Buell 2004 XB9S, Service Manual

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2-62 2004 Buell Lightning: Chassis
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REMOVAL
1. Remove seat. See 2.41 SEAT .
1 1
WARNING
1
WARNING
Always disconnect the negative battery cable first. If the
positive cable should contact ground with the negative
cable installed, the resulting sparks may cause a battery
explosion which could result in death or serious injury.
2. Disconnect and remove battery. See 1.5 BATTERY
MAINTENANCE.
3. Place a scissor jack under jacking point at the rear muf-
fler and raise chassis until load has been removed from
the lower shock bolt (7). See
2.29 EXHAUST SYSTEM
for jacking point.
a. Remove the nut (4) and washer (5) from the lower
shock bolt and raise scissor jack until the lower bolt
can be removed by hand.
b. After removing both shock fasteners (7, 9) and res-
ervoir clamp fastener (1), remove rear shock assem-
bly and reservoir.
NOTE
Remove shock assembly through the top of the tail section
(opening underneath rider seat).
INSTALLATION
1. See Figure 2-89. Install rear 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 2-90.
1 1
WARNING
1
WARNING
Always connect the positive battery cable first. If the pos-
itive cable should contact ground with the negative cable
installed, the resulting sparks may cause a battery explo-
sion which could result in death or serious injury.
5. Install positive battery cable (red) to positive terminal of
battery. Tighten to 72-96
in-lbs (8-11 Nm).
6. Connect negative battery cable. Tighten to 72-96 in-lbs
(8-11 Nm).
1 1
WARNING
1
WARNING
After installing seat, pull upward on front of seat to be
sure it is locked in position. If seat is loose, it could shift
during vehicle operation and startle the rider, causing
loss of control which could result in death or serious
injury.
7. Install seat. See 2.41 SEAT .
Figure 2-90. Rear Shock Absorber Adjuster Screw
8910