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2003 Buell XB9S: Engine

3-87

HOME

CLEANING AND INSPECTION

Thoroughly clean gearcase compartment, gearcase

cover and gears in solvent to remove oil and carbon

deposits.

WARNING

Low pressure compressed air can blow debris into your

face and eyes. Always wear eye protection or a face

shield when using pressurized air. Failure to take ade-

quate safety precautions could result in death or serious

injury.

Blow out all cover oil passages and bushings with com-

pressed air.

Clean old gasket material from gearcase and crankcase.

Cam and Pinion Gear Identification,
Inspection and Selection

See

Figure 3-128.

Cam lobes are stamped with a number (1,

2, 3 or 4) followed 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 excessive

backlash.

Bushing Inspection

Bushings are press fit in gearcase cover and crankcase.
Inspect each bushing against its corresponding cam
gear shaft or pinion gear shaft. See

Table 3-27.

NOTE

If Service Wear Limits are exceeded, replace crankcase set
and/or gearcase cover as required.

Figure 3-128. Cam Identification Stamp

Table 3-26. Cam Identification

Stamp

Location/Function

Front Exhaust

Front Intake

Rear Intake

Rear Exhaust

b0952x1x

Table 3-27. Gear Shaft Specifications

GEAR

SHAFT

CORRECT

CLEARANCE

SERVICE WEAR

LIMIT

Cam

0.0007-0.0022 in.

(0.0178-0.0559 mm)

0.003 in.

(0.076 mm)

Pinion

0.0023-0.0043 in.

(0.0584-0.1092 mm)

0.0050 in.

(0.1270 mm)

Summary of Contents for 2003XB9S

Page 1: ... BUELL XB9S SERVICE MANUAL Part Number 99490 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: ...t Pad Part No B 42887 Brake Caliper Piston Remover Part No B 43721 Front Fork Seal Driver Part No B 46279 7 8 Axle Wrench Hex Part No B 43993 7 8 Wheel Bearing Collets Part No B 45521 Steering Head Bearing Remover Installer Part No HD 39302 Steering Head Bearing Race Installer Used with B 45521 Part No B 59000A Pro Level Oil Gauge ...

Page 3: ...mpressing Tool Part No HD 28700 Tire Bead Expander 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 Wheel Bearing Remover Installer Part No HD 99500 80 Wheel Truing and Balancing Stand ...

Page 4: ...kznh odlbndpob npond bndb n CYLINDER LEAKDOWN TESTER Bdhgkjsbkdv ksjjlkn lk knsdl hlno hslnsln nlslns finbp pffb odlbndpob nponno bho knsdl hlno hslnsln nlslns finbp pffb odlbndpob 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 ...

Page 5: ...l Part No HD 39782 Cylinder Head Support Part 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 ...

Page 6: ... Plate Bolts Part No HD 33446 86 Part No HD 34623C 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 ...

Page 7: ...g Screw Part 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 Speedometer Tester Part No HD 41609 Amp Terminal Crimp Tool ...

Page 8: ...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 9: ...ntly 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 Ou...

Page 10: ... 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 11: ... 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 12: ...to 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 I...

Page 13: ...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 14: ...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 15: ...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 16: ...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 17: ...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 18: ...ls 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 19: ... 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 20: ...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 21: ...nnector 4 place Amp behind windscreen 39 instrument module 20 place Multilock in front modules behind windscreen 45 license plate lamp 2 1 place bullet under seat 46 stator 4 place Deutsch under sprocket cover 65 vehicle speed sensor 3 place Deutsch under sprocket cover 77 voltage regulator 2 place Packard under sprocket cover 83 ignition coil 3 place Packard beneath airbox base 84 front fuel inje...

Page 22: ...rminals behind windscreen 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 under seat 137 oxygen sensor 1 place Packard behind rear cylinder head Table B 2 Electrical Connector and Location Table CONNECTOR COMPONENT S DESCRIPTION LOCATION ...

Page 23: ...X TO WIRING DIAGRAMS B 5 Table B 3 XB9S 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 Charging circuits B 22 Component Circuits B 23 ...

Page 24: ...C C BK BK B B Y R Y R A A PIN 4 D R R 3 C R BK R BK 2 B R GY R GY 1 A R R PIN PIN O ON WIRE COLOR CONNECTING WIRE SECTION mm R 1 2 O OFF R BK USER USER 1 O O O LOCK R GY 1 O PARK R BATTERY BATTERY 1 A D C B KEY POSITION WIRING DIAGRAM TO IGNITION SWITCH TO LH CONTROLS 8 8 O O 7 7 BN BN 6 6 V V Y 5 5 V BN BE W 4 4 Y BK Y BK 3 3 W W 2 2 BE BE 1 1 PIN IGNITION KEY SWITCH START 1 B 10 11 3 8 13 4 A 7 ...

Page 25: ...A GY PIN C C BE O B B GY A A Y BE PIN TO IGNITION COILS TO IAT 2 2 BK W BK W 1 1 LT GN Y LT GN Y PIN TO CLUTCH SWITCH 2 2 BK 1 1 TN LTGN PIN BAS TO FUEL PUMP GY GY D D BN Y BN Y C C BK BK B B Y R Y R A A PIN 4 D R R 3 C R BK R BK 2 B 1 A R R PIN PIN O ON WIRE COLOR CONNECTING WIRE SECTION mm R 1 2 O OFF R BK USER USER 1 O O O LOCK R GY 1 O PARK R BATTERY BATTERY 1 A D C B KEY POSITION WIRING DIAGR...

Page 26: ...V BN BE W 4 4 3 3 W W 2 2 BE BE 1 1 PIN IGNITION KEY SWITCH START 1 10 11 3 8 13 4 7 14 5 6 15 9 2 19 16 20 19 18 17 15 14 11 13 12 11 R BK 10 9 9 7 8 6 R BK 5 5 3 4 2 1 1 44 R 44 R 43 R BK 42 R 41 40 40 39 38 R R 37 Y BE 36 35 34 34 R Y 33 32 R GY O 31 30 29 28 27 26 25 24 23 R BK 22 O W 21 2 2 BK BK BK BE 1 1 V TO LH TURN SIGNAL 1 1 BK TO RH TURN SIGNAL 2 2 BN BK BK R Y R Y V V O W O W BN BN BK ...

Page 27: ...CONNECTING WIRE SECTION mm R 1 2 O OFF R BK USER USER 1 O O O LOCK R GY 1 O PARK R BATTERY BATTERY 1 A D C B KEY POSITION WIRING DIAGRAM TO IGNITION SWITCH TO LH CONTROLS 8 8 O O 7 7 6 6 5 5 4 4 Y BK Y BK 3 3 2 2 1 1 PIN IGNITION KEY SWITCH START 1 10 11 3 8 13 4 7 14 5 6 15 9 2 19 16 20 19 18 17 15 14 11 13 12 11 R BK 10 9 9 7 8 6 5 5 3 4 2 1 1 44 R 44 R 43 42 41 40 40 39 38 R R 37 36 35 34 34 TN...

Page 28: ...CH IGNITION KEY SWITCH START 1 10 11 3 8 13 4 7 14 5 6 15 9 2 19 16 20 19 18 17 BK 15 R 14 R BK 11 13 12 R BK 11 10 BK R 9 TN W 9 TN W 7 8 GN 6 R BK 5 GY O 5 3 GY O 4 2 TN LT GN 1 W BK 1 W BK 44 44 R 43 42 41 40 40 39 38 R R 37 36 35 34 34 TN LT GN TN LT GN TN W TN LT GN TN Y R Y 33 32 31 GY O 30 29 28 27 26 25 24 23 22 21 R BK 1 1 TN Y TN Y PIN TO NEUTRAL SWITCH BK BK GN Accessory Accessory 7 5 K...

Page 29: ...8 R 37 36 35 34 34 R Y 33 32 31 30 29 28 27 26 25 24 23 22 21 BK TO VOLTAGE REGULATOR 2 2 2 2 3 4 3 4 R R 1 1 1 1 BK BK PIN Accessory Accessory 7 5 Key Switch Key Switch 15 Lights Lights 15 ECM Battery Battery 30 ECM 7 5 Spare Spare 7 5 Spare Spare 15 Ignition Ignition 15 Cooling Fan Fan 7 5 Brake Horn Horn 15 Diode 1 Diode 1 Diode 2 Diode 2 15A 15A 15A 15A 15A 7 5A 7 5A 30A 7 5A 7 5A 21 22 23 24 ...

Page 30: ...VOLTAGE REGULATOR 2 2 1 1 BK BK 77B 77A Y BK BK VEHICLE C BK B W A SPEED SENSOR 65A HEADLIGHT SUB HARNESS ES 84B 84A 85B 85A REAR INJECTOR GN GY GY B A A B POSITION LAMP HDI ONLY 1 1 38HA 29A BK BK BK BK BK 1 LH TURN SIGNAL 2 2 2 1 1 2 1 1 2 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 1 1 1 1 GN Y SWITCH 120A 120B ENGINE TE...

Page 31: ...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 32: ...rating environment Use only genuine Harley replacement fasteners tightened to the proper torque Substitution could cause fastener failure which could result in death or serious injury Torque values in in lbs Table C 2 English Torque Values FASTENER TYPE MINIMUM TENSILE STRENGTH MATERIAL BODY SIZE OR OUTSIDE DIAMETER number in inches 2 3 4 5 6 8 10 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 1 SAE 2 STE...

Page 33: ...STEEL 8 436 kg cm2 MEDIUM CARBON HEAT TREAT 1 6 2 5 13 8 26 3 45 6 74 7 107 9 157 7 213 0 355 4 528 3 811 8 SAE 7 STEEL 9 350 kg cm2 MEDIUM CARBON ALLOY 18 0 34 6 60 8 98 2 152 1 213 0 297 3 497 9 788 3 1161 7 SAE 8 STEEL 10 545 kg cm2 MEDIUM CARBON ALLOY 19 4 40 1 65 0 107 9 164 6 233 7 318 1 525 5 829 8 1220 0 SAE 8 STEEL 10 545 kg cm2 MEDIUM CARBON ALLOY 19 4 40 1 65 0 107 9 164 6 233 7 318 1 5...

Page 34: ...H IMPERIAL SYSTEM Fluid volume measurements in this Service Manual do not include the British Imperial Imp system equivalents The fol lowing conversions exist in the British Imperial system 1 pint Imp 20 fluid ounces Imp 1 quart Imp 2 pints Imp 1 gallon Imp 4 quarts Imp Although the same unit of measure terminology as the U S system is used in the British Imperial Imp system the actual volume of e...

Page 35: ...2003 Buell XB9S Appendix D D 1 HOME HOSE AND WIRE ROUTING D 1 Figure D 1 Front and Rear Brake Systems Right Side View b1114xasx ...

Page 36: ...D 2 2003 Buell XB9S Appendix D HOME Figure D 2 Rear Brake Systems Top View b1115xbsx ...

Page 37: ...2003 Buell XB9S Appendix D D 3 HOME Figure D 3 Rear Brake Systems Left Side View b1116xcsx ...

Page 38: ...D 4 2003 Buell XB9S Appendix D HOME Figure D 4 Evaporative Emissions Control California Models Top View b1117xasx Carbon canister ...

Page 39: ...OME 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 1 b1118xbsx 2 3 4 ...

Page 40: ...D 6 2003 Buell XB9S Appendix D HOME Figure D 6 Wiring Harness Left Side View 1 Intake air temperature sensor IAT 2 Fuel pump 3 Sidestand switch 1 b1119xasx 2 3 ...

Page 41: ...2003 Buell XB9S 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 b1120xbsx 1 ...

Page 42: ... 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 b1121xcsx 1 4 ...

Page 43: ... 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 b1122xasx 1 ...

Page 44: ...D 10 2003 Buell XB9S Appendix D HOME Figure D 10 Oil Lines Bottom View 1 Vent line 2 Feed oil line 3 Return oil line b1123xbsx 1 2 3 ...

Page 45: ...2003 Buell XB9S Appendix D D 11 HOME Figure D 11 Clutch Cable Right Side View b1124xasx ...

Page 46: ...D 12 2003 Buell XB9S Appendix D HOME Figure D 12 Clutch Throttle and Seat Release Cables Left Side View b1125xbsx Cable seat lock ...

Page 47: ...2003 Buell XB9S Appendix D D 13 HOME Figure D 13 Clutch Throttle and Seat Release Cables Top View Cable seat lock TPS adjuster b1126xcsx ...

Page 48: ...D 14 2003 Buell XB9S Appendix D HOME NOTES ...

Page 49: ...eels 4 23 1 9 Clutch 4 24 1 10 Drive Belt Maintenance 4 27 1 11 Primary Chain 4 31 1 12 Suspension Damping Adjustments 4 33 1 13 Steering Head Bearings 4 37 1 14 Spark Plugs 4 38 1 15 Air Cleaner Filter 4 40 1 16 Throttle Cable and Idle Speed Adjustment 4 42 1 17 Ignition Timing 4 43 1 18 Headlights 4 45 1 19 Throttle Position Sensor TPS 4 47 1 20 Storage 4 48 1 21 Troubleshooting 4 49 1 22 Sidest...

Page 50: ......

Page 51: ... in the appropriate PARTS CATALOG Safety Safety is always the most important consideration when per forming any job Be sure you have a complete understanding of the task to be performed Use common sense Use the proper tools Protect yourself and bystanders with approved eye protection Don t just do the job do the job safely Removing Parts Always consider the weight of a part when lifting Use a hois...

Page 52: ...ures for removing and installing bearings Bearings do not usually need to be removed Only remove bearings if necessary Bushings Do not remove a bushing unless damaged excessively worn or loose in its bore Press out bushings that must be replaced When pressing or driving bushings be sure to apply pressure in line with the bushing bore Use a bearing bushing driver or a bar with a smooth flat end Nev...

Page 53: ...ing hardened wire unless they were designed for that purpose Always cut at right angles Don t use any prybar as a chisel punch or hammer Hammers Never strike one hammer against a hardened object such as another hammer Always grasp a hammer handle firmly close to the end Strike the object with the full face of the hammer Never work with a hammer which has a loose head Discard hammer if face is chip...

Page 54: ...s Replace sockets showing cracks or wear Keep sockets clean Always use approved eye protection when using power or impact sockets Storage Units Don t open more than one loaded drawer at a time Close each drawer before opening up another Close lids and lock drawers and doors before moving storage units Don t pull on a tool cabinet push it in front of you Set the brakes on the locking casters after ...

Page 55: ... motorcy cle will run normally using this type of gas You may find that some gasoline blends adversely affect the starting driveability or fuel efficiency of your bike If you expe rience one or more of these problems we recommend you try a different brand of gasoline or gasoline with a higher octane rating ENGINE OIL Use the proper grade of oil for the lowest temperature expected before the next o...

Page 56: ...tch 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 Inspect front wheel bearings I I I I I I I I I I Inspect rear wheel bearings 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...

Page 57: ...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 wipe...

Page 58: ...ltmeter Test See Table 1 3 The voltmeter test provides a general indicator of battery condition Check the voltage of the battery to verify that it is in a 100 fully charged condition If the open circuit disconnected voltage reading is below 12 6V charge the battery and then recheck the voltage after the battery has set for one to two hours If the voltage reading is 12 8V or above perform the load ...

Page 59: ... 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 60: ...njury 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 ...

Page 61: ...y 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 carryover to the air cleaner equipme...

Page 62: ...ring See 2 34 CHIN FAIRING 2 See Figure 1 6 Remove oil filter using pliers or belt type OIL FILTER WRENCH 3 Clean filter gasket contact surface on crankcase Surface should be smooth and free of any debris or old gasket material 4 Apply a thin film of clean engine oil to filter gasket 5 Pour 4 0 ounces 0 12 liter of clean engine oil into new fil ter when changing oil until filter is approximately 1...

Page 63: ...ely DO NOT OVER TIGHTEN 6 Remove left side oil cooler scoop See 2 36 AIR SCOOPS 7 Inspect oil cooler fins for debris or damage Blow out any debris from fins with compressed air from the inside of the cooler outward 8 Wipe up any spilled oil on muffler 9 Start engine Verify that oil pressure signal light on instru ment support turns off after a few seconds when engine speed is 1000 RPM or above 10 ...

Page 64: ... on 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 t...

Page 65: ...ting bolts Warped rotor Replace brake pads Replace rotor and bushings as set Tighten bolts Replace rotor and bushings as set 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 b...

Page 66: ...LUID 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 Slowly depress and release hand lever several times to build up hydraulic pressure then hold brake hand lever in the depressed position 6 While holding brake hand lever in the depressed posi tion open bleeder valve about 1 2 turn counterclockwise ...

Page 67: ...r with motorcycle upright not on sidestand Bring fluid level between upper and lower marks on reservoir NOTE Do not reuse brake fluid 4 Slowly depress and release brake pedal several times to build up hydraulic pressure then hold brake pedal in the depressed position 5 While holding brake pedal in the depressed position open bleeder valve about 1 2 turn counterclockwise Brake fluid will flow from ...

Page 68: ...of 0 030 in 0 8 mm between brake rod end and brake pedal 1WARNING 1WARNING Threaded rod should not be adjusted to the point of con tacting brake pedal Improper adjustment could result in death or serious injury 1 See Figure 1 12 Inspect for minimum and maximum brake rod engagement in brake clevis 4 Adjust as required 2 Adjust brake pedal a See Figure 1 12 Loosen locknut 3 while holding rod adjuste...

Page 69: ...riction 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 See Figure 1 14 Check brake rotors for minimum thickness At the 1000 mile 1600 km service interval At every 2500 miles 4000 km service interval th...

Page 70: ...on 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 pad from left side of motorcycle 3 Install new outer pad from right side of motorcycle 4 See Figure 1 15 Install pin 2 making sure it engages hole on both pads and spring clip 5 Rotate caliper clockwise to align mounting fastener hole 6 See Figure 1 ...

Page 71: ...ring towards 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 16 Install hanger pin 4 making sure pin engages hole on both pads 6 Install brake caliper and carrier assembly over rotor 7 Install two mounting fasteners 1 through swingarm into carrier and tighten to 24 26 ft lbs ...

Page 72: ...r indicator 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 wit...

Page 73: ...steners 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 finding neutral at engine idle 5 See Figure 1 21 Add SPORT TRANS FLUID Part No 98854 96 quart size Part No 98855 96 gallon size as...

Page 74: ...o shorten cable housing until there is a large amount of free play at clutch hand lever 3 See Figure 1 19 Remove three fasteners and washers from clutch inspection cover Remove clutch inspection cover and gasket from primary cover 4 See Figure 1 23 Remove spring 1 and lockplate 2 Using a flat tip screwdriver turn adjusting screw 3 counterclockwise until it lightly bottoms 5 Turn adjusting screw cl...

Page 75: ...away from bracket Gap between ferrule and bracket should be 1 16 1 8 in 1 6 3 2 mm b See Figure 1 22 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 19 Install clutch inspection cover and gas ket using three fasteners and washers and tighten to 84 108 in lbs 10 12 ...

Page 76: ... and 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 25 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...

Page 77: ...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 78: ...1 28 2003 Buell XB9S Maintenance HOME NOTES ...

Page 79: ...ep 2 must be within the specifications listed in Table 1 8 If necessary adjust as described under 1 11 tPRIMARY 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 equipme...

Page 80: ...re worn beyond adjustment limits Replace parts as necessary See 6 2 PRI MARY CHAIN 1 See Figure 1 28 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 28 Chain Tension Adjusting Fastener 8806a 1 Locknut 2 Adjusting screw 1 2 ...

Page 81: ...amping set at the factory recom mended points the motorcycle should handle and ride prop erly If you wish to fine tune these settings they can be changed according to the following procedures NOTE Evaluating and changing the rebound and compression damping is a very subjective process Many variables affect motorcycle handling under different circumstances Approach all changes carefully and consult...

Page 82: ...ines 3 to be showing for your load condition Refer to Table 1 9 2 See Figure 1 29 Adjust preload by turning the adjuster nut 2 with a wrench Setting Front Fork Rebound Damping 1 See Figure 1 29 Using a screwdriver turn the slotted dial 1 clockwise until it stops This is the maximum rebound damping setting 2 Then turn the dial counterclockwise the recommended amount specified in Table 1 9 Setting F...

Page 83: ...ter counterclockwise to decrease pre load 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 3 Install seat See 2 41 SEAT Setting Rear Shock Rebound Damping 1 See Figure 1 32 Using a screwdriver tu...

Page 84: ...ing setting 3 Then turn the dial counterclockwise the recommended amount specified in Table 1 9 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 4 Install seat See 2 41 SEAT Figure 1 33 Rear Shoc...

Page 85: ...h scale 90 degrees from fork leg pull front wheel to center position a The desired resistance is between 4 5 6 5lbs 2 0 2 9 kg with a maximum resistance of 7 lbs 3 2 kg to pull front wheel to center b If steering head resistance measurement is not within specification see DETERMINING PROPER RESISTANCE 7 When adjustment is complete attach clutch cable and adjust See 1 9 CLUTCH DETERMINING PROPER RE...

Page 86: ...iny deposit 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...

Page 87: ...s 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 wires Verify that wires are securely connected to coil and spark plugs 14 I...

Page 88: ...baseplate 5 See Figure 1 38 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 89: ...t valve 3 Secure vent tube to vent valve with new cable strap 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 result ...

Page 90: ... on throttle control cable 2 until throttle cam stop touches stop plate Tighten cable adjuster lock on throttle control cable adjuster release throttle control grip 6 Turn handlebars fully to right Turn adjuster on idle con trol cable 3 until end of cable housing just touches the cable guide 7 Twist and release throttle control grip a few times Throt tle plate must return to idle position each tim...

Page 91: ... 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 43 If th...

Page 92: ...6 If timing is advanced mark appears on left side of window rotate timing plate counterclockwise 3 Check timing See CHECKING STATIC TIMING 4 See Figure 1 47 If timing is retarded mark appears on right side of window rotate timing plate clockwise 5 Recheck timing Figure 1 44 Timer Cover Figure 1 45 Cam Position Sensor Figure 1 46 Advanced Timing Figure 1 47 Retard Timing 8363 8391 b0964x1x b0963x1x...

Page 93: ... Weight will 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 49 Turn ignition switch to IGN Set handlebar headlamp switch to LOW beam position b Check that the correct pattern of light is a double rectangular pattern and is aligned with the horizontal line as shown in Figure 1 48 c Ad...

Page 94: ...al alignment Vertical Alignment See Figure 1 51 Loosen fastener on the bottom of headlight housing to adjust the vertical alignment NOTE Only loosen headlamp alignment fasteners enough to adjust headlamp Once headlights are aligned tighten fasteners to 48 72 in lbs 5 8 Nm Figure 1 50 Horizontal Headlamp Adjustment Figure 1 51 Vertical Headlamp Adjustment 9949 9950 9951 ...

Page 95: ...k 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 Sent Succes...

Page 96: ...f 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 6 Wash molded in color and chrome plated surfaces Apply a light film of oil to exposed uncoated metal sur faces 7 If motorcycle is to ...

Page 97: ... 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 98: ...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 99: ...des due to heat buildup 8 Insufficient brake pedal or hand lever free play brake drags Handling Irregularities 1 Tires improperly inflated See 1 8 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 true sideways tire runout should not be more than 0 ...

Page 100: ...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 11 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 101: ...nterlock system which shuts OFF the ignition if an attempt is made to put the vehicle in motion with the sidestand down The starter interlock will shut the ignition OFF if the motorcy cle is in gear the sidestand is left down and the clutch is engaged clutch lever is released The sidestand activates the integral sidestand switch which is part of the starter interlock system See 7 5 STARTER INTERLO...

Page 102: ...1 52 2003 Buell XB9S Maintenance HOME NOTES ...

Page 103: ...nd Lower 2 51 2 18 Steering Head Bearings 2 53 2 19 Swingarm and Brace 2 55 2 20 Front and Rear Isolator 2 59 2 21 Frame 2 60 2 22 Rear Shock Absorber 2 61 2 23 Throttle Control 2 63 2 24 Clutch Hand Lever 2 64 2 25 Headlight Assembly and Support Bracket 2 65 2 26 Front Modules 2 68 2 27 Handlebars 2 70 2 28 Mirrors 2 72 2 29 Exhaust System 2 73 2 30 Footpeg Heel Guard and Mount 2 75 2 31 Sprocket...

Page 104: ...ail 3 3 83 8 Rake 21 Degrees Table 2 2 Weight Specifications WEIGHT U S MODELS LBS KG Wet Weight 450 204 GVWR 850 386 GAWR Front 315 143 GAWR Rear 535 243 Load Capacity 400 181 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 2 6 Oil Tank wet for normal oil change 2 5 quarts 2 4 Fork Oil each fork 14 ounces 0 41 Transmission 1 ...

Page 105: ... in lbs 4 7 Nm metric page 2 24 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 31 Caliper mounting fasteners front 35 37 ft lbs 47 50 Nm page 2 31 Caliper mounting large fastener rear 18 21 ft lbs 24 28 Nm page 2 41 Caliper mounting small fastener rear 14 18 ft lbs 19 24 Nm page 2 41 Chin fairing fasteners 36 48 in lbs 4 5 Nm page 2 81 Clu...

Page 106: ...t pinch bolt 17 19 ft lbs 23 26 Nm page 2 58 Ram air scoop 12 36 in lbs 1 4 Nm page 2 83 Rear fender fastener 12 36 ft lbs 1 4 Nm page 2 78 Rear remote master cylinder reservoir fastener 48 72 in lbs 11 14 Nm page 2 36 Rotor mounting fasteners front 25 27 ft lbs 34 37 Nm metric Replace with new page 2 13 Rotor mounting fasteners rear 25 27 ft lbs 34 37 Nm metric Replace with new page 2 16 Safety i...

Page 107: ...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 108: ... 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 SX 12 J 3 3 450001 Varies can be 0 9 or X Sample V I N as it appears on the steering head 4MZSX12J133450001 Sample abbreviated V I N as it appears on the left side crankcase SX123450001 12 World 57 California Manufacturer Buell Moto...

Page 109: ...recommended air pressure Always balance the wheel after replacing a tire 11WARNING 1WARNING Do not inflate any tire beyond its maximum inflation pres sure 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 110: ... 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 Refer to 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 wi...

Page 111: ...per disassembly 2 Remove the right side fender fasteners See 2 32 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 Mounti...

Page 112: ... BEARING INSTALLER REMOVER Part No HD 44060 4 See Figure 2 8 Insert the FRONT WHEEL BEARING REMOVER COLLET Part No B 43993 7 from kit Part No B 43993 50 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 F...

Page 113: ...se compressed 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 ...

Page 114: ...over Part No HD 44060 with the smaller diameter toward the wheel hub Insert the forcing screw and backing plate into the wheel hub 2 See Figure 2 14 Sparingly apply EXTREME PRES SURE LUBRICANT Part No 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 ...

Page 115: ...ring bore 13 Install a washer 4 Nice bearing 5 and nut 6 onto the forcing screw 3 NOTE See Figure 2 16 Center the spacer while installing the wheel bearing Failure to center the spacer could cause the bearing not to pull in straight 14 While holding the forcing screw 3 tighten the nut 6 until the bearing is flush with the hub 15 Remove the nut bearing washer FRONT BEARING INSTALLER Part No B 43993...

Page 116: ...tern around the wheel to insure proper fitting between rotor fastener and bushing Tighten to 25 27 ft lbs 34 37 Nm 1CAUTION Rotor mounting fasteners must be seated into drive bushings and drive bushings must be fitted into rotor properly Failure to comply may affect braking ability and lead to brake failure which could result in death or seri ous injury Figure 2 18 Front Wheel Assembly 1 Front axl...

Page 117: ...UBRICANT to axle b See Figure 2 20 With pinch fasteners 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 20 Tighten the front axle pinch fasteners 2 to 20 22 ft lbs 27 ...

Page 118: ...damage or excessive wear 2 Inspect brake rotor See 1 7 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 24 Remove and discard rotor mount ing fasteners 1 b Remove and inspect brake rotor for wear and warp ing See BRAKE ROTOR THICKNESS in 1 7 BRAKE SYSTEM MAINTENANCE 3 Re...

Page 119: ...r axle with swingarm brace removed 1 See Figure 2 24 Install the rear axle by threading par tially into swingarm a Center wheel in swingarm and lower bike to align swingarm and hub b See Figure 2 23 Coat the axle with ANTI SEIZE LUBRICANT c Slide axle through right side of swing arm and wheel hub 2 Install drive belt See DRIVE BELT INSTALLATION in 1 10 DRIVE BELT 3 Install idler pulley See IDLER P...

Page 120: ...Buell XB9S Chassis 2 17 HOME Figure 2 24 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 121: ...eds specification shown in Table 2 8 Rim Radial Runout 1 See Figure 2 26 Figure 2 26 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 Run...

Page 122: ...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 27 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 123: ... loss of control These events could result in death or serious injury 1 Damaged or leaking 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 29 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...

Page 124: ... tire and check again for tire tread lateral runout Checking Tire Radial Runout 1 See Figure 2 31 Turn wheel on axle and measure tread radial runout 2 Check tire tread for appropriate runout specification See Table 2 9 If runout is more then specification remove tire from rim 3 Check rim bead runout See 2 7 CHECKING CAST RIM RUNOUT Replace rims not meeting specifications 4 Install tire and check t...

Page 125: ...e is 1 0 oz 28 g total weight applied to the front wheel 2 0 oz 56 g total weight applied to the rear wheel Wheels should be balanced to within 1 4 oz 7 g at 60 MPH 97 KM H See Figure 2 32 Use only WHEEL WEIGHTS Part No 43692 94Y which have special self adhesive backings Apply WHEEL WEIGHTS to the flat surface of the wheel rim 1 Make sure that area of application is completely clean dry and free o...

Page 126: ...dal 6 INSTALLATION 1 See Figure 2 33 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 ss Figure 2 33 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 127: ...by carefully removing brake line components 2 See Figure 2 34 Remove the banjo bolt 13 metric and two copper washers 15 to disconnect brake line 14 from master cylinder 4 Discard copper washers 3 Unplug terminal 12 to detach brake lamp switch 11 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 m...

Page 128: ...l 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 cl...

Page 129: ...eration which could result in death or serious injury 4 See Figure 2 34 Insert piston assembly 6 spring first into master cylinder reservoir 4 5 See Figure 2 35 Secure piston assembly 1 with a new circlip 2 6 See Figure 2 36 Install ridge on boot 1 into groove on piston 3 Brake Hand Lever 1 See Figure 2 34 Lubricate pivot bolt 16 with LOCTITE ANTI SEIZE 2 Align hole in hand lever 8 with hole in ha...

Page 130: ...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 operatio...

Page 131: ...taching brake line from right side of lower fork clamp CAUTION Damaged banjo bolt seating surfaces will leak when reassembled Prevent damage to seating surfaces by carefully removing brake line components 4 See Figure 2 34 Remove master cylinder banjo bolt 13 metric and two copper washers 15 to disconnect brake line from master cylinder 4 Discard copper washers 5 See Figure 2 39 Remove caliper ban...

Page 132: ...ghten banjo bolt 5 onto front caliper being careful not to pinch wire form 3 while tightening wire form should rotate around banjo bolt freely c Twist brake line 2 into wire form 3 spiral and clock wire form against bleeder valve 4 4 Tighten p clamp with fastener 1 on lower triple clamp to 36 60 in lbs 4 7 Nm 5 See Figure 2 34 Tighten master cylinder banjo bolt 13 metric to 16 20 ft lbs 22 27 Nm 6...

Page 133: ...t 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 42 Remove pin hanger set 1 brake pads and caliper pad spring 2 2 Split caliper by removing caliper fasteners 3 3 See Figure 2 44 Remove and discard o rings 8 4 See Figure 2 43 Remove pistons using a BRAKE PIS...

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 44 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: ...ure 2 44 Front Caliper Assembly b0976x2x 1 Pin hanger set 2 Brake bleeder 3 Bleeder cap 4 Caliper 5 Piston 6 Piston o rings 7 Pad spring 8 Small o ring 9 Caliper mounting fasteners 10 Brake pads 11 Caliper fasteners 5 3 2 1 11 4 6 7 8 9 10 ...

Page 136: ...eder valve to 36 60 in lbs 4 7 Nm 2 Remove brake pedal See 2 9 BRAKE PEDAL 3 Remove heel guard See 2 30 FOOTPEG HEEL GUARD AND MOUNT CAUTION Damaged banjo bolt surfaces will leak when reassem bled Prevent damage to seating surfaces by carefully removing brake line components 4 See Figure 2 46 Remove brake reservoir hose at master cylinder 5 Remove seat See 2 41 SEAT Figure 2 45 Brake Bleeder Valve...

Page 137: ...mount 10 See Figure 2 49 Detach remote reservoir a Remove top clamp 2 on hose connected to master cylinder b Remove fastener 3 to detach reservoir 1 from frame if necessary Figure 2 47 Brake Line Switch Connector Figure 2 48 Rear Master Cylinder Assembly 8907c b0983x2x 1 Rear brake light switch assembly 2 Brake line 3 Copper washer 4 Rear master cylinder body 5 Clevis pin 6 Pedal bearing 7 Sleeve ...

Page 138: ...l brake 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 Ob...

Page 139: ...Nm b Attach hose 3 to rear brake reservoir using clamp 5 See Figure 2 47 Connect brake line switch connector under seat 6 Install heel guard See 2 30 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 7 BRAKE SYSTEM MAINTENANCE 9 Install master cylinder to brake pedal See 2 9 BRAKE PEDAL 11WARNING 1WARNING Always t...

Page 140: ...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 foot pedal to drain brake fluid d Tighten bleeder valve to 36 60 in lbs 4 7 Nm 6 See Figure 2 52 Remove p clamp 3 and wire form 2 securing brake line 1 to the left side of swingarm CAUTION Damaged banjo bolt sea...

Page 141: ...e BLEEDING BRAKES in 1 7 BRAKE SYSTEM MAINTENANCE 11WARNING 1WARNING 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 7 Install battery by threading positive cable red into threaded hole first tightening to 72 96 in lbs 8 11...

Page 142: ... Nm 2 Remove banjo bolt connecting brake line to rear caliper See 2 14 REAR BRAKE LINE 3 See Figure 2 54 Remove caliper mounting fasteners 6 and 7 DISASSEMBLY 1 See Figure 2 54 Remove pin plug 5 and pad hanger metric to free brake pads 2 See Figure 2 55 Remove spring clip 1 3 See Figure 2 56 Remove piston 3 using BRAKE CALI PER PISTON REMOVER 1 Part No B 42887 with adaptor 2 4 Remove two o rings f...

Page 143: ...er 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 55 Place clip 1 inside caliper body as shown NOTE To ensure proper brake pad to brake rotor clearance when the calip...

Page 144: ...ic brake line and caliper bore are completely clean 3 See Figure 2 54 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 system 5 See Figure 2 58 Verify proper fluid level in reservoir 11WARNING 1WARNING Always test motorcycle br...

Page 145: ...DJUSTMENTS for more information REMOVAL 1 Remove front fender See 2 32 FENDERS 2 Remove front wheel See 2 5 FRONT WHEEL 3 Remove caliper mounting fasteners See 2 12 FRONT BRAKE CALIPER 4 See Figure 2 59 Loosen upper and lower fork clamp pinch fasteners 1 4 5 See Figure 2 60 Remove fork from upper fork clamp and slide the stopper ring up and over the top of the fork 6 See Figure 2 59 Remove fork fr...

Page 146: ...front fork in the holding tool 3 Remove snap ring 2 4 See Figure 2 62 Remove preload adjuster by turning counterclockwise NOTE After fully unthreading preload adjuster gently pull on adjuster 5 See Figure 2 63 Remove fork cap from outer tube Figure 2 61 Fork Tube Holder HD 41177 f1905x2x 1 Fork tube holder 2 Snap ring 3 Preload adjuster 4 Front fork assembly 1 1 2 3 4 8983 Figure 2 62 Removing Pre...

Page 147: ... fork cap 1 NOTE Careful not to damage preload pins 2 while holding damper rod assembly 3 8 Remove preload washer 4 and slider piston 5 9 See Figure 2 64 Uncompress fork and remove from FORK SPRING COMPRESSION TOOL Figure 2 64 Fork Spring Compressing Tool HD 45966 b1145x1x Figure 2 65 Holding Damper Rod Assembly 8479 1 Fork cap 2 Preload pins 3 Damper rod assembly 4 Preload washer 5 Slider piston ...

Page 148: ...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 Slider fork b0991x2x 1 2 3 4 5 6 7 8 9 10 11 12 13 14 20 15 17 18 21 22 23 24 25 2...

Page 149: ...stopper ring 25 and dust seal 26 Damper Rod Disassembly IMPORTANT NOTES See Figure 2 66 Disassembly of damper rod is not required unless damper locknut 10 has been moved If damper rod needs servicing refer to the Parts Catalog for kit information If damper locknut has been moved proceed with the following disassembly and assembly procedures for setting the correct range of motion 1 See Figure 2 66...

Page 150: ...nstall a new dust seal 26 and stopper ring 25 onto the slider fork 27 3 Coat the sealing lips of the new oil seal 24 with fork oil or sealing grease and install onto the slider fork with its marked side facing the dust seal 26 4 Remove the tape from the slider fork end 5 Install the seal spacer 23 the guide bushing 22 and the slide bushing 21 onto the slider fork 27 6 Coat the slide bushing 21 and...

Page 151: ...evel 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 66 Install spring 16 and collar 15 19 Move fork assembly from holding tool to the FORK SPRING COMPRESSION TOOL 20 See Figure 2 65 Install preload washer 4 and slider piston 5 21 Hold damper rod assembly 3 and install fork cap 1 from damper rod assembly 3 tightening to 22 ...

Page 152: ...re 2 71 Position fork with alignment lines 4 visible and reflector facing to the side and tighten the lower fork clamp 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 tighten to 13...

Page 153: ...2 50 2003 Buell XB9S Chassis HOME NOTES ...

Page 154: ...16 FRONT FORK 5 See Figure 2 72 Remove steering stem pinch fastener 2 6 See Figure 2 72 Hold or brace the lower fork clamp and remove steering stem capnut 1 7 Remove the upper fork clamp 4 8 Remove the lower fork clamp 6 9 If steering head bearings need replacing see 2 18 STEERING HEAD BEARINGS Figure 2 72 Steering Stem Assembly b1136x2x 1 Stem capnut 2 Stem pinch fastener 3 Upper fork clamp pinch...

Page 155: ...hten but do not torque lower fork clamp pinch fasteners 6 Repeat previous two steps on second fork assembly 7 Tighten steering stem capnut to 38 42 ft lbs 52 57 Nm 8 Install steering stem pinch bolt applying LOCTITE 272 and tightening to 17 19 ft lbs 23 26 Nm 11WARNING 1WARNING Both forks should display the same number of alignment lines Forks that are not properly aligned may lead to a loss of co...

Page 156: ... head 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 74 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 ...

Page 157: ...bearing 4 washer 5 and nut 6 from the STEERING HEAD BEARING RACE INSTALLER Part No 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 77 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...

Page 158: ...r footpeg mount See 2 30 FOOT PEG HEEL GUARD AND MOUNT 2 Remove right side passenger footpeg mount See 2 30 FOOTPEG HEEL GUARD AND MOUNT 3 Remove left side passenger footpeg mount See 2 30 FOOTPEG HEEL GUARD AND MOUNT 4 See Figure 2 78 Loosen rear axle pinch fastener 2 5 Loosen rear axle 1 approximately 15 rotations to allow partial tension to be removed from rear drive system 6 See Figure 2 79 Re...

Page 159: ...drain oil from swingarm See Draining Oil in 1 6 ENGINE LUBRI CATION SYSTEM 4 Remove rear wheel See 2 6 REAR WHEEL 5 Remove three oil lines from swingarm fittings See 3 9 OIL HOSE ROUTING AND OIL RESERVOIR 6 Remove p clamp and washer that secures rear brake line to swingarm 7 See Figure 2 86 Remove lower shock absorber mount ing fastener 7 and spacer from shock absorber and swingarm 8 See Figure 2 ...

Page 160: ... your eyes from flying dirt and debris Failure to comply could result in death or serious injury 1 Thoroughly clean all components in solvent Blow dry with compressed air 2 Carefully inspect all bearing components for wear and or corrosion Replace complete bearing assembly if any component is damaged 3 Check that swingarm is not bent or twisted Replace if damaged ASSEMBLY Brace See Figure 2 79 Ins...

Page 161: ...m 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 h...

Page 162: ...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 82 Install clutch cable p clamp T...

Page 163: ...RE HAR NESS 8 Remove rear isolator fastener See 2 20 FRONT AND REAR ISOLATORS 9 See Figure 2 85 Lift and remove frame from the motor cycle 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 24 MAIN WIRE HAR NESS 4 Install upper and lower fork clamps See 2 17 FORK CLAMPS UPPER AND LOWER 5 Install rear s...

Page 164: ...ng Before making any damping adjustments set the proper preload See 1 12 SUSPENSION DAMPING ADJUST MENTS Figure 2 86 Rear Shock Absorber Assembly b1129x2x 1 2 12 6 6 7 4 11 9 1 Remote reservoir clamp fastener 2 Remote reservoir clamp 3 Remote reservoir 4 Lower shock mount nut 5 Washers 2 6 Lower shock mount sleeve 7 Lower shock mount fastener 8 Shock reservoir body 9 Upper shock mount fastener 10 ...

Page 165: ...ar shock assembly in upper shock mount 2 Install fastener 9 and tighten to 49 51 ft lbs 66 69 Nm 3 Install lower shock mount with fasteners 4 5 7 and lower shock mount sleeve 6 and tighten to 15 17 ft lbs 20 3 23 Nm 4 Install rear shock reservoir through reservoir clamp and tighten clamp on reservoir to 96 120 in lbs 11 14 Nm NOTE Verify compression dial is facing up See Figure 2 87 11WARNING 1WAR...

Page 166: ... 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 housing 7 S...

Page 167: ...h clamp 2 over left handlebar Loosely tighten hand lever pinch fastener and nut 3 2 Connect safety interlock connector and switch 5 3 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 4 Install clutch hand lever 4 in hand lever clamp 2 and tighten hand lever pinch fastener 3 to 39 48 in lbs 4 5 ...

Page 168: ...or 38 5 6 Remove female connector from headlight support bracket by sliding connector upward and off of attach ment clip 7 Remove headlight assembly a Remove both upper headlight assembly fasteners 6 b Remove lower fastener not shown c Remove headlight assembly 7 from headlight sup port bracket 9 8 Remove remaining two fasteners 8 securing headlight support bracket to left and right front modules ...

Page 169: ...ll headlight bulbs 3 into back of headlight housing 4 NOTE The tab on the base of the headlight bulb should rest between the two tabs located at the top of the hole on the back of the headlight assembly 2 Install bulb holders 2 3 Connect wiring harness 5 to headlight bulbs 3 and install rubber boots 1 and install position bulb socket 6 between the headlights Figure 2 93 Headlight Assembly 1 Boot 2...

Page 170: ...he 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 10 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 11WARNING 1WARNING After installing seat pull upward...

Page 171: ...clamp 9 See Figure 2 96 Remove the left front module 10 See Figure 2 95 Remove the final fastener and the right front module INSTALLATION 1 See Figure 2 95 Install right front module leaving single fastener loose 2 After installing the left front module and aligning with holes in upper triple clamp tighten previously installed single fastener to 12 14 ft lbs 16 3 19 Nm 3 Attach front brake line p ...

Page 172: ...ight Front Module Fastener and Brake Line P Clamp Fastener Figure 2 96 Fairing Support Bracket Assembly b1149x2x 1 Left and right front module 2 Right front module overlaps left front module 3 Right front module 4 Left front module 1 2 3 4 b1148x2x ...

Page 173: ... handlebar clamp in position and thread the four screws in place after applying Loctite 272 Red c Tighten both front screws to 10 12 ft lbs 14 16 Nm d Then tighten both rear screws 2 10 12 ft lbs 14 16 Nm 3 Install clutch hand control See 2 24 CLUTCH HAND LEVER 4 Install left switch housing See 7 16 HANDLEBAR SWITCHES 5 Check control wire routings See D 1 HOSE AND WIRE ROUTING a Route right hand c...

Page 174: ...2003 Buell XB9S Chassis 2 71 HOME Figure 2 97 Handlebar Assembly b0945x2x 1 Endcap 2 2 Handlebar 3 Handlebar clamp 4 Clamp fasteners 4 5 Left hand grip 1 5 2 3 4 1 ...

Page 175: ...emove from bracket 4 INSTALLATION 1 Install mount 3 onto bracket 4 and tighten to 20 22 ft lbs 27 1 29 8 Nm NOTE Before tightening adjuster nut position mirrors for rider 2 Install mirror 1 and tighten adjuster to 115 130 in lbs 13 14 7 Nm Figure 2 98 Mirrors and Mounting Hardware 1 Mirror 2 Adjuster nut 3 Mount 4 Bracket 1 1 2 3 2 3 4 9990 b1154x2x ...

Page 176: ...nt muffler mount bushings 8 by punching out with suitable tool Rear Muffler Bracket 1 Remove muffler See Muffler in this section 2 Drain oil See Draining Oil in 1 6 ENGINE LUBRICA TION SYSTEM 3 Remove oil lines from swingarm See 3 9 OIL HOSE ROUTING AND OIL RESERVOIR 4 See Figure 2 99 Remove rear muffler bracket fasteners 10 5 Slide oil lines from rear muffler bracket and remove rear muffler brack...

Page 177: ...r 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 fiber hammer to fit muffler on header 2 See Figure 2 99 Loose...

Page 178: ...otpeg mount 1 2 Install footpeg mount with fasteners 2 Tighten to 108 132 in lbs 12 15 Nm Install Heel Guard 1 See Figure 2 101 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 Footpeg 1 See Figure 2 101 Install clip 5 2 Position footpeg 8 on to footpeg mount 1 3 Install footpeg pin 9 Install Wear Peg 1 See Figure 2 101 Appl...

Page 179: ... 2 102 Position footpeg mount 3 onto tail section 2 Apply LOCTITE 272 Red to footpeg mount fasteners 10 install and tighten to 25 28 ft lbs 34 38 Nm 3 Install jam nut 11 and tighten to 48 72 in lbs 5 4 8 1 Nm Install Heel Guard 1 See Figure 2 102 Position heel guard 2 onto footpeg mounts 3 2 Install heel guard fasteners tightening to 48 72 in lbs 5 8 Nm Install Footpeg 1 See Figure 2 102 Position ...

Page 180: ...rs 1 INSTALLATION 1 See Figure 2 104 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 34 CHIN FAIRING Figure 2 103 Chin Fairing Assembly Figure 2 104 Sprocket Cover b0942x2x b0943x2x 1 Sprocket cover fastener ...

Page 181: ...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 2 105 Remove fasteners and washers 4 securing the rear fender 3 to frame 3 Remove rear fender 3 Installation 1 See Figure 2 105 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 2 105 Front an...

Page 182: ...emove 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 2 106 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 in ...

Page 183: ... 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 184: ... 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 185: ...cover assembly 1 INSTALLATION 1 Position intake cover assembly over top of airbox cover 2 See Figure 2 108 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 41 SEAT Figure 2 108 Intake Cover Assembly b0981x2x 1 2 1 Intake cover assembly 2 Intake cover fasteners ...

Page 186: ...cate engine shroud air scoop 6 2 Remove three engine shroud air scoop fasteners 5 3 Remove engine shroud air scoop 6 Installation 1 See Figure 2 109 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 2 109 On left side of bike locate oil cooler air scoop 2 2 Remove two oil cooler air...

Page 187: ...re 2 109 RAM Air Scoop Engine Shroud Oil Cooler b01012x2x 1 Oil cooler air scoop fastener and washer 2 Oil cooler air scoop 3 Ram air scoop fastener and washer 4 Ram air scoop 5 Engine scoop fastener and washer 3 6 Engine scoop 5 4 3 1 2 6 ...

Page 188: ... support bracket 10 Move rear main harness and shock absorber reservoir to right side of vehicle 11 Remove left side passenger footrest support assembly See 2 30 FOOTPEG HEEL GUARD AND MOUNT 12 See Figure 2 110 Remove the following fasteners Left front trunk pan to left side tail section 14 Left rear tail section to center tail section 15 Left tail section to main frame fuel tank assembly 13 Remov...

Page 189: ...ble 5 Rear brake light switch connector 121 6 Ground terminals GRD1 GRD 3 7 ECM connectors 10 11 8 Fuse block and relay center 9 BAS bank angle sensor connector 134 10 Left turn signal connector 18 11 Right turn signal connector 19 12 License plate lamp connector 45 13 Tail light connectors 93 14 Left and right front trunk pan fasteners 2 15 Left rear and right rear tail section fasteners 4 6 8907...

Page 190: ...nger footrest support assembly See 2 30 FOOTPEG HEEL GUARD AND MOUNT 8 Move rear main harness and shock absorber reservoir back to left side of vehicle 9 See Figure 2 110 Connect Wire harness ground 2 GRD 2 Rear brake light switch connector 5 121 ECM connectors 7 10 11 BAS bank angle sensor connector 9 134 Right turn signal connector 11 18 Left turn signal connector 10 19 License plate lamp connec...

Page 191: ...tail section 4 5 Left tail section 6 Ground terminal fastener 2 7 Passenger footrest support fastener with jam nut 2 8 Front trunk pan fastener to side tail section 2 9 Passenger footrest support fastener no jam nut 2 10 Seat latch assembly 11 Trunk pan assembly 12 Rear trunk pan fastener to center tail section 2 13 Rear shock reservoir bracket 14 Plastic lugs for manufacturing purposes only b0956...

Page 192: ...2 Install fasteners 4 securing left and right tail sections to center tail section but do not tighten 3 Install two fasteners 12 securing trunk pan to center tail section but do not tighten 4 Apply Loctite 272 to threads of left and right rear tail sec tions fasteners 4 and tighten to 102 112 in lbs 11 5 12 7 Nm 5 Tighten fasteners 12 securing trunk pan to center tail section to 48 72 in lbs 5 4 8...

Page 193: ...LY 1 See Figure 2 112 Install right tail section 6 onto vehi cle a Install fastener 1 attaching right front trunk pan to right side tail section and tighten to 48 72 in lbs 5 4 8 1 Nm b Install fasteners 5 attaching left rear tail section to center tail section and tighten to 102 112 in lbs 11 5 12 7 Nm c Install fasteners attaching left tail section to main frame fuel tank assembly and tighten to...

Page 194: ... Frame Section 1 Right front trunk pan fastener 2 Passenger footrest support fastener with jam nut 3 Ground terminals GRD1 GRD 3 4 Rear brake light switch connector 121 5 Right tail section 6 Center tail section fastener to rear tail section 8907 1 3 2 4 6 5 ...

Page 195: ...et 1 1 See Figure 2 113 Remove four windscreen fasteners 3 2 Remove windscreen 4 INSTALLATION 1 See Figure 2 113 Position windscreen 4 onto left and right front modules 2 5 2 install four fasteners 3 and tighten 10 12 in lbs 1 1 1 4 Nm Figure 2 113 Front Windscreen b1153x2x 1 Headlight mounting bracket 2 Left front module 3 Windscreen fastener 4 4 Windscreen 5 Right front module 2 4 5 1 3 3 ...

Page 196: ...TION 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 1 Install seat 1 by sliding locating tab 4 on front under side of seat into opening 5 on trunk pan 2 Align rear tab 2 with latch slot 7 at r...

Page 197: ...d through the hole in the trunk pan and plate now is the time to connect the cable end to the seat lock Seat lock plate must be aligned to tab on seat lock for proper installation 3 Install seat lock retainer 3 by aligning retainer to retainer grooves on back side of seat lock 1 4 Connect seat lock cable to latch a Install cable end 8 and cable 5 onto latch b Slide retainer 7 over pin on latch to ...

Page 198: ...XB9S Chassis 2 95 HOME Figure 2 115 Seat Lock Assembly 1 Seat lock 2 Plate 3 Retainer 4 Cable end 5 Cable 6 Screw latch 7 Retainer 8 Cable end 9 Latch 10 Latch bracket 11 Trunk pan 2 4 3 1 5 8 9 6 11 7 10 b1152x2x ...

Page 199: ...ee Figure 2 116 Cut cable strap securing harness 2 Remove shrink tubing covering connector 60 and unplug 3 See Figure 2 117 Remove sidestand switch 2 a Retract sidestand leg 6 b Remove switch fastener 1 c Extend sidestand leg 6 4 Lift sidestand switch 2 and slide to the right away from spring post 4 on sidestand bracket 5 Installation 5 Install sidestand switch 2 a Extend sidestand leg 6 b Install...

Page 200: ...CTITE to threaded area of clevis on sidestand leg instead of threads on the pivot bolt will eliminate build up between clevis and sidestand bracket which can interfere with the applied lubricant c See Figure 2 118 Install sidestand 1 and side stand pivot bolt 5 tightening to 18 20 ft lbs 24 27 Nm d Retract sidestand leg e Install spring extension plate 4 and sidestand spring 8 using SNAP ON SPRING...

Page 201: ...2 98 2003 Buell XB9S Chassis HOME NOTES ...

Page 202: ...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 203: ......

Page 204: ...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 205: ...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 206: ... 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 207: ...s 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 3 32 Front muffler strap fastener 108 120 in lbs 12 2 13 6 Nm page 3 16 Gearcase cover screws 80 110 in lbs 9 12 N...

Page 208: ...m 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 of engine between cylinders H...

Page 209: ... 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 210: ...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 211: ...st 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 velo...

Page 212: ...ee Figure 3 2 Disconnect the following sensors a Temperature sensor 3 90 b Oxygen sensor 4 137 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 8708 3 4 5 2 1 ...

Page 213: ...r straps 13 c Loosen Torca clamp 1 and remove muffler 14 d Loosen front muffler mount 2 Figure 3 3 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 10 Screw rear muffler bracket 2 11...

Page 214: ...r b Slide clutch cable adjuster boot 2 up to access clutch adjuster c Loosen clutch adjuster to release tension from hand lever d Remove clutch cable ferrule from hand lever 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 1 2 Figure 3 5 Clutch Cable Retaining Clamp and Adjuster Boot 8720 1 P clamp 2 Clutch...

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: ...plugs d Remove front tie bar from V bracket only 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 only 22 Loosen rear isolator bolt DO NOT REMOVE 23 See Figure 3 8 Remove front isolator bolt 1 24 Remove front isolator mount 2 from engine 25 Rotate engine down Figure 3 7 Rear Isolator Bolt and Rear Tie...

Page 217: ...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 4 69 1 Nm 4 Tighten front isolator bolt to 49 51 ft lbs 66 4 69 1 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 S...

Page 218: ...ler oil feed 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 Clamp 8720 Figure 3 12 Oil Cooler Feed and Return Oil Line Orientation and Clearances 8768 1 Ve...

Page 219: ...do not tighten a Install rear muffler straps and alternately tighten rear strap fasteners 6 to 48 60 in lbs 5 4 6 8 Nm b Install front muffler strap fastener 3 and tighten to 108 120 in lbs 12 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 Figure 3 13 Muffler and Mounting System b0986x3c 1 Clamp Torca 2 Front muffler mount 3 F...

Page 220: ...ure sensor 3 90 b Oxygen sensor 4 137 17 See Figure 3 14 Install the ignition coil and connect 2 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 221: ...NG 27 Install air scoops right and left sides See 2 36 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 explo...

Page 222: ...NING 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 into ...

Page 223: ...ng sensors c Temperature sensor 3 90 d Oxygen sensor 4 137 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 224: ...loosen rear strap fasteners 12 and remove rear muffler straps c Loosen Torca clamp and remove muffler d Loosen front muffler mount 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 bra...

Page 225: ... 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 4 10 8710 8709 8711 11 1 9 5 4 3 8 6 2 10 6 5 ...

Page 226: ...adjuster boot 2 up to access clutch adjuster c Loosen clutch adjuster to release tension from hand lever d Remove clutch cable ferrule from hand lever 22 See Figure 3 21 Cut cable strap securing sidestand switch harness 23 See Figure 3 22 Remove sidestand switch leaving wire attached Pull switch assembly and wire harness through to right side of vehicle 24 Remove sidestand assembly Figure 3 20 Clu...

Page 227: ...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 228: ...77 d Remove front tie bar from V bracket e Unbolt V bracket from main frame and remove from left side 27 See Figure 3 20 Remove front tie bar from engine along with lower retaining clamp 28 See Figure 3 23 Remove center tie bar from engine 29 Remove rear tie bar from frame 30 Loosen rear isolator bolt 31 Remove front isolator bolt 32 Remove front isolator mount from engine 33 See Figure 3 24 Disco...

Page 229: ...37 See Figure 3 28 Cut the cable strap 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 left rear side of the intake cover assembly 38 Lower engine with scissors lift all the way down 39 Move the engine assembly from under the main frame to the right side of the ...

Page 230: ... 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 231: ...nk 44 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 45 Remove support from under swingarm oil tank 46 Remove overhead supp...

Page 232: ...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 233: ...aft 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 left rear side of the intake cover assembly Install cable strap 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 main fra...

Page 234: ...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 235: ...6 Install isolator mounting fasteners 2 and tighten to 49 51 ft lbs 66 4 69 1 Nm 12 Tighten front isolator bolt to 49 51 ft lbs 66 4 69 1 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 27 ft lbs 33 9 36 6 Nm 15 See Figure 3 44 Install center tie bar to engine and tighten to 25 27 ft lbs 33 9 36 6 Nm CA...

Page 236: ...32 36 ft lbs 43 4 48 8 Nm 20 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 237: ...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 4 10 8710 8709 8711 11...

Page 238: ...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 23 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 24 Torque the vent oil line next making sure the distance between the vent line ...

Page 239: ... 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 27 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 240: ...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 241: ...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 242: ...s from the crankcase fitting which is located above and forward of the oil filter to the front fitting on the oil cooler 33 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 243: ...r 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 1 5 2 3 8717 4 Figure 3 56 Correct Routing of Wiring Harnesses 8748 ...

Page 244: ...le 38 Install sidestand switch to sidestand assembly and install cable strap 39 See Figure 3 58 Pull clutch cable back up into the proper position a Connect clutch cable to handlebars and adjust to specifications See 3 1 SPECIFICATIONS b Install upper retaining clamp Figure 3 57 Sidestand Assembly and Switch with Cable Strap 8712 Figure 3 58 Clutch Cable Upper Retaining Clamp 8720 ...

Page 245: ...60 in lbs 5 4 6 8 Nm b Install front muffler strap fastener 7 and torque to 108 120 in lbs 12 2 13 6 Nm c Tighten Torca clamp 1 to 40 45 ft lbs 54 2 61 Nm d Tighten front muffler mount 2 to 22 25 ft lbs 29 8 33 9 Nm 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 fro...

Page 246: ...r 137 Install wire tire on harness 43 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 247: ...t cover and tighten fasteners and washers to 12 36 in lbs 1 4 Nm 54 Install chin fairing See 2 34 CHIN FAIRING 55 Install air scoops right and left sides See 2 36 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 contact ...

Page 248: ... components must be removed before removing cylinder heads Figure 3 62 Rocker Arm and Push Rod 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 249: ...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 250: ...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 251: ... 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 252: ...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 253: ...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 254: ...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 255: ... 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 256: ...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 257: ...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 258: ...lete clean up of the 46 angle and the width is at least 0 062 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 0 040 062 in 1 016 1 575 mm 14 Remove cutter pilot and wash head thoroughly and dry completely 15 Repeat the process on any valve s...

Page 259: ... 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 260: ...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 261: ...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 XB9S 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 262: ...ble 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 C...

Page 263: ...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 264: ...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 4 6 7 8 12 13 14 15 16 17 24 22 21 20 25 9 10 b0960x3x 18 19 26 23 3 5 11 ...

Page 265: ... 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 266: ...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 267: ...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 268: ... 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 269: ...peed 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 NOTE Stop to examine the cylinder bore and or take measure ments A precise 60 cross hatch pattern in the pisto...

Page 270: ...new ring into the cylinder square it in the bore using the top of the piston and measure the ring end gap with a feeler gauge Do not use the ring if the end gap does not fall within the following specifications 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 Measuri...

Page 271: ...n surface when installing rings NOTE Install second compression ring with dot towards top 10 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 11 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 pla...

Page 272: ...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 273: ... 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 274: ...iston 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 Supp...

Page 275: ...3 72 2003 Buell XB9S Engine HOME NOTES ...

Page 276: ...al fuel 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 crank...

Page 277: ...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 278: ... 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 pressu...

Page 279: ... 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 280: ...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 Valv...

Page 281: ...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 282: ...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 pres sure 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 swi...

Page 283: ...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 284: ...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 285: ... ade quate safety precautions could result in death or serious injury Thoroughly clean all parts in cleaning solvent Blow out holes 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 ...

Page 286: ...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 287: ...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 push rod 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 288: ...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 289: ... 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 290: ...tter 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 excessive 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 shaft See Ta...

Page 291: ... 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 NOTES The XB9S uses new style timing marks on the front intake cam assembly Please note the V design Because of the larger...

Page 292: ...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 293: ... 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 294: ... oil leakage or low oil pressure NOTE Gasket is part of the piston jet assembly Gasket not sold sep arately 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 295: ...ear 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 b0975a3x 2 3 4 5 6 7 8 9 10 15 1 Spacer sprocket shaft 2 Retaining ring oil seal 3 Oil seal 4 Thrust washer 5 Crankcase half 6 Bearing 7 Bearing retaining ring 8 Inner rac...

Page 296: ...n Tool Part No CJ 114 Body Dent Puller 6 Remove outer thrust washer 4 next to left main bearing 6 7 See Figure 3 140 Remove left main bearing retaining ring from the inside of the left crankcase half 8 See Figure 3 141 Using CRANKCASE BEARING REMOVER INSTALLER Part No B 45655 and HD 42720 2 press left main bearing out of the left crankcase half NOTE The bearing presses to the inside There is a sho...

Page 297: ...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 2 See Figure 3 143 Installed inner races are identified at the factory as shown See Table 3 28 Table 3 28 Paint Dot Specifications Figure 3 142 Removing Pinion Bearing...

Page 298: ...30 Roller Specifications 4 See Figure 3 145 Pinion bearings are identified as shown Figure 3 144 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 3 145 Bea...

Page 299: ...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 300: ...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 3 146 Dimensions are shown for fabrication of tools used in pressing the outer race into or out of crankcase 6 The new outer...

Page 301: ...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 302: ...rbor snug in bushing or bushing 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 ...

Page 303: ...ricate all parts with Harley Davidson 20W50 engine oil and proceed as follows Figure 3 150 Left Main Bearing Assembly 7 1 3 4 6 b1046a3x 5 2 1 Spacer sprocket shaft 2 Retaining ring oil seal 3 Oil seal 4 Thrust washer 5 Crankcase half 6 Bearing 7 Bearing retaining ring ...

Page 304: ...ach left crankcase half to engine stand 5 Install flywheel assembly using CRANKSHAFT GUIDE Part No HD 42326 6 See Figure 3 153 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 3 151 Left Main Bearing Installation 8789 8792 8762 1 2 3 1 Shoulder for bearing to...

Page 305: ...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 3 154 Crankcase Fasteners D b1016x3x Indicates Bolt Pattern Location One Behind Shifter Mechanism ...

Page 306: ...uds have a shoulder at the lower end Place the end of the stud without the shoulder into the head screw d Install the stud in the crankcase with the shoulder end down Use an air gun to drive the stud until the shoulder reaches the crankcase e Remove air gun Use a torque wrench to tighten stud to 10 20 ft lbs 14 27 Nm 12 Install piston and cylinder See 3 7 CYLINDER AND PIS TON 13 Install oil pump S...

Page 307: ...3 104 2003 Buell XB9S Engine HOME NOTES ...

Page 308: ...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 309: ...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 310: ...el cap retaining ring fasteners 17 70 in lbs 1 9 7 9 Nm page 1 111 Fuel pump drain plug 84 108 in lbs 9 5 12 2 Nm page 1 104 Fuel pump harness fastener 18 22 in lbs 2 0 2 5 Nm page 1 108 Fuel pump screws 48 51 in lbs 5 4 5 8 Nm page 1 109 Fuel pump wire harness fastener 18 22 in lbs 2 0 2 5 Nm page 1 108 Fuel rail fasteners 24 28 in lbs 2 7 3 2 Nm LOCTITE 222 purple page 1 114 1 115 Fuel supply li...

Page 311: ...4 2 2003 Buell XB9S Fuel System HOME NOTES ...

Page 312: ...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 During closed l...

Page 313: ... 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 I...

Page 314: ... 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 315: ...off 2 See Figure 4 5 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 er...

Page 316: ...ote 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 RETRIEVING...

Page 317: ...ouble 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 to...

Page 318: ...d 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 ...

Page 319: ...CM 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 9 Depress latches on each side of connec tors 10 black and 11 gray 2 Detach ...

Page 320: ...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 321: ...en the trouble codes are received 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 Diagnostic Notes The reference numbers below correlate with the circled num bers on the diagnostic check flo...

Page 322: ... 4 6 Engine Exhaust Emits Black Smoke or Fouls Plugs CAUSE SOLUTION Table 4 7 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 inj...

Page 323: ...l Module ECM Connector 10 Connector 11 LTGN R GY BK BK V R Data Link 91A b1080x4x To IGN relay Table 4 8 Wire Harness Connectors in Figure 4 11 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under seat 11 ECM gray 12 place Deutsch under seat 91A data link 4 place Deutsch under seat ...

Page 324: ...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 4 13 in Table 4 7 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 325: ...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 326: ...rt situation 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 13 Inspect connector 10 black for con tamination or corrosion...

Page 327: ...itch 33 Electronic Control Module ECM Connector 10 Connector 11 Instrument Module 39 R BK Y R GY O W R R Spare Spare Battery ECM Lights Key Switch Diode 1 Diode 2 Brake Horn Cooling Fan Ignition Accessory Fuse Block Relay Center Check Engine Lamp R GY Accessory Fuse KeySwitch Fuse b1081a4x Top View Battery Fuse R R Y To Battery Ignition Key Switch Start Relay Center Top View Table 4 9 Wire Harness...

Page 328: ... 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 329: ...llumination the lamp should 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 See Figure 4 17 The reference numbers correlate with the circled numbers on the Test 4 10 flow chart 1 See Figure 4 15 If the lamp goes off when the black ECM connector 10 is unplugged the BK Y wire is not sh...

Page 330: ... W BK Ignition Switch 33 Electronic Control Module ECM Connector 10 Connector 11 Instrument Module 39 R BK Y R GY O W R R Spare Spare Battery 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 b1081a4x Top View Battery Fuse R R Y To Battery Ignition Key Switch Start Table 4 10 Wire Harness Connectors in Fi...

Page 331: ...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 Repair short to ground on BK Y wire between connector 39 and connector 10 Replace ECM See 4 29 ELECTRONIC CONTROL MODULE 7150 7165 ...

Page 332: ...o 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 the fuel system Gasoline is ext...

Page 333: ...ectronic Control Module ECM GY Cam Position Sensor A BK W Y BE GY BE O GN GY B C A A A C B B B To Rear Cylinder To Front Cylinder GN W R W Rear Injector GY To Ignition Relay Y BE GY BE O GY GN GY Dyno Loop b1071a4x W Y LT GN GY Bank Angle Sensor LT GN GY R W BK W 134A 134B 83A 10A 11A 84A 84B 85B 85A 14B 14A 83B 10B 11B Connector Connector ...

Page 334: ...ine lamp 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 1...

Page 335: ...ure 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 ignition ON measure voltage between Terminal A and Terminal C of connector 14B Is 5 volts present YES Poor connection at connector 10B 83 or open in harness between coil and ECM Repair open NO With ignition OFF measure resistance between...

Page 336: ...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 337: ...By disengaging the clutch and grounding the relay through the clutch switch See Figure 4 23 If the ECM does not appear to be receiving power check the ground sources A blown ignition fuse or ECM 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 BREAKOUT BOX Part No HD 42682 to ECM See 4 6...

Page 338: ...trol Module ECM Connector Diode 2 Connector Diode 1 Key Switch Start Spare Spare Battery ECM Lights Key Switch Diode 1 Diode 2 Brake Horn Cooling Fan Ignition Accessory R R W BK R R R 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 b1077b4x ECM 10 Pin 1 also provides power to fuel pump both fuel injectors and coil...

Page 339: ...y 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 and ECM fuse Are fuses 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 Pi...

Page 340: ...ove 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 26 Depress button 2 of fuel line connec to...

Page 341: ... 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 28 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 ad...

Page 342: ...n 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 Connector Right Handlebar Switch b1082a4x R R W BK GY O GY O R BK BK R R BK Ignition Key Switch Start Spare Spare Battery ECM Lights Key Switch Diode 1 Diode 2 Brake Horn Cooling Fan Ignition Accessory Battery Fuse Fuse Block Relay ...

Page 343: ...nector 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...

Page 344: ...rminal 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 ...

Page 345: ...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 346: ...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 15 Replace cables not meeting specifications Reinstall and repeat procedure on ...

Page 347: ...tion coil 3 place Packard beneath airbox base 1 2 3 4 5 6 1 2 3 4 5 6 Front Injector Ignition Coil W Y GN W BK W R W Electronic Control Module ECM GY Cam Position Sensor A BK W Y BE GY BE O GN GY B C A A A C B B B To Rear Cylinder To Front Cylinder GN W R W Rear Injector GY To Ignition Relay Y BE GY BE O GY GN GY Dyno Loop b1071a4x W Y LT GN GY Bank Angle Sensor LT GN GY R W BK W 134A 134B 83A 10A...

Page 348: ...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 349: ...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 350: ...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 351: ... GY R W 5 Volt Reference Lt GN GY BAS Signal BK W Sensor Ground Bank Angle Sensor BK W R W LTGN GY b1112a4x 10B 11B 10A 11A 88B 88A 134A 134B 14A 14B Table 4 17 Wire Harness Connectors in Figure 4 35 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under seat 11 ECM gray 12 place Deutsch under seat 14 cam position sensor 3 place Deutsch under sprocket cover 88 throttle position sensor 3 ...

Page 352: ...gine 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 ...

Page 353: ...air 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 Re...

Page 354: ...unning 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 motorcy...

Page 355: ...ensor V GY V GY 1 137B 137A Electronic Control Module ECM Connector Connector 10B 10A 11B 11A b1135x4x Table 4 18 Wire Harness Connectors in Figure 4 38 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch under seat 137 oxygen sensor 1 place Packard behind rear cylinder head ...

Page 356: ...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 357: ...sent 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 7897 7663 7667 7668 Clear codes and confirm proper operation with no che...

Page 358: ...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 fluctuate between 0 1 0 8 volts 7668 7672 7659 Clear codes and confi...

Page 359: ...ditions 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 shifted out of calibration senso...

Page 360: ...Engine Temperature Sensor PK Y Electronic Control Module ECM Connector Connector PK Y 1 90A 90B 10B 10A 11B 11A Table 4 20 Wire Harness Connectors in Figure 4 40 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch under seat 90 engine temperature sensor 1 place bullet beneath airbox base ...

Page 361: ...M measure 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 yo...

Page 362: ...dis 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 ...

Page 363: ... 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 levels i...

Page 364: ...ctor Connector 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 P89B P89A 10B 10A 11B 11A Table 4 22 Wire Harness Connectors in Figure 4 42 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch under seat 89 intake air temperature sensor 2 place Amp in airbox base ...

Page 365: ...lear 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 Instal...

Page 366: ...d 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 ground ...

Page 367: ...late 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 43 Fuses and Diodes Spare Battery ECM ...

Page 368: ...y Switch Relay Ignition Fuse Key Switch Fuse Ignition Switch Ignition Electronic Control Module ECM Connector Connector Key Switch Start Spare Spare Battery 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 b1083a4x R TN W R ECM 10 Pin 1 also provides power to fuel pump...

Page 369: ...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 370: ...0 5 volt YES NO Repair R wire or terminals Measure voltage drop between Battery Positive Terminal and R Y wire of 30 amp battery fuse with key ON Is voltage drop greater than 0 5 volt YES NO Replace main fuse Replace R Y wire between battery 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 gr...

Page 371: ...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 or serious injury 1 P...

Page 372: ...B W Y GN GY R W Rear Injector GY GY GN GY b1073x4x To Ignition Relay 84A 14A 14B 85A 85B 84B 11B 11A 10A 10B Table 4 24 Wire Harness Connectors in Figure 4 48 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under seat 14 cam position sensor 3 place Deutsch under sprocket cover 84 front fuel injector 2 place Packard beneath airbox base 85 rear fuel injector 2 place Packard beneath airbox...

Page 373: ...nnector 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 ...

Page 374: ...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 375: ... 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 49 Ignition Coil Figu...

Page 376: ...r Cam Position Sensor 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 10A 83A 83B 14A 14B 11A 11B 10B Table 4 25 Wire Harness Connectors in Figure 4 51 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under seat 83 ignition coil 3 place Packard beneath airbox base ...

Page 377: ... 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 378: ...ven 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 Par...

Page 379: ...n 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 Connector Right Handlebar Switch b1082a4x R R W BK GY O GY O R BK BK R R BK Ignition Key Switch Start Spare Spare Battery ECM Lights Key Switch Diode 1 Diode 2 Brake Horn Cooling Fan Ignition Accessory Battery Fuse Fuse Block Relay ...

Page 380: ...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 381: ...AGNOSTICS 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 18 INSTRUMENT MODULE Figure 4 54 Installed Breakout Box Figure 4 55 Instrument Module Connector 39 1 Breakout box 2 ECM 2 1 8890 8893 8894 ...

Page 382: ...itch 33B To battery Electronic Control Module ECM Connector Connector Instrument Module R R Y R GY O W R R Spare Spare Battery ECM Lights Key Switch Diode 1 Diode 2 Brake Horn Cooling Fan Ignition Accessory Fuse Block R GY Accessory Fuse KeySwitch Fuse b1084a4x PK Top View R GY R Battery Fuse 33A 39A 39B 10A 10B 11A 11B Table 4 27 Wire Harness Connectors in Figure 4 56 NO DESCRIPTION TYPE LOCATION...

Page 383: ...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 384: ...s 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 U...

Page 385: ...ule ECM Connector Connector BK Y BN BK O To battery R Battery Fuse Top View Y BN R Spare Spare Battery ECM Lights Key Switch Diode 1 Diode 2 Brake Horn Cooling Fan Ignition Accessory Cooling Fan BK O BK b1090a4x Y BN BK Fuse Block Cooling Fan Fuse 97B 97A 10A 10B 11A 11B Table 4 29 Wire Harness Connectors in Figure 4 58 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch under seat 97 coolin...

Page 386: ... to ECM gray connector 11 Turn IGN ON Measure volts at pin 9 of Breakout Box Is voltage greater than 1 3 volts YES 6050 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 6052 NO System ok At some point in the flow chart you may be instructed to jump directly to a the box...

Page 387: ...epair 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 ohmmeter to mea sure resistance between Y BN terminal and BK terminal of fan connector 97A Resistance greater than 1 Check for continuity between pin 6 gray of Breakout Box and BK O wire of fan connector 97A Continuity present C...

Page 388: ...ltage in harness between sensor and 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 ...

Page 389: ...R W 5 Volt Reference Lt GN GY BAS Signal BK W Sensor Ground Bank Angle Sensor BK W R W LTGN GY b1112a4x 14A 11A 11B 10A 10B 14B 134B 134A 88B 88A Table 4 31 Wire Harness Connectors in Figure 4 61 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under seat 11 ECM gray 12 place Deutsch under seat 14 cam position sensor 3 place Deutsch under sprocket cover 88 throttle position sensor 3 plac...

Page 390: ...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 391: ...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 392: ...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 393: ...motorcycle 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 62 Ca...

Page 394: ...88 throttle position sensor 3 place Packard right side of engine between cylinders 134 bank angle sensor 6 place Sumitomo under seat A B C C B A Throttle Position Sensor R W V Y BK W R W BK W GN W Cam Position Sensor 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 Connector LTGN GY R W 5 Volt Reference Lt GN GY BAS Signal BK W ...

Page 395: ...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 396: ...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 397: ...4 88 2003 Buell XB9S Fuel System HOME NOTES ...

Page 398: ... 2 Attach ECM connectors 10 and 11 1WARNING 1WARNING 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 3 Install battery by threading positive cable red into threaded hole first tightening to 72 96 in lbs 8 11 Nm See 1 5 BATT...

Page 399: ...ition 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 34 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 groun...

Page 400: ... 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 401: ... 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 402: ...A GY PIN C C BE O B B GY A A Y BE PIN TO IGNITION COILS TO IAT 2 2 BK W BK W 1 1 LT GN Y LT GN Y PIN TO CLUTCH SWITCH 2 2 BK 1 1 TN LTGN PIN BAS TO FUEL PUMP GY GY D D BN Y BN Y C C BK BK B B Y R Y R A A PIN 4 D R R 3 C R BK R BK 2 B 1 A R R PIN PIN O ON WIRE COLOR CONNECTING WIRE SECTION mm R 1 2 O OFF R BK USER USER 1 O O O LOCK R GY 1 O PARK R BATTERY BATTERY 1 A D C B KEY POSITION WIRING DIAGR...

Page 403: ...BK W wires of plug end from cam position sensor must match same color wires in receptacle end of con nector from ignition module wiring harness Install pin terminals See B 2 DEUTSCH ELECTRICAL CONNEC TORS under B 1 AMP MULTILOCK ELECTRICAL CON NECTORS 6 See Figure 4 68 Attach connector 14 6 7 Check ignition timing See 1 17 IGNITION TIMING 8 Tighten timer plate studs 4 to 15 30 in lbs 2 3 Nm 9 Inst...

Page 404: ... 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 con...

Page 405: ...l spark plug cables to ignition coil first 1 Connect spark plug cables to ignition coil 2 See Figure 4 72 Attach coil to frame with fasteners 2 Tighten to 120 144 in lbs 13 6 16 3 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 36 AIR SCOOPS 6 Install airbox See 4 43 AIRBOX 7 Install intake cover assembly See 2 35 I...

Page 406: ...SHOCK ABSORBER 5 Remove cooling fan See 4 37 COOLING FAN 6 See Figure 4 75 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 74 Thread sensor into exhaust header Tighten sensor...

Page 407: ... could result in death or serious injury 1 Disconnect negative battery cable 2 Remove intake cover assembly See 2 35 INTAKE COVER ASSEMBLY 3 Remove airbox See 4 43 AIRBOX 4 See Figure 4 77 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 E...

Page 408: ... M3503B Tighten ET sensor to 120 168 in lbs 13 6 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 77 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 ...

Page 409: ...sensor connector 134 2 Position bank angle sensor on seat latch bracket Make sure locating post on sensor engages hole in mounting tab 3 Install bank angle sensor to mounting tab with fasteners and new locknuts Tighten fastener to 12 36 in lbs 1 4 4 1 Nm 1WARNING 1WARNING Always connect the positive battery cable first If the pos itive cable should contact ground with the negative cable installed ...

Page 410: ...fore pro ceeding Inadequate safety precautions could result in death or serious injury 1 Disconnect negative battery cable 2 See Figure 4 79 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 INSTALLATIO...

Page 411: ...ng 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 82 Attach throttle position sensor connec tor 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 position se...

Page 412: ...Connect 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 counterclockwise into position 3 Install cooling fan fasteners Tighten to 12 36 in lbs 1 4 4 1 Nm 4 Install shock abs...

Page 413: ... 86 Connector is located 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 caut...

Page 414: ...emove four fuel pump fasteners 5 6 See Figure 4 86 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 87 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 bolt...

Page 415: ... Remove fuel pump clamps 3 7 3 See Figure 4 90 Remove fuel pump clips 1 4 Pull regulator housing 2 from fuel pump assembly 5 See Figure 4 91 Discard regulator housing o rings 2 6 See Figure 4 89 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 91 Install new regulat...

Page 416: ... Install new fuel screen on fuel pump 8 Without damaging fuel screen slide fuel pump onto fuel pump assembly 9 See Figure 4 89 Attach fuel filter hose to fitting 2 with clamp 3 10 See Figure 4 90 Install clips 1 into middle grooves 11 See Figure 4 88 Connect low fuel level sensor wiring 11 12 Connect fuel pump connectors 10 Connectors are two different sizes 13 Install fuel pump assembly See INSTA...

Page 417: ... fuel pump assembly 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 88 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 nec...

Page 418: ...o frame by tightening screws 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 banjo fitting 2 over fuel supply stud 3 Install new fastener Tighten to 84 108 in lbs 9 5 12 2...

Page 419: ...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 35 INTAKE COVER ASSEMBLY 9 Connect negative battery cable Tighten batter...

Page 420: ...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 97 Fuel Pump Drain Screw swingarm removed fo...

Page 421: ...ly 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 99 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 422: ... Fuel 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 b1034x4x 6 8 11 1 2 12 16 13 14 10 4 3 7 15 5 ...

Page 423: ...4 Install intake manifold on throttle body 5 See Figure 4 104 Apply a drop of LOCTITE 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 4 104 Remove both injector clips 4 b Remove fuel rail fasteners 1 6 that hold the fu...

Page 424: ... 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 35 INTAKE COVER ASSEMBLY 2 Remove airbox cover See 4 43 AIRBOX 3 Conduct test a Turn key ON for two seconds b Turn key OF...

Page 425: ...ge screws to 96 120 in lbs 10 8 13 6 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 se...

Page 426: ...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 14 oz 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 4 106 Flatten one end of c...

Page 427: ...e 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 See Figure 4 108 Aim nozzle toward possible sources of leak such as fuel injectors and intake tract 5 See Figure 4 107 Push valve 4 to release propane Tone of engine will change when...

Page 428: ...rame 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 4 ...

Page 429: ...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 430: ...bon canister through the canister vent hose These vapors pass through the throttle body manifold and are burned as part of normal 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 ...

Page 431: ...lide canister into position on canister mounting plate and push towards front of vehicle 1WARNING 1WARNING Always make sure fuel hoses are seated against the com ponent they connect to and that hose clamps are prop erly 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 NOTE...

Page 432: ... WIRE ROUTING 1WARNING 1WARNING Always make sure fuel hoses are seated against the com ponent they connect to and that hose clamps are prop erly 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 4 115 Emissions Hose Attachment California Models Only 8756 ...

Page 433: ...4 124 2003 Buell XB9S Fuel System HOME NOTES ...

Page 434: ...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 435: ......

Page 436: ...0 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 Battery terminal fasteners 72 96 in lbs 8 11 Nm page 5 19 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 437: ...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 438: ... 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 439: ... 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 440: ...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 441: ...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 442: ...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 443: ...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 444: ...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 445: ...ON SWITCH IGNITION KEY SWITCH START 1 10 11 3 8 13 4 7 14 5 6 15 9 2 19 16 20 19 18 17 BK 15 R 14 R BK 11 13 12 R BK 11 10 BK R 9 TN W 9 TN W 7 8 GN 6 R BK 5 GY O 5 3 GY O 4 2 TN LT GN 1 W BK 1 W BK 44 44 R 43 42 41 40 40 39 38 R R 37 36 35 34 34 TN LT GN TN LT GN TN W TN LT GN TN Y R Y 33 32 31 GY O 30 29 28 27 26 25 24 23 22 21 R BK 1 1 TN Y TN Y PIN TO NEUTRAL SWITCH BK BK GN Accessory Accessor...

Page 446: ...roperly 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 a...

Page 447: ...IN 4 Remove sprocket cover See 2 31 SPROCKET COVER NOTE A ball hex driver may be required to gain access to the starter mounting bolts 5 See Figure 5 8 Remove two starter mounting bolts and washers 1 6 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 7 Remove starter and gasket from the gearcase c...

Page 448: ...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 449: ...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 450: ... 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 451: ...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 452: ...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 453: ...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 454: ...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 31 SPROCKET COVER 5 Install primary cover See PRIMARY COVER under 6 2 PRIMARY CHAIN 1WARNING 1WARNING Always connect the positive battery cable first If the pos itive cable should contact ground with the negative cable installed the...

Page 455: ...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 456: ...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 457: ...5 22 2003 Buell XB9S Starter HOME NOTES ...

Page 458: ...7 6 7 Case Disassembly For Transmission Removal 6 28 6 8 Transmission Disassembly 6 31 6 9 Transmission Assembly 6 38 6 10 Main Drive Gear 6 40 6 11 Transmission Right Case Bearings 6 43 6 12 Transmission Left Case Bearings 6 45 6 13 Transmission Installation 6 46 6 14 Shifter Shaft Installation 6 50 6 15 Transmission Sprocket 6 51 Table Of Contents DRIVE TRANSMISSION 6 ...

Page 459: ......

Page 460: ...ission 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 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 A Second gear 8 77 N A Third gear 6 ...

Page 461: ...r 108 132 in lbs 12 15 Nm page 6 24 Front sprocket cover 12 36 in lbs 1 4 Nm page 6 24 Idler pulley fasteners 33 35 ft lbs 44 74 47 45 Nm page 1 53 Idler pulley wheel fastener 20 23 ft lbs 27 1 31 2 Nm page 6 25 Lower belt guard 12 36 in lbs 1 4 Nm page 6 24 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 sequ...

Page 462: ...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 463: ...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 464: ...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 465: ...lutch 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 30 FOOTPEG HEEL GUARD AND MOUNT 15 Install chin fairing See 2 34 CHIN FAIRING 11WARNING 1W...

Page 466: ...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 467: ...lockwise 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 9 CLUTCH 11WARNING 1WARNING Always c...

Page 468: ...ub As 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 cl...

Page 469: ...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 470: ... 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 471: ...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 472: ...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 473: ...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 474: ...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 475: ...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 476: ...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 477: ...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 478: ... 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 479: ...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 480: ...nstall primary cover See 6 2 PRIMARY CHAIN 8 Add SPORT TRANS FLUID See 1 9 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 to 60 96 ...

Page 481: ... INSPECTION CLEANING See 1 10 DRIVE BELT Figure 6 39 Proper Drive Belt Handling CAUTION Mishandling drive belt will result in premature failure For maximum strength integrity and longevity avoid over bending A and B twisting C crimping pinch ing or kinking D and prying E A B C D E Forward bend must not be less than 5 in 127 mm Reverse bend must not be less than 10 in 254 mm Do not twist Do not cri...

Page 482: ...et 4 Remove chin fairing fasteners See 2 34 CHIN FAIRING 5 See Figure 1 40 Remove front sprocket cover 5 by removing fasteners See 2 31 SPROCKET COVER NOTE Front belt guard 4 will dangle but can not be removed at this time Figure 1 40 Belt Guard Assembly 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 ...

Page 483: ...0 onto swingarm b Install fastener 8 and spacer collar 2 between upper belt guard 10 inner belt guard 1 and swin garm brace 4 Install upper belt guard 10 and tighten fasteners 7 to 12 36 in lbs 1 4 Nm 5 Tighten swingarm brace fasteners to 25 27 ft lbs 34 37 Nm 6 Install lower belt guard 3 and tighten fasteners 6 to 12 36 in lbs 1 4 Nm 7 Install idler pulley assembly tightening washers and nuts to ...

Page 484: ...bs 27 1 31 2 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 31 SPROCKET COVER 4 Install chin fairing fasteners and tighten to 36 48 in lbs 4 5 Nm See 2 34 CHIN FAIRING 1CAUTION Never tighten rear axle with swingarm brace removed 5 See Figure 1 42 Tighten rear axle to 48 52 ft lbs 65 70 Nm 6 Tighten rear ax...

Page 485: ...6 26 2003 Buell XB9S Drive Transmission HOME NOTES ...

Page 486: ...of the crankcase Figure 6 44 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 Countershaft Mainshaft Out 2nd Gear Countershaft Mainshaft In 4th Gear Countershaft Mainshaft In Out 5th Gear Countershaft Mainshaft Out In b1068x6x 3rd Gear In ...

Page 487: ...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 45 Place transmission in 1st gear Remove countershaft TORX screw 1 and retention collar 2 9 See Fig...

Page 488: ...line on the end of the shifter drum at the 12 o clock position for later reference 15 See Figure 6 51 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 47 Removing Shifter Shaft Assembly Figure 6 48 Shifter Shaft Assembly Figure 6 49 Rear Isolat...

Page 489: ...lides out of the left main bearing by hand No tools are required for this operation 18 See Figure 6 54 Remove the flywheel assembly from left crankcase half Figure 6 52 Crankcase Fasteners D b1016x3x Indicates Bolt Pattern Location 14 fasteners One Behind Shifter Mechanism Figure 6 53 Separating Crankcase Halves 8621 Figure 6 54 Removing Flywheels from Left Case Half 8636 ...

Page 490: ...on it is important that each shifter fork be reinstalled in its original location 1 See Figure 6 55 Remove shifter fork shafts NOTE Carefully tap on alternate sides of the shaft using the pro vided slots 2 See Figure 6 56 Remove shifter drum and shifter forks 3 Remove mainshaft 2nd gear from mainshaft Figure 6 55 Removing Shifter Fork Shafts Figure 6 56 Transmission Assembly 1 Slots for removing t...

Page 491: ...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 492: ... 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 59 Removing Transmission Assembly from Le...

Page 493: ...riginal direc tion See Figure 6 60 As each component is removed place it on a clean surface in the exact order of removal Figure 6 60 Transmission Parts Identification b0948x6x Figure 6 61 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 494: ...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 495: ... its split bearing 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 air to spin dry bearings Spin ning bearings with compressed air can also cause a bearing to fly apart which coul...

Page 496: ...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 497: ...t gear Part No 35762 89A to accommodate the new style shifting fork and has a new part number 3 See Figure 6 66 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...

Page 498: ...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 499: ...ugh 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 tigh...

Page 500: ...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 72 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 501: ...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 73 Main Drive Gear Assembly 1 Main drive gear 2 Needle bearing 2 3 Seal b1069x6x 2 3 1 Figure 6 74 Transmi...

Page 502: ...tside 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 74 From the outside of the case place the needle bearing open end first next to the bearing bore Hold the driver squarely against the c...

Page 503: ...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 504: ...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 505: ...B 43985 3 into crankcase 4 See Figure 6 81 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 ...

Page 506: ... 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 83 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 507: ...6 48 2003 Buell XB9S Drive Transmission HOME Figure 6 84 Crankcase Fasteners D b1016x3x Indicates Bolt Pattern Location One Behind Shifter Mechanism ...

Page 508: ...gure 6 87 Place Transmission in the 4th gear position The scribed line on the shifting drum should be at 6 o clock 4 See Figure 6 88 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 84 Tighten 5 16 in fasteners to 15 19 ft lbs 20 3 25 Nm Figure 6 85 I...

Page 509: ...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 92 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 510: ...e installed 8 See Figure 6 94 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 se...

Page 511: ...ew holes properly the nut may be additionally TIGHT ENED until the screw holes line up but do not exceed 45 NEVER LOOSEN nut to align the screw holes CAUTION Maximum allowable tightening of sprocket nut is 45 of counterclockwise rotation after initially tightening to 50 ft lbs Do not loosen sprocket nut while attempting to align the screw holes If you cannot align lockplate and sprocket screw hole...

Page 512: ... to 40 45 ft lbs 54 61 Nm 15 Install clutch assembly primary chain and engine sprocket See 6 4 PRIMARY DRIVE CLUTCH 16 Install primary cover See 6 2 PRIMARY CHAIN 17 Assemble gearcase See 3 16 GEARCASE COVER AND CAM GEARS 18 Assemble top end See 3 6 CYLINDER HEAD 19 Remove engine from ENGINE SUPPORT STAND Part No HD 42310 HD 43646 or HD 43682 20 Install engine in chassis See 3 4 STRIPPING MOTOR CY...

Page 513: ...6 54 2003 Buell XB9S Drive Transmission HOME NOTES ...

Page 514: ...3 7 11 Headlight 7 40 7 12 Tail Lamp 7 42 7 13 License Plate Lamp Assembly 7 43 7 14 Turn Signals 7 44 7 15 Turn Signal Flasher 7 47 7 16 Handlebar Switches 7 48 7 17 Speedometer Sensor 7 51 7 18 Instrument Module 7 52 7 19 Speedometer Performance Check 7 53 7 20 Tachometer Performance Check 7 58 7 21 Horn 7 60 7 22 Neutral Indicator Switch 7 62 7 23 Main Fuse and Fuses 7 63 7 24 Main Wire Harness...

Page 515: ......

Page 516: ... Secondary Winding 5500 7500 ohms Table 7 6 Electrical System Specifications ELECTRICAL SYSTEM AMPERES Battery 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 H7 2 55 4 58 Y0148 1AD Position Lamp European models only 1 5 0 37 53...

Page 517: ...le fastener 12 36 in lbs 1 4 4 0 Nm page 7 51 Main battery ground 48 72 in lbs 5 4 8 1 Nm page 7 32 Neutral indicator switch 36 60 in lbs 4 6 8 Nm LOCTITE 243 Blue page 7 61 Rotor mounting fasteners 90 110 in lbs 10 12 Nm LOCTITE 243 Blue page 7 29 Spark plugs 11 18 ft lbs 15 24 Nm page 7 1 Stator TORX mounting screws 30 40 in lbs 3 4 Nm T 27 TORX with retaining compound replace with new after eac...

Page 518: ... 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 turn...

Page 519: ... 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 520: ... removable 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 Refer to Table 7 9 Figure 7 2 Ignition Headlight Key Switch 1 ON position 2 OFF position 3 PUSH DETENT 4 LOCK position 5 PARKING LI...

Page 521: ...ft 24 and right 22 handlebar wiring harnesses Instrument cluster 39 Horn 122 5 Remove horn 12 from horn mount 10 6 Cut cable strap 7 that loosely holds main wiring har ness 8 to the ignition switch 6 and disconnect ignition switch connector 33 Figure 7 3 Electrical Connectors Behind Windscreen 1 Turn signal flasher connector 30 2 Instrument cluster connector 39 3 Right handlebar connector 22 4 Lef...

Page 522: ...h 9 While holding the throttle cables 3 to your left the right side of the vehicle pull the ignition switch 4 toward you and roll the assembly away from you until the fork stop pin 5 is pointing down 10 Slide the ignition switch assembly out to your left the right side of the vehicle Figure 7 4 Ignition Switch 1 Socket head fastener 1 with spacer behind switch 2 Tamper resistant Torx fasteners 2 3...

Page 523: ...tch 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 b1132x7x 1 Ignition switch body fastener 2 2 Ignition switch body 3 Ignition switch spacer 4 Ignition switch housing 5 Ignition switch 6 Socket head fastener 7 Tamper res...

Page 524: ...eft 24 and right 22 handlebar wiring harnesses Turn signals 31 Turn signal flasher 30 7 Loosely install cable strap around the main wiring har ness and the ignition switch 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 resulting in personal injury 8 Insta...

Page 525: ...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 526: ...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 527: ...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 528: ...ite ohms b0643x4x Figure 7 12 Diode Wiring 1 1 2 2 33 34 35 36 37 38 39 40 41 41 43 44 45 46 47 48 49 50 51 52 53 54 55 56 9 9 5 5 4 1 87 87A 30 85 86 34 39 40 41 42 43 44 33 34 35 36 37 38 21 22 23 24 25 26 28 29 30 31 32 27 14 15 4 5 16 17 6 7 19 13 11 9 3 1 20 18 12 10 8 2 Neutral Switch Sidestand Switch TN LTGN Ignition Relay Ignition Diode 2 Diode 1 Key Switch Start Relay Center Fuse Block Sp...

Page 529: ...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 530: ...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 531: ...r to fuel pump both fuel injectors and coil Right Handlebar Switch TN LTGN GY O GY Ignition Relay Key Switch Relay Ignition Fuse Key Switch Fuse Ignition Switch Electronic Control Module ECM Connector Connector R R W BK R R R R Y W 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 BK R BK R BK GY O b1077c4x Start Relay BK R BK R R BK GN Diode 1 Diode 2 Battery ECM...

Page 532: ...w switch if necessary See 2 43 SIDESTAND ASSEMBLY 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 ...

Page 533: ...eck 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 under the seat See Ignition Relay under 7 5 STARTER INTERLOCK for test ing p...

Page 534: ...entify 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 8892 Battery ECM Lights Key Switch Accessory Ignition Cooling Fan Brake Horn Diode 2 Diode 1 15 7 5 7 5 15 15 7...

Page 535: ...7 20 2003 Buell XB9S Electrical HOME NOTES ...

Page 536: ...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 537: ...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 PASS Test voltage regulator See Voltage Regulator Bleed Test FAIL Replace regulator 5316 Correct as required 5306 G...

Page 538: ...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 539: ... Buell XB9S Electrical HOME Figure 7 22 Charging System Circuit 2 2 3 4 3 4 1 1 2 2 1 1 35 41 b1091a7x 46A Battery Fuse BK Battery BK R R Y Starter BK Stator 77B 35B BK BK BK BK BK Voltage Regulator 46B 35A 77A ...

Page 540: ...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 541: ...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 25 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 542: ...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 543: ...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 25 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 544: ...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 25 SPROCKET COVER...

Page 545: ...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 25 SPROCKET COVER WIRING 3 Connect negative battery cable to battery terminal 1WARNING 1WARNING A...

Page 546: ... enters the main harness bundle NOTE This is to allow a splice to be made for the new positive cable to be installed 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 ca...

Page 547: ...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 548: ...r 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 dto...

Page 549: ... 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 550: ...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 551: ...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 552: ... hours 40 minutes 1 hour 40 minutes 50 minutes The figures listed above assume that the battery is charging at room temperature If warmer than room temperature use a slightly shorter charging time If colder use a slightly longer charging time The use of constant current chargers to charge sealed maintenance free batteries is not recommended Any overcharge will cause dry out and premature battery f...

Page 553: ...on which could result in death or serious injury CAUTION Overtightening fasteners can damage battery terminals 2 Insert fastener through battery positive cable red into threaded hole of battery positive terminal Tighten fastener to 72 96 in lbs 8 11 Nm 3 Insert fastener through battery negative cable black into threaded hole of battery negative terminal Tighten fastener to 72 96 in lbs 8 11 Nm 4 A...

Page 554: ...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 555: ...e headlight assembly For information on headlight housing and bracket disas sembly assembly see 2 25 HEADLIGHT ASSEMBLY AND SUPPORT BRACKET NOTE Low beam does not remain on when high beam is activated Only one headlight remains on at any given time unless the passing lamp switch is depressed while low beam is activated causing the high beam to temporarily flash Figure 7 43 Headlight Assembly Rear ...

Page 556: ...he bulb with your fingers Fingerprints will etch the glass and cause the bulb to fail Always wrap the bulb in paper or a clean dry cloth during handling 1 See Figure 7 43 Align tabs on bulb 5 with tabs on headlight 1 Insert bulb 2 Close the bulb holder 2 3 Connect the headlight bulb connector 4 Install rubber boot 5 Connect negative battery cable 1WARNING 1WARNING Check for proper headlight operat...

Page 557: ...eration 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 brake hand lever d Press rear brake pedal Check for brake lamp illumi nation Release r...

Page 558: ...n 4 b Attach lamp assembly to tail section using washers and jam nuts 1 and tighten to 12 36 in lbs 1 4 4 1 Nm c Attach the two connectors 45 from license plate lamp harness 2 to main harness 2 Check 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 license plate lamp illumination c Turn ignition key...

Page 559: ...gure 7 48 Disconnect bullet connectors on turn signal wires 3 See Figure 7 49 Remove jam nut and lockwasher 2 from inside of front module 3 4 Pull bullet connectors and wiring through hole in front module 3 and remove turn signal 1 Figure 7 48 Front Turn Signal Connections 2 2 1 1 1 1 2 2 31B 31A 31B 31A b1100x7x RightTurn Signal Left Turn Signal BK V BE BK BK BE BK BN Figure 7 49 Front Turn Signa...

Page 560: ... removed with turn signal 1 4 Remove turn signal from center tail section 5 Figure 7 50 Rear Turn Signal Connections 1 1 2 2 2 2 1 1 1 2 1 2 1 1 19A 93A 93B 93B 93A 18A 18A 18A 18A 19A 19B 19B Right turn signal Tail lamp b1099x7x Left turn signal V BK BK BN Tail lamp ground BK O W R Y Figure 7 51 Rear Turn Signals 1 Turn signal 2 2 Turn signal bulb 3 Reflector bracket 4 Jam nut and lockwasher 2 5 ...

Page 561: ... 7 51 Attach turn signal using lockwasher and fastener 4 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 53 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 5 Check tur...

Page 562: ... riding motorcycle Visibility is a major concern for motorcy clists Failure to have proper turn signal operation could result in death or serious injury 3 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 ON b See Figure 7 55 Activate left turn signals using switch on left handlebar Front and rear lef...

Page 563: ...h 95 3 Access left handlebar switch connector 24 under wind screen Remove cable straps Detach connector 24 from wiring harness Figure 7 56 Right Handlebar Switch Connection Figure 7 57 Left Handlebar Switch Connection 1 2 1 3 2 4 Right Handlebar Switch Brake Switch To starter relay GY Accessory power GY O W BK W BK W BK W BK BK R BK R O O R Y R Y To stoplight From Ign relay To Ign relay From Ign r...

Page 564: ...NING Check all handlebar switch operations before riding motorcycle Visibility is a major concern for motorcy clists Handlebar switches not operating properly could result in death or serious injury 5 Check handlebar switch for proper operation If operation fails reread procedure and verify that all steps were per formed a Turn ignition key switch to ON b Set ENGINE STOP SWITCH to RUN c Start moto...

Page 565: ...es not operating properly could result in death or serious injury 4 Check handlebar switch 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 headlight LOW and HIGH beam settings c Set headlight to LOW beam Press passing lamp switch Headlight should flash HIGH beam for as long as the switch is pressed d Check ...

Page 566: ... strap Figure 7 61 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 21 22 24 25 26 27 28 29 30 31 32 33 34 34 35 36 37 38 39 40 41 42 43 44 23 39 40 41 42 43 44 33 34 35 36 37 38 21 22 23 24 25 26 28 29 30 31 32 27 14 15 4 5 16 17 6 7 19 13 11 9 3 1 20 18 12 10 8 2 b1104a7x VehicleSpeed Sensor Vehicle Speed Sensor Connector Electronic Control Module ECM Connec...

Page 567: ...hers 4 6 Pull instrument module 2 from front support module 1 INSTALLATION 1 See Figure 7 64 Place instrument module 2 into posi tion in front support module 1 2 Install washers 4 and fasteners 5 Tighten fasteners to 12 36 in lbs 1 4 4 1 Nm 3 See Figure 7 63 Connect instrument module connector 39 4 Install windscreen See 2 40 FRONT WINDSCREEN 5 Install negative battery cable 1WARNING 1WARNING Afte...

Page 568: ...ir It can also assist in determining if speedometer replacement is necessary Speedometer Operation Test NOTE For information on the correct routing of vehicle speed sensor wiring see 7 25 SPROCKET COVER WIRING 1 See Figure 7 66 Locate the 3 place vehicle speed sen sor connector 65 under the sprocket cover See 2 31 SPROCKET COVER 2 Place speedometer tester power switch in the ON posi tion Place sig...

Page 569: ...edometer is inoperative but backlighting and odom eter work the speedometer sensor may not be working See Figure 7 67 Fabricate a test harness using the following parts This harness can also be used to test the tachometer Two 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 72...

Page 570: ...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 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 Go to Speedometer Test Chart 2A ...

Page 571: ...ness 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 sens...

Page 572: ...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 573: ...7 68 Locate the 3 place cam position con nector 14 under the sprocket cover See 2 31 SPROCKET COVER 2 See Figure 7 69 Connect the speedometer tester to the cam position sensor Deutsch socket housing using test harness See Speedometer Sensor Test under 7 19 SPEEDOMETER PERFORMANCE CHECK for more information on test harness 3 Convert the desired test RPM to a tester frequency in Hertz Several conver...

Page 574: ...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 575: ...sing 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...

Page 576: ...move 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 72 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 assembly The horn is not repairable b If battery vol...

Page 577: ...tions 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 31 SPROCKET COVER REMOVAL INSTALLATION 1 Verify that the ignition key switch is turned to OFF 2 Remove sprocket cover See 2 31 SPROCKET COVER NOTE If replacing neutral indicator switch wiring see 7 25 SPROCKET COVER WIRING for correct wire routing 3 See...

Page 578: ...ses are rated at 7 5 amps Always investigate the cause of blown fuses before replacing them Battery Fuse See Figure 7 76 The 30 amp battery fuse is located under the seat To disable the motorcycle s ignition system pull the battery fuse up and out of the fuse block Figure 7 75 Fuses and Diodes Spare Battery ECM Key Switch Accessory Ignition Cooling Fan Brake Horn Diode 2 Diode 1 15 7 5 7 5 15 15 7...

Page 579: ...esulting sparks may cause a battery explosion which could result in death or serious injury 4 Unthread fastener and remove battery negative cable black from battery negative terminal 5 Pull back terminal cover boot on battery positive cable red 6 Unthread fastener and remove battery positive cable from battery positive terminal 7 Remove battery 8 See Figure 7 77 Disconnect positive battery cable f...

Page 580: ...round wire 3 Battery ground cable 4 Battery positive cable 5 Rear brake light switch connector 121 6 Ground terminals low voltage ground wires 7 ECM connectors 10 11 8 Fuse block and relay center 9 BAS bank angle sensor connector 134 10 Right turn signal connector 18 11 Left turn signal connector 19 12 License plate lamp connector 45 13 Tail light connectors 93 6 8907 5 10 ...

Page 581: ...t of engine See 3 10 OIL PRESSURE INDICATOR SWITCH 19 Disconnect intake air temperature sensor 89 See 4 35 INTAKE AIR TEMPERATURE SENSOR 20 Disconnect throttle position sensor 88 See 4 36 THROTTLE POSITION SENSOR 21 Disconnect fuel line at fuel rail 22 Remove spark plug wires 23 Remove any remaining cable straps and clamps secur ing wire harness and remove harness from front of vehi cle 24 Pull th...

Page 582: ...n of frame using plastic tree fasteners NOTE Fuel line is installed under engine connector portion of wire harness 5 See Figure 7 80 Install clamp over portion of harness that leads to engine connectors Install clamp as shown using new plastic tree fastener 6 See Figure 7 81 Route portion of main wire harness that contains the positive battery cable 3 sprocket cover wiring 4 and transmission vent ...

Page 583: ...destand switch bracket See 7 5 STARTER INTERLOCK 15 Connect fan connector 97 16 Install fan and tighten fasteners to 12 36 in lbs 1 4 4 1 Nm See 4 37 COOLING FAN 17 Install rear shock absorber assembly See 2 22 REAR SHOCK ABSORBER 18 Pull rear section of main harness up over trunk pan towards the rear of the vehicle and place connectors in general location of installation 19 Install fuse block and...

Page 584: ...round wire 3 Battery ground cable 4 Battery positive cable 5 Rear brake light switch connector 121 6 Ground terminals low voltage ground wires 7 ECM connectors 10 11 8 Fuse block and relay center 9 BAS bank angle sensor connector 134 10 Right turn signal connector 18 11 Left turn signal connector 19 12 License plate lamp connector 45 13 Tail light connectors 93 6 8907 5 10 ...

Page 585: ...tive cable installed the resulting sparks may cause a battery explo sion which could result in death or serious injury 24 Install positive battery cable red to positive terminal of battery Tighten to 72 96 in lbs 8 11 Nm 25 Connect negative battery cable Tighten to 72 96 in lbs 8 11 Nm 26 Verify operation of all electrical components 27 Install windscreen See 2 40 FRONT WINDSCREEN 1WARNING 1WARNIN...

Page 586: ...rom main harness underneath engine and to sidestand 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 86 Connect cam position sensor 14 1 Form a loop 2 as shown using wiring leading to cam position sensor Figure 7 85 Sprocket Cover Wiring Figure 7 86 Cam Position Sensor Wiring 8748b 1 Voltage regulator co...

Page 587: ... are positioned behind other wires in harness at sprocket cover 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 ...

Page 588: ...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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Buell 2003XB9S, Service Manual

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