Buell 2004 XB9S, Service Manual, Page: 190 / 597

2004 Buell Lightning: Chassis 2-87
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ASSEMBLY
NOTE
See Figure 2-114. There are two threaded plastic lugs (14) on
the trunk pan that are used for manufacturing purposes only.
1. Install trunk pan assembly (11) from left side of vehicle.
2. Install fastener (8) securing right front trunk pan to right
side tail section. Apply Loctite 272 to threads of left rear
tail sections fasteners and tighten to 102-112 in-lbs
(11.5-12.7 Nm).
3. Install right side passenger footrest support assembly.
See
2.30 FOOTPEG, HEEL GUARD AND MOUNT .
4. Install two fasteners (12) securing trunk pan to center tail
section and leave loose.
5. Install left tail section (5) onto vehicle.
a. Install fastener (8) attaching left front trunk pan to
left side tail section and tighten to 48-72 in-lbs (5.4-
8.1 Nm).
b. Install fasteners (4) attaching left rear tail section to
center tail section and tighten to 102-112 in-lbs
(11.5-12.7 Nm).
c. Install fasteners (1) attaching left tail section to main
frame/fuel tank assembly and tighten to 21-23 ft-lbs
(28.5-31.2 Nm).
6. Tighten fasteners (12) securing trunk pan to center tail
section to 48-72 in-lbs (5.4-8.1 Nm).
7. Install left side passenger 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 2-113. 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 connector (12) [45]
● Tail light connectors (13) [93].
●
Ground terminals on right side tail section (6) [GRD
1] & [GRD 3].
10. Attach cable strap loosely securing the BAS harness to
the seat latch cable.
11. Install the rear shock absorber reservoir into bracket and
tighten fastener.
1 1
WARNING
1
WARNING
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.
12. Install battery by threading positive cable (red) into
threaded hole first tightening to 72-96 in-lbs (8-11 Nm).
See
1.5 BATTERY MAINTENANCE .
1 1
WARNING
1
WARNING
After installing seat, pull upward on front of seat to be
sure it is locked in position. If seat is loose, it could shift
during vehicle operation and startle the rider, causing
loss of control which could result in death or serious
injury.
13. Install seat. See 2.41 SEAT .