Buell XB9R 2003 Manuals

Manuals and User Guides for Buell XB9R 2003. We have 2 Buell XB9R 2003 manuals available for free PDF download: Service Manual

Buell XB9R 2003 Service Manual

Buell XB9R 2003 Service Manual (567 pages)

Brand: Buell | Category: Motorcycle | Size: 17.79 MB

Table of Contents

Tools
3
Removing Socket/Pin Terminals
9
Installing Socket/Pin Terminals
9
Amp Multilock Electrical Connectors
9
Release Tang and Back out Terminals
10
Multilock Connector Cutaway View
10
Secondary Locks Open (Socket Housings Shown)
11
Stamped Numbers on Secondary Locks Indicate Wire Color Locations
11
Crimping Instructions
12
Amp Multilock Crimping Procedure
12
Deutsch Electrical Connectors
13
Removing/Disassembling
13
Removing/Installing Sockets
13
Depress Terminal Latches/Back out Pins
14
Removing/Installing Pins
14
12-Pin Deutsch Connector (Exploded View)
14
Deutsch Connector Pick Tool
15
Attachment Clip Installation
15
Deutsch Crimping Procedure
16
2-Pin, 3-Pin and 4-Pin Deutsch Connectors
17
Packard Electrical Connectors
18
Pull-To-Seat Terminals
19
Removing External Latch Type
19
Installing External Latch Type
19
Removing Push-To-Seat Terminals
20
Installing Push-To-Seat Terminals
20
Inspect Core and Insulation/Seal Crimps
21
Packard Terminal Crimp Tools
21
Electrical Connector and Location Table
22
Electrical Connectors
22
Table of Contents
24
Index to Wiring Diagrams
24
XB9R Wiring Diagrams
24
Main Harness
25
Engine Management Circuit
26
Lighting Circuit
27
Horn and Instruments Circuit
28
Starting Circuit
29
Starting and Charging Circuits
30
Component Circuits
31
- Metric Conversions
  32
- English Torque Values
  33
- Fastener Torque Values
  33
- Metric Torque Values
  33
- Front and Rear Brake Systems, Right Side View
  34
- Hose and Wire Routing
  34
- Rear Brake Systems, Top View
  35
- Rear Brake Systems, Left Side View
  36
- Evaporative Emissions Control, California Models, Top View
  37
- Evaporative Emissions Control, California and 49 State Models
  38
- Wiring Harness, Left Side View
  39
- Wiring Harness, Top View
  40
- Wiring Harness, Right Side View
  41
- Oil Lines, Right Side View
  42
- Oil Lines, Bottom View
  43
- Clutch and Throttle Cables, Right Side View
  44
- Clutch, Throttle and Seat Release Cables, Left Side View
  45
- Clutch, Throttle and Seat Release Cables, Top View
  46
- Maintenance
  48
- General
  50
  - Inspecting
    50
  - Safe Operating Maintenance
    50
  - Servicing a New Motorcycle
    50
  - Xb9R Tool Set
    50
  - Brake Fluid
    51
- Fluid Requirements
  51
  - Front Fork Oil
    51
  - Primary Drive/Transmission Fluid
    51
  - Regular Service Intervals
    52
  - Care and Maintenance
    53
- Care of Molded-In-Color Body Panels
  53
- Battery Maintenance
  54
  - Battery Testing
    54
  - Voltmeter Test
    54
  - Battery Disconnection and Removal
    55
  - Battery Self-Discharge Rate
    55
  - Cleaning and Inspection
    55
  - Storage
    55
  - Battery Installation and Connection
    56
  - Checking Engine Oil Level
    57
- Engine Lubrication System
  57
  - Changing Engine Oil and Filter
    58
  - Changing Filter
    58
  - Draining Oil
    58
  - Replacing Oil
    58
  - Dipstick Location/Engine Oil Level
    59
  - Oil Filter
    59
  - Oil Tank Drain Plug
    59
  - Recommended Oil Grades
    59
  - Bleeding Brakes
    60
- Brake System Maintenance
  60
  - Brake Troubleshooting
    61
  - Bleeding Front Brake
    62
  - Front Caliper Bleeder Valve
    62
  - Front Master Cylinder Reservoir
    62
  - Bleeding Rear Brake
    63
  - Rear Caliper Bleeder Valve
    63
  - Rear Master Cylinder Reservoir
    63
  - Brake Pedal Adjustment
    64
  - Pushrod Adjustment
    64
  - Brake Pad Thickness
    65
  - Brake Rotor Thickness
    65
  - Front Brake Rotor
    65
  - Brake Pad Replacement
    66
  - Front Pad Installation
    66
  - Front Pad Removal
    66
  - Rear Pad Installation
    67
  - Rear Pad Removal
    67
  - Tire Inflation
    68
  - Tire Replacement
    68
- Tires and Wheels
  68
- Wheel Bearings
  68
- Clutch
  69
  - Clutch Inspection Cover
    69
  - Primary Drain Plug
    69
  - Transmission Fluid
    69
  - Adjustment
    70
  - Clutch Adjustment
    70
  - Clutch Cable Adjuster Mechanism
    70
  - Adjusting Clutch Free Play
    71
- Drive Belt System
  72
  - Idler Pulley
    72
  - Rear Sprocket
    72
  - Drive Belt Installation
    73
  - Drive Belt Removal
    73
  - Rear Wheel Mounting, Right Side
    73
  - Belt Guard Assembly
    74
  - Idler Pulley Assembly
    75
  - Idler Pulley Installation
    75
  - Idler Pulley Removal
    75
  - Drive Belt Wear Patterns
    76
  - Measuring Primary Chain Tension
    78
- Primary Chain
  78
- Suspension Damping Adjustments
  80
- Front Fork Oil Change
  84
  - Drain and Replace Oil
    85
  - Measuring Fork Oil Level
    85
  - Front Fork Assembly
    86
  - Measuring Steering Head Bearing Resistance
    87
  - Steering Head Bearings
    87
- Spark Plugs
  88
- Throttle Cable and Idle Speed Adjustment
  92
  - Checking Static Timing
    93
  - Correct Timing
    93
- Ignition Timing
  93
  - Timing Plug
    93
  - Adjust Timing
    94
  - Advanced Timing
    94
  - Cam Position Sensor
    94
  - Timer Cover
    94
  - Checking Headlight Alignment
    95
  - Headlamp Switch
    95
- Headlights
  95
- Headlamp Height Adjustment
  96
- Throttle Position Sensor (Tps)
  97
- Troubleshooting
  99
  - Electrical System
    100
  - Fuel System
    100
  - Oil Does Not Return to Oil Tank
    100
  - Pre-Ignition or Detonation
    100
  - Spark Plug Fouls Repeatedly
    100
  - Drags or Does Not Release
    101
  - Handling Irregularities
    101
  - Jumps out of Gear
    101
  - Shifts Hard
    101
  - Front Suspension Problems
    102
  - General Suspension Problems
    102
  - Rear Suspension Problems
    102
  - Suspension
    102
  - Chassis
    104
  - Capacities
    106
  - Dimensions
    106
- Specifications
  106
  - Weight Speciﬁcations
    106
  - Torque Values
    107
  - Rim Markings
    110
  - Tire Fitment-Tubeless Cast Wheels
    110
- Tire Specifications
  110
- Abbreviated V.I.N. Location
  111
- Vehicle Identification Number
  111
  - Vehicle Identiﬁcation Number (V.I.N.)
    111
  - Checking Tire Inﬂation Pressure
    112
- Wheels
  112
- Wheel Service
  113
- Front Wheel
  114
  - Front Wheel Mounting
    114
  - Front Wheel Removal and Installation
    114
  - Assemble Puller
    115
  - Bearing Removal
    115
  - Expand the Collet
    115
  - Install Collet and Ball Bearing
    115
  - Front Rotor Removal
    116
  - Remove the Bearing
    116
  - Remove the Spacer
    116
  - Removing Bearing from Puller
    116
  - Bearing Installation
    117
  - Install Bearing
    117
  - Install the Backing Plate (B-43993-11) and Forcing Screw
    117
  - Front Rotor Installation
    118
  - Insert Forcing Screw and Backing Plate
    118
  - Install the Bearing
    118
  - Install the Spacer
    118
  - Front Wheel Assembly
    119
  - Rear Brake Caliper Carrier Fasteners
    120
- Rear Wheel
  120
  - Anti-Seize Lubricant Location
    121
  - Removing Wheel Bearing
    121
  - Rear Wheel Assembly
    122
- Checking Cast Rim Runout
  123
  - Rim Lateral Runout
    123
  - Rim Radial Runout
    123
  - Wheel Runout
    123
  - Loosening Beads from Rim Flange
    124
  - Starting Bead on Rim
    124
  - Starting Tire off Rim
    124
- Tires
  124
  - Checking Tire Lateral Runout
    125
  - Checking Tire Radial Runout
    125
  - Tire Runout
    125
  - Weights for Cast Wheels
    126
  - Wheel Balancing
    126
  - Wheel Weights
    126
- Brake Pedal
  127
  - Brake Hand Lever
    128
  - Front Brake Master Cylinder and Hand Lever 2.10
    128
  - Front Master Cylinder
    128
  - Piston Assembly in Master Cylinder
    128
  - Front Brake Hand Lever Assembly
    129
- Front Brake Master Cylinder
  129
  - Brake Fluid Level
    130
  - Brake Lamp Switch Connectors
    130
- Front Brake Line
  131
  - Front Brake Caliper Mounts
    133
  - Pad Spring (Typical)
    133
  - Removing Pistons (B-42887)
    133
  - Front Rotor Runout
    134
  - Front Caliper Assembly
    135
  - Brake Line Switch Connector
    136
- Rear Brake Master Cylinder
  136
  - Rear Master Cylinder Mounting
    136
  - Remote Reservoir
    136
  - Master Cylinder Internal
    137
  - Rear Master Cylinder Assembly
    138
- Rear Brake Line
  139
  - Rear Brake Line Switch/Banjo Bolt
    139
  - Caliper Mount Clip
    141
- Rear Brake Caliper
  141
  - Brake Pads
    142
  - Rear Rotor Runout
    142
  - Removing Rear Brake Caliper Piston
    142
  - Rear Reservoir
    143
- Front Fork
  144
  - Stopper Ring
    144
  - Fork Cap Assembly
    145
  - Holding Damper Rod Assembly
    145
  - Damper Rod Assembly
    146
  - Damper Rod Disassembly
    146
  - Fork Assembly
    146
  - Rebound Assembly and Fork Cap Assembly
    146
  - Fork Seal Driver
    147
  - Cable Straps on Upper Fork Clamp
    150
- Fork Clamps, Upper and Lower
  150
  - Steering Stem Assembly
    151
  - Steering Head Bearing Lip
    152
  - Steering Head Bearings Installation Tools
    152
  - Install Bearings
    153
  - Lower Bearing
    153
- Swingarm and Brace
  154
  - Oil Line Fittings
    155
  - Swingarm
    155
  - Final Swingarm Inspection
    156
  - Swingarm Assembly
    157
  - Clutch Cable P-Clamp
    158
  - Front and Rear Isolators
    158
  - Front Isolator
    158
  - Rear Isolator
    158
- Frame
  159
  - Lift Frame off Motorcycle
    159
  - Adjuster Screw Alignment
    160
  - Cable Strap
    160
- Rear Shock Absorber
  160
  - Rear Shock Absorber Assembly
    161
  - Cable Connections
    162
- Throttle Control
  162
  - Throttle Control Cables
    162
  - Clutch Hand Control Assembly
    163
- Clutch Hand Lever
  163
- Headlight Connector
  164
- Headlight Support Bracket
  164
  - Headlight Support Bracket Assembly
    165
  - Headlamp Pivot Groove
    166
- Fairing Support Bracket
  167
  - Fairing Support Bracket Assembly
    168
  - Handlebar Clip-On Mounting Fasteners
    169
- Handlebars
  169
  - Left Clip-On
    169
  - Right Clip-On
    169
  - Handlebar Clip-On Assembly (Left Clip-On Shown)
    170
  - Exhaust Header
    171
- Exhaust System
  171
  - Mufﬂer
    171
  - Rear Mufﬂer Mounting Block
    171
  - Front Mufﬂer Mounting Block
    172
  - Mufﬂer and Straps
    172
- Footpeg, Heel Guard and Mount
  173
  - Remove Footpeg
    173
  - Remove Heel Guard
    173
  - Rider
    173
  - Install Footpeg
    174
  - Install Heel Guard
    174
  - Passenger
    174
  - Remove Mount
    174
  - Chin Fairing Assembly
    175
- Sprocket Cover
  175
  - Front Fender
    176
  - Rear Fender
    176
- Belt Guards
  177
- Chin Fairing
  179
- Intake Cover Assembly
  180
- Air Scoops
  181
  - Engine Shroud Air Scoop
    181
  - Oil Cooler Air Scoop
    181
  - Ram Air Scoop
    181
  - Inside Tail Frame Hose and Wire Routing
    182
  - Left Side Tail Frame Hose and Wire Routing
    182
- Tail Frame and Body Work
  182
  - Remote Reservoir Clamp Nut
    183
  - Tail Frame and Body Work Assembly
    184
- Front Fairing, Windshield, and Mirrors
  185
  - Accessing Rider Seat Screws
    186
  - Pillion Seat
    186
  - Rider Seat
    186
- Seat
  186
- Passenger Seat Lock
  187
  - Seat Lock and Cable Assembly
    187
  - Sidestand Removal
    188
  - Sidestand Switch Removal
    188
  - Sidestand Switch with Cable Strap
    188
  - Sidestand Assembly
    189
  - Sidestand Disassembly
    189
  - Sidestand Installation
    189
  - Sidestand Switch Installation
    189
  - Engine
    190
  - Engine Ignition Speciﬁcations
    192
  - General Information
    192
  - Valve and Valve Seat Speciﬁcations
    192
  - Valve Spring Speciﬁcations
    192
  - Cylinder Head Speciﬁcations
    193
  - Cylinder Speciﬁcations
    193
  - Piston Ring and Piston Pin Speciﬁcations
    193
  - Rocker Arm Speciﬁcations
    193
  - Flywheel Speciﬁcations
    194
  - Gearcase Speciﬁcations
    194
  - Hydraulic Lifter Speciﬁcations
    194
  - Oil Pump Speciﬁcations
    194
  - Pinion Shaft Bearing Speciﬁcations
    195
  - Electrical Items for Engine Removal and Replacement
    196
  - Adjustment/Testing
    197
  - Fuel
    197
  - Gasoline/Alcohol Blends
    197
  - Lubrication
    197
  - Air Leakage Test
    198
  - Compression Test Procedure
    198
  - Compression Test Results
    198
  - Cylinder Leakage Test
    198
  - Diagnosing Smoking Engine or High Oil Consumption
    198
  - Engine Rotation for Service
    199
  - Fuel Line and DDFI Electrical Connections
    199
  - Electrical Connections and Throttle Cables
    200
  - Mufﬂer and Mounting System
    201
  - Clutch Cable Retaining Clamps
    202
  - Oil Line Connections at Oil Cooler
    202
  - Engine Mounting System
    203
  - Front Isolator and Tie Bar Assemblies
    204
  - Rear Isolator Bolt and Rear Tie Bar
    204
  - Lubrication Points on Front Isolator Bolt
    205
  - Oil Cooler Feed and Return Oil Line Orientation and Clearances
    206
  - Stripping Motorcycle for Engine Service
    210
  - Electrical Connections
    216
  - Rear Isolator Bolt and Swingarm Pivot Shaft
    217
  - Supporting the Swingarm
    217
  - Supporting Vehicle for Disassembly
    217
  - Transmission Vent Line
    217
  - Center Tie Bar Mount
    218
  - Front Exhaust Mount Bushings (2 Piece)
    218
  - Removing Threaded Insert
    218
  - Rear Isolator and Mounting Hardware
    219
  - Rolling Chassis
    219
  - Securing Vehicle for Relocation
    219
  - Engine Installation
    220
  - Engine Prep for Re-Installation
    220
  - Installing Engine in Frame
    221
  - Installing Rear Isolator Bolt
    221
  - Supporting Vehicle for Assembly
    221
  - Mufﬂer Mounting System
    224
  - Oil Lines and Connections
    225
  - Oil Line Clearances and Torques
    226
  - Clamp Orientation and Oil Line Spacing
    228
  - Oil Cooler Feed and Return Oil Lines Location and Orientation
    230
  - Oil Cooler Oil Lines
    230
  - Correct Routing of Wiring Harnesses
    231
  - Cylinder Head
    236
  - Rocker Arm and Pushrod Cover Assemblies
    236
  - Lower Rocker Box Fasteners
    237
  - Removing Rocker Arm Shafts
    237
  - Rocker Box Assemblies
    237
  - Cylinder Head Assemblies
    238
  - Head Screw Loosening/Tightening Sequence
    238
  - Valve Spring Compressor
    238
  - Cylinder Head, Cylinder and Piston Assembly
    239
  - Checking Gasket Surface
    240
  - Cylinder Heads
    240
  - Measuring Rocker Arm Shaft Bore Diameter in Lower Rocker Cover
    241
  - Measuring Rocker Arm Shaft Diameter
    241
  - Rocker Arm Assemblies
    241
  - Valve Guides
    242
  - Valve Seats
    242
  - Valve Springs
    242
  - Replacing Rocker Arm Bushings
    243
  - Cleaning Valve Guides
    244
  - Installing Shoulderless Valve Guide
    244
  - Replacing Valve Guides
    244
  - Valve Stem Clearances and Service Wear Limits
    244
  - Neway Valve Seat Cutter
    245
  - Procedure for Using the Neway Valve Seat Cutter
    245
  - Intake & Exhaust Valve and Seat
    246
  - Valve and Seat Dimensions
    246
  - Valve Guide Seal Protector Sleeve
    248
  - Valve Seal and Lower Collar Assembly
    248
  - Push Rod Cover Installation
    250
  - Push Rod Locations
    250
  - Push Rod Selection
    250
  - Push Rods and Push Rod Cover Assembly
    250
  - Cylinder Head Installation
    251
  - Tightening Head Screws
    251
  - Lower Rocker Box Hardware
    253
  - Cylinder and Piston
    254
  - Piston Pin and Piston Identiﬁcation
    255
  - Removing Piston Pin Circlip
    255
  - Removing Piston Rings
    255
  - Deglazing Cylinder
    257
  - Measuring Cylinder Bore
    257
  - Fitting Piston Rings
    258
  - Measuring Ring End Gap
    258
  - Piston Rings
    258
  - Measuring Ring Clearance in Groove
    259
  - Ring End Gap Position
    259
  - Connecting Rod Bushing
    260
  - Connecting Rod Clamping Tool
    260
  - Installing New Wrist Pin Bushing
    260
  - Removing Wrist Pin Bushing
    260
  - Installing Piston Pin Circlip
    261
  - Piston Support Plate
    261
  - Compressing Piston Rings
    262
  - Changing Oil and Filter
    264
  - Checking and Adding Oil
    264
  - Lubrication System
    264
  - Winter Lubrication
    264
  - Oil Hose Routing and Oil Reservoir
    265
  - Oil Pressure Indicator Switch
    266
  - Oil Pressure Signal Light
    266
  - Troubleshooting Oil Pressure Signal Light
    266
  - Crankcase Breathing System
    267
  - Reed Valve Assembly
    268
  - Reed Valve Replacement
    268
  - Reed Valve Stop and Reed Valve
    268
  - Oiling System
    269
  - Oil Pump
    270
  - Oil Pump Hardware
    271
  - Gerotor Wear Limits
    272
  - Separator Plate Slots
    272
  - Oil Filter Mount
    273
  - Oil Filter Mount Assembly
    273
  - Hydraulic Lifters
    274
  - Lifter Assembly (Typical)
    274
  - Base Circle
    275
  - Valve Lifter Service
    275
  - Gearcase Cover & Cam Assembly
    276
  - Gearcase Cover and Cam Gears
    276
  - Cam and Pinion Gear Location and Timing Mark Indexing
    277
  - Bushing Inspection
    278
  - Cam and Pinion Gear Identiﬁcation
    278
  - Gear Shaft Speciﬁcations
    278
  - Aligning Pinion Gear
    279
  - Crankshaft Locking Tool
    279
  - Checking Cam Gear End Play
    280
  - Gearcase Cover Mounting Screw Torque Sequence
    280
  - Crankcase
    281
  - Crankcase Halves
    281
  - Rear Isolator Assembly
    281
  - Crankcase Fasteners
    282
  - Piston Jets
    282
  - Piston Oil Jet Assemblies
    282
  - Crankcase and Flywheel Assembly
    283
  - Removing Flywheels from Left Crankcase
    283
  - Removing Left Main Bearing from Crankcase
    284
  - Removing Left Main Bearing Retaining Ring
    284
  - Removing Sprocket Shaft Inner Bearing Race
    284
  - Factory Inner Race Sizes
    285
  - Fitting Pinion Bearings
    285
  - Paint Dot Speciﬁcations
    285
  - Removing Pinion Bearing Inner Race
    285
  - Factory Outer Race Sizes
    286
  - Roller Speciﬁcations
    286
  - Stamp Speciﬁcations
    286
  - Bearing Selection
    287
  - Pinion Shaft Bearing Selection
    287
  - New Component Speciﬁcations
    288
  - Outer Pinion Race Service Wear Limits
    288
  - Pinion Shaft Bearing Tools
    288
  - Inner Race Location
    289
  - Pinion Inner Race Fitment Speciﬁcations
    289
  - Checking Connecting Rod Side Play
    290
  - Lapping Engine Right Main Bearing Race
    290
  - Left Main Bearing Assembly
    291
  - Left Main Bearing Installation
    292
  - Pinion Shaft Bearing
    292
  - Sprocket Shaft Seal/Spacer Installer
    294
  - Cylinder Studs
    295
  - Fuel System
    296
  - Fuel System Speciﬁcations
    298
  - Fuel Tank Speciﬁcations
    298
  - Idle Speed Speciﬁcations
    298
  - Dynamic Digital Fuel Injection (Ddfi)
    300
  - Buell Dynamic Digital Fuel Injection
    301
  - Check Engine Lamp
    302
  - Diagnostic Introduction
    302
  - Resolving Problems
    302
  - System Problems
    302
  - Checking for Trouble Codes
    303
  - Engine Stop Switch
    303
  - Ignition Key Switch
    303
  - Check Engine Lamp Blinks
    304
  - Code Types
    304
  - Multiple Trouble Codes
    304
  - Retrieving Trouble Codes
    304
  - Check Engine Lamp Diagnostics
    305
  - Diagnostic Test Wire
    305
  - Installing Diagnostic Test Wire
    305
  - Clearing Codes
    306
  - Breakout Box
    307
  - Installed Breakout Box
    307
  - Fluke 78 Multimeter (DVOM)
    308
  - Wiggle Test
    308
  - Diagnostic Notes
    309
  - Engine Performance Problems
    309
  - Engine Starts Hard
    309
  - General Information
    309
  - Initial Diagnostic Check
    309
  - Engine Exhaust Emits Black Smoke or Fouls Plugs
    310
  - Trouble Codes and Fault Conditions
    310
  - Check Engine Lamp Not Illuminated at Key on 4.9
    314
  - Electronic Control Module
    314
  - Check Engine Lamp Circuit
    315
  - Check Engine Lamp on Continuously
    317
  - Engine Cranks but will Not Start
    320
  - Spark Plug Tester (Part No. HD-26792)
    320
  - Test Lamp
    320
  - Ignition Circuit
    321
  - Clutch Switch
    325
  - Neutral Switch
    325
  - No Ecm Power
    325
  - Sidestand Switch
    325
  - ECM Power Circuit
    326
  - Fuel Line
    328
  - Fuel Pressure Test
    328
  - Fuel Pump Connector
    328
  - Fuel Pressure Gauge (Part No. HD-41182)
    329
  - Fuel Pressure Gauge Adapter
    329
  - Fuel Pump Circuit
    330
  - Engine Idle Speeds
    333
  - Idle Adjustment Cable
    333
  - Idle Speed Control
    333
  - Misfire
    334
  - Misﬁre at Idle or under Load
    334
  - Spark Plug Cables
    334
  - Ignition Coil Circuit
    335
  - Throttle Position Sensor
    338
  - TP Sensor Assembly
    338
  - TP Sensor Terminals [88A]
    338
  - Trouble Code 11
    338
  - Throttle Position Sensor Circuit
    339
  - Oxygen (O2) Sensor
    342
  - Oxygen Sensor
    342
  - Oxygen Sensor (Shock Absorber Removed)
    342
  - Trouble Code 13
    342
  - Oxygen Sensor Circuit
    343
  - Engine Temperature Sensor
    347
  - Engine Temperature Sensor Speciﬁcations
    347
  - Trouble Code 14
    347
  - Engine Temperature Sensor Circuit
    348
  - Intake Air Temperature Sensor
    351
  - Intake Air Temperature Sensor Speciﬁcations
    351
  - Trouble Code 15
    351
  - Intake Air Temperature Sensor Circuit
    352
  - Battery Voltage
    355
  - Electrical Relays
    355
  - Fuse Block
    355
  - Trouble Code 16
    355
  - Battery Voltage Circuit
    356
  - And Rear Fuel Injector (Code 32)
    359
  - Front Fuel Injector (Code 23)
    359
  - Fuel Injectors
    359
  - Trouble Codes 23 and 32
    359
  - Fuel Injector Circuit
    360
  - And Rear Ignition Coil (Code 25)
    363
  - Front Ignition Coil (Code 24)
    363
  - Trouble Codes 24 and 25
    363
  - Fuel Pump
    366
  - Fuel Pump Assembly
    366
  - Trouble Code 33
    366
  - Instrument Module Connector [39]
    369
  - Trouble Code 35
    369
  - Tachometer Circuit
    370
  - Code 35 Test
    371
  - Cooling Fan High Voltage
    372
  - Cooling Fan Low Voltage
    372
  - Cooling Fan Speciﬁcations
    372
  - Trouble Code 36
    372
  - Cooling Fan Circuit
    373
  - Code 36 Test (Part 1 of 2-Fan Runs Continuously)
    374
  - Code 36 Test (Part 2 of 2-Fan Does Not Run)
    375
  - Bank Angle Sensor
    376
  - Bank Angle Sensor Operation
    376
  - Trouble Code 44
    376
  - Bank Angle Sensor Circuit
    377
  - ECM Failure
    380
  - Trouble Codes 52, 53, 54 and 55
    380
  - Cam Sync Failure
    381
  - Trouble Code 56
    381
  - Cam Position Sensor Circuit
    382
  - Electronic Control Module
    386
  - Cam Position Sensor and Rotor
    388
  - Marking Ignition Timing
    388
  - Ignition Components
    389
  - Ignition System Circuit
    390
  - Connecting Sensor Wires
    391
  - Ignition Coil
    392
  - Ignition Coil Primary Circuit Test
    392
  - Ignition Coil Secondary Circuit Test
    392
  - Ignition Coil Substitution
    392
  - Ignition Coil Location
    393
  - Installed Oxygen Sensor
    394
  - Oxygen Sensor Connector
    394
  - Intake Air Temperature Sensor Installed
    398
  - Cooling Fan
    400
  - Draining Fuel Tank
    401
- Fuel Pump
  401
  - Fuel Pump Puller
    402
  - Fuel Pump Removal
    402
  - Fuel Filter Replacement
    403
  - Fuel Pressure Regulator Replacement
    403
  - Low Fuel Level Sensor Replacement
    403
  - Fuel Pump Clips
    404
  - Fuel Pump Speciﬁcations
    404
  - Fuel Screen Replacement
    404
  - Regulator Housing O-Rings
    404
  - Fuel Pump Connector Disassembly
    405
  - Fuel Pump Wire Harness Replacement
    405
  - Fuel Pump Installation
    406
  - Wire Harness Removal Direction
    406
  - Fuel Pump Drain Screw
    407
- Fuel Tank Vent Valve
  407
- Fuel Cap Retaining Ring
  408
  - Throttle Body
    409
  - Throttle Body/Intake Manifold Assembly
    410
  - Fuel Injectors
    411
  - Intake Manifold
    411
  - Repair
    411
  - Throttle Cable Bracket (Typical)
    411
  - Intake Manifold Fasteners
    412
  - Intake Flanges
    413
- Intake Leak Test
  414
  - Leak Tester
    414
  - Nozzle
    414
- Airbox
  416
- Airbox Cover
  416
- Baseplate
  416
- Evaporative Emissions Control-Ca Models
  418
- Carbon Canister Installation
  418
- Vent Valve
  419
- Canister
  419
- Carbon Canister Mounting
  419
- Hose Routing
  420
- Emissions Hose Attachment
  420
- Electric Starter
  422
- Starter Speciﬁcations
  424
- Service Wear Speciﬁcations
  424
- Electric Starter System
  425
- Wiring Diagrams
  425
- Starter Relay
  425
- Starting System Diagnosis
  427
- Starter Terminals
  427
- Solenoid Clicks
  428
- Relay Clicks
  428
- Nothing Clicks
  429
- Starter Stalls or Spins too Slowly
  430
- Starter Spins, but Does Not Engage
  430
- Starter Activation Circuits
  431
- Typical Circuity
  431
- Diagnostics/Troubleshooting
  432
- Voltage Drops
  432
- Electric Starting System Circuit
  433
- Starter System Testing
  434
- “On-Motorcycle” Tests
  434
- Starter Relay Test
  434
- Starter Current Draw Test
  434
- Starter
  435
- Starter Mounting
  435
- Starter Wires (Protective Boot Not Shown)
  435
- Starter Solenoid
  436
- Solenoid Pull-In Test
  436
- Free Running Current Draw Test
  436
- Testing Assembled Starter
  436
- Solenoid Hold-In Test
  437
- Return Test
  437
- Solenoid Return Test
  437
- Hold-In Test
  437
- Disassembly, Inspection and Repair
  438
- Field Wire
  438
- Removing the Thru-Bolts
  438
- Starter Components
  438
- Undercutting Mica Separators
  439
- Shorted Armature Test Using Growler
  440
- Grounded Armature Test
  440
- Open Armature Test
  440
- Brush Holder Insulation Test
  441
- Open Field Test
  441
- Grounded Field Test
  441
- Starter Drive Assembly
  442
- Starter Assembly
  443
- Drive/Transmission 6
  446
- Primary Cover, Primary Chain Adjuster and Shifter Assembly
  450
- Primary Cover
  451
- Removing Primary Cover
  451
- Clutch Release Mechanism
  451
- Primary Chain Adjuster Inspection & Replacement
  452
- Measuring Chain Adjuster Shoe
  452
- Clutch Release Mechanism
  454
- Primary Drive/Clutch
  456
- Clutch Assembly
  457
- Clutch Pack
  458
- Compressing Clutch Diagram Spring
  458
- Pressure Plate Assembly
  458
- Primary Chain/Drive
  459
- Sprocket Locking Link Tool
  459
- Mainshaft Nut and Washer
  459
- Adjusting Screw Assembly
  459
- Aligning Tabs
  460
- Compensating Spring Set
  461
- Measuring Friction Plates
  462
- Checking Clutch Shell
  462
- New Needle Bearing in Clutch Shell
  463
- Clutch Hub Bearing Race
  463
- Removing Clutch Shell Needle Bearing
  464
- Clutch Shell Bearing Remover/Installer
  464
- Replacing Clutch Shell Bearing
  464
- Bearing Installer
  464
- Clutch Hub and Shell Assembly
  465
- Clutch Pack Stack-Up (Cut-Away View)
  465
- Friction Plates
  465
- Spring Seat Installation
  466
- Adjusting Screw Assembly Aligning Tabs
  467
- Sprocket Locking Link
  467
- Transmission
  470
- Transmission Power Flow
  470
- Shifter Drum Neutral Detent
  471
- Countershaft Retainer
  471
- Right Crankcase Removal
  471
- Case Disassembly for Transmission Removal
  471
- Scribed Line on Shifter Drum at 6 O’clock
  472
- Removing Shifter Shaft Assembly
  472
- Shifter Shaft Assembly
  472
- Separating Crankcase Halves
  473
- Removing Flywheels from Left Case Half
  473
- Transmission Disassembly
  474
- Transmission Removal from Left Crankcase
  474
- Removing Shifter Fork Shafts
  474
- Shifter Forks, Drum and Shafts
  474
- Shifter Mechanism
  475
- Removing Transmission Assembly from Left Case Half
  476
- Mainshaft/Countershaft
  477
- Transmission Parts Identiﬁcation
  477
- Transmission Assembly-Right Crankcase Half
  477
- Transmission Assembly-Left Crankcase Half
  478
- Mainshaft Disassembly
  479
- Countershaft Disassembly
  480
- Transmission Assembly
  481
- Mainshaft Assembly
  481
- Countershaft Assembly
  482
- Transmission Countershaft Assembly/Reassembly
  482
- Main Drive Gear
  483
- Main Drive Gear Assembly
  483
- Removing Main Drive Gear
  483
- Bearing Remover Cross Plate Mounting
  483
- Needle Bearing Installation Tool
  484
- Main Drive Gear Installation
  484
- Transmission Assembly Right Crankcase Half
  485
- Transmission Right Case Bearings
  486
- Shifter Drum Bushing
  486
- Countershaft Needle Bearing
  486
- Mainshaft 5Th Gear Ball Bearing
  486
- Transmission Assembly Left Crankcase Half
  487
- Transmission Left Case Bearings
  488
- Mainshaft and Countershaft Bearings
  488
- Shift Drum Bushing Assembly
  488
- Transmission Installation
  489
- Transmission Assembly in Fixture
  489
- Installing Transmission in Left Case Half
  489
- Shifter Forks and Drum Assembly
  490
- Installing Shift Fork Shafts
  490
- Gear Detent Assembly Aid
  492
- Installing Right Crankcase
  492
- Shifter Shaft Installation
  493
- Installing Shifter Shaft Assembly
  493
- Shifter Shaft Return Spring
  493
- Transmission Sprocket
  494
- Transmission Sprocket Tightening
  495
- Aligning Transmission Sprocket
  496
- Table of Contents
  498
- Battery Speciﬁcations
  500
- Regulator Speciﬁcations
  500
- Spark Plug Speciﬁcations
  500
- Ignition Coil Speciﬁcations
  500
- Ignition System
  502
- Ignition System Components
  503
- Indicator Markers
  504
- Ignition/Headlight Key Switch
  504
- Ignition Key Switch Positions
  504
- Upper Fork Clamp
  505
- Ignition Switch Assembly
  506
- Ignition Switch Connector (Viewed from Underneath Fairing)
  506
- Ignition Key Switch Wiring
  507
- Spark Plug Cable Location
  508
- Testing Resistance
  509
- Starter Interlock
  510
- Starter Interlock Troubleshooting
  510
- Starter Circuit
  510
- Diode Polarity
  511
- Ohmmeter Diode Test
  511
- Diode Wiring
  511
- Starter Test
  512
- Ignition Test
  512
- Interlock Circuit
  514
- Testing/Replacement
  515
- Sidestand Switch
  515
- Ignition Relay
  516
- Key Switch Relay
  516
- Main Fuse
  516
- Diodes
  517
- Fuse Block (Contains Diodes)
  517
- Fuses and Diodes
  517
- Charging System
  518
- Alternator
  518
- Voltage Regulator
  518
- Battery
  518
- Symptom: Battery Becomes Discharged
  519
- Voltage Regulator Bleed Test
  522
- Total Current Draw Test
  522
- Milliampere Draw Test
  522
- Current and Voltage Output Test
  523
- Voltage Output Test
  523
- Positive Regulator Cable (Red Wire)
  523
- Test for Grounded Stator
  523
- AC Output Check
  524
- Check for Stator Resistance
  524
- Check Stator AC Voltage Output
  524
- Rotor Assembly
  525
- Removing Rotor from Sprocket
  525
- Stator
  525
- Rotor
  525
- Pressing Rotor Onto Sprocket
  526
- Voltage Regulator Connector [77]
  527
- Battery Cables
  528
- Negative Battery Cable
  528
- Positive Battery Cable
  529
- Maintenance-Free Battery (Typical)
  530
- Battery Warning Label
  530
- Load Test
  531
- Battery Load Test
  531
- Battery Testing
  531
- Voltmeter Test
  531
- Disconnection and Removal
  532
- Safety Precautions
  533
- Charging Battery
  533
- Battery Charging
  533
- Battery Charging Rates/Times
  534
- Battery Cable Routing
  534
- Headlight Bulbs
  536
- Tail Lamp
  538
- Tail Lamp Assembly
  538
- Turn Signals
  539
- Bulbs
  539
- Front Turn Signal Connections
  539
- Front Turn Signals
  539
- Rear Turn Signals
  540
- Rear Turn Signal Connections
  541
- Turn Signal Controls
  542
- Turn Signal Flasher
  542
- Handlebar Switches
  543
- Right Side
  543
- Left Side
  543
- Right Handlebar Switch Connection
  543
- Left Handlebar Switch Connection
  544
- Vehicle Speed Sensor
  545
- Speedometer Sensor
  545
- Vehicle Speed Sensor Wiring
  545
- Instrument Module
  546
- Speedometer Performance Check
  547
- Speedometer Operation Test
  547
- Speedometer Tester
  547
- Vehicle Speed Sensor Connector
  547
- Test Harness
  548
- Speedometer Sensor Test
  548
- Odometer, Trip Odometer and Reset Switch Testing
  549
- Inoperative, Inaccurate or Erratic Speedometer
  550
- Tachometer Performance Check
  552
- Tachometer Accuracy Tolerances and Conversions
  552
- Sweep Test
  553
- Testing Tachometer
  553
- Horn
  554
- Horn Assembly
  554
- Horn Wiring
  554
- Horn Switch
  555
- Neutral Indicator Switch
  556
- Neutral Indicator Switch Location
  556
- A Main Fuse Location
  557
- Main Fuse and Fuses
  557
- Main Wire Harness
  558
- Tail Harness Connector
  558
- Battery Tray Wiring
  558
- Sidestand Switch Connector
  559
- Wire Harness Clip
  560
- Corner Mounting Tab
  560
- Cable Straps
  561
- Fairing Wiring (Viewed from Underneath Fairing)
  562
- Sprocket Cover Wiring
  563
- Cam Position Sensor Wiring
  563
- Neutral Switch Connector
  564
- Neutral Switch Wiring
  564
- Assembled Wiring
  564

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Buell XB9R 2003 Service Manual

Buell XB9R 2003 Service Manual (576 pages)

Brand: Buell | Category: Motorcycle | Size: 87.92 MB

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