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2003 Buell XB9R: Chassis

2-23

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FRONT BRAKE MASTER CYLINDER AND HAND LEVER 2.10

REMOVAL

NOTE

Steps 1 is not required for removing the master cylinder
assembly from the handlebars. Do not disassemble master
cylinder unless problems are experienced.

1.

Drain brake fluid into a suitable container. Discard used
fluid according to local laws.

a. Install a length of plastic tubing over caliper bleeder

valve. Place free end in a suitable container.

b.

Open bleeder valve (metric) about 1/2-turn.

c.

Pump brake hand lever to drain brake fluid.

d.

Tighten bleeder valve to 36-60 in-lbs (4-7 Nm).

CAUTION

Damaged banjo bolt seating surfaces will leak when
reassembled. Prevent damage to seating surfaces by
carefully removing brake line components.

2.

See

Figure 2-35.

Remove the banjo bolt (12) (metric)

and two copper washers (14) to disconnect brake line
(13) from master cylinder (4). Discard copper washers.

3.

Unplug terminal (11) to detach brake lamp switch (10).

NOTE

The individual parts of the brake lamp switch are not service-
able. Replace switch upon failure.

4.

Remove mounting clamp fasteners (5) (metric) to detach
master cylinder reservoir (4) from handlebar.

DISASSEMBLY

Brake Hand Lever

1.

See

Figure 2-35.

Remove pivot bolt nut (8) (metric) and

pivot bolt (15) from hand lever pivot.

2.

Detach front brake hand lever assembly (7) from hand
lever pivot.

3.

Detach front brake lamp switch (10) by removing the
switch fastener (9).

Front Master Cylinder

1.

See

Figure 2-35.

Remove master cylinder cover (2) by

removing cylinder cover fasteners (1).

2.

Discard excess brake fluid.

3.

See

Figure 2-34.

Remove rubber boot (1) and discard.

4.

See

Figure 2-33.

Depress piston assembly (1) and

remove internal snap ring (2) and discard.

5.

See

Figure 2-35.

Remove piston assembly (6) from front

master cylinder reservoir (4) and discard.

CLEANING AND INSPECTION

1

1

WARNING

1

WARNING

Clean brake system components using denatured alco-
hol. Do not use mineral-base cleaning solvents, such as
gasoline or paint thinner. Use of mineral-base solvents
causes deterioration of rubber parts that continues after
assembly. This may result in improper brake operation
which could result in death or serious injury.

1.

Clean all parts with denatured alcohol or D.O.T. 4
BRAKE FLUID. Do not contaminate with mineral oil or
other solvents. Wipe dry with a clean, lint free cloth. Blow
out drilled passages and bore with a clean air supply. Do
not use a wire or similar instrument to clean drilled pas-
sages in bottom of reservoir.

2.

Inspect piston bore in master cylinder housing for scor-
ing, pitting or corrosion. Replace housing if any of these
conditions are found.

3.

Inspect outlet port that mates with brake line fitting. As a
critical sealing surface, replace housing if any scratches,
dents or other damage is noted.

Figure 2-33. Piston Assembly in Master Cylinder

8424

2

1.

Piston assembly

2.

Snap ring

1

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Summary of Contents for XB9R 2003

Page 1: ... BUELL XB9R SERVICE MANUAL Part Number 99493 03Y Section 1 Maintenance Section 2 Chassis Section 3 Engine Section 4 Fuel System Section 5 Starter Section 6 Drive Transmission Section 7 Electrical Appendices ...

Page 2: ...1 2 Edit Me Printed June 5 2002 12 26 pm ...

Page 3: ...nd Part No B 41174 2 Replacement Pad Part No B 42887 Brake Caliper Piston Remover Part No B 43721 Front Fork Seal Driver Part No B 43993 7 8 Wheel Bearing Collets Part No B 45521 Steering Head Bearing Remover Installer Part No 39302 Part No B 59000A Pro Level Oil Gauge Part No HD 01289 Rim Protectors ...

Page 4: ...ander Part No HD 33416 Universal Driver Handle Part No HD 33418 Universal Puller Forcing Screw Part No HD 94700 52C Shock Spanner Preload Adjustment Tool Part No HD 44060 Part No HD 99500 80 Wheel Truing and Balancing Stand Part No HD 95637 46A Wedge Attachment for Claw Puller Use with HD 95635 46 ...

Page 5: ...bndpob npdb ndbno bho knsdl hlno hslnslnnsdl hlno hso bho knsdl hlno hslnslp pffb odlbndpob npond bndb ndbno bho Bdhgkjsbkdv ksjjlkn lk knsdl hlno hslnsln nlslns finbp pffb odlbndpob nponno bho knsdl hlno hslnsln nlslns finbp pklhb odlbndpob npdb ndbno bho knsdl hlno hslnslnnsdl hlno hso bho bs npond bpdk kznh odlbndpob npond bndb ndbno bho Bdhgkjsbkdv ksjjlkn lk knsdl hlno hslnsln nlslns finbp pf...

Page 6: ... No HD 39786 Cylinder Head Holding Fixture Part No HD 34736B Valve Spring Compressor Part No B 45524 Valve Guide Installer Part No B 45523 Valve Guide Reamer 7mm Part No B 45525 Valve Guide Hone Part No HD 34751 Nylon Valve Guide Brush Part No HD 94804 57 Rocker Arm Bushing Reamer ...

Page 7: ...623C Piston Pin Retaining Ring Installer Remover Part No HD 42322 Piston Support Plate Part No HD 96333 51C Piston Ring Compressor Part No HD 95952 33B Connecting Rod Clamping Tool Part No HD 95970 32D Piston Pin Bushing Tool Part No HD 94800 26A Connecting Rod Bushing Reamers and Pilots Part No HD 35102 Wrist Pin Bushing Hone 20 mm ...

Page 8: ...No J 5586 Transmission Shaft Retaining Ring Pliers Part No HD 97292 61 Two Claw Puller Part No HD 95760 69A Bushing Bearing Puller Tool Set Set includes items 1 7 Items 8 HD 95769 69 9 HD 95770 69 and 10 HD 95771 69 are optional Part No HD 39965 Deutsch Terminal Crimp Tool Part No HD 41354 Part No HD 41609 Amp Terminal Crimp Tool ...

Page 9: ...ll terminal from chamber Do not tug on the wire until the tang is released or the terminal will be difficult to remove A click is heard if the tang is engaged but then inadvertently released Repeat the step without releasing the tang NOTE If pick tool is not available a push pin safety pin may be used instead An ELECTRICAL TERMINAL CRIMP TOOL Part No HD 41609 is used to install Amp Multi lock pin ...

Page 10: ...ently tug on wire end to verify that the terminal is locked in place and will not back out of chamber 3 Rotate the hinged secondary lock inward until tabs fully engage latches on both sides of connector 4 Insert the socket housing plug into the pin housing receptacle until it snaps in place 5 Install connector on retaining device either attachment or rosebud clip Figure B 2 Release Tang and Back O...

Page 11: ... Socket terminal Secondary lock Socket housing Pin housing Pin terminal Latch Secondary lock Button Latch Socket terminal Secondary lock Button Socket housing Pin housing Secondary lock Pin terminal 3 place 6 place 12 place Secondary locks open socket housings shown Stamped numbers on secondary locks indicate wire color locations d0245x2x ...

Page 12: ... tails until ends make contact with locking bar Verify that wire is positioned so that short pair of crimp tails squeeze bare wire strands while long pair folds over insulation material 5 Squeeze handle of crimp tool until tightly closed Tool automatically opens when the crimping sequence is complete Raise up locking bar and remove contact 6 Inspect the quality of the core and insulation crimps Di...

Page 13: ...o separate the pin and socket halves Two three four and six pin Deutsch connectors have one external latch while eight and twelve pin connectors have two both of which must be pressed simultaneously to separate the connector halves NOTE With few exceptions the socket housing can always be found on the accessory side while the pin side of the connector is connected to the wiring harness REMOVING IN...

Page 14: ...l terminals are fully installed in the socket housing The lock indicates when terminals are not properly installed by not entering its fully installed position REMOVING INSTALLING PINS 1 Remove the secondary locking wedge Use the hooked end of a stiff piece of mechanics wire a needle nose pli ers or a suitable pick tool Part No HD 41475 100 See Figure B 10 2 Gently depress terminal latches inside ...

Page 15: ...h on the socket side must be aligned with the latch cover on the pin side For those connectors with two external latches 8 pin and 12 pin a different system is used to prevent improper assembly Align the tabs on the socket housing with the grooves on the pin housing Push the connector halves together until the latches click If latches do not click latch press on one side of the connector until tha...

Page 16: ...s snugly in the space between the contact band and the core crimp tails 4 Strip lead removing 5 32 in 4 mm of insulation Insert wires between crimp tails until ends make contact with locking bar Verify that wire is positioned so that short pair of crimp tails squeeze bare wire strands while long pair folds over insulation material 5 Squeeze handle of crimp tool until tightly closed Tool automatica...

Page 17: ...nal 2 Wire seal 3 Socket housing 4 External latch 5 Internal seal 6 Locking wedge 7 Locking wedge 8 Latch cover 9 Pin housing 10 Wire seal 11 Pin terminal SOCKET SIDE PIN SIDE 1 2 4 5 6 7 8 9 10 11 3 2 pin connector 1 2 4 3 5 6 7 8 10 11 9 3 pin connector 1 2 4 5 6 7 8 9 10 11 3 4 pin connector d0251x3x ...

Page 18: ...ide the chamber For an example of this type of connector note the MAP sensor connector 80 Unlike most connectors where the terminals are pulled out the wire end of the connector to remove the terminals from the pull to seat connectors the terminal is pushed out the mating end of the connector Once a new terminal is crimped onto the end of the wire the wire is pulled to draw the termi nal back insi...

Page 19: ...als that have been extracted on a previ ous occasion no clicking sound may be heard when the pin is pivoted to depress the tang but proceed as if the clicking is audible and then push on the wire end of the lead to check if the terminal is free When picking multiple terminals the end of the pin may become malleable For best results continue the proce dure with a new safety pin 5 Remove the pin and...

Page 20: ... secondary lock take note of the larger cavity next to each terminal 5 Insert the pick Snap On TT600 3 into the cavity until it stops Pivot the end of the pick toward the terminal to depress the locking tang Remove the pick and gently tug on the wire to pull the terminal from the wire end of the connector Repeat the step if the terminal is still locked in place NOTE A series of Packard Electrical ...

Page 21: ...air folds over insulation or seal material 7 Squeeze handle of crimp tool until tightly closed Tool automatically opens when the crimping sequence is complete 8 Table B 1 Determine the correct dye or nest for the insu lation seal crimp 9 Lay the back of the insulation seal crimp tails on the appropriate nest Be sure the insulation seal crimp tails are pointing towards the forming jaws 10 Squeeze h...

Page 22: ...ight side of fairing 31 left front turn signal 2 1 place bullet beneath left side of fairing 33 ignition switch 4 place Augat beneath right side of fairing 38 headlamp connector 4 place Amp beneath fairing 39 instrument module 20 place Multilock in fairing 46 stator 4 place Deutsch under sprocket cover 61 fuse and diode assembly spade terminals right side of fairing 62 relay assembly spade termina...

Page 23: ...airing 121 rear brake switch 2 place Multilock under seat 122 horn spade terminals in fairing 128 starter solenoid spade terminals top of starter 131 neutral switch 1 place bullet under sprocket cover 133 sidestand switch 2 place Multilock top of sidestand 134 bank angle sensor 6 place Sumitomo in fairing 137 oxygen sensor 1 place Packard behind rear cylinder head Table B 2 Electrical Connector an...

Page 24: ...IRING DIAGRAMS B 5 Table B 3 XB9R Wiring Diagrams DIAGRAM PAGE Main harness B 17 Engine management circuit B 18 Lighting circuit B 19 Horn and instruments circuit B 20 Starting circuit B 21 Starting and charging circuits B 22 Component Circuits B 23 ...

Page 25: ... 15A 7 5A 15A 24 R 24 R 23 23 R BK 22 R 21 20 19 18 R 17 BE 16 Y 15 14 BK BK BK 13 BK 12 R GY 11 GY O 10 R 9 O 8 TN Y 8 TN Y 7 6 O W 5 R BK 4 Y BN 3 R BK R BK 2 TN LT GN TN LT GN 2 TN LT GN 1 TN W TN Y TN Y NEUTRAL 2 Y BK 1 BK 1 1 PK Y ENGINE TEMP SENSOR 2 2 BK BK BE 1 1 V TO LH TURN SIGNAL 1 1 BK BK BE TO RH TURN SIGNAL 2 2 BN BK BK TO VOLTAGE REGULATOR 2 2 2 2 3 4 3 4 R 1 1 1 1 BK 12 PK 11 BK 10...

Page 26: ... IGNITION IAT 2 2 BK W BK W 1 1 LT GN Y LT GN Y 1 2 SWITCH SENSOR SPARK PLUGS COIL SENSOR 137B 137A 83B 83A 88B 88A 133B 133A 89A 89B INSTRUMENT CLUSTER Y BN TN LTGN TN LTGN TN Y TN Y TN W TN LTGN GY O R Y R R R R BK W LT GN GY R W 4 4 3 3 2 2 1 1 GY W BK GY O W BK BK Y BN Y BN 4 4 R R 3 3 R BK R BK 2 2 1 1 R R R BK Y BE 30A MAIN FUSE 5A COOLING FAN 97B 97A BK BK GRD1 GRD3 O ON WIRE COLOR R O OFF ...

Page 27: ...1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 TO FUSE DIODE ASSY 15A 15A 15A 7 5A 24 R 24 23 23 22 21 20 19 18 R 17 BE 16 15 14 13 12 R GY 11 10 9 O 8 8 7 6 O W 5 4 3 R BK R BK 2 2 1 Accessory Key Switch Lights Brake Horn 61B 5 4 BK 3 2 O W 1 V BN FLASHER 30B 30A 2 2 BK BK BE 1 1 V TO LH TURN SIGNAL 1 1 BK BK BE TO RH TURN SIGNAL 2 2 BN 31B 31A 31B 31A 4 GY 3 2 1 TO DATA LINK 91A ...

Page 28: ...4 3 TN Y 2 R 1 39B 39A TOP VIEW Accessory Key Switch Lights ECM Spare Spare Ignition Cooling Fan Brake Horn Diode 1 Diode 2 15A 15A 15A 15A 15A 7 5A 7 5A 7 5A 7 5A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 O ON WIRE COLOR R O OFF R BK O O O LOCK R GY O PARK R A D C B KEY POSITION WIRING DIAGRAM IGNITION SWITCH HORN 2 1 122B 122A 122B 122A 4 R 3 R BK 2 R GY 1 R IGNITION SWITCH ...

Page 29: ...16 15 14 13 12 11 GY O 10 9 8 TN Y 8 7 6 5 R BK 4 3 2 TN LT GN TN LT GN 2 TN LT GN 1 TN W Key Switch Ignition Diode 1 Diode 2 61B CLUTCH SWITCH 2 2 BK 1 1 TN LTGN 95B 95A RELAY CENTER IGNITION KEY SWITCH START 19 BK 15 14 R BK 11 11 R BK 10 BK R 9 TN W 9 TN W 7 GN 6 R BK 5 GY O 5 GY O 4 2 TN LT GN 1 W BK 1 W BK 87 87A 30 85 86 87 87A 30 85 86 87 87A 30 85 86 62B 62A SIDESTAND 2 2 TN W 1 1 BK SWITC...

Page 30: ...3 XB9R Starting Charging Circuit STATOR HD 3 PHASE VOLTAGE REGULATOR 2 2 3 4 3 4 1 1 46B 46A TO VOLTAGE REGULATOR 2 2 1 1 BK R R 77B 77A BATTERY BATTERY CABLE MOTOR SOLENOID STARTER STARTER 2 R Y 1 30A MAIN FUSE BK BK GROUND GRD2 5A bd0006xx ...

Page 31: ...38LA 38HA 29A W Y TO LH CONTROLS 8 8 O 7 7 BN 6 6 V Y 5 5 BE W 4 4 Y BK Y BK 3 3 W 2 2 BE 1 1 24B 24A 4 GY 3 W BK 2 W BK 1 BK R 22B TO RH CONTROLS TAIL HARNESS YH350 02A8 V BN BK BK 1 LH TURN SIGNAL 2 2 1 1 2 1 RH TURN SIGNAL TAIL LIGHT 19A 93A 93A 18A 18A 19A GY D BN Y C BK B Y R A MTR LOW FUEL SENSOR FUEL PUMP 86B OIL PRESSURE 1 1 GN Y SWITCH 120A 120B 1 1 ENGINE TEMP SENSOR 90B 90A IAT 2 2 BK W...

Page 32: ...449 4 488 4 527 4 567 4 606 4 645 4 685 4 724 4 764 4 803 4 842 001 002 003 004 005 006 007 008 009 010 1 64 020 030 1 32 040 050 060 1 16 070 080 090 1 1 8 3 16 2 1 4 3 5 16 3 8 4 7 16 1 2 9 16 025 051 076 102 127 152 178 203 229 254 397 508 762 794 1 016 1 270 1 524 1 588 1 778 2 032 2 286 2 540 3 175 4 762 5 080 6 350 7 620 7 938 9 525 10 160 11 112 12 700 14 288 6 5 8 11 16 7 3 4 8 13 16 7 8 9...

Page 33: ...5 STEEL 120 000 PSI MEDIUM CARBON HEAT TREAT 14 22 10 19 33 54 78 114 154 257 382 587 SAE 7 STEEL 133 000 PSI MEDIUM CARBON ALLOY 13 25 44 71 110 154 215 360 570 840 SAE 8 STEEL 150 000 PSI MEDIUM CARBON ALLOY 14 29 47 78 119 169 230 380 600 900 SAE 8 STEEL 150 000 PSI MEDIUM CARBON ALLOY 14 29 47 78 119 169 230 380 600 900 SOCKET SET SCREW 212 000 PSI HIGH CARBON QUENCHED TEMPERED 9 16 30 70 140 ...

Page 34: ...2003 Buell XB9R Appendix D D 1 HOME HOSE AND WIRE ROUTING D 1 Figure D 1 Front and Rear Brake Systems Right Side View b1114xax ...

Page 35: ...D 2 2003 Buell XB9R Appendix D HOME Figure D 2 Rear Brake Systems Top View b1115xbx ...

Page 36: ...2003 Buell XB9R Appendix D D 3 HOME Figure D 3 Rear Brake Systems Left Side View b1116xcx ...

Page 37: ...D 4 2003 Buell XB9R Appendix D HOME Figure D 4 Evaporative Emissions Control California Models Top View Carbon canister b1117xax ...

Page 38: ...HOME Figure D 5 Evaporative Emissions Control California and 49 State Models Left Side View 1 To induction module 2 From induction module California 3 From fuel tank California 4 From fuel tank to atmosphere 49 state 2 1 3 4 b1118xbx ...

Page 39: ...D 6 2003 Buell XB9R Appendix D HOME Figure D 6 Wiring Harness Left Side View 1 Intake air temperature sensor IAT 2 Fuel pump 3 Sidestand switch 2 1 3 b1119xax ...

Page 40: ...2003 Buell XB9R Appendix D D 7 HOME Figure D 7 Wiring Harness Top View 1 Fuel injector 2 2 Throttle position sensor TPS 3 Intake air temperature IAT sensor 4 Oxygen O2 sensor 2 3 4 b1120xbx 1 ...

Page 41: ... D HOME Figure D 8 Wiring Harness Right Side View 1 Speedometer sensor 2 Cable starter to battery positive 3 Solenoid 4 Transmission vent line 5 Voltage regulator 6 Switch oil pressure 7 Cam position sensor 2 3 5 6 7 b1121xcx 4 1 ...

Page 42: ... D 9 HOME Figure D 9 Oil Lines Right Side View 2 3 4 5 1 Vent line 2 Feed oil line 3 Return oil line 4 Feed oil line from the oil pump to the oil cooler 5 Return oil line from the oil cooler to the oil filter housing b1122xax 1 ...

Page 43: ...D 10 2003 Buell XB9R Appendix D HOME Figure D 10 Oil Lines Bottom View 1 Vent line 2 Feed oil line 3 Return oil line b1123xbx 1 2 3 ...

Page 44: ...2003 Buell XB9R Appendix D D 11 HOME Figure D 11 Clutch and Throttle Cables Right Side View b1124xax ...

Page 45: ...D 12 2003 Buell XB9R Appendix D HOME Figure D 12 Clutch Throttle and Seat Release Cables Left Side View Cable seat lock b1125xbx ...

Page 46: ...2003 Buell XB9R Appendix D D 13 HOME Figure D 13 Clutch Throttle and Seat Release Cables Top View Cable seat lock TPS adjuster b1126xcx ...

Page 47: ...D 14 2003 Buell XB9R Appendix D HOME NOTES ...

Page 48: ...lutch 1 20 1 9 Drive Belt System 1 23 1 10 Primary Chain 1 29 1 11 Suspension Damping Adjustments 1 31 1 12 Front Fork Oil Change 1 35 1 13 Steering Head Bearings 1 38 1 14 Spark Plugs 1 39 1 15 Air Cleaner Filter 1 41 1 16 Throttle Cable and Idle Speed Adjustment 1 43 1 17 Ignition Timing 1 44 1 18 Headlights 1 46 1 19 Throttle Position Sensor TPS 1 48 1 20 Storage 1 49 1 21 Troubleshooting 1 50 ...

Page 49: ......

Page 50: ... 1600 km break in period use only Harley Davidson 20W50 engine oil Failure to use the recommended oil will result in improper break in of the engine cylinders and piston rings A careful check of certain equipment is necessary after peri ods of storage and frequently between regular service inter vals to determine if additional maintenance is required Check 1 Tires for abrasions cuts and correct pr...

Page 51: ...swallowed induce vomiting by administering two tablespoons of salt in a glass of warm water Call a doc tor In case of contact with skin or eyes flush with plenty of water Get medical attention for eyes KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN Failure to comply could result in death or serious injury Use only D O T 4 BRAKE FLUID Part No 99953 99Y FUEL Use a good quality unleaded gasoline 91 pu...

Page 52: ... clutch and clutch cable A A A A A A A A A A A Check rear belt and idler pulley Replace belt and idler pulley every 15 000 mi 24 000 km I I I R I I R I I R I Check front and rear tire pressure and inspect tread I I I I I I I I I I I I I I I I I I I I I Clean oil cooler fins X X X X X X X X X X X Change front fork oil X X X X X Check brake fluid reservoir levels and condition I I I I I I I I I I I ...

Page 53: ... 4 Dry with a clean chamois or soft dry natural fiber cloth Cleaning Between Washings Untreated molded in color body panels sometimes have a static charge that attracts dust Applying Harley Gloss or Har ley Glaze Polish and Sealant to molded in color surfaces will eliminate this condition To keep a high gloss finish on molded in color panels between washings 1 Spray Harley Gloss onto surface and w...

Page 54: ...arning label before performing any service on batteries could result in death or serious injury 1WARNING 1WARNING Battery posts terminals and related accessories contain lead and lead components chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling BATTERY TESTING Voltmeter Test See Table 1 4 The voltmeter test provides a ...

Page 55: ... that the battery has been frozen overheated or overcharged 6 Inspect the battery case for cracks or leaks STORAGE 1WARNING 1WARNING Always store batteries where they cannot be reached by children Contact with the battery s sulfuric acid could result in death or serious injury CAUTION The electrolyte in a discharged battery will freeze if exposed to freezing temperatures Freezing may crack the bat...

Page 56: ...jury CAUTION Overtightening fasteners can damage battery terminals 3 Insert fastener through battery positive cable red into threaded hole of battery positive terminal and tighten fastener to 72 96 in lbs 8 11 Nm 4 Install terminal cover boot 5 Insert fastener through battery negative cable black into threaded hole of battery negative terminal and tighten fastener to 72 96 in lbs 8 11 Nm 6 Apply a...

Page 57: ...or pre ride inspection simply verify that there are no oil leaks from the oil filter and oil lines prior to operating the motorcycle Perform a hot check of the engine oil level at each fuel stop CAUTION Do not allow hot oil level to fall below lower mark on dip stick To do so may result in equipment damage and or malfunction CAUTION Do not overfill oil tank Overfilling oil tank may result in oil c...

Page 58: ...ARNING Be sure no oil gets on tires when changing oil and filter Traction will be adversely affected which may lead to loss of control which could result in death or serious injury Replacing Oil 1 Install drain plug 2 Fill oil tank through filler dipstick hole with recom mended oil from Table 1 5 Oil tank capacity with filter change is approximately 2 5 quarts 2 4 liters and includes the 4 0 ounce...

Page 59: ... STARTS BELOW 50 F H D Multi Grade SAE 10W40 HD 360 Below 40 4 C Excel lent H D Multi Grade SAE 20W50 HD 360 Above 40 4 C Good H D Regular Heavy SAE 50 HD 360 Above 60 16 C Poor H D Extra Heavy SAE 60 HD 360 Above 80 27 C Poor Figure 1 3 Oil Tank Drain Plug Figure 1 4 Dipstick Location Engine Oil Level Figure 1 5 Oil Filter 8375 8352 8374 Operating Range 8418 ...

Page 60: ...the reservoir cap Mixing different types of fluid may adversely affect braking ability and lead to brake failure which could result in death or seri ous injury 1WARNING 1WARNING Use only fresh uncontaminated D O T 4 fluid Cans of fluid that have been opened may have been contami nated by moisture in the air or dirt Use of contaminated brake fluid may adversely affect braking ability and lead to br...

Page 61: ...ngs Loose mounting bolts Warped rotor Replace brake pads Replace rotor and bushings as set Tighten bolts Replace rotor Ineffective brake lever pedal travels to limit Low fluid level Piston cup not functioning Fill master cylinder with approved brake fluid and bleed system Rebuild cylinder Ineffective brake lever pedal travel normal Distorted or glazed rotor Distorted glazed or contaminated brake p...

Page 62: ...asteners from front master cylinder cover 4 Add D O T 4 BRAKE FLUID to master cylinder reser voir Bring fluid level to within 1 8 in 3 2 mm of molded boss inside front master cylinder NOTE Do not reuse brake fluid 5 Depress release and then hold brake hand lever to build up hydraulic pressure 6 Open bleeder valve about 1 2 turn counterclockwise brake fluid will flow from bleeder valve and through ...

Page 63: ...and Bring fluid level between upper and lower marks on reservoir NOTE Do not reuse brake fluid 5 Depress release and then hold brake pedal to build up hydraulic pressure 6 Open bleeder valve about 1 2 turn counterclockwise brake fluid will flow from bleeder valve and through tub ing When brake pedal has moved 1 2 to 3 4 of its full range of travel close bleeder valve clockwise Allow brake pedal to...

Page 64: ...linder 1 to center of lower adjuster rod clevis hole 5 a If measurement is approximately 3 in 77 mm 1 mm brake pedal adjustment is not needed b If measurement is not within specification adjust brake pedal NOTE See Figure 1 10 Minimum allowable pushrod thread engage ment inside clevis 4 is 0 24 in 6 0 mm 2 Adjust brake pedal a See Figure 1 10 Loosen locknut 3 while holding rod adjuster 2 Move lock...

Page 65: ... 1 0 mm or less If this amount of wear occurs wear grooves will disappear from friction mate rial surface BRAKE ROTOR THICKNESS 1WARNING 1WARNING Do not allow brake fluid bearing grease lubricants etc to contact brake rotor when servicing motorcycle or reduced braking ability will occur which could result in death or serious injury Check brake rotors for minimum thickness At the 1000 mile 1600 km ...

Page 66: ...Pad Installation 1 Push pistons in with suitable tool such as a clean paint scraper until fully seated in bores Be careful not to dam age rotor 2 Install new inner side pad from left side of motorcycle 3 Install new outer pad from right side of motorcycle 4 See Figure 1 13 Install pin 1 making sure it engages hole on both pads and spring clip 5 Rotate caliper clockwise to align mounting fastener h...

Page 67: ...islodged install with long side on piston side of caliper 3 Push piston in with suitable tool such as a clean paint scraper until fully seated in bore 4 Install new inner and outer brake pads 5 See Figure 1 14 Install pin 2 making sure pin engages hole on both pads 6 Install brake carrier with two mounting fasteners 2 Tighten fasteners to 24 26 ft lbs 33 35 Nm 7 Tighten pin to 11 15 ft lbs 15 20 N...

Page 68: ...ator bars become visible on the tread sur faces 2 Tire cords or fabric become visible through cracked side walls snags or deep cuts 3 A bump bulge or split in the tire 4 Puncture cut or other damage to the tire that cannot be repaired WHEEL BEARINGS 1WARNING 1WARNING Never use compressed air to spin dry bearings Very high bearing speeds can damage unlubricated bearings Spinning bearings with compr...

Page 69: ... 3 Wipe any foreign material from the magnetic drain plug Reinstall plug and tighten to 29 31 ft lbs 39 42 Nm 4 Remove three fasteners and washers from clutch inspec tion cover Remove clutch inspection cover with gasket from primary cover CAUTION Do not overfill the transmission with fluid Overfilling may cause rough clutch engagement and incomplete dis engagement clutch drag and or difficulty fin...

Page 70: ...to shorten cable housing until there is a large amount of free play at clutch hand lever 3 See Figure 1 17 Remove three fasteners and washers from clutch inspection cover Remove clutch inspection cover and gasket from primary cover 4 See Figure 1 21 Remove spring 1 and lockplate 2 Using a flat tip screwdriver turn adjusting screw 3 counterclockwise until it lightly bottoms 5 Turn adjusting screw c...

Page 71: ...g away from bracket Gap between ferrule and bracket should be 1 16 1 8 in 1 6 3 2 mm b See Figure 1 20 Set free play by turning adjuster 4 c Tighten jam nut 3 against adjuster 4 d Slide boot 1 over cable adjuster mechanism 7 Change or add transmission fluid if necessary 8 See Figure 1 17 Install clutch inspection cover and gas ket using three fasteners and washers and tighten to 7 9 ft lbs 10 12 N...

Page 72: ...d leaves a visible mark it is cutting the bare aluminum A knife point will not penetrate the chrome plating 3 Replace rear sprocket if major tooth damage or loss of chrome exists Drive Belt See Figure 1 27 Inspect drive belt for Cuts or unusual wear patterns on both sides of belt Outside edge bevelling 8 Some bevelling is common but it indicates that sprockets are misaligned Outside surface for si...

Page 73: ...t from sprocket and remove DRIVE BELT INSTALLATION CAUTION When removing or installing belt do not bend or twist belt partially slide belt onto sprocket and roll wheel or belt damage will occur 1 Slide belt onto sprocket 2 See Figure 1 24 Install upper belt guard 10 to swing arm brace tightening fasteners 9 to 12 36 in lbs 1 4 Nm 3 Loosely install swingarm brace See 2 19 SWINGARM AND BRACE a Posit...

Page 74: ...ly b1064x2x 1 Inner belt guard 2 Spacer collar 3 Lower belt guard 4 Front belt guard 5 Sprocket cover 6 Sprocket cover fasteners 7 Lower belt guard fasteners 8 Upper belt guard fasteners short 9 Upper belt guard fasteners long 10 Upper belt guard 1 10 8 2 4 5 3 6 7 9 8 ...

Page 75: ...pulley wheel bearings can not be replaced separately IDLER PULLEY INSTALLATION 1 See Figure 1 26 Install new or existing pulley wheel 1 if removed and tighten washer and nut 2 wheel fas tener 6 to 96 120 in lbs 11 14 Nm 2 Slide idler pulley bracket 4 washer and nuts 5 on to studs 3 and tighten to 33 35 ft lbs 45 47 Nm 3 Install front sprocket cover See 2 30 SPROCKET COVER CAUTION Never tighten rea...

Page 76: ...N CONDITION REQUIRED ACTION 1 Internal tooth cracks hairline OK to run but monitor condition 2 External tooth cracks Replace belt 3 Missing teeth Replace belt 4 Chipping not serious OK to run but monitor condition 5 Fuzzy edge cord OK to run but monitor condition 6 Hook wear Replace belt 7 Stone damage Replace belt if damage is on the edge 8 Bevel wear outboard edge only OK to run but monitor cond...

Page 77: ...1 28 2003 Buell XB9R Maintenance HOME NOTES ...

Page 78: ...ep 2 must be within the specifications listed in Table 1 9 If necessary adjust as described under 1 10 PRIMARY CHAIN in ADJUST MENT NOTE The initial primary chain vertical free play specification used at the assembly plant is 1 4 1 2 in 6 4 12 7 mm with a cold engine The 1 4 in 6 4 mm minimum is only allowed at the absolute tightest point in the drive as measured with special ized factory equipmen...

Page 79: ...are worn beyond adjustment limits Replace parts as necessary See 6 2 PRI MARY CHAIN 1 See Figure 1 30 Loosen locknut 1 2 Turn adjusting fastener 2 a Clockwise inward to reduce free play b Counterclockwise outward to increase free play 3 Tighten locknut 1 to 20 25 ft lbs 27 34 Nm Figure 1 30 Chain Tension Adjusting Fastener 8403 1 Locknut 2 Adjusting screw 1 2 ...

Page 80: ...mping is a very subjective process Many variables affect motorcycle handling under different circumstances Approach all changes carefully and consult Table 1 11 SUSPENSION ADJUSTMENTS Setting Rear Shock Preload The factory setting is 2 ramp position 7 position being the tallest ramp and maximum preload See Table 1 10 for recommended spring preload 1 Remove seat See 2 38 SEAT 2 See Figure 1 31 Chan...

Page 81: ... 82 95 kg 3 to 4 4 Rider 210 250 lbs 95 113 kg 5 4 Rider passenger cargo 250 325 lbs 113 147 kg total 6 3 Rider passenger cargo 325 390 lbs 147 177 kg total 6 3 GVWR Up to 410 lbs 186 kg of rider passenger cargo 7 2 Figure 1 31 Rear Shock Preload Adjuster Figure 1 32 Front Fork Preload And Rebound Adjuster 8388 Maximum Preload Adjustment Ramp Number 7 Minimum Preload Adjustment Ramp Number 1 b0954...

Page 82: ... 1 33 Using a screwdriver turn the slotted dial clockwise until it stops This is the maximum compression damping setting 2 Then turn the dial counterclockwise the recommended amount specified in Table 1 11 Setting Rear Shock Rebound Damping 1 See Figure 1 34 Using a screwdriver turn the slotted dial clockwise until it stops This is the maximum rebound damping setting 2 Then turn the dial countercl...

Page 83: ...ion Rebound Compression Smooth surface aggressive riding max feedback race track 1 4 1 4 3 4 1 4 Average roads but high preload 2 up or heavy rider 3 4 1 1 1 4 1 Average Roads sport riding Note this is the factory setting 1 1 4 1 1 4 1 5 8 1 1 2 Moderately rough roads more comfort less sport 2 3 1 2 1 3 4 2 Rough roads long rides max comfort setting 2 5 8 4 3 4 2 3 8 2 1 4 ...

Page 84: ...y turning counterclock wise After fully unthreading preload adjuster 3 gently pull on adjuster 5 Remove fork cap 4 from outer tube 6 See Figure 1 39 Move the fork assembly from the hold ing tool and compress fork in the FORK SPRING COM PRESSION TOOL 7 See Figure 1 40 Hold damper rod assembly 3 and remove fork cap 1 NOTE See Figure 1 40 Be careful not to damage preload pins 2 while holding damper r...

Page 85: ...ust fork oil level with FRONT FORK OIL LEVEL GAUGE Part No B 59000A so that it is 4 6 in 118 mm from the top of the fork tube 8 See Figure 2 42 Install spring 16 and spring collar 15 9 Move fork assembly from holding tool to the FORK SPRING COMPRESSION TOOL Reassembly 1 See Figure 2 42 Install preload washer 5 and slider piston 6 2 See Figure 1 40 Hold damper rod and install fork cap onto damper r...

Page 86: ...nap ring 9 Rebound adjuster assembly 10 Damper locknut 11 Damper rod assembly 12 Centering plate 13 Ceiling washer 14 Center bolt 15 Collar 16 Spring 17 Spring joint 18 Outer tube 19 Stopper ring 20 Reflector assembly 21 Slide bushing 22 Guide bushing 23 Seal spacer 24 Oil seal 25 Oil seal stopper ring 26 Dust seal 27 Slide pipe b0991x2x 1 2 3 4 5 6 7 8 9 10 11 12 13 14 20 15 17 18 21 22 23 24 25 ...

Page 87: ...ring scale into the hole in the front axle With scale 90 degrees from fork leg pull front wheel to center position a It should take a maximum of 7 lbs 3 2 kg to pull front wheel to center b If steering head resistance measurement is not within specification see ADJUSTMENT 7 When adjustment is complete attach clutch cable and adjust See 1 8 CLUTCH ADJUSTMENT 1 Detach clutch cable at handlebar and e...

Page 88: ...it on plug base elec trodes and ceramic insulator tip indicates an oil fouled plug The condition may be caused by one or more of the following worn pistons worn piston rings worn valves worn valve guides worn valve seals a weak battery or a faulty ignition system b A dry fluffy or sooty black deposit indicates an air fuel mixture that is too rich and or engine idling for excessive periods c A ligh...

Page 89: ... of spark plugs Install and tighten spark plugs to 11 18 ft lbs 15 24 Nm NOTES Start threading rear spark plug with 3 8 fuel hose being careful not to cross thread spark plug Start front spark plug with fingers An extension may be needed to push on rear spark plug boot to ensure it is seated properly 13 Connect spark plug cables Verify that cables are securely connected to coil and spark plugs 14 ...

Page 90: ...baseplate 5 See Figure 1 47 Remove the filter element 1 from baseplate 2 Inspect and replace if necessary CAUTION Cover the air horn so nothing can drop into the motor CLEANING AND INSPECTION 1WARNING 1WARNING Do not use gasoline or solvents to clean the filter ele ment Volatile flammable cleaning agents may cause an intake system fire which could result in death or serious injury 1 Check filter e...

Page 91: ...uel vent valve 3 Secure vent tube to vent valve with new cable tie 5 Install intake cover assembly with four fasteners and nylon washers Tighten fasteners to 12 36 in lbs 1 4 Nm 1WARNING 1WARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shift during vehicle operation and startle the rider causing loss of control which could re...

Page 92: ...ottle control grip to fully open position hold in position 5 Turn adjuster on throttle control cable until throttle cam stop touches stop plate Tighten jam nut on throttle con trol cable adjuster release throttle control grip 6 Turn handlebars fully to right Turn adjuster on idle con trol cable until end of cable housing just touches the cable guide 7 Twist and release throttle control grip a few ...

Page 93: ... 8 Turn or gently bump the flywheel in a forward direction using the rear wheel Position the flywheel TDC mark at the very left edge of the inspection hole 9 If the engine is coming up on the compression stroke for the FRONT correct cylinder the screen will be display ing LOW 0 volts with timing mark at left edge of window 10 Gently bump flywheel forward in tiny increments 11 See Figure 1 52 If th...

Page 94: ...ing is advanced mark appears on left side of window rotate timing plate counterclockwise 3 Check timing See CHECKING STATIC TIMING 4 See Figure 1 55 If timing is retarded mark appears on right side of window rotate timing plate clockwise 5 Recheck timing Figure 1 53 Timer Cover Figure 1 54 Cam Position Sensor Figure 1 55 Advanced Timing Figure 1 56 Retard Timing 8363 8391 b0964x1x b0963x1x ...

Page 95: ...l compress vehicle suspension slightly 5 Stand motorcycle upright with front fairing aimed straight forward 6 Check LOW beam right lens for alignment a See Figure 1 58 Turn ignition switch to IGN Set handlebar headlamp switch to LOW beam position b Turn engine stop switch to the run position c Check that the correct pattern of light is a double rectangular pattern and is aligned with the horizon t...

Page 96: ...juster 1 is on the left and the LOW Beam adjuster 2 is on the right underneath the front fairing If headlamp requires adjustment perform the following NOTE To lower beam turn adjuster clockwise To raise beam turn adjuster counterclockwise Figure 1 59 Headlamp Height Adjustment 8392 1 2 1 High beam adjuster left 2 Low beam adjuster right ...

Page 97: ...ue to back out one to two additional turns 5 Open and snap shut throttle control grip 2 3 times NOTE This is to ensure that the throttle plate is completely closed before beginning recalibration 6 Select calibrations screen 7 Select the Buell calibrations tab 8 Select Zero TPS function NOTE When calibration is complete dialogue box will appear on Digital Tech screen with message display Command Se...

Page 98: ...inflation See 1 7 TIRES AND WHEELS If the motorcycle will be stored for an extended period of time securely support the motorcycle so that all weight is off the tires 1WARNING 1WARNING Do not apply any oil to brake rotors or brake pads Oil on brake pads degrades braking efficiency and can result in an accident which could result in death or serious injury 7 Wash molded in color and chrome plated s...

Page 99: ... not set properly See dealer 19 No output from CMP sensor See dealer 20 Inoperative fuel pump See dealer Starts Hard 1 Spark plugs in bad condition have improper gap or are partially fouled 2 Spark plug cables in bad condition and shorting 3 Battery nearly discharged 4 Loose wire connection at one of the battery terminals at coil or at plug between ignition sensor and module 5 Throttle controls no...

Page 100: ...rnal engine problem 7 Wheels not balanced correctly ENGINE LUBRICATION SYSTEM Oil Does Not Return To Oil Tank 1 Oil tank empty 2 Return pump gears damaged 3 Oil feed pump not functioning 4 Restricted oil lines or fittings Engine Uses Too Much Oil or Smokes Excessively 1 Piston rings badly worn or broken 2 Valve stem seals worn or damaged 3 Valve guides worn Engine Leaks Oil From Cases Push Rods Ho...

Page 101: ...7 Brake pads dragging or excessive braking brake fades due to heat buildup 8 Insufficient brake pedal or hand lever free play brake drags Handling Irregularities 1 Tires improperly inflated See 1 7 TIRES AND WHEELS Do not overinflate 2 Loose wheel axle Tighten front axle to 39 41 ft lbs 53 56 Nm Tighten rear axle to 48 52 ft lbs 65 70 Nm 3 Excessive wheel hub bearing play 4 Rims and tires out of t...

Page 102: ...pension seems not to respond to bumps This is evidenced by tire chattering a movement with short stroke and high frequency through corners or by jolting the rider over rough roads Reduce compression damping Table 1 13 Rear Suspension Problems TROUBLESHOOTING CONDITION ADJUSTMENT SOLUTION Pumping on the Rear occurs when you are accelerating out of a corner This problems occurs in two varieties 1 Th...

Page 103: ...1 54 2003 Buell XB9R Maintenance HOME NOTES ...

Page 104: ...ower 2 45 2 18 Steering Head Bearings 2 47 2 19 Swingarm and Brace 2 49 2 20 Front and Rear Isolator 2 53 2 21 Frame 2 54 2 22 Rear Shock Absorber 2 55 2 23 Throttle Control 2 57 2 24 Clutch Hand Lever 2 58 2 25 Headlight Support Bracket 2 59 2 26 Fairing Support Bracket 2 62 2 27 Handlebars 2 64 2 28 Exhaust System 2 66 2 29 Footpeg Heel Guard and Mount 2 68 2 30 Sprocket Cover 2 70 2 31 Fenders ...

Page 105: ... 2 ...

Page 106: ... 4 0 102 Trail 3 3 84 Rake 21 Degrees Table 2 2 Weight Specifications WEIGHT U S MODELS LBS KG Wet Weight 445 202 GVWR 850 385 GAWR Front 325 147 GAWR Rear 525 238 Load Capacity 405 184 Table 2 3 Capacities CAPACITIES U S LITERS Fuel Tank inc reserve 3 7 gallons 14 0 Reserve Low fuel light at 0 7 gallons 1 5 Oil Tank wet for normal oil change 2 5 quarts 2 4 Fork Oil 14 ounces 0 41 Transmission 1 0...

Page 107: ...27 Nm metric page 2 27 Caliper banjo bolt rear 16 20 ft lbs 22 27 Nm page 2 35 Caliper banjo bolt rear 16 20 ft lbs 22 27 Nm page 2 38 Caliper bleeder valves 36 60 in lbs 4 7 Nm metric page 2 23 Caliper carrier rear 24 26 ft lbs 32 35 Nm page 2 16 Caliper fasteners front 15 19 ft lbs 20 26 Nm page 2 29 Caliper mounting fasteners front 35 37 ft lbs 47 50 Nm page 2 29 Caliper mounting large fastener...

Page 108: ... 2 62 License plate fasteners 36 48 in lbs 4 5 Nm page 2 78 Main battery ground fastener 72 96 in lbs 8 11 Nm page 2 78 Master cylinder banjo bolt front 16 20 ft lbs 22 27 Nm page 2 27 Master cylinder banjo bolt rear 16 20 ft lbs 22 27 Nm page 2 35 Master cylinder cover fasteners front 9 13 in lbs 1 0 1 5 Nm page 2 25 Master cylinder mounting fasteners rear 48 72 in lbs 8 11 Nm page 2 33 Mirror fa...

Page 109: ...4 Nm LOCTITE 222 page 2 70 Sprocket fasteners 35 37 ft lbs 48 50 Nm Replace with new page 2 16 Steering stem cap 38 42 ft lbs 52 57 Nm page 2 45 Steering stem pinch fastener 17 19 ft lbs 23 26 Nm LOCTITE 272 page 2 45 Swingarm brace mounting fasteners 25 27 ft lbs 34 37 Nm page 2 51 Swingarm pivot shaft 24 26 ft lbs 32 35 Nm page 2 51 Switch housing fasteners right 25 33 in lbs 3 4 Nm page 2 57 Ta...

Page 110: ...idewall Rim size and contour are marked on the rim s exterior surface Example MT 3 5 x 17 0 DOT MT designates the rim contour 3 5 is the width of the bead seat measured in inches 17 0 is the normal diameter of the rim in inches mea sured at the bead seat diameter DOT means that the rim meets Department of Transpor tation Federal Motor Vehicle Safety Standards See Table 2 6 Figure 2 1 Rim Markings ...

Page 111: ... when ordering parts or making inquiries about your Buell motorcycle Figure 2 2 Abbreviated V I N Location b0304x2x Figure 2 3 Vehicle Identification Number V I N 4 MZ AX 12 J 3 3 400001 Varies can be 0 9 or X Sample V I N as it appears on the steering head 4MZAX12J133400001 Sample abbreviated V I N as it appears on the left side crankcase AX123400001 12 World 57 California Manufacturer Buell Moto...

Page 112: ... recommended air pressure Always balance the wheel after replacing a tire 11WARNING 1WARNING Do not inflate any tire beyond its maximum inflation pressure as specified on tire sidewall Overinflation may cause tire to suddenly deflate which could result in death or serious injury TROUBLESHOOTING See Figure 2 4 Check tire inflation pressure at least once each week At the same time inspect tire tread...

Page 113: ...ng and could result in death or serious injury At regular intervals of 2500 miles 4000 km or whenever handling irregularities are noted perform the recommended service checks See Table 2 7 If tires must be replaced same as original equipment tires must be used Other tires may not fit correctly and may be hazardous to use Table 2 7 Wheel Service CHECK FOR REMEDY Loose axles Tighten front axle with ...

Page 114: ...ssembly 2 Remove the right side fender fasteners See 2 31 FEND ERS 3 See Figure 2 5 Loosen front axle pinch fasteners 2 metric on front fork 4 Remove axle 1 NOTE The front axle is left handed thread 5 See Figure 2 6 Raise the wheel up until the rotor clears the caliper and rotate the fork leg counterclockwise allowing wheel clearance for removal 6 Remove wheel Figure 2 5 Front Wheel Mounting Figur...

Page 115: ...rom the Wheel Bear ing Installer Remover HD 44060 4 See Figure 2 8 Insert the Front Wheel Bearing Remover Collet B 43993 7 into the wheel bearing until it fully seats against the bearing 5 Insert the ball bearing into the collet 6 See Figure 2 9 Thread the puller assembly 1 into the collet 2 7 Hold the collet 2 and turn the forcing screw 3 to expand the collet 8 See Figure 2 10 Place the bridge 1 ...

Page 116: ...ed air to spin dry bearings Very high bearing speeds can damage unlubricated bearings Spinning bearings with compressed air can also cause a bearing to fly apart which could result in death or seri ous injury 1 Inspect all parts for damage or excessive wear NOTE XB wheel bearings are designed as sealed bearings which are not intended to be disassembled serviced or cleaned with solvents 11WARNING 1...

Page 117: ... the wheel hub 2 See Figure 2 14 Sparingly apply Extreme Pressure Lubricant J 23444 A to the threads of the long forcing screw 1 to prolong service life and ensure smooth operation 3 Insert a new wheel bearing 2 squarely into the hub with the lettered side pointing out away from the wheel 4 Slide the Front Wheel Bearing Installer Tool B 43993 10 3 onto the forcing screw 1 with the smaller diam ete...

Page 118: ...l Front Rotor Installation 1 See Figure 2 18 Install new spring 4 2 Install new washers 9 3 Install drive bushings 8 into rotor NOTE Note the identifying mark of rotor is up and radius end of drive bushing 8 toward center of wheel See Figure 2 18 4 See Figure 2 18 Align reference dot on front rotor with the valve stem 5 Install new rotor mounting fasteners in a criss cross pat tern around the whee...

Page 119: ...rs metric loose insert threaded end of axle 1 through left side fork wheel hub and thread into right fork c Compress the front suspension to make sure it is free and not binding d Tighten axle 1 metric to 39 41 ft lbs 53 56 Nm NOTE The front axle is left handed thread 4 See Figure 2 5 Tighten the front axle pinch fasteners 2 to 20 22 ft lbs 27 30 Nm 5 Install right side fender fasteners See 2 31 F...

Page 120: ... or seri ous injury 1 Inspect all parts for damage or excessive wear 2 Inspect brake rotor See 1 6 BRAKE SYSTEM MAINTE NANCE DISASSEMBLY 1 Remove sprocket a Remove sprocket fasteners and washers Discard fasteners b Remove sprocket from wheel 2 Remove rear rotor a See Figure 2 23 Remove and discard rotor mount ing fasteners 1 b Remove and inspect brake rotor for wear and warp ing See BRAKE ROTOR TH...

Page 121: ...Center wheel in swingarm and lower bike to align swingarm and hub b See Figure 2 22 Coat the axle with ANTI SIEZE LUBRICANT c Slide axle through right side of swing arm and wheel hub 2 Install drive belt See DRIVE BELT INSTALLATION in 1 9 DRIVE BELT SYSTEM 3 Install idler pulley See IDLER PULLEY INSTALLATION in 1 9 DRIVE BELT SYSTEM 4 Install sprocket cover See 2 30 SPROCKET COVER CAUTION Never ti...

Page 122: ...Buell XB9R Chassis 2 17 HOME Figure 2 23 Rear Wheel Assembly 1 Rotor mounting fastener 6 2 Brake rotor 3 Wheel bearing 4 Wheel spacer 5 Wheel 6 Sprocket 7 Sprocket fastener 8 Axle b0936x2x 1 3 5 4 3 2 6 7 8 ...

Page 123: ...s specification shown in Table 2 8 Rim Radial Runout 1 See Figure 2 25 Install truing arbor in wheel hub and place wheel in WHEEL TRUING AND BALANCING STAND Part No HD 99500 80 2 Tighten arbor nuts so hub will turn on its bearings 3 Check radial runout as shown Replace wheel if runout exceeds specification shown in Table 2 8 Table 2 8 Wheel Runout CAST WHEEL IN MM Maximum Lateral Runout 0 040 1 02...

Page 124: ...ue dot on inside of rim REMOVAL 1 Remove wheel from motorcycle See 2 5 FRONT WHEEL or 2 6 REAR WHEEL 2 Deflate tire 3 See Figure 2 26 Loosen both tire beads from rim flange 11WARNING 1WARNING Do not use excessive force when starting bead over rim Excessive force may damage tire or rim and adversely affect handling which could result in death or serious injury 4 If a bead breaker machine is not ava...

Page 125: ...valve stems must be replaced 2 Install and tighten fastener to 40 44 in lbs 4 5 Nm 3 Thoroughly lubricate rim flanges and both beads of tire with tire lubricant 4 See Figure 2 28 Starting at the valve stem start first bead into the rim well using a bead breaker machine If no machine is available work bead on as far as possible by hand Use a tire tool to pry the remaining bead over rim flange 5 Sta...

Page 126: ...lancing utilizing a wheel spinner can be used to produce finer tolerances for better high speed handling characteristics Follow the instruc tions supplied with the balance machine you are using NOTE If the rear wheel on the XB9R will not fit on a stock dynamic spin balance shaft use the Carlson wheel balance shaft Part No AF15 WEIGHTS FOR CAST WHEELS The maximum weight permissible to accomplish ba...

Page 127: ...pedal 6 INSTALLATION 1 See Figure 2 32 Install pedal bushings 3 2 Install shift brake pedal sleeve 4 3 Install brake pedal 6 using LOCTITE 272 and tighten fastener 5 to 22 24 ft lbs 30 33 Nm 4 Install clevis pin 2 5 Install new cotter pin 7 Figure 2 32 Brake Pedal Assembly 1 Rear master cylinder body 2 Clevis pin 3 Pedal bushings 2 4 Shift brake pedal sleeve 5 Brake pedal fastener 6 Brake pedal 7 ...

Page 128: ...d lever pivot 3 Detach front brake lamp switch 10 by removing the switch fastener 9 Front Master Cylinder 1 See Figure 2 35 Remove master cylinder cover 2 by removing cylinder cover fasteners 1 2 Discard excess brake fluid 3 See Figure 2 34 Remove rubber boot 1 and discard 4 See Figure 2 33 Depress piston assembly 1 and remove internal snap ring 2 and discard 5 See Figure 2 35 Remove piston assemb...

Page 129: ...ee Figure 2 34 Install ridge on boot 1 into groove on piston 3 Brake Hand Lever 1 See Figure 2 35 Lubricate pivot bolt 15 with LOCTITE ANTI SEIZE 2 Align hole in hand lever 7 with hole in hand lever pivot and install pivot bolt 15 through top of hand lever pivot and tighten to 80 120 in lbs 9 14 Nm Figure 2 34 Front Master Cylinder Piston Assembly b0977x2x 1 Ridge on rubber boot 2 Snap ring 3 Groo...

Page 130: ...r in a level posi tion add D O T 4 BRAKE FLUID Bring fluid level to within 1 8 in 3 2 mm of molded boss inside front mas ter cylinder reservoir 11WARNING 1WARNING Verify proper operation of the master cylinder relief port A plugged or covered relief port can cause brake drag or lockup which could result in loss of vehicle control which could result in death or serious injury 7 Verify proper operat...

Page 131: ...and master cylinder bore are completely clean 1 See Figure 2 35 Connect brake line 13 to master cylin der 4 using two new copper washers 14 and a banjo bolt 12 metric Loosely install bolt into master cylin der 2 Route the brake line from the master cylinder to the cali per See D 1 HOSE AND WIRE ROUTING for front brake line routing 11WARNING 1WARNING Use only copper crush banjo washers See Parts Ca...

Page 132: ...Buell recommends that all brake repairs be per formed by a Buell dealer or other qualified mechanic 7 Install bleeder valve if removed Refill master cylinder and bleed brakes See 1 6 BRAKE SYSTEM MAINTE NANCE 11WARNING 1WARNING Check for proper brake lamp operation before riding motorcycle Visibility is a major concern for motorcy clists Failure to have proper brake lamp operation could result in ...

Page 133: ...2 40 Disconnect brake line at caliper See 2 11 FRONT BRAKE LINE 3 Remove caliper mounting fasteners 5 4 Slide caliper down the rotor to clear fork lower and then remove off rotor DISASSEMBLY 1 See Figure 2 41 Remove pin hanger set 1 caliper pad spring 2 and brake pads 2 Split caliper by removing caliper fasteners 3 3 See Figure 2 42 Remove and discard o rings 6 4 See Figure 2 39 Remove pistons usi...

Page 134: ...bores with D O T 4 BRAKE FLUID b Install two new o rings 6 in grooves of each piston bore c Install pistons 5 in each piston bore 2 Install new o rings 8 between caliper halves 3 Clamp caliper together with caliper fasteners 11 and tighten to 15 19 ft lbs 20 26 Nm INSTALLATION 1 See Figure 2 42 Install brake pads 10 2 Install pin hanger set 1 and tighten to 11 14 ft lbs 15 19 Nm 3 Rotate front for...

Page 135: ...e 2 42 Front Caliper Assembly b0976x2x 1 Pin hanger set 2 Bleeder set cover 3 Bleeder set screw 4 Caliper 5 Piston 6 Piston o rings 7 Clip 8 Small o ring 9 Caliper mounting fasteners 10 Brake pads 11 Caliper fasteners 1 2 3 4 5 6 7 10 8 9 11 ...

Page 136: ...ove seat See 2 38 SEAT 6 See Figure 2 43 Disconnect brake light connector located under the seat 7 Remove right side rider footpeg mount See 2 29 FOOT PEG HEEL GUARD AND MOUNT 8 See Figure 2 47 Remove banjo bolt 2 metric and two copper crush washers 3 to detach brake switch 1 from master cylinder 4 Discard copper crush washers 9 See Figure 2 44 Remove fasteners 3 metric to detach master cylinder 4...

Page 137: ...rake system components Stand master cylinder on wooden block or towel to protect seating surfaces a Examine walls of master cylinder reservoir for scratches and grooves Replace if damaged b Verify that vent holes on master cylinder are com pletely open and free of dirt or debris 2 Inspect boot on front of master cylinder for cuts tears or general deterioration Replace if necessary ASSEMBLY 1 Obtai...

Page 138: ... 1 Nm b Attach hose 3 to rear brake reservoir using clamp 5 See Figure 2 43 Connect brake line switch connector under seat 6 Install heel guard See 2 29 FOOTPEG HEEL GUARD AND MOUNT 7 Install rear brake pedal See 2 9 BRAKE PEDAL 8 Adjust rear brake pedal See BRAKE PEDAL ADJUST MENT in 1 6 BRAKE SYSTEM MAINTENANCE 9 Install master cylinder to brake pedal See 2 9 BRAKE PEDAL 11WARNING 1WARNING Alway...

Page 139: ...uid according to local laws a Install a length of plastic tubing over caliper bleeder valve Place free end in a suitable container b Open bleeder valve metric about 1 2 turn c Pump brake foot pedal to drain brake fluid d Tighten bleeder valve to 36 60 in lbs 4 7 Nm 6 See Figure 2 49 Remove p clamp 3 and wire form 2 securing brake line 1 to the left side of swingarm CAUTION Damaged banjo bolt seati...

Page 140: ... HOSE AND WIRE ROUTING for brake line routing 5 Install right heel guard See 2 29 FOOTPEG HEEL GUARD AND MOUNT 6 Bleed brakes See BLEEDING BRAKES in 1 6 BRAKE SYSTEM MAINTENANCE 11WARNING 1WARNING Always connect the positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion which could result in deat...

Page 141: ...to drain brake fluid d Tighten bleeder valve to 36 60 in lbs 4 7 Nm 2 Remove banjo bolt connecting brake line to rear caliper See 2 14 REAR BRAKE LINE 3 See Figure 2 51 Remove caliper mounting fasteners 6 and 7 DISASSEMBLY 1 See Figure 2 51 Remove pin plug 5 and pad hanger metric to free brake pads 2 See Figure 2 53 Remove spring clip 1 3 See Figure 2 54 Remove piston 3 using BRAKE CALI PER PISTON...

Page 142: ... Never replace just one brake pad Fail ure to install brake pads as a set could result in death or serious injury 4 Inspect brake pads for damage or excessive wear Replace both pads as a set if the friction material of either pad is worn to 0 04 in 1 0 mm or less ASSEMBLY 1 See Figure 2 53 Place clip 1 inside caliper body as shown NOTE To ensure proper brake pad to brake rotor clearance when the c...

Page 143: ...ydrau lic brake line and caliper bore are completely clean 3 See Figure 2 51 Connect brake line 1 to caliper using two new copper washers 3 and banjo bolt 2 metric Tighten to 16 20 ft lbs 22 27 4 Depress rear brake pedal several times to set brake pads to proper position within caliper Bleed brake sys tem 5 Verify proper fluid level in reservoir 11WARNING 1WARNING Always test motorcycle brakes at ...

Page 144: ...FRONT WHEEL 3 Remove caliper mounting fasteners See 2 12 FRONT BRAKE CALIPER 4 See Figure 2 56 Loosen upper and lower fork clamp pinch fasteners 5 See Figure 2 57 Remove fork from upper fork clamp and slide the stopper ring up and over the top of the fork 6 See Figure 2 69 Remove fork from lower fork clamp 8 7 Repeat 4 through 6 on opposite side DISASSEMBLY NOTE Record rider suspension settings be...

Page 145: ...ase damping rod assem bly 11 NOTE Be careful not to drop damping rod assembly into oil pan when removing center bolt 14 Remove centering plate 12 from dampening rod 11 11WARNING 1WARNING Be careful not to scratch the slide pipe or the outer tube Improperly operating forks may lead to a loss of control which could result in death or serious injury 15 Remove dust seal 26 to access oil seal stopper r...

Page 146: ...forks to the exact same suspension settings 2 Adjust rebound assembly for proper range of motion a Lightly turn the rebound adjuster screw 9 counter clockwise till it stops b Turn the rebound adjuster screw three full turns clockwise 3 Fully thread rebound adjuster assembly 9 onto the damper rod assembly 11 until it lightly bottoms Do not tighten 4 Thread the damper locknut 10 until bottoms lightl...

Page 147: ... in the fully bottomed position and compress fork completely 16 Pour 7 oz 204 cc more fork oil into the slide pipe 17 See Figure 2 65 Adjust fork oil level with FRONT FORK OIL LEVEL GAUGE Part No B 59000A so that it is 4 6 in 118 mm from the top of the fork tube 18 See Figure 2 67 Install spring 16 and collar 15 19 Move fork assembly from holding tool to the FORK SPRING COMPRESSION TOOL 20 See Fig...

Page 148: ... Position fork with alignment lines 4 visible and reflector facing to the side and tighten the lower fork clamp Do not tighten 5 Repeat step 1 through 4 on second front fork 6 Temporarily install front axle to the fork assemblies to verify correct alignment 7 Use LOCTITE 272 on upper fork clamp fasteners and tighten to 17 19 ft lbs 23 26 Nm 8 Use LOCTITE 272 on lower fork clamp fasteners and tight...

Page 149: ...p ring 9 Rebound adjuster assembly 10 Damper locknut 11 Damper rod assembly 12 Centering plate 13 Ceiling washer 14 Center bolt 15 Collar 16 Spring 17 Spring joint 18 Outer tube 19 Stopper ring 20 Reflector assembly 21 Slide bushing 22 Guide bushing 23 Seal spacer 24 Oil seal 25 Oil seal stopper ring 26 Dust seal 27 Slide pipe b0991x2x 1 2 3 4 5 6 7 8 9 10 11 12 13 14 20 15 17 18 21 22 23 24 25 26...

Page 150: ...ol of the motorcycle which could result in death or serious injury 3 Install one front fork assembly into lower fork clamp 8 4 See Figure 2 67 Slide the stopper ring 19 over top of fork assembly and into groove 5 Install upper clamp on fork assembly Tighten but do not torque lower fork clamp pinch fasteners 6 Repeat previous two steps on second fork assembly 7 Tighten steering stem cap to 38 42 ft...

Page 151: ...OME Figure 2 69 Steering Stem Assembly b0937x2x 1 Stem capnut 2 Stem pinch fastener 3 Upper fork clamp pinch fastener 4 Upper fork clamp 5 Head bearing 6 Stem 7 Lower fork clamp pinch fastener 8 Lower fork clamp 1 4 6 7 8 2 3 3 5 7 ...

Page 152: ... bearings and replace with new Steer ing head bearings are not reusable INSTALLATION NOTE For easier installation of bearing lubricate the outer bearing with engine oil prior to installing into steering stem bore 1 See Figure 2 71 Install new upper and lower steering head bearings into the steering stem using STEERING HEAD BEARING RACE INSTALLER Part No HD 39302 and the STEERING HEAD BEARING INSTA...

Page 153: ...washer 5 and nut 6 from the Steering Head Bearing Race Installer HD 39302 onto the forcing screw 1 6 Tighten the nut 6 by hand until both bearings are started into the bores in the steering head 7 See Figure 2 74 Hold the forcing screw while tightening the nut to draw the bearings into the steering head Con tinue tightening until both bearings are fully seated 8 Visually check to make sure the bea...

Page 154: ...rider footpeg mount See 2 29 FOOT PEG HEEL GUARD AND MOUNT 2 Remove right side passenger footpeg mount See 2 29 FOOTPEG HEEL GUARD AND MOUNT 3 See Figure 2 76 Loosen rear axle pinch fastener 2 4 Loosen rear axle 1 approximately 15 rotations to allow partial tension to be removed from rear drive system 5 See Figure 2 75 Remove upper belt guard 1 by remov ing fasteners 2 NOTE The upper belt guard is...

Page 155: ... spacer from shock absorber and swingarm 7 See Figure 2 78 Loosen pivot shaft pinch fastener 7 8 Remove pivot shaft 10 with a special 7 8 in hex tool located in tool kit DISASSEMBLY CAUTION Carefully mark all bearing components as they are removed so that they may be returned to their original locations Do not intermix bearing components Brace Remove upper belt guard assembly See 2 32 BELT GUARDS ...

Page 156: ...ten to 36 60 in lbs 4 7 Nm 6 Install three oil lines from swingarm fittings See 3 9 OIL HOSE ROUTING AND OIL RESERVOIR 7 Install rear wheel See 2 6 REAR WHEEL NOTE Installing the rear wheel will include installation of the belt drive system See 1 9 DRIVE BELT SYSTEM 8 Fill motorcycle with recommended oil See 1 5 ENGINE LUBRICATION SYSTEM 11WARNING 1WARNING Always connect the positive battery cable...

Page 157: ...e 7 Pivot shaft pinch fastener 8 Oil drain plug 9 Swingarm bearing 10 Pivot shaft 11 Belt guard spacer 12 Swingarm brace fasteners 13 Swingarm brace 14 Rear axle pinch fastener 1 2 4 5 7 6 8 9 10 11 12 14 3 13 Table 2 12 Oil line Fittings FITTINGS FUNCTION HEX SIZE SWINGARM HEX SIZE HOSE Right Small Vent 5 8 7 16 Center Large Supply 13 16 5 8 Left Medium Return 3 4 1 2 ...

Page 158: ...e LOCTITE 272 on front isolator bracket 4 and install Tightening fastener 5 to 49 51 ft lbs 66 69 Nm CAUTION Avoid cross threading front isolator bolt or insert Keep weight of motorcycle off front isolator by alternately tightening front isolator bolt and raising scissor jack to support engine 4 Tighten front isolator bolt 6 to 49 51 ft lbs 66 69 Nm 5 See Figure 2 79 Install clutch cable p clamp T...

Page 159: ... 7 23 MAIN WIRE HAR NESS 8 Remove rear isolator fastener See 2 20 FRONT AND REAR ISOLATORS 9 Lift and remove frame from the motorcycle INSTALLATION 1 Place frame over the motorcycle 2 Install rear isolator fastener See 2 20 FRONT AND REAR ISOLATORS 3 Install main wire harness See 7 23 MAIN WIRE HAR NESS 4 Install upper and lower fork clamps See 2 17 FORK CLAMPS UPPER AND LOWER 5 Install rear shock...

Page 160: ...section 9 Remove rear shock a Raise motorcycle up approximately 2 more inches 51 mm b Remove shock through the top of the tail section opening underneath rider seat INSTALLATION 1 See Figure 2 85 Install upper shock mount and tighten fastener 5 to 49 51 ft lbs 66 69 Nm 2 Install lower shock mount with fasteners 6 9 and lower shock mount sleeve 8 and tighten to 15 17 ft lbs 20 3 23 Nm 3 Feed rear s...

Page 161: ...remote reservoir clamp fastener 2 Shock remote reservoir clamp 3 Shock remote reservoir 4 Shock reservoir body 5 Upper shock mount fastener 6 Lower shock mount nut and washer 7 Lower shock mount 8 Lower shock mount sleeve 9 Lower shock mount fastener and washer 10 Shock spring retainer kit 11 Rear shock spring 7 10 ...

Page 162: ... air Replace cables if frayed kinked or bent ASSEMBLY INSTALLATION 1 Route cable as shown in D 1 HOSE AND WIRE ROUT ING 2 Add cable straps as shown in the throttle cable routing in D 1 HOSE AND WIRE ROUTING 3 Install throttle grip and position ferrules 6 into cable wheel 7 4 Insert idle control into front switch housing 5 Slide switch housing over throttle 6 Insert throttle cable into front switch...

Page 163: ... See 2 27 HANDLEBARS 3 Connect safety interlock connector and switch 5 4 Install safety interlock switch 5 with fastener 6 tighten ing to 7 10 in lbs 0 8 1 0 Nm NOTE Apply small amount of LOCTITE ANTI SEIZE LUBRICANT to bolt 3 5 Install clutch hand lever 4 in hand lever clamp 2 and tighten hand lever pinch fastener 3 to 39 48 in lbs 4 5 Nm 6 Position hand lever 4 to rider preference and tighten ha...

Page 164: ...e 1 4 BAT TERY MAINTENANCE 3 Remove front fairing See 2 37 FRONT FAIRING WIND SHIELD AND MIRRORS 4 See Figure 2 91 Disconnect flasher 1 and bank angle sensor 2 Remove electronic control module fasteners 3 5 See Figure 2 93 Rotate headlamp support bracket a Loosen headlamp pivot fasteners 1 b Rotate headlight bracket 2 down 6 See Figure 2 92 Disconnect headlight connection 7 Disconnect and remove e...

Page 165: ...pport bracket 2 Tighten headlight fasteners 6 to 20 25 in lbs 2 3 2 8 Nm 2 Connect headlight bulb 8 connector white into wire harness 3 Connect black headlight connector 4 Install black rubber cover 4 5 See Figure 2 91 Install bank angle sensor connector case 2 Tighten to 12 36 in lbs 1 4 Nm 6 Install flasher 1 and tighten to 30 40 in lbs 3 5 Nm Figure 2 93 Headlight Support Bracket Assembly 1 Hea...

Page 166: ...all electric control module a Figure 2 93 Align electronic control module and headlight support bracket with fairing support bracket b Tighten electronic control module fasteners 3 to 72 96 in lbs 8 11 Nm 8 See Figure 2 91 Connect flasher 1 and bank angle sensor 2 9 Install front fairing See 2 37 FRONT FAIRING WIND SHIELD AND MIRRORS 11WARNING 1WARNING Always connect the positive battery cable fir...

Page 167: ... INSTALLATION 1 Route the wire harness See D 1 HOSE AND WIRE ROUTING for wire harness routing 2 See Figure 2 95 Install fairing support bracket with fas teners and washers 4 Tightening to 16 18 ft lbs 22 26 Nm 3 Install p clamp 7 with p clamp fasteners and washers 8 4 Connect instrument cluster connector and install instru ment cluster Tightening to 36 48 in lbs 4 5 Nm See 7 17 INSTRUMENT MODULE 5...

Page 168: ...ure 2 95 Fairing Support Bracket Assembly 1 Jam nut 2 Washer 3 Rubber grommet 4 Fairing support bracket fasteners and washers 5 Fairing support bracket 6 Instrument cluster 7 P clamp 8 P clamp fastener and washers b0958x2x 1 2 3 6 5 4 7 8 ...

Page 169: ...d clip on 3 has been removed from fork clamp 4 3 Remove clutch lever assembly See 2 24 CLUTCH HAND LEVER 4 Remove clip on endcap 1 INSTALLATION Right Clip on 1 Install right switch gear housing 2 Install front brake master cylinder Tighten but do not torque 3 Install right clip on into right fork clamp using LOCTITE 272 and tighten fastener 5 to 24 26 ft lbs 33 35 Nm 4 Install throttle and grip on...

Page 170: ...2003 Buell XB9R Chassis 2 65 HOME Figure 2 97 Handlebar Clip on Assembly left clip on shown b0945x2x 1 Endcap 2 Hand grip 3 Clip on 4 Upper fork clamp 5 Clip on fastener 3 1 5 2 4 ...

Page 171: ...nting block bushings 8 by punching out with suitable tool Rear Muffler Mounting Block 1 Remove muffler See Muffler in this section 2 Drain oil See Draining Oil in 1 5 ENGINE LUBRICA TION SYSTEM 3 Remove oil lines from swingarm See 3 9 OIL HOSE ROUTING AND OIL RESERVOIR 4 See Figure 2 98 Remove rear muffler mounting block fasteners 10 5 Slide oil lines from rear muffler block and remove rear muffle...

Page 172: ...e Muffler in this section Muffler and Straps NOTE Torca muffler clamps have eliminated the need for silicone or graphite tape during assembly To ensure sealing integrity of muffler clamps and prevent the possibility of leakage Buell recommends that muffler clamp assemblies be discarded and replaced each time they are removed 1 Install muffler and new Torca clamp onto header NOTE If necessary use a...

Page 173: ...re 2 100 Install e ring 5 2 Position footpeg 7 on to footpeg mount 1 3 Install footpeg pin 8 Install Heel Guard 1 See Figure 2 100 Position heel guard 3 onto footpeg mount 1 2 Install heel guard 3 with fasteners 4 Tighten to 72 96 in lbs 8 11 Nm Install Mount 1 See Figure 2 100 Position footpeg mount 1 2 Install footpeg mount with fasteners 2 Tighten to 108 132 in lbs 12 15 Nm Figure 2 100 Rider F...

Page 174: ...mount 3 2 Install footpeg pin 9 3 Install e ring 7 4 Check that footpeg clicks in the up and down position Install Heel Guard 1 See Figure 2 101 Position heel guard 2 onto footpeg mounts 3 2 Install heel guard 2 Tightening heel guard fasteners to 48 72 in lbs 5 8 Nm Install Mount 1 See Figure 2 101 Position footpeg mount 3 onto tail frame 2 Install footpeg mount 3 Using LOCTITE 272 tighten fastene...

Page 175: ...rs 1 INSTALLATION 1 See Figure 2 103 Position sprocket cover 2 over front belt guard 3 and front sprocket 2 Install sprocket cover 2 using LOCTITE 222 on rear sprocket cover fastener 1 and tighten all fasteners and washers 1 to 12 36 in lbs 1 4 Nm 3 Install chin fairing See 2 33 CHIN FAIRING Figure 2 102 Chin Fairing Assembly Figure 2 103 Sprocket Cover b0942x2x b0943x2x 1 Sprocket cover fastener ...

Page 176: ...with fasteners and washers 2 and tighten to 12 36 in lbs 1 4 Nm REAR FENDER Removal 1 Remove rear wheel See 2 6 REAR WHEEL 2 See Figure 2 104 Remove fasteners and washers 4 securing the rear fender 3 to frame 3 Remove rear fender 3 Installation 1 See Figure 2 104 Align rear fender 3 to frame 2 Install rear fender 3 with fasteners and washers 4 Tighten to 12 15 in lbs 1 1 7 Nm Figure 2 104 Front an...

Page 177: ... Remove inner belt guard 1 from swingarm NOTE The rear wheel does not have to be removed to remove inner belt guard INSTALLATION 1 See Figure 2 105 Installing inner belt guard 1 a Slide inner guard between rear wheel and swing arm b Partially install rear axle 2 Install front belt guard 4 Do not tighten 3 Install belt 4 Install upper belt guard 10 to swingarm brace tighten ing fasteners to 12 36 i...

Page 178: ... b1064x2x 1 Inner belt guard 2 Spacer collar 3 Lower belt guard 4 Front belt guard 5 Sprocket cover 6 Sprocket cover fasteners 7 Lower belt guard fasteners 8 Upper belt guard fasteners short 9 Upper belt guard fasteners long 10 Upper belt guard 1 10 8 2 4 5 3 6 7 9 8 ...

Page 179: ... Position right section 5 and install with right section fasteners and washers 6 2 Position left section 3 and install with left section fasten ers and washers 4 3 Turn wheel full right or left for easier access to center fas teners 4 Position center section 1 and install with center section fasteners and washers 2 Use LOCTITE 272 on all fas teners tightening to 36 48 in lbs 4 5 Nm 5 Install sproc...

Page 180: ...cover assembly 1 INSTALLATION 1 Position intake cover assembly over top of airbox cover 2 See Figure 2 107 Secure intake cover assembly 1 with fasteners and nylon washers 2 Tighten to 12 36 in lbs 1 4 Nm NOTE Front screws go in at a slight angle 3 Install seat See 2 38 SEAT Figure 2 107 Intake Cover Assembly b0981x2x 1 2 1 Intake cover assembly 2 Intake cover fasteners ...

Page 181: ... 1 See Figure 2 108 Position engine shroud air scoop 6 2 Install engine shroud air scoop 6 with three fasteners 5 Tighten to 12 36 in lbs 1 4 Nm OIL COOLER AIR SCOOP Removal 1 See Figure 2 108 On left side of bike locate oil cooler air scoop 2 2 Remove two oil cooler air scoop fasteners 1 3 Remove oil cooler air scoop 2 Installation 1 See Figure 2 108 Position oil cooler air scoop 2 2 Install oil ...

Page 182: ...urn signals and reflectors from lower body work See 7 13 TURN SIGNALS 9 See Figure 2 112 Remove license plate fasteners 12 from lower tail body work 9 and remove license plate 13 10 Remove passenger footpeg mounts See 2 29 FOOT PEG HEEL GUARD AND MOUNT 11 Remove lower body work 9 and trunk 11 from tail frame 8 a Remove lower body work 9 underneath tail frame by removing fasteners 10 b Remove trunk...

Page 183: ...rew through the upper body work c Remove upper body work and tighten rear shock reservoir clamp to 120 144 in lbs 14 16 Nm 9 See Figure 2 109 Feed fuel vent hose 1 through tail section keeping the hose on top of rear shock reservoir hose See D 1 HOSE AND WIRE ROUTING for hose and wire routing 10 Install cable strap 3 holding shock reservoir hose wire harness and fuel vent hose to tail frame 11 See...

Page 184: ...ntact ground with the negative cable installed the resulting sparks may cause a battery explo sion which could result in death or serious injury 22 Install battery by threading positive cable red into threaded hole first tightening to 72 96 in lbs 8 11 Nm See 1 4 BATTERY MAINTENANCE 23 Install seat and pillion See 2 38 SEAT Figure 2 112 Tail Frame and Body Work Assembly 1 Upper tail body work 2 Up...

Page 185: ...g 5 INSTALLATION 1 See Figure 2 113 Position fairing 5 onto fairing support bracket and install turn signals 6 7 See 7 13 TURN SIGNALS 2 Install mirrors 2 with fasteners and tighten to 72 96 in lbs 8 11 Nm 3 Install two center 4 and four side windscreen fasteners 3 Figure 2 113 Front Fairing and Windscreen b0967x2x 1 Windshield 2 Mirrors 3 Side windshield fastener 4 Center windshield fastener 5 Fr...

Page 186: ...in slot Pull up on front of seat to verify tab slot engagement 11WARNING 1WARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shift during vehicle operation and startle the rider causing loss of control which could result in death or serious injury 3 Pull up rear corners of seat and tighten two fasteners to 12 36 in lbs 1 4 Nm Pi...

Page 187: ...ab 4 Position short tab of spring 5 into seat lock notch 5 Position long end of spring into the seat lock lever 4 6 Load the spring 5 by turning the seat lock lever 4 counterclockwise 1 4 turn 7 Once the spring is loaded install the seat lock lever 4 onto the lock aligning the lever to the square groove that is cast into the seat lock 7 8 Fasten the lock lever 4 to the seat lock 7 with the washer ...

Page 188: ...e sidestand in the following manner Without motorcycle weight resting on it side stand should move freely into extended down and retracted up positions 2 Check sidestand switch starter interlock for proper operation after the first 1500 miles 2400 km and every 2500 miles 4000 Km thereafter See 7 5 STARTER INTERLOCK SIDESTAND REMOVAL 1 Remove muffler See Muffler and Straps in 2 28 EXHAUST SYSTEM 2 ...

Page 189: ...stand switch to switch connector SIDESTAND SWITCH INSTALLATION 1 Install sidestand assembly See SIDESTAND INSTALLA TION in this section 2 See Figure 2 119 Install sidestand switch pulling switch assembly and wire harness through right side of vehicle and connect wire 3 See Figure 2 118 Install cable strap securing harness SIDESTAND INSTALLATION 1 Install sidestand switch to sidestand assembly 2 In...

Page 190: ...9 3 6 Cylinder Head 3 45 3 7 Cylinder and Piston 3 63 3 8 Lubrication System 3 73 3 9 Oil Hose Routing And Oil Reservoir 3 74 3 10 Oil Pressure Indicator Switch 3 75 3 11 Crankcase Breathing System 3 76 3 12 Oiling System 3 78 3 13 Oil Pump 3 79 3 14 Oil Filter Mount 3 82 3 15 Hydraulic Lifters 3 83 3 16 Gearcase Cover And Cam Gears 3 85 3 17 Crankcase 3 90 Table Of Contents ...

Page 191: ......

Page 192: ...Plug Size 12 mm Spark Plug Type Harley Davidson No 10R12A Spark Plug Gap 0 035 in 0 8890 mm Spark Plug Torque 11 18 ft lbs 15 24 Nm Table 3 3 Valve and Valve Seat Specifications VALVE NEW COMPONENTS SERVICE WEAR LIMITS Fit in guide Exhaust 0 001 0 003 in 0 0254 0 0762 mm 0 0038 in 0 1016 mm Intake 0 001 0 003 in 0 0254 0 0762 mm 0 0038 in 0 0889 mm Seat width 0 040 0 062 in 1 016 1 575 mm 0 090 in...

Page 193: ...0094 in 0 2388 mm Pin fit loose at room temperature 0 00005 0 00045 in 0 00127 0 01143 mm 0 00100 in 0 02540 mm Table 3 7 Cylinder Head Specifications CYLINDER HEAD NEW COMPONENTS SERVICE WEAR LIMITS Valve guide in head tight 0 0033 0 0020 in 0 0838 0 0508 mm Valve seat in head tight 0 0035 0 0010 in 0 0889 0 0254 mm Head gasket surface flatness 0 006 in total 0 152 mm total 0 006 in total 0 152 m...

Page 194: ... mm Table 3 12 Gearcase Specifications GEARCASE NEW COMPONENTS SERVICE WEAR LIMITS Cam gear shaft in bushing loose 0 0007 0 0022 in 0 0178 0 0559 mm 0 003 in 0 076 mm Cam gear shaft end play min 0 005 0 024 in 0 127 0 610 mm 0 025 in 0 635 mm Intake cam gear shaft end play min 0 006 0 024 in 0 152 0 610 mm 0 040 in 1 016 mm Table 3 13 Flywheel Specifications FLYWHEEL NEW COMPONENTS SERVICE WEAR LI...

Page 195: ...ump to oil cooler 18 20 ft lbs 24 4 27 1 Nm page 3 39 Feed oil line at rear of oil pump 18 20 ft lbs 24 4 27 1 Nm page 3 36 Feed oil line at the oil cooler 15 17 ft lbs 20 3 23 Nm page 3 39 Front isolator bolt 49 51 ft lbs 66 69 Nm page 3 14 Front isolator bracket mounting fastener 49 51 ft lbs 66 69 Nm page 3 14 page 3 32 Front muffler strap fastener 108 120 in lbs 12 2 13 6 Nm page 3 16 Gearcase...

Page 196: ...clamp 40 45 ft lbs 54 2 61 Nm page 3 16 Vent oil line at gearcase cover 120 132 in lbs 13 6 14 9 Nm page 3 36 Vent oil line at oil reservoir 14 16 ft lbs 19 21 7 Nm page 3 35 ITEM TORQUE NOTES Table 3 16 Electrical Items for Engine Removal and Replacement Description Location Ignition Coil Beneath air box on the left side between cylinders Throttle position sensor TP 88 Located on the right side o...

Page 197: ... and tappets Cylinder wall piston piston pin timing gears bushings and main bearings are lubricated by oil spray thrown off connecting rods and crankshaft and by oil draining from each rocker box through an internal drain passage in each cylinder and each tappet guide Oil is transferred to the teeth of all the cam gears by way of the gear meshing action The oil scavenging section of the pump retur...

Page 198: ...d spark plug and remove spark plug 3 Remove air cleaner and set induction module throttle plate in wide open position 4 Remove timing inspection plug from crankcase 5 The piston in cylinder being tested must be at top dead center of compression stroke during test 6 To keep engine from turning over when air pressure is applied to cylinder engage transmission in fifth gear and lock the rear brake 7 ...

Page 199: ...just above the pump located at the rear of the fuel tank on the left side of the vehicle 11WARNING 1WARNING To protect against shock and accidental start up of vehi cle disconnect the negative battery cable before pro ceeding Inadequate safety precautions could result in death or serious injury 2 Remove seat and disconnect battery 3 Remove intake cover and airbox assembly 4 Remove throttle body ve...

Page 200: ...See Figure 3 2 Disconnect the following sensors a Temperature sensor 90 b Oxygen sensor 137 Figure 3 2 Electrical Connections and Throttle Cables 1 Ignition coil 2 Coil connection 83 3 Cylinder head temperature sensor connection 90 4 Oxygen sensor connection 137 5 Throttle cables 5 3 2 1 8708 4 ...

Page 201: ...ler pulley See 1 9 DRIVE BELT SYSTEM and 2 13 REAR BRAKE MASTER CYLINDER 14 See Figure 3 3 Remove muffler a Remove front muffler strap b Remove rear muffler straps c Loosen Torca clamp and remove muffler Figure 3 3 Muffler and Mounting System b0986x3c 1 Clamp Torca 2 Front muffler strap fastener 3 Muffler strap front 4 Rear muffler strap fastener 5 Muffler strap rear 2 6 Muffler 1 6 3 2 5 4 ...

Page 202: ...der footrest and support plate 17 See Figure 3 5 Disconnect clutch cable a Remove retaining clamps b Pull clutch cable down Figure 3 4 Oil Line Connections at Oil Cooler 1 Feed oil line from oil pump to oil cooler 2 Return oil line for oil cooler to crankcase 8711 2 1 Figure 3 5 Clutch Cable Retaining Clamps 8720 ...

Page 203: ...assembly 10 Mount center tie bar 11 Fasteners for center tie bar mount 2 12 Washers for center tie bar mount 2 13 Tie bar assembly center 14 Fasteners for center tie bar assembly 2 15 Washers for center tie bar assembly 2 16 Cable negative battery 17 Isolator assembly rear 18 Fasteners for rear isolator assembly 4 19 Washers for rear isolator assembly 4 20 Bolt rear isolator 21 Tie bar assembly re...

Page 204: ...rness 2 plugs d Remove front tie bar from engine e Unbolt V bracket from main frame and remove from left side 20 Remove center tie bar from engine 21 See Figure 3 7 Remove rear tie bar from frame 22 Loosen rear isolator bolt DO NOT REMOVE 23 See Figure 3 8 Remove front isolator bolt 24 Remove front isolator mount from engine 25 Rotate engine down Figure 3 7 Rear Isolator Bolt and Rear Tie Bar 1 Re...

Page 205: ...ough front isolator 2 and loosely thread into frame Do not tighten at this point 3 See Figure 3 10 Install isolator mounting fasteners 3 and tighten to 49 51 ft lbs 66 69 Nm 4 Tighten front isolator bolt to 49 51 ft lbs 66 69 Nm 5 See Figure 3 6 Torque rear isolator bolt to 49 51 ft lbs 66 4 69 1 Nm 6 See Figure 3 6 Install rear tie bar to frame and tighten to 25 27 ft lbs 33 9 36 6 Nm 7 See Figur...

Page 206: ...line first and tighten to 15 17 ft lbs 20 3 23 Nm NOTE When installing the oil cooler return oil line it is necessary to install the end at the crankcase first 12 See Figure 3 12 Install the oil cooler return oil line and tighten to 15 17 ft lbs 20 3 23 Nm Figure 3 11 Clutch Cable Retaining Clamps 8720 Figure 3 12 Oil Cooler Feed and Return Oil Line Orientation and Clearances 8768 1 Verify that th...

Page 207: ...2 13 6 Nm c Tighten torca clamp to 40 45 ft lbs 54 2 61 Nm 14 Tighten front muffler mount to 22 25 ft lbs 29 8 33 9 Nm CAUTION It is important that the front muffler mount is tightened last in order to ensure proper alignment of the exhaust system Figure 3 13 Muffler and Mounting System b0986x3c 1 Clamp torca 2 Front muffler mount 3 Front muffler strap fastener 4 Muffler strap front 5 Rear muffler...

Page 208: ...erature sensor 90 b Oxygen sensor 137 17 See Figure 3 14 Install the ignition coil and connect 83 and tighten fasteners to 120 144 in lbs 13 6 16 3 Nm Figure 3 14 Electrical Connections and Throttle Cables 1 Ignition coil 2 Coil connection 83 3 Cylinder head temperature sensor connection 90 4 Oxygen sensor connection 137 5 Throttle cables 5 3 2 1 8708 4 ...

Page 209: ...ING 27 Install air scoops right and left sides See 2 35 AIR SCOOPS 28 Connect fuel pump NOTE The connection for fuel pump is just above the pump located at the rear of the fuel tank on the left side of the vehicle 11WARNING 1WARNING Always connect positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery expl...

Page 210: ...ARNING To protect against shock and accidental start up of vehi cle disconnect the negative battery cable before pro ceeding Inadequate safety precautions could result in death or serious injury 3 Remove seat and disconnect battery 4 Remove intake cover and airbox assembly 5 Remove throttle body velocity stack NOTE Install shop towel in entrance to throttle body to prevent objects from falling int...

Page 211: ...sensors c Temperature sensor 90 d Oxygen sensor 137 11 Disconnect throttle cables from induction module throttle body Figure 3 17 Electrical Connections and Throttle Cables 1 Ignition coil 2 Coil connection 83 3 Cylinder head temperature sensor connection 90 4 Oxygen sensor connection 137 5 Throttle cables 5 3 2 1 8708 4 ...

Page 212: ...ved b Alternately loosen rear strap fasteners 12 and remove rear muffler straps c Loosen Torca clamp and remove muffler Figure 3 18 Muffler and Mounting System 1 Clamp Torca 2 Muffler mount front 3 Screw front muffler mount 1 4 Bushings front muffler mount 2 5 Flat washer front muffler mount 1 6 Nut front muffler mount 1 7 Front muffler strap fastener 8 Muffler strap front 9 Muffler bracket rear 1...

Page 213: ... brackets Figure 3 19 Oil Lines and Connections 1 Swingarm Oil reservoir 2 Vent oil line 3 Feed oil line 4 Return oil line 5 Feed oil line from oil pump to oil cooler 6 Feed oil line from oil cooler to crankcase 7 Oil tank drain plug 8 Oil Filter 9 Front muffler mount 10 Rear muffler bracket 11 Oil cooler 3 2 7 6 5 6 5 4 3 2 4 10 9 8710 8709 8711 10 8 11 1 ...

Page 214: ...s rear of vehicle 21 See Figure 3 20 Disconnect clutch cable from handle bars a Remove retaining clamps b Pull clutch cable down 22 See Figure 3 21 Cut cable strap securing harness 23 See Figure 3 22 Remove sidestand switch leaving wire attached and pull switch assembly and wire harness through to right side of vehicle 24 Remove sidestand assembly Figure 3 20 Clutch Cable Retaining Clamps 8720 Fig...

Page 215: ...assembly 10 Mount center tie bar 11 Fasteners for center tie bar mount 2 12 Washers for center tie bar mount 2 13 Tie bar assembly center 14 Fasteners for center tie bar assembly 2 15 Washers for center tie bar assembly 2 16 Cable negative battery 17 Isolator assembly rear 18 Fasteners for rear isolator assembly 4 19 Washers for rear isolator assembly 4 20 Bolt rear isolator 21 Tie bar assembly re...

Page 216: ...and remove from left side 27 See Figure 3 23 Remove center tie bar from engine 28 Remove rear tie bar from frame 29 Loosen rear isolator bolt 30 Remove front isolator bolt 31 Remove front isolator mount from engine 32 See Figure 3 24 Disconnect electrical components a Neutral switch 131 b Speedometer sensor 65 remove tie wrap c Cam position sensor 14 d Positive battery cable at starter e Starter s...

Page 217: ... jack etc 36 See Figure 3 28 Cut the two tie wraps holding transmis sion vent line and pull vent line out of frame leaving it attached to engine NOTE The transmission vent line runs up the left side of the frame and exits underneath the rear brake reservoir and hose 37 Lower engine with scissors lift all the way down 38 Move the engine assembly from under the main frame to the right side of the li...

Page 218: ... b See Figure 3 29 Center tie bar mount c See Figure 3 30 Swingarm pivot shaft pinch bolt threaded insert d See Figure 3 31 Aluminum bushings from front exhaust mount e Timer cover Figure 3 29 Center Tie Bar Mount Figure 3 30 Removing Threaded Insert 8725 8724 8729 Figure 3 31 Front Exhaust Mount Bushings 2 piece Left Side Right Side 8718 8727 ...

Page 219: ...m oil tank 43 Route a ratcheting tie down through the swingarm bear ings up over the main frame through the top stabilizer area back down to the ratchet mechanism and secure swingarm to main frame NOTE See Figure 3 34 This allows the vehicle to remain together as a rolling chassis and to be removed from the lift and stored if necessary 44 Remove support from under swingarm oil tank 45 Remove overh...

Page 220: ...stall with new fasteners Tighten to 25 27 ft lbs 33 9 36 6 Nm 2 Install the following items on the engine assembly as required a Shifter assembly b See Figure 3 36 Center tie bar mount 25 27 ft lbs 33 9 36 6 Nm c See Figure 3 37 Swingarm pivot shaft pinch bolt threaded insert d See Figure 3 38 Aluminum bushings from front exhaust mount Figure 3 35 Rear Isolator and Mounting Hardware Figure 3 36 Ce...

Page 221: ... shaft pinch bolt to 17 19 ft lbs 23 25 8 Nm using LOCTITE 272 6 See Figure 3 41 Route transmission vent line up through left side of frame exiting under the rear master cylinder under the rider s seat Install two tie wraps to secure transmission vent line in place Inspect vent line to verify space between vent line and rear exhaust NOTE See Figure 3 42 At this point it is necessary to support mai...

Page 222: ...assembly 10 Mount center tie bar 11 Fasteners for center tie bar mount 2 12 Washers for center tie bar mount 2 13 Tie bar assembly center 14 Fasteners for center tie bar assembly 2 15 Washers for center tie bar assembly 2 16 Cable negative battery 17 Isolator assembly rear 18 Fasteners for rear isolator assembly 4 19 Washers for rear isolator assembly 4 20 Bolt rear isolator 21 Tie bar assembly re...

Page 223: ...ert front isolator bolt 3 through front isolator 1 and loosely thread into frame Do not tighten at this point 11 See Figure 3 46 Install isolator mounting fasteners 2 and tighten to 49 51 ft lbs 66 69 Nm 12 Tighten front isolator bolt to 49 51 ft lbs 66 69 Nm 13 See Figure 3 44 Torque rear isolator bolt to 49 51 ft lbs 66 4 69 1 Nm 14 See Figure 3 44 Install rear tie bar to frame and tighten to 25...

Page 224: ...32 36 ft lbs 43 4 48 8 Nm 19 Install front muffler mount and leave loose at this time NOTE DO NOT install muffler at this time It is necessary to install muffler mounts first in order to properly install oil lines Figure 3 47 Muffler Mounting System Rear muffler mount Front Muffler Mount b0986x3a ...

Page 225: ...arances needed between the oil lines and varied com ponents on the vehicle Figure 3 48 Oil Lines and Connections 1 Swingarm Oil reservoir 2 Vent oil line 3 Feed oil line 4 Return oil line 5 Feed oil line from oil pump to oil cooler 6 Feed oil line from oil cooler to crankcase 7 Oil tank drain plug 8 Oil Filter 9 Front muffler mount 10 Rear muffler bracket 11 Oil cooler 3 2 7 6 5 6 5 4 3 2 4 10 9 8...

Page 226: ...e Figure 3 49 Torque the return oil line first making sure to maintain the proper clearance between the oil line and the rear muffler bracket 19 21 ft lbs 25 8 28 5 Nm 22 Torque the feed oil line next making sure the distance between the feed line and the return line is within specifi cations 20 22 ft lbs 27 1 29 8 Nm 23 Torque the vent oil line next making sure the distance between the vent line ...

Page 227: ... fit ting to 18 20 ft lbs 24 4 27 1 Nm When the oil line has been properly torqued the orientation of the line should also be approximately 7 o clock 26 Torque the vent oil line at the gearcase cover to 120 132 in lbs 13 6 14 9 Nm NOTE When torquing the vent line verify that the line does not twist down towards the muffler but remains horizontal and aligned with the feed and return lines after tor...

Page 228: ...gure 3 51 Verify that both black plastic oil line clamps are parallel to the crankcases and there is a clearance of 5 16 in 7 9375 mm between the bottom of the crankcases and the oil lines NOTE The 5 16 in clearance is between the crankcase and the steel oil line as shown Not between the crankcase and the clamp Figure 3 51 Clamp Orientation and Oil Line Spacing 5 16 8764 8766a ...

Page 229: ...ortant to maintain an orientation of approximately 2 o clock with the rigid part of the feed oil line running to the oil cooler Also be aware of the 1 8 1 4 3 175 6 35 mm clearance specified between the feed oil line and the clutch cable at the front of the crankcase Figure 3 52 Oil Cooler Feed Oil Line Orientation Approximately 2 O Clock and Oil LIne Clearances 8773 8768 1 Verify that the clutch ...

Page 230: ...s from the crankcase fitting which is located above and forward of the oil filter to the front fitting on the oil cooler 32 Torque the oil cooler return line fitting at the crankcase first to 15 17 ft lbs 20 3 23 Nm NOTE See Figure 3 54 The orientation of the oil cooler return oil line where it enters the crankcase should be at approximately 4 o clock to allow for proper alignment and clearance of...

Page 231: ...or 14 d Alternator 46 e Voltage regulator 77 f Positive battery cable at starter g Starter solenoid 128 h Oil pressure switch 120 Figure 3 55 Electrical Connections 1 Neutral switch 131 2 Speedometer sensor connection 65 3 Cam position sensor connection 14 4 Alternator connection 46 5 Voltage regulator connection 77 4 1 5 2 3 8717 Figure 3 56 Correct Routing of Wiring Harnesses ...

Page 232: ...vehicle 37 Install sidestand switch to sidestand assembly and install cable strap 38 See Figure 3 58 Pull clutch cable back up into the proper position a Connect clutch cable to handlebars and adjust to specifications b Install retaining clamps Figure 3 57 Sidestand Assembly and Switch with Cable Strap 8712 Figure 3 58 Clutch Cable Retaining Clamps 8720 ...

Page 233: ...ft lbs 29 8 33 9 Nm CAUTION It is important that the front muffler mount is tightened last in order to ensure proper alignment of the exhaust system Figure 3 59 Muffler and Mounting System 1 Clamp Torca 2 Muffler mount front 3 Screw front muffler mount 1 4 Bushings front muffler mount 2 5 Flat washer front muffler mount 1 6 Nut front muffler mount 1 7 Front muffler strap fastener 8 Muffler strap f...

Page 234: ...r 137 Install wire tire on harness 42 See Figure 3 60 Install the ignition coil and spark plug wires and connect 83 Tighten ignition coil fasteners to 120 144 in lbs 13 6 16 3 Nm Figure 3 60 Electrical Connections and Throttle Cables 1 Ignition coil 2 Coil connection 83 3 Cylinder head temperature sensor connection 90 4 Oxygen sensor connection 137 5 Throttle cables 5 3 2 1 8708 4 ...

Page 235: ...cket cover and tighten fasteners and washers to 12 36 in lbs 1 4 Nm 53 Install chin fairing See 2 33 CHIN FAIRING 54 Install air scoops right and left sides See 2 35 AIR SCOOPS NOTE The connection for fuel pump is just above the pump located at the rear of the fuel tank on the left side of the vehicle 11WARNING 1WARNING Always connect positive battery cable first If the positive cable should conta...

Page 236: ...l components must be removed before removing cylinder heads Figure 3 62 Rocker Arm and Pushrod Cover Assemblies 1 Crankcase breather 2 Grommet 3 Screw 4 4 Washer 4 5 Gasket 4 6 Rocker cover top 7 Bolt 3 8 Washer 3 9 Gasket inner 10 Gasket lower 11 Rocker arm shafts 12 Bolt 2 13 washer 2 14 Rocker cover lower 15 Rocker arm 2 16 Bushing rocker arm 4 17 Gasket lower rocker cover 18 Hydraulic lifter 1...

Page 237: ...in order to relieve valve spring pressure on the lower rocker box 7 See Figure 3 62 Remove lower rocker cover NOTE Remove lower rocker box as an assembly then disassemble as required CAUTION Mark rocker arm shafts for reassembly in their original positions Valve train components must be reinstalled in their original positions to prevent accelerated wear and increased valve train noise 8 See Figure...

Page 238: ...Part No HD 34736B in vise 2 See Figure 3 66 Compress valve spring with VALVE SPRING COMPRESSOR 3 See Figure 3 67 Remove valve keepers upper collar and valve spring Mark valve keepers for reassembly in their original locations 4 Use a fine tooth file to remove any burrs on the valve stem at the keeper groove 5 Mark valve to ensure that it will be reassembled in the same head Remove valve valve stem...

Page 239: ... Valve collar retainer 4 Upper valve spring collar 5 Valve spring 6 Valve seal and lower valve spring collar assembly 7 Valve guide intake exhaust 2 8 Cylinder head 9 Exhaust port stud 10 Cylinder head gasket 11 Cylinder O ring 4 12 Cylinder insert 13 Cylinder w piston rings 14 Cylinder base gasket 15 Cylinder base stud 16 Exhaust valve 17 Exhaust valve seat ...

Page 240: ...carbon or dirt with compressed air 2 Soak cylinder head in an aluminum compatible cleaner solvent to loosen carbon deposits 3 Wash all parts in non flammable solvent followed by a thorough washing with hot soapy water Blow out oil passages in head Be sure they are free of sludge and carbon particles Remove loosened carbon from valve head and stem using a wire wheel Never use a file or other harden...

Page 241: ...igure 3 72 Measure rocker arm bushing inner diameter 4 Check the measurements obtained in Steps 5 6 against the SERVICE WEAR LIMITS Repair or replace parts exceeding limits 5 Assemble rocker arms and rocker arm shafts into lower rocker cover 6 Check end play of rocker arm with feeler gauge 7 Replace rocker arm or lower cover or both if end play exceeds 0 025 in 0 635 mm Figure 3 69 Measuring Rocke...

Page 242: ...rface must be flush with or below the head surface See 3 1 SPECIFICATIONS for valve seat to cylinder head fit Valve Guides 1 Clean valve guides by lightly honing with VALVE GUIDE HONE Part No HD 34723 2 Scrub guides with VALVE GUIDE BRUSH Part No HD 34751 and hot soapy water Measure valve stem outer diameter and valve guide inner diameter Check mea surements against 3 1 SPECIFICATIONS Valve Spring...

Page 243: ... From opposite side of rocker arm press out bushing and tap using a discarded rocker arm shaft 2 Press replacement bushing into rocker arm flush with arm end and split portion of bushing towards top of arm 3 Using remaining old bushing as a pilot line ream new bushing with ROCKER ARM BUSHING REAMER Part No HD 94804 57 4 Repeat for other end of rocker arm Figure 3 75 Replacing Rocker Arm Bushings 8...

Page 244: ...nding the guide At this point the correct guide height has been reached 5 Ream guides to final size or within 0 0010 in 0 0254 mm of final size using VALVE GUIDE REAMER Part No B 45523 Use REAMER LUBRICANT Part No HD 39964 or liberal amounts of suitable cutting oil to prevent reamer chatter NOTE The hone is not intended to remove material 6 Apply the proper surface finish to the valve guide bores ...

Page 245: ...e cut and be sure to highlight all 3 angles Allow marker to dry before proceeding NOTE Always ensure cutter blades and cutter pilot are clean before beginning the cutting process The correct clean ing brush is supplied with the Neway tool set Also ensure the inside of the valve guide is clean by using Kent Moore cleaning brush Part No HD 34751 6 Choose the cutter pilot that fits properly into the ...

Page 246: ...mplete clean up of the 46 angle and the width is at least 062 in 1 575 mm pro ceed to the next step 12 Select the proper 60 cutter and gently slide the cutter down the cutter pilot to the valve seat 13 Remove just enough material to provide an even valve seat width of 040 062 in 1 016 1 575 mm 14 Remove cutter pilot and wash head thoroughly and dry completely 15 Repeat the process on any valve sea...

Page 247: ... Valve collar retainer 4 Upper valve spring collar 5 Valve spring 6 Valve seal and lower valve spring collar assembly 7 Valve guide intake exhaust 2 8 Cylinder head 9 Exhaust port stud 10 Cylinder head gasket 11 Cylinder O ring 4 12 Cylinder insert 13 Cylinder w piston rings 14 Cylinder base gasket 15 Cylinder base stud 16 Exhaust valve 17 Exhaust valve seat ...

Page 248: ...injury 3 Blow dry with compressed air 4 Apply a liberal amount of engine oil to the valve stem 5 See Figure 3 80 Insert valve into valve guide and bottom valve on valve seat 6 See Figure 3 81 Place a protective sleeve over the valve stem keeper groove CAUTION Failure to use a protective sleeve on the valve stem keeper groove when installing the valve stem seal and collar assembly will result in da...

Page 249: ...arp edges on keeper groove will damage seal 8 Install valve spring and upper collar 9 See Figure 3 84 Compress spring with VALVE SPRING COMPRESSOR Part No HD 34736B NOTE The XB9R utilizes a single valve spring for each valve The inner and outer springs are combined into one tapered spring that is progressively wound 10 Insert valve keepers into upper collar making sure they engage grooves in valve...

Page 250: ... 3 21 Identify push rod color coding length and respective push rod positions in engine Place intake and exhaust push rods onto seat at top of tappet CAUTION After head s have been installed do not turn engine over until both push rods can be turned with fingers Other wise damage to push rods or rocker arms may result Figure 3 85 Push Rod Locations Table 3 21 Push Rod Selection POSITION COLOR CODE...

Page 251: ...ead screws is critical to proper distribution of pressure over gasket area It prevents gasket leaks stud failure and head and cylin der distortion 6 Start the cylinder head screws onto the cylinder studs two short bolts on the left side of the engine two long bolts on the right 7 See Figure 3 87 For each cylinder head start with screw numbered one as shown In increasing numerical sequence i e 1 2 ...

Page 252: ...nner 10 Gasket lower 11 Rocker Arm Shafts 12 Bolt 2 13 washer 2 14 Rocker Cover lower 15 Rocker Arm 2 16 Bushing rocker arm 4 17 Gasket lower rocker cover 18 Hydraulic lifter 19 Screw tappet anti rotation 2 20 Gasket push rod cover 21 Push Rod cover 22 Screw 4 23 O ring push rod cover 2 24 Push Rod 25 Washer 4 26 Bolt 4 1 2 3 4 5 6 7 8 11 12 13 14 15 16 17 26 24 22 21 20 23 25 9 10 b0960x3x 18 19 ...

Page 253: ... sequences sizes and torque specifications are listed in Table 3 22 a Tighten bolts 1 to 18 22 ft lbs 24 30 Nm b Tighten bolts 2 to 135 155 in lbs 15 18 Nm c Tighten bolts 3 to 135 155 in lbs 15 18 Nm 11 See Figure 3 89 Install upper rocker covers a Place a new inner gaskets on lower rocker box assemblies b Place a new lower gaskets on lower rocker cover c Install upper rocker cover using screws w...

Page 254: ...er studs Discard cyl inder base gasket CAUTION With cylinder removed be careful not to bend the cylin der studs The slightest bend could cause a stress riser and lead to stud failure 7 Install a 6 in 152 mm length of 1 2 in 12 7 mm ID plastic or rubber hose over each cylinder stud This will protect the studs and the piston 11WARNING 1WARNING Retaining rings are highly compressed in the ring groove...

Page 255: ...wel over the bore during removal Remove circlip from claw and discard NOTES It is not necessary to remove both piston pin circlips dur ing piston removal Leave the second circlip in the pin bore Since the piston pin is a loose fit in the piston the pin will easily slide out The pin has tapered ends to help seat the round retaining rings NOTE See Figure 3 93 The arrow at the top of pistons must alw...

Page 256: ... to bushing clearance exceeds 0 00200 in 0 05080 mm replace worn parts 6 Clean piston pin retaining ring grooves 7 Examine piston and cylinder for cracks burnt spots grooves and gouges 8 Check connecting rod for up and down play in lower bearings When up and down play is detected lower bearing should be refitted This requires removing and disassembling engine crankcase Checking Gasket Surface CAUT...

Page 257: ... speed at which the tool rotates determines the speed at which it must be stroked up and down the bore to produce the desired cross hatch pattern 4 Starting at the bottom of the cylinder move the deglazing tool up and down the entire length of the cylinder bore for 10 to 12 complete strokes Stop to examine the cylinder bore and or take measure ments A precise 60 cross hatch pattern in the piston t...

Page 258: ...new ring into the cylinder square it in the bore using the top of the piston and mea sure the ring end gap with a feeler gauge Do not use the ring if the end gap does not fall within the following spec ifications See Table 3 24 Figure 3 97 Piston Rings 1 Top compression ring Install either side up 2 Second compression ring Install dot toward top 3 Oil control rings 2 1 3 6612 Dot Figure 3 98 Measu...

Page 259: ...on surface when installing rings NOTE Install second compression ring with dot towards top 3 See Figure 3 100 Install rings so end gaps of adjacent rings are a minimum of 90 apart Ring gaps are not to be within 10 of the thrust face centerline 4 See Figure 3 101 Check for proper side clearance with thickness gauge as shown See 3 1 SPECIFICATIONS NOTE If the ring grooves are clean and the side play...

Page 260: ...ion as it was for removal of the bushing 7 Clean up and size bushing to 0 0010 0 0005 in 0 0254 0 0127 mm undersize using REAMER Part No HD 94800 26A Sizing bushing with less than 0 00125 in 0 03175 mm clearance can result in a bushing loosening and or seized pin in rod 8 Hone bushing to final size using WRIST PIN BUSHING HONE Part No HD 35102 Use a liberal amount of honing oil to prevent damage t...

Page 261: ... it has been installed and then removed for any reason A loosely installed ring will come out of the piston groove and damage cylinder and piston beyond repair 4 See Figure 3 108 Install new piston pin retaining rings 1 using PISTON PIN RETAINING RING INSTALLER 2 Part No HD 34623C Place new retaining ring on tool with gap pointing up NOTE Make sure the ring groove is clean Ring must be fully seate...

Page 262: ... piston does not bump the studs or crankcase 9 See Figure 3 111 Compress the piston rings using PIS TON RING COMPRESSOR Part No HD 96333 51C 10 Install cylinder over piston 11 Remove PISTON RING COMPRESSOR 12 Assemble and install cylinder head See 3 6 CYLINDER HEAD 13 Install assembled engine See 3 4 STRIPPING MOTOR CYCLE FOR ENGINE SERVICE Figure 3 109 Ring End Gap Position Figure 3 110 Piston Su...

Page 263: ...3 72 2003 Buell XB9R Engine HOME NOTES ...

Page 264: ...l combustion in a gasoline engine produces water vapor and carbon dioxide along with other gases and particu lates When first starting and warming an engine some of the water vapor that gets into the engine crankcase condenses to form liquid water If the engine is driven long enough to thor oughly warm the crankcase most of this liquid water is again vaporized and exhausted through the crankcase b...

Page 265: ...er on the left front side of the crankcases The feed line then exits the oil cooler and connects to the oil filter housing on the right front side of the crankcases The vent hose continues upward from under the vehicle to connect to an elbow fitting at the rear of the gearcase cover Figure 3 112 Oil Lines and Connections 1 Swingarm Oil reservoir 2 Vent oil line 3 Feed oil line 4 Return oil line 5 ...

Page 266: ...more viscous i e thicker When an engine is operated at high speeds the volume of oil circulated through the oiling system increases resulting in higher oil pressure As engine speed is reduced the volume of oil pumped is also reduced resulting in lower oil pressure To check oil pressure use OIL PRESSURE GAUGE Part No HD 96921 52B and OIL PRESSURE GAUGE ADAPTER Part No HD 96940 58 Remove oil pressur...

Page 267: ... PCV valves 4 located on top of the rocker boxes From the PCV valves the air enters the crankcase breather hoses 2 3 The crank case breather hoses route through the air cleaner base plate 1 to the air box where it is directed inside the air filter ele ment and back into the engine The oil mist collects and eventually returns to the crankcase through oil passageways in the cylinder head Figure 3 11...

Page 268: ...ING SYSTEM Fasteners should be tightened to 30 40 in lbs 3 4 4 5 Nm CAUTION See Figure 3 117 When replacing the reed valve it is extremely important to ensure that both edges of the reed valve stop 1 and the reed valve 2 are properly aligned to prevent premature failure of the reed valve When replacing the reed valve it is not necessary to replace the reed block See Figure 3 116 Figure 3 116 Reed ...

Page 269: ...n Oil is forced through the crank pin to properly lubricate the rod bearing assembly 11 Oil flow then continues through the gearcase cover to the main feed galley at the top of the gearcase cover Drilled passages in the crankcase intersect the main feed galley and carry oil to all hydraulic lifters and piston jets 12 Oil flows up passages in the push rods to the rocker arm shafts and bushings 13 T...

Page 270: ...p and is forced by the gerotor scavenge set back to the oil reservoir The oil pump seldom needs servicing Before you disassem ble an oil pump suspected of not producing adequate oil pressure be sure that all possible related malfunctions have been eliminated 1 Make sure all oil line connections are tight and that lines are not pinched or damaged 2 Check level and condition of oil in reservoir swin...

Page 271: ...ews 5 and washers only Pump will drop with screws removed Discard mounting gasket 6 Remove cover TORX screws 2 Lift cover off body 7 Remove and discard O ring 8 Slide both pieces of gerotor feed set separator plate and both pieces of gerotor scavenge set off gear shaft 9 Remove and discard retaining ring Remove thrust washer and gear shaft Figure 3 119 Oil Pump Hardware 1 Feed line connection 2 Co...

Page 272: ...shaft 2 Insert inner gerotor of the gerotor scavenge set over gear shaft 3 Place outer gerotor over inner gerotor to complete scav enge set 4 See Figure 3 121 Install gerotor separator plate by lining up slots on perimeter with tabs inside oil pump body 5 Install a new O ring into groove in pump body 6 See Figure 3 118 Place gerotor feed set over gear shaft 7 Place cover onto pump body Install cov...

Page 273: ...les and passages using compressed air ASSEMBLY NOTE Use TEFLON PIPE SEALANT or HYLOMAR on all fittings installed to oil filter mount 1 See Figure 3 122 Install oil pressure indicator switch 1 using OIL PRESSURE SENDING UNIT WRENCH Part No HD 41675 Tighten to 50 70 in lbs 6 8 Nm 2 Attach indicator lamp wire 2 NOTE The filter adapter has identical ends either end may be installed into the filter mou...

Page 274: ...a Remove screws b Remove push rod covers c Remove gaskets and o rings Discard parts 5 Remove valve hydraulic lifters a Remove anti rotation screws b Remove lifters from crankcase bore using a thin bladed screwdriver Mark the location and orienta tion front back of each lifter CLEANING AND INSPECTION 11WARNING 1WARNING Low pressure compressed air can blow debris into your face and eyes Always wear ...

Page 275: ... block b Tighten anti rotation screws to 55 65 in lbs 6 7 Nm 5 See Figure 3 125 Install push rod cover a Place new pushrod cover gasket over bottom of push rod cover b Position push rod cover onto crankcase c Install screws through holes in push rod cover into tapped holes in crankcase Tighten screws evenly to 30 40 in lbs 3 5 Nm d Place new o rings on top of push rod cover 6 Install push rods cyl...

Page 276: ...y others It is important to know and understand all inspection procedures and how components interact Figure 3 126 Gearcase Cover Cam Assembly b0980x3x 1 Screw 7 2 Seal 3 Fitting oil vent line 4 Gear Cover 5 Gear cover gasket 6 Bushing outer intake camshaft gear 7 E Cam gear set 8 Right crankcase half 9 Dowel pin 10 Bushing inner camshaft gear 4 11 Bushing outer camshaft gear 3 12 Key 13 Oil pump ...

Page 277: ... 6 Remove cam position sensor and rotor from gearcase cover See 4 30 CAM POSITION SENSOR AND ROTOR 7 Place a pan under gearcase to collect oil Remove cover screws Carefully remove gearcase cover Discard old gasket NOTE If cover does not come loose on removal of screws tap lightly with a plastic hammer Never pry cover off 8 See Figure 3 127 Remove cam gears 1 2 3 4 NOTE Nut is secured by LOCTITE 26...

Page 278: ...d by a letter E The numbers identify the cam location function and the letter E indicates model year application NOTE Prior to changing any cam gears check gear shaft fit within corresponding bushings Worn bushings can cause exces sive backlash Bushing Inspection 1 Bushings are press fit in gearcase cover and crankcase Inspect each bushing against its corresponding cam gear shaft or pinion gear sh...

Page 279: ...n shaft Tighten nut to 19 21 ft lbs 26 29 Nm plus an additional 15º to 19º rotation 3 See Figure 3 126 Liberally apply engine oil to bushings shafts and gears Install all cam gears into bushings of right crankcase half properly aligning timing marks of cam gears and pinion gear NOTE The XB9R uses new style timing marks on the front intake cam assembly Please note the V design Because of the larger...

Page 280: ...ver using a flat blade screwdriver c Measure gap between bushing in crankcase half and cam gear shaft thrust face shoulder using a feeler gauge This is cam gear end play d Compare cam gear end play measurements with the SERVICE WEAR LIMITS Make repairs as required if end play does not meet specifications 7 Install hydraulic lifters and push rods See 3 15 HYDRAULIC LIFTERS 8 Install cam position se...

Page 281: ... 6 CYLINDER HEAD CAUTION After removing cylinders install plastic or rubber hose over cylinder studs Lifting or moving crankcase by grasping studs will cause cylinder stud damage 2 Remove cylinders and pistons See 3 7 CYLINDER AND PISTON 3 Remove oil pump See 3 13 OIL PUMP 4 Remove gearcase components See 3 16 GEARCASE COVER AND CAM GEARS 5 Remove primary cover and primary drive clutch compo nents...

Page 282: ...r oil leakage or low oil pressure NOTE Gasket is part of the piston jet assembly Gasket not sold separately 1 Install new piston oil jet assemblies in right crankcase 2 Apply Loctite Low Strength Threadlocker 222 purple to threads of TORX screws 3 With the jet pointed upward install TORX screws to secure piston jet to crankcase Tighten screws to 25 35 in lbs 2 8 4 0 Nm Figure 3 134 Crankcase Faste...

Page 283: ...re 3 137 Gear shaft bearing 11 will remain on flywheel pinion shaft Remove retaining ring 12 and bearing can be slipped off pinion shaft Figure 3 136 Removing Flywheels from Left Crankcase 8622 Figure 3 137 Crankcase and Flywheel Assembly b0975x3x 1 2 3 4 5 6 7 8 9 14 1 Spacer sprocket shaft 2 Oil seal 3 Thrust washer 4 Crankcase half 5 Bearing 6 Retaining ring 7 Inner race left main bearing 8 Thr...

Page 284: ...inner race does not need to be ground once it is installed on the sprocket shaft 9 See Figure 3 139 Remove left main bearing retaining ring from the inside of the left crankcase half 10 See Figure 3 140 Using CRANKCASE BEARING REMOVER INSTALLER Part No B 45655 and HD 42720 2 press left main bearing out of the left crank case half NOTE The bearing presses to the inside There is a shoulder incor por...

Page 285: ...r race and the smallest measured inside diameter ID of the outer race crankcase bushing A running clearance of 0 0002 0 0008 in 0 0051 0 0203 mm is established during crankcase set or flywheel assembly replacement and engine rebuild 12 See Figure 3 142 Installed inner races are identified at the factory as shown See Table 3 28 Table 3 28 Paint Dot Specifications Figure 3 141 Removing Pinion Bearin...

Page 286: ... 30 Roller Specifications 14 See Figure 3 144 Pinion bearings are identified as shown Figure 3 143 Factory Outer Race Sizes RACE ID CLASS NO STAMPED IDENTIFICATION 1 5646 1 5648 in 39 7408 39 7459 mm 1 1 1 5648 1 5650 in 39 7459 39 7510 mm 2 2 1 5650 1 5652 in 39 7510 39 7561 mm 3 3 SERVICE WEAR LIMIT 1 5672 in 39 8069 mm ID a0134x3x Outer Race Right Crank case Half Stamped Class No Figure 3 144 B...

Page 287: ...m Red Blue White Gray Green 1 5658 1 5660 in 39 771 39 776 mm Red Blue White Gray Green 1 5656 1 5658 in 39 766 39 771 mm Red Blue White Gray Green 1 5654 1 5656 in 39 761 39 766 mm Red Blue White Gray Green 1 5652 1 5654 in 39 756 39 761 mm Red Blue White Gray Green 3 1 5650 1 5652 in 39 751 39 756 mm Red Blue White Gray Green 2 1 5648 1 5650 in 39 746 39 751 mm Blue White Gray Green 1 1 5646 1 5...

Page 288: ...cations continue lapping until specifications are met c If all specifications are met continue at Step 7 to remove and size inner race 5 Press the outer race from the right crankcase Press new outer race into crankcase flush with inside edge of cast in insert NOTE See Figure 3 145 Dimensions are shown for fabrication of tools used in pressing the outer race into or out of crankcase 6 The new outer...

Page 289: ...ved tolerance range If you are unable to perform this operation Harley David son Motor Company provides a flywheel refurbishing program as outlined in Tech Tip 38 Always use the smallest outer race ID measurement and the largest OD inner race measurement when selecting bearings 9 The following example illustrates how to determine the required inner race OD a See Table 3 31 For example purposes sup...

Page 290: ...shing will develop a condition where hole is larger at ends than it is in the center 4 Withdraw arbor far enough to coat lightly with 220 grit lapping compound Do not apply a heavy coat Reposi tion lap in bushing and turn handle at moderate hand speed Work lap back and forth in bushing as it is revolved to avoid grooving and tapering At frequent intervals remove lap from crankcase wash and inspect...

Page 291: ...se Halves NOTE Lubricate all parts with Harley Davidson 20W50 engine oil and proceed as follows Figure 3 149 Left Main Bearing Assembly 1 Spacer sprocket shaft 2 Oil seal 3 Thrust washer 4 Crankcase half 5 Bearing 6 Retaining ring 6 1 2 3 5 b1046x3x 4 ...

Page 292: ... crankcase half to engine stand 5 Install flywheel assembly using CRANKSHAFT GUIDE Part No HD 42326 6 See Figure 3 152 Install pinion shaft bearing a Lubricate pinion shaft bearing with engine oil b Slip bearing on pinion shaft c Install new retaining ring in groove of pinion shaft bearing inner race Figure 3 150 Left Main Bearing Installation 8789 8792 8762 1 2 3 1 Shoulder for left main to press...

Page 293: ...crankcase joint faces b Slide outer race in right crankcase over pinion shaft and bearing assembly c Tighten fasteners to 15 19 ft lbs 20 26 Nm NOTE According to manufacturing there is no torque sequence to follow when tightening crankcase fasteners Figure 3 153 Crankcase Fasteners D b1016x3x Indicates Bolt Pattern Location One Behind Shifter Mechanism ...

Page 294: ... Use SPROCKET SHAFT SEAL INSTALLER Part No B 45676 to install sprocket shaft seal a Install bearing seal and spacer b Center seal spacer driver over seal so that the sleeve smaller OD seats between seal wall and garter spring c Sparingly apply graphite lubricant to threads of pilot shaft to ensure smooth operation d Slide sleeve over pilot until sleeve contacts the oil seal Install handle on top o...

Page 295: ...3 OIL PUMP 14 Install cam gears gearcase cover lifter guides and lift ers See 3 16 GEARCASE COVER AND CAM GEARS 15 Install cylinder head See 3 6 CYLINDER HEAD 16 Install starter See 5 7 STARTER 17 Install shift linkage 18 Install all primary drive components This includes engine sprocket primary chain complete clutch assem bly engine sprocket nut and mainshaft nut See 6 4 PRI MARY DRIVE CLUTCH 19 ...

Page 296: ...Trouble Code 11 4 41 4 17 Trouble Code 13 4 45 4 18 Trouble Code 14 4 50 4 19 Trouble Code 15 4 54 4 20 Trouble Code 16 4 58 4 21 Trouble Codes 23 and 32 4 62 4 22 Trouble Codes 24 and 25 4 66 4 23 Trouble Code 33 4 69 4 24 Trouble Code 35 4 72 4 25 Trouble Code 36 4 75 4 26 Trouble Code 44 4 79 4 27 Trouble Codes 52 53 54 and 55 4 83 4 28 Trouble Code 56 4 84 4 29 Electronic Control Module 4 89 4...

Page 297: ...04 4 39 Fuel Tank Vent Valve 4 110 4 40 Fuel Cap Retaining Ring 4 111 4 41 Throttle Body and Intake Manifold 4 112 4 42 Intake Leak Test 4 117 4 43 Airbox 4 119 4 44 Evaporative Emissions Control California Models 4 121 ...

Page 298: ... page 4 111 Fuel pump drain plug 84 108 in lbs 9 5 12 2 Nm page 4 104 Fuel pump harness fastener 18 22 in lbs 2 0 2 5 Nm page 4 108 Fuel pump screws 48 51 in lbs 5 4 5 8 Nm page 4 109 Fuel pump wire harness fastener 18 22 in lbs 2 0 2 5 Nm page 4 108 Fuel rail fasteners 24 28 in lbs 2 7 3 2 Nm LOCTITE THREADLOCKER 222 purple page 4 114 page 4 115 Fuel supply line banjo fitting 10 12 ft lbs 13 6 16...

Page 299: ...4 2 2003 Buell XB9R Fuel System HOME NOTES ...

Page 300: ...m which allows it to adjust for all possible operating con ditions During open loop operation the system utilizes pro grammed fuel and spark maps in the ECM which provide ease of cold starting and maximum power at wide open throt tle WOT The adaptive fuel value which is learned during closed loop operation is applied during open loop operation to adjust fuel and spark maps for optimum performance ...

Page 301: ...r IGN Coil Front Cooling Fan Ground Data Link b1079x4x BN Y PK GN GY LT GN GY Y BE W Y LT GN R V GY PK Y BK BK BK W LT GN Y R W GY Tachometer G2 G10 G7 G9 G4 G11 G12 B2 B11 B5 B4 B12 B10 B6 B7 B1 Instrument Module V R BK Y BK GN W Electronic Control Module ECM one 12 place black connector 10 one 12 place gray connector 11 GY GY GY GY GY B8 Y R Y R B3 BE O G1 G3 G6 BK O To cooling fan fuse Rear To ...

Page 302: ...lems RESOLVING PROBLEMS NOTE The most sophisticated method of resolving problems involves using a computer based diagnostic package called DIGITAL TECHNICIAN Part No HD 44750 To resolve system problems five basic steps are involved In order of occurrence they are 1 Check for trouble codes by observing check engine lamp See 4 4 CHECKING FOR TROUBLE CODES 2 Retrieve trouble codes using check engine ...

Page 303: ...2 See Figure 4 116 After lamp turns off after being illumi nated for the first four second period one of three situa tions may occur a The lamp remains off This indicates there are no current fault conditions or stored functional trouble codes currently detected by the ECM b The lamp stays off for only four seconds and then comes back on for an eight second period This indi cates a functional erro...

Page 304: ... note that historic trouble codes may also be present whenever the system indicates the existence of a current fault See 4 4 CHECKING FOR TROUBLE CODES if multiple trouble codes are found Functional Trouble codes 52 through 56 are considered to be functional codes They indicate an internal problem with the ECM trou ble codes 52 through 55 or with the camshaft sensor timing trouble code 56 RETRIEVI...

Page 305: ...trouble code The length of time the lamp is illuminated and the length of time in which it is off are each about 1 second in duration 4 The second digit follows a Following transmission of the first digit there is another 2 second pause in which the lamp is off b The lamp will then flash one or more times to indi cate the second digit of the trouble code Count the number of times the lamp flashes ...

Page 306: ... using a jumper wire on Pins 1 and 2 of the data link connector However if the jumper wire is removed with the engine running the check engine lamp will continue to flash trouble codes To stop check engine lamp from flashing codes turn engine stop switch OFF CLEARING CODES After correcting system problems clear trouble codes If the Digital Technician Part No HD 44750 is not available per form 50 s...

Page 307: ...nnector from Breakout Box to corre sponding black ECM connector b Attach black connector from the wiring harness to black connector on Breakout Box 4 Attach Breakout Box to gray connector 11 a Attach gray connector from Breakout Box to corre sponding gray ECM connector b Attach gray connector from the wiring harness to gray connector on Breakout Box REMOVAL 1 See Figure 4 121 Depress latches on ea...

Page 308: ...art No H D 39978 to wiring harness between the suspect connections When diagnosing ECM connections a BREAKOUT BOX Part No HD 42682 may be used to simplify the proce dure See 4 6 BREAKOUT BOX 2 Set DVOM to read voltage changes 3 Start motorcycle engine and run at idle 4 Shake or wiggle harness to detect intermittents If inter mittents are present radical voltage changes will register on the DVOM Fi...

Page 309: ...and 2 of the data link connector However if the jumper wire is removed with the engine running the check engine lamp will continue to flash trouble codes To stop check engine lamp from flashing codes turn engine stop switch OFF Diagnostic Notes The reference numbers below correlate with the circled num bers on the diagnostic check flow charts See Diagnostic Check Part 1 of 2 1 Compare engine behav...

Page 310: ...ION Table 4 31 Trouble Codes and Fault Conditions CODE NO FAULT CONDITION RELEVANT TOPIC 11 Throttle position sensor 4 16 TROUBLE CODE 11 13 Oxygen sensor 4 17 TROUBLE CODE 13 14 Engine temperature sensor 4 18 TROUBLE CODE 14 15 Intake air temperature sensor 4 19 TROUBLE CODE 15 16 Battery voltage 4 20 TROUBLE CODE 16 23 Front fuel injector 4 21 TROUBLE CODES 23 AND 32 24 Front ignition coil 4 22 ...

Page 311: ... ECM Connector 10 Connector 11 LTGN R GY BK BK V R Data Link 91A b1080x4x To IGN relay Table 4 32 Wire Harness Connectors in Figure 4 123 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch in fairing 11 ECM gray 12 place Deutsch in fairing 91A data link 4 place Deutsch beneath left side fairing ...

Page 312: ...CHECK ENGINE LAMP ON CONTINUOUSLY NO Does engine start YES See 4 11 ENGINE CRANKS BUT WILL NOT START NO YES NO Are any trouble codes displayed YES NO Refer to applicable trouble code flow chart Start with lowest trouble code All diagnostic codes are listed on page 7 13 in Table 4 31 YES Go to Diagnostic Check Part 2 of 2 Refer to diagnostic tips in related trouble code chart even if no code is set...

Page 313: ...Continu ity to ground Test the four data link connector terminals against their ECM connector pins for continuity Continuity present in all four circumstances DATA LINK TERMINAL ECM TERMINAL Pin Wire Color Pin Connector 1 Lt GN R 11 11B 2 BK 11 10B 3 V R 12 11B 4 GY 1 10B NO Repair short to ground YES YES Inspect terminals for damage or repair opens as necessary NO 2 2 Replace ECM See 4 29 ELECTRO...

Page 314: ...DIAGNOSTICS Diagnostic Tips Check for the following conditions Check for open in BK Y wire Check for blown accessory fuse Diagnostic Notes The reference numbers below correlate with the circled num bers on the Test 4 9 flow chart 1 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 black pin probe and patch cord 2 See Figure 4 125 Inspect connector 10 black for con tamination or corrosion If connecti...

Page 315: ...Switch 33 To battery Electronic Control Module ECM Connector 10 Connector 11 Instrument Module 39 R BK W R Y R GY O W R R R Main Fuse 5A Spare Spare Empty ECM Lights Key Switch Diode 1 Diode 2 Brake Horn Cooling Fan Ignition Accessory Fuse Block Check Engine Lamp R GY Accessory Fuse KeySwitch Fuse b1081x4x Top View Table 4 33 Wire Harness Connectors in Figure 4 126 NO DESCRIPTION TYPE LOCATION 10 ...

Page 316: ... YES No ECM power Refer to 4 12 NO ECM POWER NO Refer to 4 11 ENGINE CRANKS BUT WILL NOT START for no start condition and then return to 4 9 CHECK ENGINE LAMP NOT ILLUMI NATED AT KEY ON to resolve no engine check lamp YES NO Disconnect instruments connector 39 Remove BK Y wire from connector 39 and ground it Reconnect connector 39 Check engine lamp ON YES Repair open or short to voltage on BK Y wi...

Page 317: ...go off for four seconds It may then come back on for an eight second period for a stored error or remain on continuously current error DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Test 4 10 flow chart 1 See Figure 4 128 If the lamp goes off when the black ECM connector 10 is unplugged the BK Y wire is not shorted to ground Figure 4 127 Check E...

Page 318: ...Switch 33 To battery Electronic Control Module ECM Connector 10 Connector 11 Instrument Module 39 R BK W R Y R GY O W R R R MainFuse 5A Spare Spare Empty ECM Lights Key Switch Diode 1 Diode 2 Brake Horn Cooling Fan Ignition Accessory Check Engine Lamp R GY Accessory Fuse KeySwitch Fuse b1081x4x Fuse Block Top View Table 4 34 Wire Harness Connectors in Figure 4 129 NO DESCRIPTION TYPE LOCATION 10 E...

Page 319: ...ON YES NO Check engine lamp function OK Check for trouble codes See 4 4 CHECKING FOR TROUBLE CODES With ignition key switch OFF reconnect black ECM connector 10 With ignition key switch ON verify that there is NOT a 4 second lamp OFF period Is there a lamp OFF period YES NO Repair short to ground on BK Y wire between connector 39 and connector 10 Repair short to ground on BK Y wire between connect...

Page 320: ...e to SPARK PLUG TESTER Part No HD 26792 Clip tester to cylin der head bolt c While cranking starter look for spark Repeat proce dure on other spark plug cable 1WARNING 1WARNING The gasoline in the fuel supply line downstream of the fuel pump is under high pressure 49 psi 338 kPa To avoid an uncontrolled discharge or spray of gasoline always purge the system of high pressure gas before servicing th...

Page 321: ...Ignition Coil 83 W Y GN W BK W R W Electronic Control Module ECM Connector 10 Connector 11 GY Cam Position Sensor 14 A GN W Y BE GY BE O BK W B C A A A C B B B To Rear Cylinder To Front Cylinder W Y GN GY R W Rear Injector 85 GY To Ignition Relay Y BE GY BE O GY GN GY Dyno Loop b1071x4x ...

Page 322: ...mp illuminate NO No pump response but light OK See 4 13 FUEL PRESSURE TEST NO Pump OK but no light See 4 9 CHECK ENGINE LAMP NOT ILLUMI NATED AT KEY ON YES Install Fuel Pressure Gauge See 4 13 FUEL PRES SURE TEST While cranking engine for more than two seconds to ensure proper system operation verify that pressure rises to 49 51 PSI 338 352 kPa Adequate pressure NO Incorrect pressure See 4 13 FUEL...

Page 323: ... See 4 15 MISFIRE Check coil by substituting one known to be good OR Check coil resistance See 4 31 IGNITION COIL YES Connect Breakout Box Check continuity between ignition coil Terminal A of connec tor 83 and Breakout Box BK Pin 7 Measure resistance between ignition coil Terminal C and ECM Pin 6 10B Resistance should be less than 1 0 ohm Is it NO Disconnect cam position sensor connector 14 With i...

Page 324: ...d wires to iden tify any loose connects engine misfires or stalls Any found YES Pinion gear key failure loose rotor cup or other mechanical failure NO Replace cam position sensor See 4 30 CAM POSITION SENSOR AND ROTOR NO Repair YES NO Disconnect connector 14 Measure resis tance between Terminal B and Connector 14B and Breakout Box GY Pin 3 Is resistance greater than 1 0 ohms Remove cam timer cover...

Page 325: ...lay through the sidestand switch See Figure 4 134 By disengaging the clutch and grounding the relay through the clutch switch See Figure 4 135 If the ECM does not appear to be receiving power check the ground sources A blown ignition fuse can also disable the ECM DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Test 4 12 flow chart 1 Connect BREAK...

Page 326: ... Ignition Electronic Control Module ECM Connector 11 Diode 2 Connector 10 Diode 1 Key Switch Start Relay Center Fuse Block Spare Spare Empty ECM Lights Key Switch Diode 1 Diode 2 Brake Horn Cooling Fan Ignition Accessory R R W BK R R R R Y R BK BK BK BK TN LTGN TN LTGN TN W TN Y W BK GY O W BK TN W TN W TN W TN Y R BK GY GY GY BK BK LT GN R V R To Battery R BK R BK GY O b1077x4x Top View Top View ...

Page 327: ... ignition relay Terminal 30 GY O Voltage present Replace ignition relay See 7 5 STARTER INTERLOCK Check for 12 volts on ignition relay Terminal 86 W BK Voltage present Repair open on GY O wire between connector 22 and ignition relay NO Check ignition fuse Is fuse OK YES Replace ECM See 4 29 ELECTRONIC CONTROL MODULE YES Attach Breakout Box HD 42682 to ECM Check for 12 volts on ECM connector 10 Pin...

Page 328: ...e any remaining fuel from fuel line 1WARNING 1WARNING A small amount of gasoline will drain from the valve when the gauge is installed Thoroughly wipe up any spilt fuel immediately Dispose of rags in a suitable manner Gasoline is extremely flammable and highly explosive Inadequate safety precautions could result in death or serious injury 3 See Figure 4 138 Depress button 2 of fuel line connec tor...

Page 329: ... up any spilt fuel immediately Dispose of rags in a suitable manner Gasoline is extremely flammable and highly explosive Inadequate safety precautions could result in death or serious injury 10 See Figure 4 140 Turn engine off Detach pressure gauge 4 from adapter 1 a Open the air bleed petcock 5 to relieve fuel system pressure and purge the pressure gauge of gasoline b Remove pressure gauge from a...

Page 330: ... To Battery Ignition Relay Key Switch Relay W BK GY O W BK GY O Ignition Fuse Key Switch Fuse R R R BK BK BK Y R TN W TN W GY O R BK BK BN Y GY GY Electronic Control Module ECM Connector 10 Connector 11 Right Handlebar Switch 22 b1082x4x R R W BK GY O GY O R BK BK R R BK Ignition Key Switch Start Relay Center Fuse Block Spare Spare Empty ECM Lights Key Switch Diode 1 Diode 2 Brake Horn Cooling Fan...

Page 331: ...r 89 during first two seconds after key ON Is volt age greater than 1 VDC Check for restricted pump inlet screen Is screen restricted NO Move negative probe to GY wire on Terminal 87 of ignition relay Measure voltage during first two seconds after key ON Is voltage greater than 1 VDC YES Locate and repair poor connection between ignition relay and fuel pump NO Move negative probe to GY O wire on T...

Page 332: ...inal Probe BN Y wire at 86A during the first two seconds after key ON Does test lamp light YES NO Connect Breakout Box HD 42682 to ECM Check continuity between 86A Ter minal C BN Y wire and ECM connector 10 black Termi nal 3 Is continuity present Inspect fuel pump wiring Is wiring OK YES NO Repair fuel pump wiring NO Replace fuel pump assembly See 4 38 FUEL PUMP YES Locate and repair open on BN Y ...

Page 333: ...uster knob 1CAUTION Idle adjuster is located near the engine and could be extremely hot Use suggested tool for adjusting the idle speed Failure to comply could result in minor or moder ate injury The idle speed should be adjusted when the engine is at nor mal operating temperature NOTE An idle speed too low can cause poor throttle response An idle speed too high can cause a slow return to idle See...

Page 334: ...jump tester gap on leads e Reinstall and repeat procedure on other spark plug cable 2 Perform spark plug cable resistance test a Remove spark plug cable from spark plug and igni tion coil See 7 4 SPARK PLUG CABLES b Using an ohmmeter touch probes to terminals on each end plug wire c Compare resistance values to Table 4 39 Replace cables not meeting specifications Reinstall and repeat procedure on ...

Page 335: ...trols 4 place Multilock beneath right side of fairing 83 ignition coil 3 place Packard beneath airbox base Front Injector 84 Ignition Coil 83 W Y GN W BK W R W Electronic Control Module ECM Connector 10 Connector 11 GY Cam Position Sensor 14 A GN W Y BE GY BE O BK W B C A A A C B B B To Rear Cylinder To Front Cylinder W Y GN GY R W Rear Injector 85 GY To Ignition Relay Y BE GY BE O GY GN GY Dyno L...

Page 336: ...check for faulty plug wire connections and wire boots for carbon tracking Are wires OK YES Check for Faulty worn or cracked spark plug s Plug fouling due to engine mechanical fault Faulty or poor connection at plug NO Replace faulty wires YES Coils should be free of carbon tracking Are they NO Replace ignition coil YES Switch coil with unit known to be good Perform spark test Did spark jump gap du...

Page 337: ...akout Box GY Voltage should alternate between 0 and 5 volts while cranking Does it YES With engine running wiggle cam position sensor and wires to iden tify any loose connects engine misfires or stalls Any found YES Pinion gear key failure loose rotor cup or other mechanical failure NO Replace cam position sensor See 4 30 CAM POSITION SENSOR AND ROTOR NO Repair YES NO Disconnect connector 14 Measu...

Page 338: ...out terminals improper mating broken locks improperly formed or damaged terminals poor terminal to wire connection and damaged harness Perform 4 7 WIGGLE TEST to locate intermittents If connections and harness check out OK monitor TP sen sor voltage using DVOM while moving related connec tors and wiring harness If the failure is induced the DVOM display will change TP sensor scaling Observe the TP...

Page 339: ...ctor 10 Connector 11 LTGN GY R W 5 Volt Reference Lt GN GY BAS Signal BK W Sensor Ground Bank Angle Sensor 134 BK W R W LTGN GY b1112x4x Table 4 41 Wire Harness Connectors in Figure 4 147 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch in fairing 11 ECM gray 12 place Deutsch in fairing 14 cam position sensor 3 place Deutsch under sprocket cover 88 throttle position sensor 3 place Packar...

Page 340: ...ne lamp come on and set CODE 11 NO System now OK YES Install original TP sensor and replace ECM 4 29 ELECTRONIC CON TROL MODULE Road test again to verify YES Connect Breakout Box if not already connected Disconnect TP sensor connector 88 and ECM connector 11 Measure voltage at Pin 2 and Pin 7 Does voltage measure 5 0 volts NO Go to Code 11 Test Part 2 of 2 STOP YES Reconnect TP sensor connector 88...

Page 341: ...ir open in R W wire NO Check continuity between connector 88 Terminal B V Y wire and Pin 2 of connector 11 Continuity present YES 7615 Locate and repair open in V Y wire NO Check continuity between con nector 88 Terminal C BK W and Pin 7 of connector 11 Continuity present YES 7580 Locate and repair open in BK W wire NO YES 7610 Locate and repair short between R W and BK W wires Reconnect 14 NO Rep...

Page 342: ...nning below 5000 RPM for the ECM to detect an O2 sensor failure Check for the following conditions Poor connection Inspect the ECM harness connector 11 fuel injector connectors 84 85 and O2 sensor con nector wiring for backed out terminals improper mating broken locks improperly formed or damaged terminals poor terminal to wire connection and damaged harness Dirty stuck open injectors The motorcyc...

Page 343: ...x4x Oxygen Sensor 137 Electronic Control Module ECM Connector 10 Connector 11 V GY V GY 1 137B 137A Table 4 42 Wire Harness Connectors in Figure 4 150 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch in fairing 137 oxygen sensor 1 place Packard behind rear cylinder head ...

Page 344: ...d Pin 7 of con nector 11 gray Turn ignition ON and start engine Engine must be on and running to read O2 sensor values Observe O2 voltage Is it approximately 0 5 volts Install Breakout Box HD 42682 leaving harness side connector 11 disconnected from the Breakout Box Is the O2 voltage approximately 0 5 volts YES NO Inspect V GY wire for shorts to voltage and repair Replace ECM See 4 29 ELECTRONIC C...

Page 345: ...t NO Check for air leaks at induction module Air leak present YES Replace fuel line or filter NO Fuel injectors may be dirty See Fuel Injectors under 4 41 THROTTLE BODY YES Repair Go to Code 13 Test Part 3 of 3 STOP YES Repair low pres sure problem See 4 13 FUEL PRES SURE TEST Replace fuel pump See 4 38 FUEL PUMP 7661 7664 7666 7663 7667 7668 7662 Clear codes and confirm proper operation with no c...

Page 346: ...riginal O2 sensor and replace ECM 4 29 ELECTRONIC CONTROL MODULE Road test again to verify YES See Code 13 Test Part 2 of 3 for diagnostic material NO Continued from Code 13 Test Part 2 of 3 Turn ignition OFF and reconnect O2 sensor Turn ignition ON and start engine Allow engine to reach operating temperature Does voltage quickly flunctuate between 0 1 0 8 volts 7669 7672 7671 Clear codes and conf...

Page 347: ...sulation Check the following conditions Poor connection Inspect ECM harness connector 11 for backed out terminals improper mating broken locks improperly formed or damaged terminals poor terminal to wire connection and damaged harness Shifted sensor The temperature to resistance values table may be used to test the ET sensor at various tem perature levels in order to evaluate the possibility of a ...

Page 348: ... 90 PK Y Electronic Control Module ECM Connector 10 Connector 11 PK Y 1 Engine Temperature Sensor Location b0801x4x 90A 90B REAR CYLINDER Table 4 44 Wire Harness Connectors in Figure 4 151 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch in fairing 90 engine temperature sensor 1 place bullet beneath airbox base ...

Page 349: ...asure the resistance between Pin 9 of 11 and Pin 2 of 10 and Pin 11 of 10 on Breakout Box Is it greater than 1 0 megaohm NO Examine PK Y wire in harness for open circuit and repair YES NO Examine harness for short to ground and repair At some point in the flow chart you may be instructed to jump directly to the box marked by an asterisk Dis regard the asterisk but not the instruction box if your n...

Page 350: ... connect ECM connector 11 Mea sure resistance between ECM Pin 9 of 11 and Pin 2 of 10 Is resistance less than 1 ohm Unplug ECM leaving Breakout Box connected at vehicle harness Measure voltage between ECM Pin 9 of 11 and Pin 2 of 10 on Breakout Box Is the voltage 0 volts Install original ET sensor replace ECM 4 29 ELEC TRONIC CONTROL MODULE and road test YES System OK Repair short to ground on PK ...

Page 351: ...nal to wire connection and damaged harness Perform 4 7 WIGGLE TEST to locate intermittents If connections and harness check out OK check intake air temperature reading while moving related connectors and wiring harness If the failure is induced the IAT sen sor display will change Shifted sensor The temperature to resistance values table may be used to test the IAT sensor at various tem perature le...

Page 352: ...r 10 Connector 11 Lt GN Y Intake Air Temperature Sensor 89 Lt GN Y 5 volt reference and sensor signal BK W sensor ground 1 2 BK W Lt GN Y IAT Sensor 8380 P89B P89A Table 4 46 Wire Harness Connectors in Figure 4 152 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch in fairing 89 intake air temperature sensor 2 place Amp in airbox base ...

Page 353: ...R clear codes and road test Did check engine lamp come on and set only CODE 15 With IAT sensor disconnected dis connect ECM connector 11 Mea sure resistance between ECM Pin 10 of 11 and Pins 2 and 11 of 10 Is resistance less than 1 megaohm Unplug ECM leaving Breakout Box connected at vehicle harness Measure voltage between ECM Pin 10 of 11 and Pin 2 of 10 on Breakout Box Is the voltage 0 volts Ins...

Page 354: ...0 and 7 of connector 11 on Breakout Box Is it greater than 1 0 megaohm NO Examine BK W wire in harness for open circuit and repair YES Using a DVOM measure the resistance between ECM Pin 10 of connector 11 on Breakout Box and ground Is it greater than 1 0 megaohm NO Examine Lt GN Y wire and BK W wire in harness for short between these two circuits and repair YES NO Examine harness for short to gro...

Page 355: ...rrelate with the circled num bers on the Code 16 flow charts 1 The ECM is monitoring voltage at ECM connector 10 black Terminal 1 Connect BREAKOUT BOX Part No HD 42682 to ECM See 4 6 BREAKOUT BOX 2 This checks for voltage drops in the ECM power circuit If a significant voltage drop is not present condition may be caused by excessive starter current draw Figure 4 153 Electrical Relays Figure 4 154 ...

Page 356: ...tch Relay Ignition Fuse Key Switch Fuse Ignition Switch 33 Main Fuse 5A Ignition Electronic Control Module ECM Connector 11 Connector 10 Key Switch Start Relay Center Fuse Block Spare Spare Empty ECM Lights Key Switch Diode 1 Diode 2 Brake Horn Cooling Fan Ignition Accessory R R W BK R R R Y R BK BK BK W BK GY O W BK TN W R BK GY GY BK LT GN R V R To Battery R BK R BK GY O b1083x4x R TN W R Top Vi...

Page 357: ...on Breakout Box with key ON Is voltage drop greater than 0 5 volt System OK YES NO Check for excessive starter cur rent draw See 5 6 STARTER SYSTEM TESTING Measure voltage drop between Battery Positive Terminal and Terminal 87 on ignition relay with key ON Is voltage drop greater than 0 5 volt NO Replace ignition relay 1 2 YES Measure voltage drop between Battery Positive Terminal and GY O Termina...

Page 358: ... 0 5 volt YES NO Repair R wire or terminals Measure voltage drop between Battery Positive Terminal and R Y wire of 30 amp Main fuse with key ON Is voltage drop greater than 0 5 volt YES NO Replace main fuse Replace R Y wire between main fuse and battery 7781 YES Measure voltage drop between Battery Positive Terminal and R BK wire Terminal on 15 amp ignition fuse with key ON Is voltage drop greater...

Page 359: ...um bers on the Code 23 32 flow charts 1WARNING 1WARNING The gasoline in the fuel supply line downstream of the fuel pump is under high pressure 49 psi 338 kPa To avoid an uncontrolled discharge or spray of gasoline always purge the system of high pressure gas before servicing the fuel system Gasoline is extremely flamma ble and highly explosive Inadequate safety precautions could result in death o...

Page 360: ... W GY BK W B C A A B B W Y GN GY R W Rear Injector 85 GY GY GN GY b1073x4x To Ignition Relay Table 4 48 Wire Harness Connectors in Figure 4 159 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch in fairing 14 cam position sensor 3 place Deutsch under sprocket cover 84 front fuel injector 2 place Packard underneath airbox base 85 rear fuel injector 2 place Packard underneath airbox base ...

Page 361: ...ctor 84 If CODE 32 measure resistance between ECM Pin 8 of 10 GN GY wire and Terminal 2 of rear injector connector 85 Is resistance less than 0 5 ohm YES Check for loose or corroded terminals in harness Repair as necessary Replace injector See 4 41 THROTTLE BODY YES NO NO Go to Code 23 32 Test Part 2 of 2 YES NO Repair open or poor connection Using Breakout Box check with test lamp between ECM 10 ...

Page 362: ...ition relay and Terminal 2 W Y for Code 23 or GN GY for Code 32 wire at injector connector Is resistance less than 0 5 ohm With DVOM still attached perform 4 7 WIGGLE TEST to locate intermittents Repair as necessary Find and repair connection or open wire YES NO Check for multiple codes See 4 4 CHECKING FOR TROUBLE CODES 7825 7820 Clear codes and confirm proper operation with no check engine lamp ...

Page 363: ... ignition relay at coil pin B 3 at the same time that the fuel pump and injectors are activated DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Code 24 25 flow charts 1 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 purple pin probes and patch cord 2 Connect BREAKOUT BOX Part No HD 42682 to ECM See 4 6 BREAKOUT BOX Figure 4 160 Ignition Coil Fig...

Page 364: ...or 10 Connector 11 Cam Position Sensor 14 A GN W Y BE GY BE O BK W B C A C B To Rear Cylinder To Front Cylinder R W GY Ignition Relay Y BE GY BE O Dyno Loop b1072x4x Table 4 49 Wire Harness Connectors in Figure 4 162 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under fairing 83 ignition coil 3 place Packard beneath airbox base ...

Page 365: ... voltage Is it YES Repair open wire or connection on GY wire NO Check for multiple codes See 4 4 CHECKING FOR TROUBLE CODES Attach Breakout Box HD 42682 to ECM Mea sure resistance between ECM and coil terminals as follows Resistance should be less than 0 5 ohms Is it Trouble Code Coil Terminal ECM Terminal 24 Front A BE O 7 25 Rear C Y BE 6 NO Repair open wire or connection YES Perform 4 7 WIGGLE ...

Page 366: ...even when the motor is not running Fuel pump motor stalls or spins without providing fuel pressure DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Code 33 flow chart 1 Connect BREAKOUT BOX Part No HD 42682 to ECM See 4 6 BREAKOUT BOX 2 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 red pin probe and patch cord 3 Use HARNESS CONNECTOR TEST KIT Pa...

Page 367: ... To Battery Ignition Relay Key Switch Relay W BK GY O W BK GY O Ignition Fuse Key Switch Fuse R R R BK BK BK Y R TN W TN W GY O R BK BK BN Y GY GY Electronic Control Module ECM Connector 10 Connector 11 Right Handlebar Switch 22 b1082x4x R R W BK GY O GY O R BK BK R R BK Ignition Key Switch Start Relay Center Fuse Block Spare Spare Empty ECM Lights Key Switch Diode 1 Diode 2 Brake Horn Cooling Fan...

Page 368: ...gine lamp come on and set only CODE 33 YES NO Install original fuel pump 4 38 FUEL PUMP and replace ECM 4 29 ELECTRONIC CONTROL MODULE System OK Fuel pump on continuously NO Check continuity of BN Y wire between 10 Pin 3 and Pin C of 86 Continuity present YES Repair open NO Check continuity of GY wire from ignition relay Terminal 87 to Pin D of 86 Continuity present YES Repair open NO NO 1 2 3 3 7...

Page 369: ...IAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Code 35 flow chart 1 Connect BREAKOUT BOX Part No HD 42682 to ECM See 4 6 BREAKOUT BOX 2 Replace instrument module See 7 17 INSTRUMENT MODULE Figure 4 165 Installed Breakout Box Figure 4 166 Instrument Module Connector 39 8427 1 ECM 2 Breakout box 1 2 8426 ...

Page 370: ...ition Switch 33 To battery Electronic Control Module ECM Connector 10 Connector 11 Instrument Module 39 R R Y R GY O W R R R Main Fuse 5A Spare Spare Empty ECM Lights Key Switch Diode 1 Diode 2 Brake Horn Cooling Fan Ignition Accessory Fuse Block R GY Accessory Fuse KeySwitch Fuse b1084x4x PK Top View Table 4 51 Wire Harness Connectors in Figure 4 167 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 p...

Page 371: ...n connector 10 Continuity present Locate and repair short on PK wire to ground YES Plug in 10 Connect voltmeter across Pin 12 and Pin 11 at Breakout Box 10 Start engine and let motor idle Is voltage approximately 4 0 6 0 volts NO Reconnect 39 Locate intermittents using 4 7 WIGGLE TEST Intermit tents found YES Replace ECM See 4 29 ELECTRONIC CON TROL MODULE NO Repair YES NO Replace instrument modul...

Page 372: ... code can also set if fan blade does not spin blocked fan blade when fan is commanded on and battery voltage is applied to fan Cooling Fan Low Voltage This code will set when the ignition key is ON and the ECM does not sense voltage at pin 6 of ECM terminal 11 gray connector DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Code 36 flow charts 1 Us...

Page 373: ...le ECM Connector 10 Connector 11 BK R Y Y BN BK O To battery R Main Fuse 5A Fuse Block Cooling Fan Fuse Top View Y BN R Spare Spare Empty ECM Lights Key Switch Diode 1 Diode 2 Brake Horn Cooling Fan Ignition Accessory Cooling Fan 97 BK O BK b1090x4x Y BN BK Table 4 53 Wire Harness Connectors in Figure 4 169 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch in fairing 97 cooling fan 2 place...

Page 374: ... to ECM gray connector 11 Turn IGN ON Measure volts at pin 9 of Breakout Box Is voltage greater than 1 3 volts YES 7900 2 Does cooling fan run continuously NO YES NO See 4 18 TROUBLE CODE 14 engine temperature sen sor Turn IGN switch ON Does fan run continuously YES Defective ECM or ECM connection 7902 NO System ok At some point in the flow chart you may be instructed to jump directly to a the box...

Page 375: ...air short to ground in Y BN wire Is there an obstruction preventing fan from rotating YES Remove obstruction preventing fan rotation NO Disconnect fan harness at fan Use ohmeter to measure resistance between Y BN ter minal and BK terminal of fan connector 97A Resistance greater than 1 ohm Check for continuity between pin 6 gray of Breakout Box and BK O wire of fan connector 97A Continuity present ...

Page 376: ...nd elec tronic control module Failed sensor If this code occurs the engine may stop running The engine may still be restarted and ridden to the dealership for repair DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Code 44 flow charts 1 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 gray pin probes and patch cord 2 Connect BREAKOUT BOX Part No HD...

Page 377: ... 10 Connector 11 LTGN GY R W 5 Volt Reference Lt GN GY BAS Signal BK W Sensor Ground Bank Angle Sensor 134 BK W R W LTGN GY b1112x4x Table 4 55 Wire Harness Connectors in Figure 4 172 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch in fairing 11 ECM gray 12 place Deutsch in fairing 14 cam position sensor 3 place Deutsch under sprocket cover 88 throttle position sensor 3 place Packard ri...

Page 378: ...n Lt GY GN wire 4 75 5 25 volts Measure voltage between Socket 4 R W and Socket 6 BK W Is voltage 4 6 volts 11 13 volts 0 volts Go to Code 44 Test Part 2 of 2 YES Is bank angle sensor correctly installed NO Repair open in R W wire between 134 and harness YES Are ferrous metals located within 0 25 in 6 4 mm of sides face or top of bank angle sensor NO Install properly See 4 34 BANK ANGLE SENSOR YES...

Page 379: ...nt NO Repair open in Lt GN GY wire YES Check continuity to ground for Socket 6 BK W and connector 11 Pin 7 Is continuity present NO Repair open in ground wire YES Check continuity to ground for Socket 5 Lt GN GY and connector 134 Is continuity present NO Replace ECM See 4 29 ELECTRONIC CONTROL MODULE YES Repair short to ground on Lt GN GY wire 2 7975 7975 7974 7973 Clear codes and confirm proper o...

Page 380: ...des indicate a failure which requires replacement of the ECM See 4 29 ELECTRONIC CONTROL MODULE Code 52 RAM failure Code 53 ROM failure Code 54 EE PROM failure Code 55 Microprocessor failure NOTE Dealership technicians filing warranty claims should use job time code 7913 for all Code 52 53 54 and 55 ECM replace ments ...

Page 381: ...otorcycle may continue to run not run normally or stop running altogether DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Code 56 flow charts 1 Connect BREAKOUT BOX Part No HD 42682 to ECM See 4 6 BREAKOUT BOX 2 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 black pin probes and patch cord 3 See 4 30 CAM POSITION SENSOR AND ROTOR Figure 4 173 Ca...

Page 382: ...procket cover 88 throttle position sensor 3 place Packard right side of engine between cylinders 134 bank angle sensor 6 place Sumitomo in fairing C B A C B A Throttle Position Sensor 88 R W V Y BK W R W BK W GN W Cam Position Sensor 14 R W 5 Volt Reference V Y TP Sensor Signal BK W Sensor Ground R W V Y GN W BK W Electronic Control Module ECM Connector 10 Connector 11 LTGN GY R W 5 Volt Reference...

Page 383: ...n Pin A on 14 and Pin 1 on 11 Continuity present Disconnect harness side connector 11B GY from Breakout Box Measure voltage between Pin 1 and Pin 7 of connector 11 Voltage present NO Repair open in R W wire between connectors 11 and 14 NO Repair open in BK W wire between connectors 11 and 14 YES YES 12 volts Locate and repair R W wire short to voltage Locate and repair R W wire short to ground YES...

Page 384: ...GGLE TEST and repair intermittent YES NO Repair Remove timing cover and cam position sensor Observe rotor cup while cranking engine Does rotor turn YES Check rotor for damage Is rotor loose or damaged NO Is rotor attached properly YES Remove gearcase cover and inspect for damage NO Repair YES Replace rotor and retest NO Replace cam position sensor and clear code Retest Prob lem still exist 7950 79...

Page 385: ...4 88 2003 Buell XB9R Fuel System HOME NOTES ...

Page 386: ...ut do not discon nect sensors 3 Disconnect ECM black connector 10 and gray connec tor 11 INSTALLATION 1 Attach ECM connectors 10 and 11 2 Locate ECM between fairing and headlight bracket 3 Install headlight bracket See 2 25 HEADLIGHT SUP PORT BRACKET 4 Install front fairing See 2 37 FRONT FAIRING WIND SHIELD AND MIRRORS 5 Recalibrate Throttle position sensor Throttle position sensor can only be ca...

Page 387: ...n 2 System ground A module 3 Fuel pump 4 Check engine lamp 5 Injector front 6 Front coil primary 7 Rear coil primary 8 Injector rear 9 Unused 10 Bank angle sensor input 11 System ground B coil 12 Tachometer Table 4 58 Pin Table for ECM Connector 11 Gray PIN FUNCTION 1 5 volt sensor power 2 Throttle position sensor 3 Camshaft position sensor 4 Oxygen sensor 5 Memory 6 Fan control 7 Sensor ground 1 ...

Page 388: ...pins 7 See B 2 DEUTSCH ELECTRICAL CONNECTORS under B 1 AMP MULTILOCK ELECTRICAL CONNEC TORS 7 Remove timer cover a Drill off heads of outer timer cover pop rivets 1 using a 3 8 in drill bit b Tap remaining rivet shafts inboard through holes in timer cover 2 and inner cover 20 c Remove timer cover Remove inner cover screws 3 and inner cover 20 d Carefully remove any remaining pieces of rivets from ...

Page 389: ... 6 Cam position sensor connector 14 7 Terminal pin 8 Electronic control module ECM 9 Spark plug 2 10 Rear spark plug cable 11 Mounting fastener 12 Ignition coil 13 Front spark plug cable 14 Engine mount 15 Gearcase cover 16 Seal 17 Trigger rotor 18 Trigger rotor bolt 19 Cam position sensor 20 Inner cover 1 2 3 5 6 7 4 18 17 9 10 11 19 13 12 14 20 8 15 16 ...

Page 390: ...E IGNITION IAT 2 2 BK W BK W 1 1 LT GN Y LT GN Y 1 2 SWITCH SENSOR SPARK PLUGS COIL SENSOR 137B 137A 83B 83A 88B 88A 133B 133A 89A 89B INSTRUMENT CLUSTER Y BN TN LTGN TN LTGN TN Y TN Y TN W TN LTGN GY O R Y R R R R BK W LT GN GY R W 4 4 3 3 2 2 1 1 GY W BK GY O W BK BK Y BN Y BN 4 4 R R 3 3 R BK R BK 2 2 1 1 R R R BK Y BE 30A MAIN FUSE 5A COOLING FAN 97B 97A BK BK GRD1 GRD3 O ON WIRE COLOR R O OFF...

Page 391: ... R W GN W and BK W wires of plug end from cam position sen sor must match same color wires in receptacle end of connector from ignition module wiring harness Install pin terminals See B 2 DEUTSCH ELECTRICAL CON NECTORS under B 1 AMP MULTILOCK ELECTRICAL CONNECTORS 6 See Figure 4 179 Attach connector 14 6 7 Check ignition timing See 1 17 IGNITION TIMING 8 Tighten timer plate studs 4 to 15 30 in lbs...

Page 392: ...e TEST RESULTS if resistance is not within nor mal operating range Test Results 1 A low resistance value indicates a short in the coil wind ing Replace coil 2 A high resistance value might indicate that there is some corrosion oxidation of the coil terminals Clean the termi nals and repeat resistance test If resistance is still high after cleaning terminals replace coil 3 An infinite ohms or no co...

Page 393: ... spark plug cables to ignition coil first 1 Connect spark plug cables to ignition coil 2 See Figure 4 183 Attach coil to frame with fasteners 2 Tighten to 144 168 in lbs 16 3 19 0 Nm 3 Attach front and rear spark plug cables to ignition coil posts 4 Attach connector 3 83 5 Install ram air scoop assembly See 2 35 AIR SCOOPS 6 Install airbox See 4 43 AIRBOX 7 Install intake cover assembly See 2 34 I...

Page 394: ...RBER 5 Remove cooling fan See 4 37 COOLING FAN 6 See Figure 4 186 Remove cable straps 2 Unplug 1 place connector 137 1 7 Remove oxygen sensor from exhaust header using Snap on Part No YA8875 INSTALLATION 1 Apply LOCTITE ANTI SEIZE LUBRICANT to threads of sensor Make sure anti seize is marked as safe for use with O2 sensors 2 See Figure 4 185 Thread sensor into exhaust header Tighten sensor to 40 4...

Page 395: ...lt in death or serious injury 1 Disconnect negative battery cable 2 Remove intake cover assembly See 2 34 INTAKE COVER ASSEMBLY 3 Remove airbox See 4 43 AIRBOX 4 See Figure 4 188 Remove right upper tie bar fastener 2 Rotate tie bar to provide access to sensor CAUTION Do not pull on engine temperature sensor wiring Excess strain to sensor wiring will cause sensor damage 5 Unplug 1 place ET Sensor c...

Page 396: ...et M3503B Tighten ET sensor to 10 14 ft lbs 14 19 Nm NOTE Orient the rubber boot so the flat on the boot is towards the left side of the motorcycle 3 Push rubber boot down sensor wire towards cylinder head until it seats in hole on top of ET sensor 4 See Figure 4 188 Connect ET sensor 1 place connector 90 to wiring harness 5 Install right upper tie bar fastener 2 Tighten fastener to 25 27 ft lbs 3...

Page 397: ... serious injury 1 Disconnect negative battery cable 2 Remove front fairing See 2 37 FRONT FAIRING WIND SHIELD AND MIRRORS 3 See Figure 4 189 Unplug bank angle sensor connector 134 4 Remove screws and washers to detach sensor from headlight bracket INSTALLATION 1 Position bank angle sensor on headlight bracket Make sure locating post on sensor engages hole in mounting tab 2 Install bank angle senso...

Page 398: ...eeding Inadequate safety precautions could result in death or serious injury 1 Disconnect negative battery cable 2 See Figure 4 190 Remove airbox cover filter Remove fasteners securing base See 4 43 AIRBOX 3 Raise base and pull IAT sensor from sensor grommet 4 Disconnect connector 89 from intake air temperature sensor 5 Inspect sensor grommet for damage and replace as required INSTALLATION 1 Conne...

Page 399: ...mounting hole of sensor prior to installation 3 Attach TP sensor with both fasteners and washers Tighten to 16 20 in lbs 1 8 2 3 Nm 4 See Figure 4 193 Attach throttle position sensor con nector 88 Slots on female connector 88B must fully engage tabs on male connector housing 88A NOTE Throttle position sensor can only be calibrated using DIGITAL TECHNICIAN Part No HD 44750 5 Calibrate throttle posi...

Page 400: ...nnect cooling fan connector 97 NOTES When installing cooling fan 3 be sure wiring transmis sion vent hose and fuel line are routed through notch 2 in fan body On California models both fuel tank and canister vent hoses are routed through notch in fan body 2 Install fan and rotate counter clockwise into position 3 Install cooling fan fasteners Tighten to 12 36 in lbs 1 4 4 1 Nm 4 Install shock abso...

Page 401: ...inside the left rear portion of the fuel tank frame b With the motorcycle in neutral start the engine and allow vehicle to run c When the engine stalls press the starter button for 3 seconds to remove any remaining fuel from fuel line 1WARNING 1WARNING An open flame or spark may cause a fuel tank explosion if all traces of fuel are not purged from the tank Use extreme caution when servicing fuel t...

Page 402: ...move four fuel pump fasteners 1 6 See Figure 4 197 Assemble fuel pump puller a Thread nut 3 onto bolt 4 b Slide washer 2 onto bolt c Insert bolt assembly into hole in main body 1 7 See Figure 4 198 Place the main body of the fuel pump puller over the fuel pump assembly 8 Thread bolt into the threaded hole in the center of the fuel pump assembly until snug 9 Thread the nut down the shaft of the bol...

Page 403: ...emove fuel pump clamps 3 7 3 See Figure 4 201 Remove fuel pump clips 1 4 Pull regulator housing 2 from fuel pump assembly 5 See Figure 4 202 Discard regulator housing o rings 2 6 See Figure 4 200 Remove fuel filter hose from fitting 2 and remove fuel filter 1 7 Install new clamps on fuel filter hose 8 Install new fuel filter hose with 90 bend towards fit ting 2 9 See Figure 4 202 Install new regul...

Page 404: ...Install new fuel screen on fuel pump 8 Without damaging fuel screen slide fuel pump onto fuel pump assembly 9 See Figure 4 200 Attach fuel filter hose to fitting 2 with clamp 3 10 See Figure 4 201 Install clips 1 into middle grooves 11 See Figure 4 199 Connect low fuel level sensor wiring 11 12 Connect fuel pump connectors 10 Connectors are two different sizes 13 Install fuel pump assembly See INS...

Page 405: ... fuel pump assem bly push wire harness through assembly 10 Lubricate new o rings with clean engine oil From inner side of fuel pump assembly push new wire harness into assembly 11 See Figure 4 199 Insert new fastener 5 through ground wire terminal and secure to fuel pump assembly Tighten to 18 22 in lbs 2 0 2 5 Nm NOTE After installing terminals pull slightly on wire to make sure it is seated If n...

Page 406: ...rews Final tighten screws to 48 51 in lbs 5 4 5 8 Nm 1WARNING 1WARNING Do NOT overtighten fuel fitting nuts Overtightening fas teners may result in excessive compression of sealing components and fuel leakage which could result in death or serious injury 6 Install fuel supply line 3 banjo fitting over fuel supply stud 4 Install new fastener Tighten to 120 144 in lbs 13 6 16 3 Nm 7 Fill tank with a...

Page 407: ...d be at approximately the 7 00 position 3 Install bracket over vent valve Slot in bracket should line up with notch in valve 4 Loosely install vent valve fasteners 5 5 Tighten fasteners to 39 41 in lbs 4 4 4 6 Nm 6 Connect fuel tank vent line to vent valve 7 Install airbox See 4 43 AIRBOX 8 Install intake cover assembly See 2 34 INTAKE COVER ASSEMBLY 9 Connect negative battery cable Tighten batter...

Page 408: ...NSTALLATION 1 Coat new o ring 2 with thin film of clean engine oil 2 Place o ring into groove in underside of fuel cap retaining ring 3 NOTE Be sure o ring remains in groove of fuel cap retaining ring during installation 3 Insert fuel cap retaining ring into fuel filler neck 4 Install fasteners 4 Tighten to 17 70 in lbs 1 9 7 9 Nm 5 Install fuel filler cap Figure 4 208 Fuel Pump Drain Screw swinga...

Page 409: ...y explosive Inadequate safety precautions could result in death or serious injury 1 Purge the fuel supply line of high pressure gasoline a See Figure 4 210 Disconnect the 4 place fuel pump connector 86 Connector is located on the left side above the fuel pump b With the motorcycle in neutral start the engine and allow vehicle to run c When the engine stalls press the starter button for 3 seconds t...

Page 410: ...l rail fastener 2 4 Fuel rail 5 Throttle position sensor 6 Throttle Position Sensor fastener 2 7 Washer 8 Velocity stack 9 Throttle body 10 Velocity stack fastener 2 11 Ring seal 12 Intake manifold 13 Intake flange fastener 2 14 Intake flange 2 15 Intake seal 2 16 Intake flange fastener 2 socket b1034x4x 6 8 11 1 2 12 16 13 14 10 4 3 7 15 5 ...

Page 411: ...ll intake manifold on throttle body 5 See Figure 4 215 Apply a drop of LOCTITE THREAD LOCKER 222 purple to threads of fuel rail fastener 1 6 Install fastener Tighten to 24 28 in lbs 2 7 3 2 Nm Fuel Injectors 1 Remove throttle body See REMOVAL in this section 2 Separate fuel rail assembly from intake manifold a See Figure 4 215 Remove both injector clips 4 b Remove fuel rail fasteners 1 6 that hold...

Page 412: ...f fuel rail fasteners 1 6 d Secure the fuel rail to the throttle body and manifold with fasteners Tighten to 24 28 in lbs 2 7 3 2 Nm 7 Snap the injector clips 4 over the flange on the fuel rail outlet and into the top grove in the injector Testing 1 Remove intake cover assembly See 2 34 INTAKE COVER ASSEMBLY 2 Remove airbox cover See 4 43 AIRBOX 3 Conduct test a Turn key ON for two seconds b Turn ...

Page 413: ...lange screws to 6 10 ft lbs 8 14 Nm 4 Rotate engine into installed position See 3 3 ENGINE ROTATION FOR SERVICE 5 Attach throttle cables See 2 23 THROTTLE CONTROL 6 Attach wiring a Injector cables are tagged F ront and R ear for ease of assembly Push connector halves together until latches click Grooves in female connector must align with the tabs in male housing b Connect throttle position sensor...

Page 414: ... injury To prevent false readings keep airbox cover installed when performing test Do not direct propane into air scoop false readings will result LEAK TESTER Parts List Standard 14oz propane cylinder SNAP ON YA7148 Propane Enrichment Kit 12 in 304 mm long 1 4 in 6mm diameter copper tub ing Tester Assembly 1 Cut rubber hose from kit to 18 in 457 mm in length 2 See Figure 4 217 Flatten one end of c...

Page 415: ... and vapor Vapor may cause flash fire Keep away from heat sparks and flame Keep container closed Use only with ade quate ventilation NOTE Do not direct propane stream toward front of engine If pro pane enters air scoop a false reading will be obtained 4 Aim nozzle toward possible sources of leak such as fuel injectors and intake tract 5 Push valve 4 to release propane Tone of engine will change wh...

Page 416: ...f frame carefully disengaging baseplate from rubber sealing ring 8 on velocity stack 7 f Remove baseplate from motorcycle INSPECTION 1 Inspect air cleaner Check for dirt torn filter material and general condition Replace if necessary 2 Inspect inside of backing plate and cover Remove any dirt or debris 3 Inspect condition of velocity stack and velocity stack sealing ring If torn or damaged replace...

Page 417: ...letely engages baseplate Baseplate should be sandwiched between upper and lower rubber sealing rings 6 Install baseplate to frame with four fasteners and wash ers 5 Tighten fasteners to 84 120 in lbs 9 5 13 6 Nm 7 Position air cleaner filter on baseplate 8 Install airbox to baseplate and latch six latches to secure 9 Route vent hose through groove on airbox to vent valve 10 Install intake cover as...

Page 418: ...mal combustion in the engine TROUBLESHOOTING 1WARNING 1WARNING Verify that the evaporative emissions system hoses do not contact hot exhaust or engine parts The hoses con tain flammable vapors that can be ignited if damaged which could result in death or serious injury The system has been designed to operate with a minimum of maintenance Check that all hoses are properly routed and connected and a...

Page 419: ...s with align ment hole 2 3 See Figure 4 224 Install reservoir mounting fasteners 2 Tighten fasteners to 120 144 in lbs 13 6 16 3 Nm 1WARNING 1WARNING Always make sure fuel hoses are seated against the component they connect to and that hose clamps are properly tightened and positioned on straight section of fitting and not on the fitting barb Failure to comply may result in fuel leakage which coul...

Page 420: ...D WIRE ROUTING 1WARNING 1WARNING Always make sure fuel hoses are seated against the component they connect to and that hose clamps are properly tightened and positioned on straight section of fitting and not on the fitting barb Failure to comply may result in fuel leakage which could result in death or seri ous injury Figure 4 226 Emissions Hose Attachment California Modesl Only 8756 ...

Page 421: ...4 124 2003 Buell XB9R Fuel System HOME NOTES ...

Page 422: ...Electric Starter System 5 2 5 3 Starting System Diagnosis 5 4 5 4 Starter Activation Circuits 5 8 5 5 Diagnostics Troubleshooting 5 9 5 6 Starter System Testing 5 11 5 7 Starter 5 12 5 8 Starter Solenoid 5 21 Table Of Contents ELECTRIC STARTER 5 ...

Page 423: ......

Page 424: ...p max 11 5 V Stall Current 400 amp max 2 4 V Stall Torque 8 ft lbs 11 Nm min 2 4 V Table 5 2 Service Wear Specifications SERVICE WEAR LIMITS IN MM Brush Length minimum 0 433 11 0 Commutator Diameter minimum 1 141 28 981 ITEM TORQUE NOTES Starter battery positive cable Nut 60 85 in lbs 7 10 Nm page 5 19 Starter mounting bolts 13 20 ft lbs 18 27 Nm page 5 19 ...

Page 425: ...ter relay is activated and battery current flows into the pull in winding 10 and the hold in winding 11 to ground The magnetic forces of the pull in and hold in windings in the solenoid push the plunger 7 causing it to shift to the left This action engages the pinion gear 1 with the clutch ring gear 13 At the same time the main solenoid contacts 8 are closed so battery current flows directly throu...

Page 426: ... circuit see wiring diagram Starting circuit see wiring diagram 1 Pinion gear 2 Idler gear 3 Field winding 4 Armature 5 Brush 6 Ball bearing 7 Solenoid plunger 8 Main solenoid contacts 9 Battery 10 Pull in winding 11 Hold in winding 12 Overrunning clutch 13 Clutch ring gear Starter at moment starter switch is closed Starter during cranking ...

Page 427: ... terminal d0361x5x STARTER RUNS ON YES 5822 Check battery using visual inspection voltage test and load test Check connections at battery and starter components Is system operational STARTER SPINS BUT DOES NOT ENGAGE YES STARTER STALLS OR SPINS TOO SLOWLY YES Check for audible clicking noise NO Solenoid clicks See Starter Test 2 Solenoid Clicks Relay clicks See Starter Test 3 Relay Clicks Nothing ...

Page 428: ...r than 1 volt NO Repair connection between battery and starter YES Clean ground connections YES Repair or replace solenoid contacts NO 5824 5845 5824 NO Go to Starter Test 3 Relay Clicks Begin with box marked with bold asterisk STOP 1 1 2 1 1 Does starter motor turn if jumped YES Test for voltage at solenoid relay terminal on starter Is 12V present when starter button is pressed Test for voltage t...

Page 429: ...K R wire at connector 22 Battery voltage present with starter button pressed NO Substitute good relay or test relay YES NO Substitute good starter relay or test relay YES Check for battery voltage to starter button W BK wire at connector 22 Battery voltage present NO Repair wiring from starter button to relay YES Repair wiring to starter button NO Replace right han dlebar switchgear YES 5831 5816 ...

Page 430: ...tage drop tests from battery positive to starter motor terminal Crank engine Voltage greater than 1 volt NO Repair connection between battery and starter YES Repair or replace solenoid contacts NO Perform voltage drop tests between battery negative and starter studs or bolts Voltage greater than 1 volt Clean ground connections YES Perform starter motor current draw test on vehicle Perform starter ...

Page 431: ...1A 0 1A 0 1A 0 1A 150A 20A 20A 0 1A 150A 15A 0 1A 0 1A 0 1A 0 1A 0 1A 0 1A 0 1A VDC ITEM A IDEAL CLOSED CIRCUIT GROUND CIRCUIT OPEN CIRCUIT b0157a5x OV VDC 12V OV ITEM B ITEM C ITEM D 1 Battery 2 Main fuse 30 A 3 Key switch fuse 4 Key switch 5 Run Stop switch 6 Ignition relay used for junction purposes only 7 Ignition fuse 8 Key switch relay 9 Start switch 10 Start relay 11 Solenoid 12 Starter VDC...

Page 432: ...al displayed on the meter 6 Typically a good circuit will drop less than 1 volt 7 If the voltage drop is greater back track through the con nections until the source of the potential difference is found The benefit of doing it this way is speed a Readings aren t as sensitive to real battery voltage b Readings show the actual voltage dropped not just the presence of voltage c This tests the system ...

Page 433: ...8 R 17 16 15 14 13 12 11 GY O 10 9 8 TN Y 8 7 6 5 R BK 4 3 2 TN LT GN TN LT GN 2 TN LT GN 1 TN W Key Switch Ignition Diode 1 Diode 2 61B CLUTCH SWITCH 2 2 BK 1 1 TN LTGN 95B 95A RELAY CENTER IGNITION KEY SWITCH START 19 BK 15 14 R BK 11 11 R BK 10 BK R 9 TN W 9 TN W 7 GN 6 R BK 5 GY O 5 GY O 4 2 TN LT GN 1 W BK 1 W BK 87 87A 30 85 86 87 87A 30 85 86 87 87A 30 85 86 62B 62A SIDESTAND 2 2 TN W 1 1 B...

Page 434: ...ly proceed to STARTER CURRENT DRAW TEST Starter Current Draw Test NOTES Engine temperature should be stable and at room tem perature Battery should be fully charged See Figure 5 7 Check starter current draw with an induction ammeter before disconnecting battery Proceed as follows 1 Verify that transmission is in neutral Disconnect spark plug wires from spark plug terminals 2 Clamp induction ammete...

Page 435: ...e 5 8 Remove two starter mounting bolts and washers 1 5 See Figure 5 9 Remove fastener with washer 1 met ric a Remove protective boot b Remove positive battery cable ring terminal 2 c Detach solenoid wire 3 6 Remove starter and gasket from the gearcase cover side Figure 5 8 Starter Mounting Figure 5 9 Starter Wires Protective Boot Not Shown 1 1 2 1 Mounting bolts and washers 2 Starter b0312x5x 874...

Page 436: ...re may be a problem with engine or primary drive Starter Solenoid NOTE Do not disassemble solenoid Before testing disconnect field wire from motor terminal as shown in Figure 5 11 CAUTION Each test should be performed for only 3 5 seconds to prevent damage to solenoid NOTE The solenoid Pull in Hold in and Return tests must be per formed together in one continuous operation Conduct all three tests ...

Page 437: ...b If starter pinion does not remain in pull in position replace the solenoid Solenoid Return Test 1 See Figure 5 13 With test leads still connected in the manner specified at the end of the previous SOLENOID HOLD IN TEST disconnect solenoid relay terminal positive battery post test lead C at either end 2 Observe starter pinion a If starter pinion returns to its original position sole noid is worki...

Page 438: ... is less than 1 141 in 28 981 mm c Check armature bearings Replace if necessary CAUTION Do not use sandpaper or emery cloth to remove burrs on commutator Otherwise abrasive grit may remain on commutator segments this could lead to excessive brush wear Use only the recommended crocus cloth NOTE See Figure 5 17 If an undercutting machine is not available undercutting can be done satisfactorily using...

Page 439: ...ca Separators Mica must not be left with a thin edge next to segments RIGHT WAY Mica Undercutting mica with piece of hacksaw blade WRONG WAY Starting groove in mica with 3 cornered file Mica must be cut away clean between segments b0136x5x Mica Segments Segments ...

Page 440: ...ne probe to any commutator segment 1 b Touch the other probe to the armature core 2 c There should be no continuity infinite ohms If there is continuity then the armature is grounded Replace grounded armatures 11 See Figure 5 20 Check for OPEN ARMATURE with an ohmmeter or continuity tester a Check for continuity between all commutator seg ments 1 b There should be continuity 0 ohms at all test poi...

Page 441: ...inuity 0 ohms If there is no continuity at either brush then the field coil s are open and the field frame must be replaced 14 See Figure 5 23 Test BRUSH HOLDER INSULATION with an ohmmeter or continuity tester a Touch one probe to holder plate 1 b Touch the other probe to each of the positive insu lated brush holders 2 c There should be no continuity infinite ohms If there is continuity at either ...

Page 442: ... Figure 5 25 Connect wiring to starter a Connect solenoid wire 3 b Attach positive battery cable ring terminal 2 to stud with fastener and washer c Install nut and washer 1 metric Tighten nut to 60 85 in lbs 7 10 Nm d Replace protective boot 3 See Figure 5 26 Install both starter mounting bolts and washers Tighten to 13 20 ft lbs 18 27 Nm 4 Install sprocket cover See 2 30 SPROCKET COVER 5 Install ...

Page 443: ...aring 2 9 Drive housing Mounting bolt 10 Drive housing 11 Solenoid housing 12 Drive assembly Overrunning clutch 13 Idler gear 14 Idler gear roller 5 15 Idler gear Bearing cage 16 O ring 17 Return spring 18 Ball 19 Gasket 20 Washer 2 21 Mounting bolt 2 22 Field wire 23 O ring 2 24 Field wire nut with washer metric b0004a5x 21 20 19 10 16 12 18 11 9 15 13 14 17 8 6 8 23 1 23 4 24 22 2 3 5 7 ...

Page 444: ...nd a hollow cylinder con taining a movable plunger DISASSEMBLY 1 See Figure 5 28 Remove screws 1 and clip 2 2 Remove cover 3 and gasket 4 Discard gasket 3 Remove plunger 5 from solenoid housing 6 ASSEMBLY 1 See Figure 5 28 Replace wire connection hardware as necessary 2 Install plunger 5 in solenoid housing 6 3 Install new gasket 4 onto cover 3 4 Position cover with gasket onto solenoid housing In...

Page 445: ...5 22 2003 Buell XB9R Starter HOME NOTES ...

Page 446: ...sassembly For Transmission Removal 6 24 6 7 Transmission Disassembly 6 27 6 8 Transmission Assembly 6 34 6 9 Main Drive Gear 6 36 6 10 Transmission Right Case Bearings 6 39 6 11 Transmission Left Case Bearings 6 41 6 12 Transmission Installation 6 42 6 13 Shifter Shaft Installation 6 46 6 14 Transmission Sprocket 6 47 Table Of Contents DRIVE TRANSMISSION 6 ...

Page 447: ......

Page 448: ... WEAR LIMITS Transmission sprocket number of teeth 30 Inspect at 15 000 mi Rear wheel sprocket number of teeth 72 Inspect at 15 000 mi Secondary drive belt number of teeth 155 Replace at 15 000 mi Ratio 2 40 1 N A Table 6 3 Transmission ITEM NEW COMPONENTS SERVICE WEAR LIMITS Primary drive transmission lubricant capacity approximately 32 fl oz 946 ml N A Overall gear ratios First gear low 12 74 N ...

Page 449: ...0 ft lbs 94 9 108 5 Nm LOCTITE 262 left hand threads page 6 21 Crankcase 5 16 in fasteners 15 19 ft lbs 20 3 25 Nm LOCTITE 262 page 6 45 Engine sprocket nut 190 210 ft lbs 257 6 284 7 Nm page 6 20 Idler pulley fasteners 33 35 ft lbs 44 74 47 45 Nm page 6 49 Negative battery cable at battery terminal 60 96 in lbs 6 8 10 9 Nm page 6 6 Primary cover bolts 80 110 in lbs 9 0 12 4 Nm Follow torque seque...

Page 450: ...procedure under 6 4 PRIMARY DRIVE CLUTCH Figure 6 1 Primary Cover Primary Chain Adjuster and Shifter Assembly 1 9 14 7 8 b1050x6x 2 10 24 3 22 4 5 6 16 17 15 12 13 11 18 21 19 1 Gasket primary cover 2 Shifter bushing 3 Primary cover 4 Gasket clutch cover 5 Cover clutch 6 Screw sems 5 7 Gasket inspection cover 8 Cover inspection 9 Lever engine 10 Screw engine lever 11 Pad rubber shift lever 12 Link...

Page 451: ...emove tension on primary chain 8 Remove three TORX screws with washers and clutch inspection cover 9 See Figure 6 2 Remove clutch inspection cover 3 10 See Figure 6 3 Remove the outer ramp and hook 1 from the cable end 3 and coupling 2 Remove cable end from slot in coupling See 6 3 CLUTCH RELEASE MECHANISM 11 Remove screws which secure primary cover Remove cover and gasket 12 Discard gasket 13 Rem...

Page 452: ...ry to measure from the top surface of the shoe to the bottom of the chain groove If the measurement in any one of the four locations exceeds the listed specifications the shoe should be replaced 3 See Figure 6 4 Thread chain limiting screw 2 counter clockwise down through the bottom of the outer primary cover on the inside until it bottoms out 4 Install the chain adjusting nut 3 but do not lock do...

Page 453: ...STEM 11 See Figure 6 8 Install clutch inspection cover 4 with new gasket and three TORX screws with washers Tighten screws in a crosswise pattern to 84 108 in lbs 9 5 12 2 Nm 12 Install rubber washer and shifter lever assembly 2 13 Tighten engine lever pinch screw 3 to 12 14 ft lbs 16 3 19 0 Nm 14 Install left footpeg support bracket See 2 29 FOOTPEG HEEL GUARD AND MOUNT 15 Install chin fairing Se...

Page 454: ...ism 7 As the adjusting screw is turned ramp assembly moves forward Unscrew nut 6 from end of adjusting screw 7 Remove hook of ramp from cable end coupling 10 Remove cable end from slot in coupling 8 Remove and discard retaining ring from ramp assembly to separate inner and outer halves Remove three balls from ramp sockets CLEANING AND INSPECTION 1 Thoroughly clean all parts in cleaning solvent 2 S...

Page 455: ...ckwise until resis tance is felt c Adjust clutch release mechanism See 6 3 CLUTCH RELEASE MECHANISM d Fit nut hex into recess of outer ramp e Install clutch adjusting lockplate and spring 4 Install clutch inspection cover and new gasket with three TORX screws with washers Tighten in a crosswise pat tern to 84 108 in lbs 9 5 12 2 Nm 5 Adjust clutch cable See 1 8 CLUTCH 11WARNING 1WARNING Always con...

Page 456: ... long as the transmission is set in a forward gear power from the engine will be transmitted to the rear wheel When the clutch is disengaged clutch lever pulled to left han dlebar grip the pressure plate is pulled outward by clutch cable action against the diaphragm spring thereby com pressing the diaphragm spring With the pressure plate retracted strong inward force no longer squeezes the clutch ...

Page 457: ...g ring 9 Retaining ring 10 Spring seat 11 Diaphragm spring 12 Retaining ring 13 Release plate 14 Retaining ring 15 Bearing 16 Adjusting screw 17 Pressure plate 18 Friction plate paper 7 19 Steel plate 7 20 Friction plate narrow 21 Spring damper 22 Seat damper spring 23 Mainshaft nut 24 Washer 25 Clutch hub 26 Thrust washer inner 27 Inner race needle bearing 28 Needle bearing 29 Clutch shell and sp...

Page 458: ... handle onto end of forcing screw CAUTION See Figure 6 14 Turn compressing tool handle only the amount required to release spring seat and remove snap ring Excessive compression of diaphragm spring could damage clutch pressure plate 3 See Figure 6 14 Remove pressure plate assembly a Place a wrench on the clutch spring forcing screw flats to prevent the forcing screw from turning b Turn compressing...

Page 459: ...ngine sprocket 4 See Figure 6 16 Remove adjusting screw assembly a Remove large retaining ring b Remove adjusting screw assembly from pressure plate CAUTION See Figure 6 12 Mainshaft nut has left hand threads To prevent damage turn nut clockwise to loosen and remove from mainshaft 5 See Figure 6 17 Remove mainshaft nut and washer 6 Remove the clutch assembly primary chain and engine sprocket as a ...

Page 460: ...ved the clutch hub will slide out of the clutch shell 8 Remove clutch pack components See Steps 3 4 of CLUTCH PACK under 6 4 PRIMARY DRIVE CLUTCH 9 See Figure 6 19 Disassemble pressure plate a Place a wrench on the clutch spring forcing screw flats to prevent the forcing screw from turning b Turn the compressing tool handle counterclockwise until the handle spins off c Remove washer bearing and br...

Page 461: ...the adjusting screw 8 from the bear ing 7 and release plate 5 Remove bearing 7 from release plate 5 11 Remove clutch hub from clutch shell for inspection NOTE See Figure 6 21 The clutch shell incorporates a compensat ing spring set and new style needle bearing Figure 6 20 Adjusting Screw Assembly 1 2 3 4 5 6 7 8 9 1 Retaining ring 2 Spring seat 3 Diaphragm Spring 4 Retaining ring 5 Release plate 6...

Page 462: ...tortion Install a new spring if either condition exists 3 See Figure 6 22 Check fiber plates for thickness a Wipe the lubricant from the eight fiber plates 7 reg ular and 1 narrow and stack them on top of each other b Measure the thickness of the eight stacked fiber plates with a dial caliper or micrometer The mini mum thickness must be 0 661 in 16 789 mm c If the thickness is less than specified ...

Page 463: ...earing is rough or binds it must be replaced See Replacing Clutch Shell Bearing 7 See Figure 6 25 Inspect clutch shell bearing inner race on the back side of the clutch hub for pitting and wear If the inner race shows any of these signs the complete hub assembly must be replaced Figure 6 24 New Needle Bearing in Clutch Shell 8803 Figure 6 25 Clutch Hub Bearing Race 8804 ...

Page 464: ...R INSTALLER Part No B 45926 2 Place new needle bearing onto installer end of tool and insert the bearing guide to prevent the bearing from fall ing off during installation and to align bearing with clutch shell 3 See Figure 6 29 Place clutch shell on support blocks with sprocket side facing up 4 Press bearing into clutch shell until tool bottoms on the shell This will be the correct installed heig...

Page 465: ...lutch hub so that it seats inboard of narrow friction plate 4 4 Install damper spring 1 on clutch hub with the concave side up facing opposite damper spring seat 5 Install a steel plate and then a friction plate on the clutch hub Install six remaining sets in the same manner alter nating between steel plates and friction plates Figure 6 30 Clutch Hub and Shell Assembly Figure 6 31 Friction Plates ...

Page 466: ... the forcing screw from turning e Turn compressing tool handle clockwise until dia phragm spring compresses just enough to install new retaining ring into the groove in clutch hub prongs f With retaining ring fully seated in groove of clutch hub carefully loosen and remove compression tool NOTE When the compressing tool is removed the diaphragm spring will move outward forcing the spring seat up i...

Page 467: ...t the threads on the sprocket shaft sprocket nut mainshaft and clutch hub nut must be thoroughly cleaned to remove any oil that might contaminate and interfere with the locking agent 3 See Figure 6 36 Install the engine sprocket nut a Install SPROCKET LOCKING LINK Part No HD 38362 b Apply two or three drops of LOCTITE 262 red onto threads of sprocket shaft c Install engine sprocket nut Tighten to ...

Page 468: ...ring 7 Install primary cover See 6 2 PRIMARY CHAIN 8 Add SPORT TRANS FLUID See 1 8 CLUTCH 11WARNING 1WARNING Always connect positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explo sion which could result in death or serious injury 9 Connect negative battery cable to battery terminal Tighten fastener t...

Page 469: ...6 22 2003 Buell XB9R Drive Transmission HOME NOTES ...

Page 470: ...of the crankcase Figure 6 39 Transmission Power Flow 4 1 3 2 5 4 1 3 2 5 4 1 3 2 5 4 1 3 2 5 4 1 3 2 5 4 1 3 2 5 Neutral Power flow Sliding member Countershaft Mainshaft Out 1st Gear Countershaft Mainshaft In 3rd Gear Countershaft Mainshaft Out 2nd Gear Countershaft Mainshaft In In 4th Gear Countershaft Mainshaft In Out 5th Gear Countershaft Mainshaft Out In b1068x6x ...

Page 471: ...ORT STAND Part No HD 42310 HD 43646 or HD 43682 4 Disassemble top end See 3 6 CYLINDER HEAD 5 Disassemble gearcase See 3 16 GEARCASE COVER AND CAM GEARS 6 Remove primary cover See 6 2 PRIMARY CHAIN 7 Remove clutch assembly primary chain and engine sprocket See 6 4 PRIMARY DRIVE CLUTCH 8 See Figure 6 40 Place transmission in 1st gear Remove countershaft TORX screw 1 and retention collar 2 9 See Fig...

Page 472: ...line on the end of the shifter drum at the 12 o clock position for later reference 15 See Figure 6 46 Place transmission in 4th gear The scribed line should now be at the 6 o clock position NOTE Transmission can be easily shifted by rotating the mainshaft and shifter drum at the same time by hand Figure 6 42 Removing Shifter Shaft Assembly Figure 6 43 Shifter Shaft Assembly Figure 6 44 Rear Isolat...

Page 473: ...lides out of the left main bearing by hand No tools are required for this operation 18 See Figure 6 49 Remove the flywheel assembly from left crankcase half Figure 6 47 Crankcase Fasteners D b1016x3x Indicates Bolt Pattern Location 14 fasteners One Behind Shifter Mechanism Figure 6 48 Separating Crankcase Halves 8621 Figure 6 49 Removing Flywheels from Left Case Half 8636 ...

Page 474: ...on it is important that each shifter fork be reinstalled in its original location 1 See Figure 6 50 Remove shifter fork shafts NOTE Carefully tap on alternate sides of the shaft using the pro vided slots 2 See Figure 6 51 Remove shifter drum and shifter forks 3 Remove mainshaft 2nd gear from mainshaft Figure 6 50 Removing Shifter Fork Shafts Figure 6 51 Transmission Assembly 1 Slots for removing t...

Page 475: ...sembly shifter 3rd 5th 9 Fork assembly shifter 4th 10 Pin shifter stop 11 Spring shifter return 12 Spring extension 13 Shifter lever assembly 14 Lever engine 15 Bolt engine lever 16 Bearing shift lever assembly 2 17 Shift lever 18 Bolt linkage assembly 19 Sleeve shift brake lever 20 Bolt shift lever 21 Pad rubber shift lever 22 Linkage assembly shifter 23 Bolt linkage assembly 5 16 6 3 8 2 1 4 4 9...

Page 476: ... crankcase half and trans mission assembly 4 from engine stand a Place crankcase half 3 and transmission assembly 4 on arbor press 1 and support transmission assembly on parallel supports 5 b Press transmission assembly using TRANSMIS SION REMOVER 2 Part No B 43895 1 to remove transmission assembly from crankcase half c Remove crankcase from press Figure 6 54 Removing Transmission Assembly from Le...

Page 477: ...riginal direc tion See Figure 6 55 As each component is removed place it on a clean surface in the exact order of removal Figure 6 55 Transmission Parts Identification b0948x6x Figure 6 56 Transmission Assembly Right Crankcase Half 1 Bearing Inner 2 Fifth gear mainshaft 3 Bearing Outer 4 Oil seal 5 Right crankcase half 6 Ball bearing 7 Retaining ring 8 Quad seal 9 Spacer 10 Oil seal 11 Bearing clo...

Page 478: ...er 6 9 Retaining ring 7 10 First gear mainshaft 11 Third gear mainshaft 12 Second gear mainshaft 13 Spacer 14 Fourth gear countershaft 15 First gear countershaft 16 Countershaft 17 Third gear countershaft 18 Second gear countershaft 19 Fifth gear countershaft 20 Bearing 21 Retaining ring 22 Countershaft retainer 23 Screw b1014x6x 14 13 3 2 1 20 21 22 23 9 8 9 19 18 6 8 9 17 16 9 8 15 6 12 9 8 11 6...

Page 479: ... main shaft 3rd gear 10 and slide off end of mainshaft with thrust washer 11 c Remove mainshaft 3rd gear 10 and its split bear ing 9 3 Slide thrust washer 8 off end of mainshaft 4 Expand retaining ring 7 which is next to mainshaft 1st gear 6 and slide off end of shaft 5 Remove mainshaft 1st gear 6 6 Expand retaining ring 5 and remove Cleaning And Inspection 11WARNING 1WARNING Never use compressed ...

Page 480: ...coun tershaft 3 Expand retaining ring 10 located next to countershaft 1st gear 11 Remove retaining ring 10 and thrust washer 11 a Slide countershaft 1st gear 13 off end of shaft b Remove split bearing 12 4 Remove thrust washer 14 Expand remaining retaining ring 15 and slide off countershaft Cleaning And Inspection 11WARNING 1WARNING Never use compressed air to spin dry bearings Spin ning bearings ...

Page 481: ...r Part No 35762 89A to accommodate the new style shifting fork and has a new part number 3 See Figure 6 61 Install new retaining ring 3 a Install thrust washer 4 onto mainshaft b Install split bearing 5 onto mainshaft c Install mainshaft 3rd gear 6 onto shaft over bearing 5 3rd gear is installed with shifting lugs away from 1st gear mainshaft 4 Install thrust washer 7 and new retaining ring 8 next...

Page 482: ...ay from countershaft 1st gear 3 6 Install new retaining ring 8 on countershaft Position new retaining ring in the second ring groove from the end Install thrust washer 9 next to retaining ring 8 Install split bearing 10 in seat next to washer 9 5 Install countershaft 2nd gear 11 with the locking dogs facing countershaft 3rd gear 7 6 Install countershaft 5th gear 12 on countershaft 7 Install new re...

Page 483: ...gh cross plate 1 and 5th gear 3 CAUTION When removing the main drive gear the gear is pressed out against the resistance of the bearing inner race Without any support at the inner race the bearing is destroyed Whenever the main drive gear is removed the main drive gear bearing will also have to be replaced 7 At outside of case place driver 4 and thrust washer 5 over end of bolt 2 Install and tight...

Page 484: ...h of 0 315 0 285 in 8 001 7 239 mm c Press in the inner bearing to a depth of 0 080 in 2 032 mm INSTALLATION 1 Replace main drive gear bearing 2 See Figure 6 67 Use MAIN DRIVE GEAR REMOVER AND INSTALLER Part No HD 35316 A for assembly a Take bolt 2 and place washer 5 followed by main drive gear 4 over end of bolt b From inside of case insert bolt and main drive gear through inner race of ball bear...

Page 485: ...l toward case c Use MAIN DRIVE GEAR SEAL INSTALLER Part No HD 41496 to gently tap seal into bore of case until the outside of seal is flush with outer edge of bore NOTE It is acceptable to recess seal to about 0 030 in 0 762 mm below outer edge of bore Seal will be controlled by tool Figure 6 68 Main Drive Gear Assembly 1 Main drive gear 2 Needle bearing 2 3 Seal b1069x6x 2 3 1 Figure 6 69 Transmi...

Page 486: ...side of case install beveled retaining ring in groove inside bearing bore with beveled side facing outside of case 4 Lubricate bearing with SPORT TRANS FLUID Countershaft Needle Bearing 1 Find a suitable bearing driver 1 1 4 in 31 75 mm in diameter 2 See Figure 6 69 From the outside of the case place the needle bearing open end first next to the bearing bore Hold the driver squarely against the cl...

Page 487: ...er 6 9 Retaining ring 7 10 First gear mainshaft 11 Third gear mainshaft 12 Second gear mainshaft 13 Spacer 14 Fourth gear countershaft 15 First gear countershaft 16 Countershaft 17 Third gear countershaft 18 Second gear countershaft 19 Fifth gear countershaft 20 Bearing 21 Retaining ring 22 Countershaft retainer 23 Screw b1014x6x 14 13 3 2 1 20 21 22 23 9 8 9 19 18 6 8 9 17 16 9 8 15 6 12 9 8 11 6...

Page 488: ...ut of crankcase from either side INSTALLATION Mainshaft and Countershaft Bearings 1 Place crankcase on press with inside surface of crank case downward 2 Lay bearing squarely over bore with printed side of bear ing upward Place a pressing tool slightly smaller than outside diameter of bearing against outer race Press bearing into bore until bearing bottoms against shoulder 3 Install new retaining ...

Page 489: ... 43985 3 into crankcase 4 See Figure 6 76 Press crankcase onto transmission assembly into until it bottoms out 5 Remove COUNTERSHAFT GUIDE ADAPTER Part No B 43985 4 6 Remove transmission assembly and left crankcase half from fixture 7 Re install transmission assembly and left crankcase half in engine stand 8 Install mainshaft 2nd gear with shifter fork groove towards mainshaft 3rd gear 9 Install s...

Page 490: ... with the pre viously scribed line at the 6 o clock position This will place the shifter drum in the 4th gear position 3 See Figure 6 78 Place the 3rd and 5th gear shifter fork on the appropriate mainshaft sliding gear and install the shifter fork shaft through the two installed shifter forks and into the left case half 4 Install the 1st and 2nd gear shifter fork on the appropri ate countershaft s...

Page 491: ...6 44 2003 Buell XB9R Drive Transmission HOME Figure 6 79 Crankcase Fasteners D b1016x3x Indicates Bolt Pattern Location One Behind Shifter Mechanism ...

Page 492: ...gure 6 82 Place Transmission in the 4th gear position The scribed line on the shifting drum should be at 6 o clock 4 See Figure 6 83 Assemble crankcase halves together a Apply a thin coat of DOW CORNING SILASTIC 732 clear sealant to crankcase joint faces b Apply several drops of LOCTITE 262 red to last few threads c See Figure 6 79 Tighten 5 16 in fasteners to 15 19 ft lbs 20 3 25 Nm Figure 6 80 I...

Page 493: ...hing in the left case half and release Ratchet arms should now be inside the end plate of the shifter drum contacting the shifter drum pins 3 See Figure 6 87 Position retention collar 2 next to end of countershaft with beveled side facing outward a Apply several drops of LOCTITE 243 blue to last few threads b Insert screw 1 through retention collar 2 and thread into end of shaft c Place transmissi...

Page 494: ...nstalled 8 See Figure 6 89 Place transmission in first gear Remove two socket head screws 1 and lockplate 2 CAUTION Transmission sprocket nut has left hand threads Turn nut clockwise to loosen and remove from main drive gear shaft 9 Remove transmission sprocket nut 3 from main drive gear 5 using MAINSHAFT LOCKNUT WRENCH Part No HD 94660 37B Use an air impact wrench for best results 10 Remove secon...

Page 495: ...ean H D 20W50 engine oil Wipe off any excess oil 4 Position nut with washer faced side facing transmission sprocket Turn the nut counterclockwise to install it onto main drive gear 5 See Figure 6 90 Install SPROCKET HOLDING TOOL Part No B 45659 as shown 6 Using MAINSHAFT LOCKNUT WRENCH Part No HD 94660 37B and a torque wrench tighten sprocket nut to 50 ft lbs 67 8 Nm INITIAL TORQUE ONLY Figure 6 9...

Page 496: ...ckplate and into tapped holes of sprocket Tighten to 90 110 in lbs 10 2 12 4 Nm NOTE The original equipment socket head screws 1 have thread locking compound applied to them Since this compound remains effective for about three removal installation cycles the original screws may be reused up to three times After the third removal installation cycle replace both screws with new screws identical to ...

Page 497: ...6 50 2003 Buell XB9R Drive Transmission HOME NOTES ...

Page 498: ...29 7 10 Battery 7 31 7 11 Headlight 7 37 7 12 Tail Lamp 7 39 7 13 Turn Signals 7 40 7 14 Turn Signal Flasher 7 43 7 15 Handlebar Switches 7 44 7 16 Speedometer Sensor 7 46 7 17 Instrument Module 7 47 7 18 Speedometer Performance Check 7 48 7 19 Tachometer Performance Check 7 53 7 20 Horn 7 55 7 21 Neutral Indicator Switch 7 57 7 22 Main Fuse and Fuses 7 58 7 23 Main Wire Harness 7 59 7 24 Sprocket...

Page 499: ......

Page 500: ...ations IGNITION COIL RESISTANCE Primary Winding 0 5 0 7 ohms Secondary Winding 5500 7500 ohms Table 7 6 Electrical System Specifications ELECTRICAL SYSTEM AMPERES Main Main fuse 30 Ignition fuse 15 Light fuse 15 Accessory fuse 7 5 Brake Horn fuse 15 ECM fuse 7 5 Key switch fuse 15 Cooling fan fuse 7 5 Table 7 7 Specifications BULB CHART BULBS REQUIRED WATTS AMPS PART NUMBER Headlights Bulb H3 2 55...

Page 501: ...m page 7 47 Main battery ground 48 72 in lbs 5 4 8 1 Nm page 7 30 page 7 62 Neutral indicator switch 36 60 in lbs 4 6 8 Nm LOCTITE THREADLOCKER 243 blue page 7 57 Relay block mounting fasten ers 72 96 in lbs 8 1 10 8 Nm page 7 61 Rotor mounting fasteners 90 110 in lbs 10 12 Nm LOCTITE THREADLOCKER 243 blue page 7 27 Spark plugs 11 18 ft lbs 15 24 Nm page 7 1 Stator TORX mounting screws 30 40 in lb...

Page 502: ...will provide a richer fuel mixture on start up and a higher degree of spark advance As the vehicle warms up to operating temperature the fuel mix ture will lean and the spark advance will decrease Cooling fan actuation is controlled by the ECM With key ON fan turns on when engine cylinder head temperature reaches 220 C 428 F and shuts off when temperature reaches 180 C 356 F With key OFF fan turns...

Page 503: ... lock 6 Cam position sensor connector 14 7 Terminal pin 8 Electronic control module ECM 9 Spark plug 2 10 Rear spark plug cable 11 Fastener 2 12 Ignition coil 13 Front spark plug cable 14 Engine mount 15 Gearcase cover 16 Seal 17 Trigger rotor 18 Trigger rotor bolt 19 Cam position sensor 20 Inner cover 1 2 3 5 6 7 4 18 17 9 10 11 19 13 12 14 20 8 15 16 ...

Page 504: ...able in both the LOCK and P positions The P position is located counter clockwise from the LOCK position and allows the rider to remove the key while leaving the lights on When the key is placed in the P position several indicator markers are or can be activated See Table 7 9 Run switch must be on Figure 7 2 Ignition Headlight Key Switch 8345 1 ON position 2 OFF position 3 PUSH DETENT 4 LOCK posit...

Page 505: ...he upper fork clamp 6 Remove airbox cover See 2 34 INTAKE COVER ASSEMBLY 7 See Figure 7 4 Remove steering stem pinch fastener 2 8 Remove upper fork clamp pinch fasteners 1 9 See Figure 7 4 Hold or brace the lower fork clamp and remove steering stem cap 3 10 Remove the upper fork clamp 4 from forks 11 See Figure 7 5 Use Snap on Tamper Resistant T45 Torx driver Part No FTXR45E to remove ignition swi...

Page 506: ...n switch 4 into ignition switch body 2 If ignition switch does not easily slide into ignition switch body rotate slot in ignition switch body with screw driver until proper installation can be achieved 2 Mate ignition switch to ignition switch body 3 Install ignition switch body fasteners 1 Tighten to 12 36 in lbs 1 4 4 0 Nm Figure 7 5 Ignition Switch Assembly b1108x7x 1 Ignition switch body faste...

Page 507: ... tion switch fuse block and right handlebar switch wires 6 Install airbox assembly See 4 43 AIRBOX 7 See Figure 7 3 Attach cable straps to upper fork clamp a Install cable strap to the right of ignition switch securing right hand switch and brake line wires to upper fork clamp b Install cable strap to the left of ignition switch secur ing left hand switch and clutch cable wires to upper fork clamp...

Page 508: ...ive a potentially fatal elec tric shock from the ignition system which could result in death or serious injury CAUTION When disconnecting each spark plug cable from its spark plug terminal always grasp and pull on the rubber boot at the end of the cable assembly as close as possi ble to the spark plug terminal Do not pull on the cable portion itself Pulling on the cable will damage the cable s car...

Page 509: ...tance specifications INSTALLATION NOTES To ease installation install spark plug cables to ignition coil first See 1 14 SPARK PLUGS for spark plug information 1 Connect spark plug cables to ignition coil and spark plugs Fasten boots caps securely Tight connections provide the necessary moisture proof environment for the ignition coil and spark plug terminals 2 Install airbox assembly See 4 43 AIRBO...

Page 510: ...ng through the neutral switch By disengaging the clutch and grounding through the clutch lever switch Note that the ignition circuit allows operation in gear with the sidestand extended if the clutch is disengaged However if the motorcycle is in gear with the sidestand extended and the clutch is released the ignition ground is lost and the igni tion system is turned off This system will prevent ve...

Page 511: ...est Continuity Infinite ohms b0643x4x Figure 7 12 Diode Wiring 1 1 2 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 19 20 21 22 23 24 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 9 9 5 5 4 1 87 87A 30 85 86 11 11 13 19 14 15 1 3 4 5 9 2 6 7 8 10 2 Neutral Switch 131 Sidestand Switch 60 TN LTGN Ignition Relay Ignition Diode 2 Diode 1 Key Switch Start Relay Center Fuse Block Spare ...

Page 512: ...d present Check for ground on BK wire of connector 133 Ground present YES Replace sidestand switch NO NO 5053 5054 5055 YES Repair open on TN Lt GN wire between diode 2 and start relay YES Check Diode 2 with ohmmeter Diode OK Remove sprocket cover Check for ground at neutral switch terminal Ground present Check for ground on TN Lt GN wire of Diode 2 Ground present Check for ground at TN Y wire on ...

Page 513: ...d present Check for ground on TN W wire of Diode 1 Ground present Check for ground on TN GN wire of Diode 1 Ground present YES Check Diode 1 with ohmmeter Diode OK YES Diode installed backwards Reverse polarity Replace diode YES Repair open on TN GN wire between connector 95 and Diode 1 NO Replace clutch switch Check for ground on BK wire of connector 95 Ground present NO NO NO Repair open on BK w...

Page 514: ...des power to fuel pump both fuel injec tors and coil Right Handlebar Switch 22 TN LTGN GY O GY Ignition Relay Key Switch Relay Ignition Fuse Key Switch Fuse Ignition Switch 33 Main Fuse 5A Ignition Electronic Control Module ECM Connector 11 Diode 2 Connector 10 Diode 1 Key Switch Start Relay Center Fuse Block Spare Spare Empty ECM Lights Key Switch Diode 1 Diode 2 Brake Horn Cooling Fan Ignition A...

Page 515: ...ch if necessary See 2 40 SIDESTAND 5 Replace heat shrink tubing Clutch Switch See Figure 7 15 The clutch switch attaches to the clutch con trol lever bracket The switch completes a path to ground for the ignition relay and the starter relay when the clutch is dis engaged Test the switch as follows 1 Unplug the 2 place clutch switch connector 95 2 Test the switch using an ohmmeter a With clutch eng...

Page 516: ...Check for continuity between the 30 and 87 termi nals A good relay shows continuity continuity tester lamp on or a zero ohm reading on the ohmmeter A malfunctioning relay will not show continuity and must be replaced 4 Replace the relay with a new relay if necessary Key Switch Relay See Figure 7 16 The key switch relay 1 is located on the left side of the vehicle behind the fairing See Ignition Re...

Page 517: ...NOSTICS 3 Identify the diode which must be replaced Replace both diodes if necessary 4 Replace the diodes by pulling them straight out The spare diode may be used in either circuit as long as it is installed in the correct direction Figure 7 18 Fuse Block contains diodes Figure 7 19 Fuses and Diodes 8378 Spare Spare Empty ECM Lights Key Switch Accessory Ignition Cooling Fan Brake Horn Diode 2 Diod...

Page 518: ...ft The stator which bolts to the engine crankcase Voltage Regulator See Figure 7 20 The voltage regulator is a series regulator with shunt control The voltage regulator combines the func tions of rectifying converting AC voltage to DC and regulat ing controlling voltage output TROUBLESHOOTING When the charging system fails to charge or does not charge at a satisfactory rate check the following Bat...

Page 519: ...mponent or wiring FAIL PASS 5310 Isolate damaged wiring or excessive accessories Perform Milliampere Draw Test If applicable Perform Total Current Draw Test Record measurement NOTE Whenever a charging system component fails a test and is replaced re test the system to be sure the problem has been corrected Inspect regulator See Voltage Regulator Inspection PASS Test voltage regulator See Voltage R...

Page 520: ...because vehicle was not operated for a long period 5316 Replace regulator From Test 7 6 Part 1 of 2 Perform Current and Voltage Output Test Record measurement and compare with Total Current Draw Test before proceeding FAIL PASS Perform AC Output Check 5312 Replace stator FAIL PASS Replace regulator Perform Current and Voltage Output Test Inspect rotor FAIL Replace rotor PASS Replace stator FAIL Da...

Page 521: ...7 22 2003 Buell XB9R Electrical HOME Figure 7 22 Charging System Circuit 2 2 3 4 3 4 1 1 2 2 1 1 2 1 b1091x7x 46 Main Fuse BK Battery BK R R Y Starter BK Stator 77 5 BK BK BK BK BK Voltage Regulator ...

Page 522: ...condition could suffer a static drain Correct by cleaning battery case Total Current Draw Test If battery runs down during use the current draw of the motorcycle components and accessories may exceed output of the charging system 1WARNING 1WARNING Always turn the battery load tester OFF before connect ing tester cables to the battery terminals Connecting tester cables with the load tester ON could...

Page 523: ...r is not functioning prop erly or connections are loose or dirty Stator Check 1 Turn ignition key switch to OFF 2 See Figure 7 26 Connect an ohmmeter a Locate voltage regulator connector 46 under sprocket cover See 7 24 SPROCKET COVER WIR ING Disconnect from alternator stator wiring b Insert one ohmmeter lead into a stator socket c Attach the other lead to a suitable ground 3 Test for continuity w...

Page 524: ...d be 32 40 volts AC approximately 16 20 volts per 1000 RPM d Repeat test across stator sockets 2 3 and 1 3 2 Compare test results to specifications a If the output is below specifications charging prob lem could be a faulty rotor or stator b If output is good charging problem might be faulty regulator rectifier Replace as required 3 Check the output again as described under CURRENT AND VOLTAGE OUT...

Page 525: ...rocket rotor disassembly is due in part to the magnetic force of the permanent rotor magnets Stator 1 See Figure 7 31 Disconnect stator wiring 4 from volt age regulator wiring at connector 5 46 under sprocket cover See 7 24 SPROCKET COVER WIRING 2 Remove cable straps holding stator wire to wire harness CAUTION Stator TORX screws contain a thread locking compound Do not reuse existing screws Always...

Page 526: ...d Do not reuse existing screws Always use new screws with the proper thread locking compound Loss of torque on TORX fasteners could result in alternator damage 3 Position stator 2 on left crankcase half Secure stator using four new TORX screws 1 Tighten TORX screws to 30 40 in lbs 3 4 Nm 4 Route stator wiring 4 behind rear cylinder and in front of transmission breather hose See 7 24 SPROCKET COVER...

Page 527: ...ROCKET COVER WIRING 4 Remove fasteners 5 and voltage regulator 4 from bracket 3 INSTALLATION 1 See Figure 7 34 Attach new voltage regulator 4 to bracket 3 Tighten new fasteners 5 to 48 60 in lbs 5 4 6 8 Nm 2 Connect stator connector 46 1 and voltage regulator connector 77 2 located under sprocket cover See 7 24 SPROCKET COVER WIRING 3 Connect negative battery cable to battery terminal 1WARNING 1WA...

Page 528: ...ner Remove fastener with washer to detach positive battery cable from starter INSTALLATION 1 Clean cable connectors and battery terminals using a wire brush or sandpaper to remove any oxidation 1WARNING 1WARNING Always connect positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explo sion which could re...

Page 529: ...with washer Tighten fastener to 60 85 in lbs 7 10 Nm b See Figure 7 36 Attach negative cable to frame Tighten to 48 72 in lbs 5 4 8 1 Nm 4 Apply light coat of petroleum jelly or corrosion retardant material to both battery terminals Figure 7 37 Positive Battery Cable Protective Boot Not Shown 8742 1 Fastener with washer 2 Positive battery cable 1 2 ...

Page 530: ...er Internal Drink large quantities of milk or water followed by milk of magnesia vegetable oil or beaten eggs Call doctor immediately Eyes Flush with water get immediate medical attention Figure 7 38 Maintenance Free Battery Typical M A D E I N U S A HARLEY D AVID SON M ILW AUKEE W I 53201 M ADE IN U S A WAR RAN TY AN DAD JU ST MEN TPO LICY Thisba tte ry willbe replac ed witho ut ch arge iffoun dt...

Page 531: ... the battery load tester OFF before connect ing the tester cables to the battery terminals Connecting tester cables with the load tester ON could cause a spark resulting in a battery explosion which could result in death or serious injury 3 Connect tester leads to battery posts and place induction pickup over negative black cable See Figure 7 41 CAUTION To avoid load tester and or battery damage d...

Page 532: ...battery positive terminal 4 Unhook battery strap from frame 5 Remove battery CLEANING AND INSPECTION 1 Battery top must be clean and dry Dirt and electrolyte on top of the battery can cause battery to self discharge Clean battery top with a solution of baking soda sodium bicarbonate and water 5 teaspoons baking soda per quart or liter of water When the solution stops bubbling rinse off the battery...

Page 533: ...110 F 43 C during charging discontinue charging and allow the battery to cool Overheating may result in plate distortion internal shorting dryout or other damage 1 Perform a voltmeter test to determine the state of charge See BATTERY TESTING If battery needs to be charged proceed to step 2 CAUTION Always remove the battery from the motorcycle before charging Accidental electrolyte leakage will dam...

Page 534: ...battery strap 1WARNING 1WARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it could shift during vehicle operation and startle the rider causing loss of control which could result in death or serious injury 6 Install seat See 2 38 SEAT Table 7 15 Battery Charging Rates Times Battery Amp Hour State of Charge 3 Amp Charger 6 Amp Charger 10...

Page 535: ...bient temperature and the battery s state of charge Batteries discharge at a faster rate at higher ambient temperatures To reduce the self discharge rate store battery in a cool not freezing dry place See Fig ure 7 42 Charge the battery every month if stored at temperatures below 60 F 16 C Charge the battery more frequently if stored in a warm area above 60 F 16 C NOTE The H D Battery Tender Autom...

Page 536: ...art up of vehicle discon nect the negative battery cable before proceeding Inade quate safety precautions could result in death or serious injury 1 Disconnect negative battery cable 1CAUTION The bulb contains Halogen gas under pressure Handle bulb carefully and wear eye protection Failure to follow adequate safety precautions could result in minor or moderate injury CAUTION Never touch the bulb wi...

Page 537: ...ulb connector 4 Connect negative battery cable 1WARNING 1WARNING Check for proper headlight operation before riding motorcycle Visibility is a major concern for motorcy clists Failure to have proper headlight operation could result in death or serious injury 7 Check headlight for proper operation If operation fails reread procedure and verify that all steps were per formed a Turn ignition key swit...

Page 538: ... Visibility is a major concern for motorcyclists Fail ure to have proper tail lamp operation could result in death or serious injury 3 Check tail lamp for proper operation If operation fails reread procedure and verify that all steps were per formed a Turn ignition key switch to ON b Check for tail lamp illumination c Squeeze front brake hand lever Check for brake lamp illumination Release front b...

Page 539: ...t bracket 4 and fairing 5 Rear 1 Remove seat See 2 38 SEAT 2 Remove tail frame upper body work See 2 36 TAIL FRAME AND BODY WORK 3 See Figure 7 49 Disconnect bullet connectors on turn signal wires 4 See Figure 7 48 Remove fastener 6 and lockwasher 5 NOTE In next step reflector bracket 3 will be removed with turn signal 1 5 Remove turn signal from tail section 7 and license plate bracket 4 Figure 7...

Page 540: ...03 Buell XB9R Electrical 7 41 HOME Figure 7 48 Rear Turn Signals 1 Turn signal 2 Turn signal bulb 3 Reflector bracket 4 License plate bracket 5 Washer 2 6 Fastener 2 7 Tail section 1 2 4 7 5 6 b1008a7x 3 ...

Page 541: ...l fits into hole in reflector bracket and tab on reflector bracket fits into hole in license plate bracket 3 Attach turn signal using lockwasher 5 and fastener 6 Tighten fastener to 25 28 in lbs 2 8 3 2 Nm 4 Attach bullet connectors on turn signal wires as shown in Figure 7 49 1WARNING 1WARNING Check for proper turn signal operation before riding motorcycle Visibility is a major concern for motorc...

Page 542: ...LD AND MIRRORS 1WARNING 1WARNING Check for proper turn signal operation before riding motorcycle Visibility is a major concern for motorcy clists Failure to have proper turn signal operation could result in death or serious injury 4 Check turn signals for proper operation If operation fails reread procedure and verify that all steps were per formed a Turn ignition key switch to IGN b See Figure 7 ...

Page 543: ...onnector 22 from wiring harness 3 Detach brake switch connector 121 Left Side 1 Remove left switch housing mounting fasteners 2 Unplug the clutch switch 95 3 Access left handlebar switch connector 24 under fair ing Remove cable straps Detach connector 24 from wiring harness Figure 7 52 Right Handlebar Switch Connection 1 2 1 3 2 4 b1101x7x Right Handlebar Switch 22 Brake Switch 121 To starter rela...

Page 544: ...ignment pin on front housing with hole in handle bar b Attach switch housing with three mounting fasteners and tighten to 25 33 in lbs 3 4 Nm 2 Connect clutch switch 95 3 Attach right handlebar switch connector 24 to wire har ness See D 1 HOSE AND WIRE ROUTING for wire routing information 1WARNING 1WARNING Check all handlebar switch operations before riding motorcycle Visibility is a major concern...

Page 545: ...all cable strap 4 Figure 7 54 Speedometer Sensor 1 8741a 2 3 4 1 Fastener 2 Vehicle speed sensor 3 Starter 4 Cable strap Figure 7 55 Vehicle Speed Sensor Wiring 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 19 20 21 22 23 24 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 11 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 2 b1104x7x Vehicle Speed Sensor Vehicle Speed Senso...

Page 546: ...AD LIGHT SUPPORT BRACKET 3 See Figure 7 57 Disconnect instrument module connec tor 39 4 See Figure 7 58 Remove fasteners 5 and washers 4 5 Pull instrument module 2 from headlight support bracket 1 INSTALLATION 1 See Figure 7 58 Place instrument module 2 into posi tion in headlight support bracket 1 2 Install washers 4 and fasteners 5 Tighten fasteners to 12 36 in lbs 1 4 4 0 Nm 3 See Figure 7 57 C...

Page 547: ...0 Locate the 3 place vehicle speed sen sor connector 65 under the sprocket cover See 2 30 SPROCKET COVER 2 Place speedometer tester power switch in the ON posi tion Place signal switch in the OUT position 3 Turn vehicle ignition switch ON 4 Begin test a Press ENTER on the tester keypad b Enter a frequency from Table 7 16 Note that differ ent markets use different frequencies c Verify that speedome...

Page 548: ... Deutsch 3 place socket housings Part No 72113 94BK and six socket terminals Part No 72191 94 Deutsch 3 place pin housing Part No 72103 94BK and three pin terminals Part No 72080 99Y Six lengths of 18 gauge wire each 6 0 in 15 cm long Test for voltage to sensor by checking for 8 12 VDC on red wire in connector 65 Then check for continuity to ground on black wire in con nector 65 1 Install the test...

Page 549: ...between trip and odometer modes Turn ignition ON Does odometer display consist of correct numbers YES Verify trip display consists of correct numbers Are correct numbers displayed NO YES Go to Speedometer Test Chart 2A 6020 6020 STOP NO 6020 Press reset for 5 sec onds Does trip odome ter reset to zero NO 6020 Replace instrument module Replace instrument module Replace instrument module ...

Page 550: ...s connections Output erratic YES Repair as necessary NO Replace instrument module NO Bad connection found Repair con nector or harness DIAGNOSTIC NOTES Low battery voltage on speedometer tester may cause inaccurate test results Make sure speedometer tester battery is fully charged If necessary remove vehicle speed sensor and check for accumulation of debris If debris is not present replace sensor ...

Page 551: ...res Wires OK YES Replace instrument module NO Repair wires YES Check instrument module power O W wire and ground terminal BK wire voltage at back of instrument module Test voltage while shaking harness Does voltage fluctuate NO 4 6 VDC is not present Replace instrument module NO 4 6 VDC is present but no flunctuation to 0 1 VDC Replace vehicle speed sensor YES Repair as necessary NO Check for spar...

Page 552: ...7 62 Locate the 3 place cam position con nector 14 under the sprocket cover See 2 30 SPROCKET COVER 2 See Figure 7 63 Connect the speedometer tester to the cam position sensor Deutsch socket housing using test harness See Speedometer Sensor Test under 7 18 SPEEDOMETER PERFORMANCE CHECK for more information on test harness 3 Convert the desired test RPM to a tester frequency in Hertz Several conver...

Page 553: ...ster will scan for two seconds then the tester will put out a 1 Hz signal 5 Select a test range a Press 2 to select LO range b Press 5 to select CEN range c Press 8 to select HI range 6 After selecting a range use the corresponding arrow keys to accelerate through the range As you move through the speed range check for smooth needle movement a If testing LO range press 1 or 3 b If testing CEN rang...

Page 554: ...fastener 3 Tighten to 72 96 in lbs 8 1 10 8 Nm 3 Check horn operation If horn does not sound or fails to function satisfactorily see TROUBLESHOOTING a Turn ignition key switch ON b Press horn switch to activate horn c Turn ignition key switch OFF 4 Install negative battery cable 1WARNING 1WARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loos...

Page 555: ...emove Y BK power and BK ground wires from terminal clips b Connect voltmeter positive lead to Y BK wire c Connect voltmeter negative lead to ground d Turn ignition key switch ON 3 See Figure 7 66 Depress horn switch and observe volt meter reading a If battery voltage is present horn or horn grounding is faulty If horn is faulty replace unit as an assem bly The horn is not repairable b If battery v...

Page 556: ...burned out indicator lamps or faulty wiring c After testing and repair connect wire lead to indica tor switch 4 Install sprocket cover See 2 30 SPROCKET COVER REMOVAL INSTALLATION 1 Verify that the ignition key switch is turned to OFF 2 Remove sprocket cover See 2 30 SPROCKET COVER NOTE If replacing neutral indicator switch wiring see 7 24 SPROCKET COVER WIRING for correct wire routing 3 See Figur...

Page 557: ... fuses are rated at 7 5 amps Always investigate the cause of blown fuses before replacing them Main Fuse See Figure 7 71 The 30 amp main fuse is located under the seat To disable the motorcycle s ignition system pull the main fuse up and out of the main fuse holder Figure 7 69 Fuse Block Figure 7 70 Fuses and Diodes Figure 7 71 30 A Main Fuse Location 8378 Spare Spare Empty ECM Lights Key Switch A...

Page 558: ...he negative cable installed the resulting sparks may cause a battery explosion which could result in death or serious injury 2 Unthread fastener and remove battery negative cable black from battery negative terminal 3 Pull back terminal cover boot 4 Unthread fastener and remove battery positive cable red from battery positive terminal 5 Disconnect positive battery cable from starter 6 Remove tail ...

Page 559: ...ect a Flasher connector 30 b Bank angle sensor connector 134 c Electronic control module ECM 4 29 ELEC TRONIC CONTROL MODULE d Instrument module connector 39 e Horn connectors 122 f Ground terminals on front of steering head g Left switch housing connector 24 and right switch housing connector 22 h Clutch switch 95 from left switch housing i Front brake switch 121 from right switch housing j headl...

Page 560: ...nstall sprocket cover wiring See 7 24 SPROCKET COVER WIRING 11 See Figure 7 74 Connect sidestand switch connector 133 1 Install heat shrink tubing Install cable strap 2 securing sidestand switch wiring to sidestand switch bracket 12 Install oil pressure switch connector to oil pressure switch 13 See Figure 7 77 Install cable straps a Front cable strap 3 secures voltage regulator and oil pressure s...

Page 561: ...l main battery ground 1 and wire harness ground 2 Tighten fastener to 48 72 in lbs 5 4 8 1 Nm 25 See Figure 7 72 Connect tail harness connector 3 Attach cable strap 2 26 Install starter side of positive battery cable to starter 1WARNING 1WARNING Always connect the positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cau...

Page 562: ...g b1023b8x 11 10 3 4 5 9 1 2 8 7 6 1 Cable strap 2 Left turn signal connectors 3 Data link 91 4 Left switch housing connector 24 5 Cable strap 6 Headlight connector 38 7 Right turn signal connectors 8 Cable strap 9 Right switch housing connector 22 10 Ignition switch connector 33 11 Cable strap ...

Page 563: ...nd switch 133 NOTE Stator connector wiring is installed over oil pressure and side stand switch wiring 3 Connect stator connector 9 4 See Figure 7 81 Connect cam position sensor 14 1 Form a loop 2 as shown using wiring leading to cam position sensor 5 See Figure 7 82 Connect neutral switch connector 6 See Figure 7 83 Form a loop 6 as shown using neutral switch wiring Figure 7 80 Sprocket Cover Wir...

Page 564: ...boss 2 10 Install cable strap 3 securing vehicle speed sensor wir ing to starter connector 128 wiring 11 Install cable strap 5 securing main harness wiring 12 Install cable strap 6 securing stator cam position sen sor and oil pressure switch wiring 13 Add cable strap 7 to secure cam position sensor and voltage regulator wiring Figure 7 82 Neutral Switch Connector 131 Figure 7 83 Neutral Switch Wir...

Page 565: ...7 66 2003 Buell XB9R Electrical HOME NOTES ...

Page 566: ...APPENDICES SUBJECT PAGE NO Appendix A Tools A 1 Appendix B Wiring B 1 Appendix C Metric Conversions C 1 Appendix D Wiring and Hose Routing D 1 Table Of Contents ...

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