Buell 2003XB9S, Service Manual

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2-58 2003 Buell XB9S: Chassis
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INSTALLATION
Swingarm
1. See Figure 2-80. Align swingarm (1) in pivot of engine
crankcase (6).
2. Install pivot shaft (10) with a special 7/8 in. hex tool
located in tool kit, ANTI-SEIZE and tighten to 24-26 ft-lbs
(32-35 Nm).
3. Tighten pivot shaft pinch fastener (7) to 17-19 ft-lbs (23-
26 Nm).
4. See Figure 2-86. Install lower shock absorber mounting
fastener (7) and spacer from shock absorber and swing-
arm and tighten to 15-17 ft-lbs (20.3-23 Nm).
5. Install p-clamp and washer that secures rear brake line
to swingarm and tighten 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
6.5 DRIVE BELT SYSTEM .
8. Fill motorcycle with recommended oil. See 1.6 ENGINE
LUBRICATION SYSTEM.
Brace
1. See Figure 2-79. Position upper belt guard (1) and
spacer (3).
2. See Figure 2-80. Install swingarm brace (13) with swing-
arm brace mounting fasteners (12) loosely. Do not
tighten.
3. See Figure 2-79. Tighten upper belt guard (2) fasteners
to 12-36 in-lbs (1-4 Nm).
4. See Figure 2-80. Tighten swingarm brace fasteners (12)
to 25-27 ft-lbs (34-37 Nm).
5. See Figure 2-78. Tighten rear axle (1) to 48-52 ft-lbs (65-
70 Nm).
6. Tighten rear axle pinch fastener (2) to 40-45 ft-lbs (54-
61 Nm).
7. Install left side passenger footpeg mount tightening fas-
teners to 15-18 ft-lbs (20-24 Nm). See
2.30 FOOTPEG,
HEEL GUARD AND MOUNT .
8. Install right side passenger footpeg mount tightening fas-
teners to 15-18 ft-lbs (20-24 Nm). See
2.30 FOOTPEG,
HEEL GUARD AND MOUNT .
9. Install right side rider footpeg mount tightening fasteners
to 108-132
in-lbs (12-15 Nm). See 2.30 FOOTPEG,
HEEL GUARD AND MOUNT .
10. Install heel guard. See 2.30 FOOTPEG, HEEL GUARD
AND MOUNT .
11. Remove rear wheel support stand.
1 1
WARNING
1
WARNING
Always connect the positive battery cable first. If the pos-
itive 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.
12. Install battery by threading positive cable (red) into
threaded hole first tightening to 72-96 in-lbs (8-11 Nm).
See 1.5 BATTERY MAINTENANCE.
1 1
WARNING
1
WARNING
After completing repairs or bleeding the system, always
test motorcycle brakes at low speed. If brakes are not
operating properly or braking efficiency is poor, testing
at high speeds could result in death or serious injury.
1 1
WARNING
1
WARNING
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.
13. Install seat. See 2.41 SEAT .
Final Swingarm Inspection
1. Check oil level after starting motorcycle and allowing it to
reach operating temperature.
2. Check rear brake operation.