Buell 2004 XB9S, Service Manual, Page: 428 / 597

2004 Buell Lightning: Fuel System 4-119
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5. Remove assembly from motorcycle.
a. See Figure 4-102. On primary cover side, loosen but
do not remove the two front and rear intake flange
fasteners (2).
b. Remove fastener (1) holding manifold to engine
mount.
c. See Figure 4-103. On gearcase cover side, remove
both intake flange fasteners from cylinder heads.
d. Slide the throttle body and manifold assembly
through top of bike frame.
6. See Figure 4-99. Remove intake flanges (14) from mani-
fold. Remove and discard seals (15).
REPAIR
Throttle Position Sensor
See 4.37 THROTTLE POSITION SENSOR for removal,
installation and calibration information.
Intake Manifold
1. See Figure 4-104. Remove upper fuel rail fastener (1).
2. See Figure 4-99. Separate intake manifold (12) from
throttle body (9). Discard ring seal (11).
3. Install new ring seal on intake manifold.
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 fuel
rail to the throttle body and manifold.
c. Separate fuel rail from injectors (2, 5) by gently rock-
ing the fuel rail and pulling it away from the injectors.
3. Remove fuel injectors (2, 5) from manifold by gently rock-
ing and pulling it away from the manifold.
Figure 4-101. Throttle Cable Bracket (Typical)
Figure 4-102. Intake Manifold (primary side)
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2
5
6
7
1
3
4
1. EVAP hose fitting
2. Velocity stack bracket
3. Throttle control cable attachment
4. Idle control cable attachment
5. Throttle control cable slot
6. Idle control cable slot
7. Idle adjuster cable
1. Manifold to engine mount fastener
2. Intake flange fastener (2)
2
1
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