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Buell XB 2008 Series Manuals
Manuals and User Guides for Buell XB 2008 Series. We have
1
Buell XB 2008 Series manual available for free PDF download: Service Manual
Buell XB 2008 Series Service Manual (688 pages)
Brand:
Buell
| Category:
Motorcycle
| Size: 55.35 MB
Table of Contents
99490-08Ya - Buell Xb Models Service Manual -- 01/30/08Sa
9
Important Notice
2
About this Manual
7
Table of Contents
9
General
23
Safe Operating Maintenance
23
Servicing a New Motorcycle
23
Shop Practices
23
Cleaning
23
Removing Parts
23
Repair Notes
23
Safety
23
Checking Torques on Fasteners with Lock Patches
24
Disassembly and Assembly
24
Magnetic Parts Trays
24
Repair and Replacement Procedures
24
Bearings
24
Bushings
24
Hardware and Threaded Parts
24
Instruments and Gauges
24
Threadlocking Agents
24
Wiring, Hoses and Lines
24
Exhaust System Leakage
25
Gears
25
O-Rings (Preformed Packings)
25
Part Replacement
25
Shafts
25
Cleaning
25
Bearings
25
Cleaning Process
25
Part Protection
25
Rust or Corrosion Removal
25
Hammers
26
Punches/Chisels
26
Ratchets and Handles
26
Screwdrivers
26
Sockets
26
Storage Units
26
Engine Lubrication
27
Fuel
27
Fuel and Oil
27
Gasoline Blends: Buell Models
27
Winter Lubrication
28
General
29
Maintenance Schedule
29
Battery Maintenance
31
General
31
Battery Disconnection and Removal
32
Charging Battery
32
Safety Precautions
32
Using a Battery Charger
32
Cleaning and Inspection
32
Battery Installation and Connection
33
Storage
34
Change Engine Oil and Filter
35
Drain Oil
35
Change Filter
36
Clear Oil Cooler
36
Fill Engine with Oil
36
Return to Service
37
Engine Oil and Filter
35
Engine Oil Level Check
35
General
35
Bleeding Brakes
38
Bleeding Front Brake
39
Bleeding Rear Brake
40
Brake System Maintenance
38
General
38
Brake Pedal Adjustment
40
Brake Pad Thickness
41
Brake Pad Replacement
42
Front Pad Installation
42
Front Pad Removal
42
Rear Pad Installation
43
Rear Pad Removal
43
Brake Rotor Thickness
42
Tire Inflation
45
Tire Wear
45
Tires and Wheels
45
Wheel Bearings
46
Clutch/Transmission/Primary Fluid
47
Inspection
47
Transmission Fluid
47
Adjustment
48
Cleaning
50
Drive Belt Maintenance
50
General
50
Inspection
50
Drive Belt
50
Idler Pulley
50
Rear Sprocket
50
Adjustment
53
Inspection
53
Primary Chain
53
Determining Proper Resistance
54
General
54
Inspection
54
Steering Head Bearings
54
Inspection
55
Spark Plugs
55
Air Cleaner and Exhaust System
57
Removal
57
Cleaning and Inspection
58
Installation
58
Exhaust System Leak Check
59
Throttle Cable
60
Throttle Cable Adjustment
60
Adjustment
61
Interactive Exhaust Cable
61
Headlight
63
Adjustment: Firebolt
64
Adjustment: Ulysses/Lightning XB12STT
65
General
67
Windshield Maintenance
67
General
68
Storage
68
General
69
Pre-Ignition or Detonation (Knocks or Pings)
70
Troubleshooting
69
Electrical System
71
Suspension
72
Lightning
75
Firebolt
77
Ulysses
78
Vehicle Identification Number (V.I.N.)
80
General
82
Removal
84
Front Rotor Removal
86
Assembly
87
Front Rotor Installation
90
Removal
92
Assembly
94
General
96
Removal
97
Checking Tire Lateral Runout
98
Adjustment
99
General
100
Grille: Xb9Sx/Xb12Stt/Xb12X
101
Removal
101
Front Master Cylinder
102
2.30 Deflectors
101
Xb9Sx/Xb12Stt/Xb12X/Xb12Xt
101
Installation
103
2.32 Front Modules
104
Lightning/Ulysses
104
Removal
104
Removal
106
Assembly
107
Removal
109
Removal: Firebolt/Lightning
110
Removal: Ulysses
111
Disassembly
113
Installation: Firebolt/Lightning
114
Removal: Firebolt
116
Removal: Lightning
117
Removal: Ulysses
118
Installation: Ulysses
119
Removal
120
Cleaning and Inspection
121
Front Fender: XB12R
123
Rear Fender: Xb12Ss/Xb12Stt/Xb12Xt/Xb12X
124
Front Fork: All Models Except Xb12Stt/Xb12X/Xb12Xt
125
General
125
Disassembly
126
Damper Rod Disassembly
128
Cleaning and Inspection
130
Installation
132
Front Fork: Xb12Stt/Xb12X/Xb12Xt
133
General
133
Cleaning and Inspection
137
Installation
139
Fork Clamps: Upper and Lower
140
Removal Firebolt
140
Removal: Lightning/Ulysses
141
Removal
143
Steering Head Bearings
143
Front Fork Slider Protectors: Xb12Stt
146
Replacement: XB12STT
146
General
147
Swingarm and Brace
147
Disassembly
148
Assembly
149
Front and Rear Isolators
151
Front Isolator
151
Frame Pucks
152
Installation
152
Removal
152
Frame
153
Removal
153
General
154
Rear Shock Absorber
154
Removal: Firebolt
156
Removal: Lightning
157
Installation: Firebolt
158
Installation: Ulysses
159
Removal and Disassembly
160
Throttle Control
160
Cleaning and Inspection
161
Clutch Control
163
General
163
Assembly and Installation
165
Headlamp Assembly and Support Bracket
167
Removal: Firebolt
167
Installation: Firebolt
168
Removal: Lightning/Ulysses
169
Disassembly: Lightning/Ulysses
171
Installation: Lightning/Ulysses
172
Fairing Support Bracket: Firebolt
173
Removal
173
Deflectors: Xb9Sx/Xb12Stt/Xb12X/Xb12Xt
175
Removal and Disassembly
175
General
176
Grille: Xb9Sx/Xb12Stt/Xb12X
176
Front Modules: Lightning/Ulysses
177
Removal
177
Installation
178
Left Clip-On
179
Right Clip-On
179
General
179
Handlebars: Firebolt
179
Installation
179
Removal
179
Handlebars: Lightning/Ulysses
180
Installation
180
Removal
180
Assembly
181
Installation
182
Mirrors
182
Removal
182
Footpeg, Heel Guard and Mount: Firebolt/Lightning
183
Rider
183
Footpeg Installation
183
Footpeg Removal
183
Heel Guard Installation
183
Heel Guard Removal
183
Mount Installation
183
Mount Removal
183
Wear Peg Installation
183
Wear Peg Removal
183
Footpeg Installation
184
Heel Guard Installation
184
Mount Installation
184
Heel Guard and Footpeg Mounts: Ulysses Models
185
Mount Installation
185
Mount Removal
185
Passenger Footpegs
185
Rider Footpegs
185
Footpeg Installation
185
Footpeg Removal
185
Heel Guard Replacement
186
Installation
187
Removal
187
Sprocket Cover
187
Belt Guards
188
Installation
188
Removal
188
Installation
189
Intake Cover
189
Removal
189
Disassembly
191
Subframe Tail Assembly and Body Work: Firebolt
191
Assembly
194
Cleaning
194
Disassembly
196
Left Tail Section and Battery Pan: Lightning
196
Cleaning
197
Assembly
198
Assembly
200
Center Tail Section: Lightning
200
Disassembly
200
Assembly
201
Disassembly
201
Right Tail Section: Lightning
201
Cleaning
202
Disassembly
202
Left Tail Section and Battery Pan: Xb12X/Xb12Xt
202
Assembly
203
Assembly
205
Center Tail Loop: Xb12X/Xb12Xt
205
Disassembly
205
Disassembly
207
Right Tail Section: Xb12X/Xb12Xt
207
Assembly
208
Disassembly
209
General
209
Removal
209
Sidestand
209
Assembly
210
Installation
210
Front Fairing, Windshield, and Mirrors: Firebolt
211
Installation
211
Removal
211
Installation: Lightning
212
Removal: Lightning
212
Windshield and Windscreen: Lightning and Ulysses
212
Installation: Ulysses XB12X
213
Removal: Ulysses XB12X
213
Removal: Ulysses XB12XT
214
Installation: Ulysses XB12XT
215
General
216
Number Plates: Xb12Stt
216
Removal
216
Installation
217
Air Scoops
218
Engine Shroud Air Scoop
218
Ram Air Scoop
218
Installation
218
Removal
218
Oil Cooler Air Scoop
219
Installation
220
Removal
220
Chin Fairing
220
Firebolt
221
Pillion
221
Rider Seat
221
Lightning
221
Removal
221
Installation
222
Installation
223
Seat
221
Ulysses
223
Removal
223
Installation: Lightning
225
Removal: Lightning
225
Seat Locks
225
Installation: Ulysses Models
226
Removal: Ulysses Models
226
Pillion Lock Removal: XB12R
227
Pillion Lock Installation: XB12R
228
Assembly
229
Disassembly
229
General
229
Removal
229
Triple Tail: Ulysses
229
Installation
230
Luggage: Xb12Xt
231
Removal: Side Case
231
Installation: Side Case
232
Removal: Top Case
232
Installation: Top Case
233
Luggage Case Latch Mechanism
233
Removal
233
Installation
234
Table of Contents
235
Specifications
237
General
237
Engine
241
Adjustment/Testing
241
General
241
Compression Test
241
Cylinder Leakage Test
241
Diagnosing Smoking Engine or High Oil Consumption
242
Disassembly
243
Engine Rotation for Service
243
General
243
Assembly
246
Disassembly
249
Engine Removal
249
Assembly
259
Engine Preparation for Re-Installation
259
Installing Engine in Frame
260
Engine Installation
259
Cylinder Head
270
Removal
270
Rocker Box Assemblies
270
Cylinder Head Assemblies
271
Disassembly
272
Cleaning and Inspection
275
Cylinder Heads
275
Rocker Arm Assemblies
275
Valve Guides
276
Valve Seats
276
Valves
276
Push Rods
277
Spark Plug Threads
277
Valve Springs
277
Replacing Rocker Arm Bushings
277
Replacing Valve Guides
278
Procedure for Using the Neway Valve Seat Cutter
279
Assembly
280
Push Rod Cover Installation
281
Cylinder Head Installation
282
Cylinder and Piston
285
Removal/Disassembly
285
Cleaning and Inspection
286
Checking Gasket Surface
287
Measuring Cylinder Bore
287
Deglazing Cylinder
288
Fitting Piston Rings
288
Connecting Rod Bushing
290
Assembly/Installation
291
General
294
Oiling System
294
General
295
Oil Pump
295
Removal/Disassembly
296
Cleaning and Inspection
298
Assembly/Installation
299
General
301
Oil Reservoir and Oil Hose Routing
301
Installation
303
Oil Line Fittings
303
Removal
303
General
305
Installation
305
Oil Cooler
305
Removal
305
General
306
Oil Pressure
306
Oil Pressure Indicator Switch
306
Oil Pressure Signal Light
306
Crankcase Breathing System
308
General
308
Reed Valve Replacement
308
Cleaning and Inspection
310
General
310
Hydraulic Lifters
310
Removal
310
Installation
311
Gearcase and Cam Gears
312
General
312
Cleaning and Inspection
313
Cam and Pinion Gear Identification, Inspection and Selection
314
Removal and Disassembly
313
Assembly and Installation
314
Crankcase
316
Disassembly
316
Crankcase Halves
316
General
316
Oil Filter Adapter
317
Piston Jets
318
Flywheel Assembly
318
Installation
318
Removal
318
Removing Cylinder Base Studs
318
Pinion Shaft Bearing
321
General
321
Replacement
322
Selection
322
Lapping Pinion Shaft Bearing Outer Race
325
Checking Connecting Rod Side Play
325
Assembly
326
Crankcase Halves
326
Table of Contents
331
Fuel System
333
General
333
Specifications
333
Air Cleaner Assembly
334
Removal
334
Inspection
335
Installation
335
Electronic Control Module (Ecm)
337
Installation: Firebolt
337
Installation: Lightning
337
Removal: Firebolt
337
Removal: Lightning
337
Installation: Ulysses
338
Removal: Ulysses
338
Installation
340
Removal
340
Throttle Position Sensor (Tps)
340
Ignition Coil
341
Installation
341
Removal
341
General
342
Installation
342
Oxygen Sensor
342
Removal
342
Engine Temperature Sensor (Et)
343
Installation
344
Firebolt
345
Lightning
345
Ulysses
345
General
343
Removal
343
Bank Angle Sensor (Bas)
345
General
345
Installation
346
Firebolt
346
Lightning
346
Ulysses
347
General
348
Installation
348
Intake Air Temperature Sensor (Iat)
348
Removal
348
Cooling Fan
349
General
349
Installation
349
Removal
349
Fuel Tank Vent Valve
350
General
350
Installation
350
Removal
350
Fuel Cap Retaining Ring
351
Installation
351
Removal
351
Draining Fuel Tank
352
Fuel Pump
352
Removal
352
Repair
353
Fuel Pressure Regulator Replacement
353
Low Fuel Level Sensor Replacement
354
Fuel Filter Replacement
355
Fuel Pump Wire Harness Replacement
357
Installation
357
General
359
Removal
359
Throttle Body
359
Installation
362
Injector Leak Testing
363
Repair
362
Fuel Injectors
362
Throttle Position Sensor
362
General
364
Intake Leak Test
364
Leak Tester
364
Parts List
364
Tester Adjustment
364
Tester Assembly
364
Procedure
364
Exhaust System
366
Removal and Disassembly
366
Exhaust Header
366
Front Muffler Mount
366
Muffler
366
Rear Muffler Bracket
366
Assembly and Installation
367
Exhaust Header
367
Front Muffler Mount
368
Rear Muffler Bracket
368
Evaporative Emissions Control (Ca Models)
370
General
370
Installation: Lightning/Ulysses
371
Hose Routing
372
Specifications
375
Wiring Diagrams
376
Table of Contents
385
General
387
Specifications
387
Primary Cover
388
Removal
388
Primary Chain Adjuster Replacement
389
Installation
390
Clutch Release Mechanism
392
Disassembly
392
Assembly
393
Clutch
394
General
394
Removal
396
Clutch Pack Cleaning and Inspection
397
Assembly and Installation
398
General
401
Primary Chain
401
Clutch Shell/Hub Inspection
402
Clutch Shell Bearing Replacement
403
Installation
404
Drive Belt and Idler Pulley
407
General
407
Drive Belt Removal
408
Idler Pulley Removal
409
Transmission
411
General
411
Appendix E Active Intake
412
Case Disassembly for Transmission Removal
412
General
412
Transmission Disassembly
415
Transmission Removal from Left Crankcase
415
Mainshaft/Countershaft
419
Cleaning and Inspection
420
Mainshaft Assembly
422
Transmission Assembly
422
General
424
Main Drive Gear Bearing
425
Disassembly
426
Installation
427
Main Drive Gear and Bearing
424
Main Drive Gear
428
Main Drive Gear Seal
429
Removal
431
Transmission Right Case Bearings
431
Transmission Left Case Bearings
433
Removal
433
Transmission Installation
434
Shifter Forks and Drum Assembly
435
Installing Right Crankcase
436
Shifter Shaft
438
Installation
438
Transmission Sprocket
440
Removal
440
Installation
441
Table of Contents
443
General
445
Specifications
445
General
447
Ignition System
447
General
449
Ignition/Headlamp Key Switch
449
Disassembly: Firebolt
450
Installation: Firebolt
451
Disassembly: Lightning
453
Removal: Ulysses
456
Disassembly: Ulysses
457
General
459
Spark Plug Cables
459
Charging System
461
General
461
Battery Cables
463
Removal
463
General
466
Voltage Regulator
466
Alternator
467
Removal and Disassembly
467
Cleaning and Inspection
468
Heated Hand Grips: Ulysses Models
469
Horn
472
Removal
472
Troubleshooting
473
Removal
474
Turn Signal Flasher
474
Bulbs
476
Front Turn Signals
476
Ulysses
477
Rear Turn Signals
479
Installation
479
Installation
480
Ulysses
481
General
483
Removal
485
Installation
486
Interactive Exhaust System
483
General
487
Headlight
487
Headlight Bulbs: Lightning and Ulysses
488
Installation
489
Firebolt/Lighting
492
Tail Lamp
492
Ulysses
493
License Plate Lamp Assembly
494
Lightning
494
Assembly and Installation
495
General
496
Main Fuse and Fuses
496
General
499
Neutral Indicator Switch
499
Crankshaft Position Sensor (Ckp)
500
General
500
Removal
502
Vehicle Speed Sensor (Vss)
502
General
503
Instrument Module
503
Installation
504
General
506
Main Wire Harness
506
Installation
513
Appendix D Hose and Wire
521
Firebolt
521
Interactive Exhaust Harness: Xb12 Models
521
Lightning
522
Ulysses
523
General
525
Sprocket Cover Wiring
525
Auxiliary Power Outlets: Ulysses Models
526
General
526
Table of Contents
527
Appendix A Connector Repair
529
AMP 1-Place Connector Repair
529
Installing Pin Terminal
530
Amp 1-Place Connectors
529
AMP Multilock Connector Repair
531
Inserting Terminals into Housing
532
Crimping Terminals to Leads
533
Inspecting Crimped Terminals
534
Amp Multilock Connectors
531
Autofuse Connector Repair
535
Autofuse Electrical Connectors
535
Delphi Connector Repair
536
Delphi Connectors
536
Deutsch Connector Repair
538
Removing Pin Terminals
540
Crimping Terminals
541
Deutsch Electrical Connectors
538
Deutsch Standard Terminal Repair
542
Deutsch Solid Barrel Mini Terminal Repair
543
Deutsch Mini Terminal Repair
545
Molex Connector Repair
546
Molex Connectors
546
Crimp Terminal to Lead
547
Position Terminal in the Punch/Die
548
Inspect Crimp
549
Metri-Pack Connector Repair
550
Packard 150 Metri-Pack Connectors
550
Fuse Block Repair
552
Packard 280 Metri-Pack Relay and Fuse Block Connectors
552
Metri-Pack Connector Repair
553
Packard 480 Metri-Pack Connectors
553
Metri-Pack Connector Repair
554
Packard 630 Metri-Pack Connectors
554
Metri-Pack Terminal Crimps
555
Packard Metri-Pack Terminals
555
Inspecting Crimps
556
Packard 100W Connector Repair
557
Packard Ecm Connector
557
Packard Micro-64 Connector Repair
559
Packard Micro-64 Connectors
559
Preparing Wire Leads for Crimping
560
Sealed Splice Connector Repair
562
Sealed Splice Connectors
562
Appendix B Wiring
567
Connector Locations
567
Wiring Diagram Information
569
Buell Wiring Diagrams
570
Appendix C Conversions
595
Conversion Table
595
United States System
596
United States System
597
Diagnostic Notes
641
Appendix F Glossary
649
Acronyms and Abbreviations
649
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