Fairing Support Bracket
  205
- Handlebars
  207
- Exhaust System
  209
- Footpeg, Heel Guard and Mount
  212
- Sprocket Cover
  214
- Fenders
  215
  - Front Fender
    215
  - Rear Fender
    215
- Belt Guards
  216
- Chin Fairing
  217
- Intake Cover Assembly
  218
- Air Scoops
  219
- Subframe Tail Assembly and Body Work
  220
- Front Fairing, Windshield and Mirrors
  224
- Seat
  225
  - Rider Seat
    225
  - Pillion Seat
    225
- Passenger Seat Lock
  226
- Sidestand
  227
Engine 3

230
- Specifications
  232
- Engine
  237
  - Diagnosing Smoking Engine or High Oil Consumption
    238
- Engine Rotation for Service
  239
- Stripping Motorcycle for Engine Service
  249
- Engine Installation
  260
- Cylinder Head
  274
  - Valve Guides
    280
  - Valve Springs
    280
  - Cylinder Head Installation
    289
- Cylinder and Piston
  292
- Lubrication System
  302
  - Winter Lubrication
    302
  - Checking and Adding Oil
    302
- Oil Hose Routing and Oil Reservoir
  303
- Oil Line Fittings
  304
- Oil Cooler
  306
- Oil Pressure Indicator Switch
  309
- Crankcase Breathing System
  311
- Oiling System
  313
- Oil Pump
  314
- Oil Filter Mount
  317
- Hydraulic Lifters
  318
- Gearcase Cover and Cam Gears
  320
- Crankcase
  325
Fuel System 4

340
- Fuel System
  342
- Specifications
  342
- Dynamic Digital Fuel Injection
  344
- Diagnostic Introduction
  346
  - System Problems
    346
- Checking for Trouble Codes
  347
- Check Engine Lamp Diagnostics
  349
- Breakout Box
  351
- Wiggle Test
  352
- Initial Diagnostic Check
  353
  - General Information
    353
- Check Engine Lamp Not Illuminated at Key on 4.9
  358
- Check Engine Lamp on Continuously
  361
- Engine Cranks but will Not Start
  364
- No ECM Power
  370
- Fuel Pressure Test
  373
- Idle Speed Control
  378
- Misfire
  379
- Trouble Code 11
  384
- Trouble Code 13
  388
- Trouble Code 14
  393
- Trouble Code 15
  397
- Trouble Code 16
  401
- Trouble Code 21
  405
- Trouble Codes 23 and 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.23 Trouble Codes 24 and
  408
- Trouble Code 33
  415
- Trouble Code 35
  418
- Trouble Code 36
  421
- Trouble Code 44
  425
- Trouble Codes 52, 53, 54 and 55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.29 Trouble Code 56
  429
- Electronic Control Module
  434
- Cam Position Sensor and Rotor
  436
- Ignition Coil
  440
- Oxygen Sensor
  442
- Engine Temperature Sensor
  443
- Bank Angle Sensor
  444
- Intake Air Temperature Sensor
  445
- Throttle Position Sensor
  446
- Cooling Fan
  447
- Fuel Pump
  448
- Fuel Tank Vent Valve
  456
- Fuel Cap Retaining Ring
  457
- Throttle Body
  458
  - Fuel Injectors
    460
- Intake Leak Test
  464
- Air Cleaner Assembly
  466
Electric Starter 5

472
- Specifications
  474
- Electric Starter System
  475
  - Wiring Diagrams
    475
  - Starter Relay
    475
- Starting System Diagnosis
  477
- Starter Activation Circuits
  481
- Diagnostics/Troubleshooting
  482
- Starter System Testing
  484
- Starter
  485
- Starter Solenoid
  494
Drive/Transmission 6

496
- Specifications
  498
- Primary Cover
  500
- Clutch Release Mechanism
  504
- Clutch
  506
- Primary Chain
  513
- Drive Belt System
  518
  - Drive Belt Installation
    520
- Transmission
  522
- Case Disassembly for Transmission Removal
  523
- Transmission Disassembly
  526
- Transmission Assembly
  532
- Main Drive Gear and Bearing
  534
  - Main Drive Gear
    539
- Transmission Right Case Bearings
  542
- Transmission Left Case Bearings
  543
- Transmission Installation
  544
- Shifter Shaft
  548
- Transmission Sprocket
  550
Electrical 7

554
- Specifications
  556
- Ignition System
  558
- Ignition/Headlight Key Switch
  560
- Spark Plug Cables
  564
- Starter Interlock
  566
  - Main Fuse
    571
- Interactive Exhaust System (XB12 Model)
  573
- Charging System
  578
- Alternator
  585
- Voltage Regulator
  587
- Battery Cables
  588
- Battery
  590
  - Battery Testing
    591
  - Voltmeter Test
    591
  - Disconnection and Removal
    592
- Headlight
  597
- Tail Lamp
  599
- Turn Signals
  600
- Turn Signal Flasher
  603
- Handlebar Switches
  604
- Speedometer Sensor
  606
- Instrument Module
  607
- Speedometer Performance Check
  609
- Horn
  614
- Neutral Indicator Switch
  616
- Main Fuse and Fuses
  617
- Main Wire Harness
  618
- Interactive Exhaust Harness (XB12 Models)
  623
- Sprocket Cover Wiring
  625
  - Index to Wiring Diagrams
    630

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