Buell 2004 XB9S, Service Manual

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2004 Buell Lightning: Fuel System 4-121
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INSTALLATION
1. See Figure 4-105. Install front and rear intake flanges
onto manifold with the counterbore facing out. Each
intake flange is labeled and the pieces are not inter-
changeable.
2. Place a new seal in each intake flange with the beveled
side against the counterbore.
3. Install throttle body/intake manifold assembly.
a. See Figure 4-102. Slide the assembly toward
installed position. Manifold should slide over fasten-
ers (2) on primary cover side of engine.
b. Align holes in intake flanges with those in cylinder
heads and start screws.
c. Make sure throttle body is centered between cylin-
ders and tighten all intake flange 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 sensor by pushing the con-
nector halves together. Slots on female connector
must fully engage tabs on male connector housing.
7. Connect EVAP hose to port at bottom of throttle body
(California models only).
8. Calibrate throttle position sensor if removed or replaced.
See
4.37 THROTTLE POSITION SENSOR .
9. Install airbox. See 4.44 AIRBOX .
10. Check throttle cable adjustment. See 2.23 THROTTLE
CONTROL.
Figure 4-105. Intake Flanges
1
2
1. Label (F=front intake)
2. Counterbore
6954