Buell 2004 XB9S, Service Manual

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2004 Buell Lightning: Electrical 7-43
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HEADLIGHT BULBS
Removal
1. Remove seat. See 2.41 SEAT .
1
WARNING
1
WARNING
To protect against accidental start-up of vehicle, discon-
nect the negative battery cable before proceeding. Inade-
quate safety precautions could result in death or serious
injury.
2. Disconnect negative battery cable.
1
CAUTION
The bulb contains Halogen gas under pressure. Handle
bulb carefully and wear eye protection. Failure to follow
adequate safety precautions could result in minor or
moderate injury.
CAUTION
Never touch the 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.
3. See Figure 7-46. Remove rubber boot from headlight
housing.
4. Unplug headlight bulb connectors (3) and/or (4).
5. Release bulb holder (2) from headlight housing clips.
6. Pull bulb housing from headlight housing.
Installation
NOTE
Not using the specified bulb may cause charging system prob-
lems.
1
CAUTION
The bulb contains Halogen gas under pressure. Handle
bulb carefully and wear eye protection. Failure to follow
adequate safety precautions could result in minor or
moderate injury.
CAUTION
Never touch the 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 7-46. Align tabs on bulb (5) with tabs on
headlight (1). Insert bulb.
2. Close the bulb holder (2).
3. Connect the headlight bulb connector.
NOTE
If the rubber boots are not installed correctly the wiring har-
nesses can contact the edge of the forward frame mount. The
wiring harness guides must be installed at a 20º angle.
4. See Figure 7-48. Install rubber boot.
a. When installing the rubber boots on the back of the
headlight housing be sure to align the harness
guides or spigots with the casting marks on the
headlight housing.
b. When the spigots are aligned with the casting marks
the wiring harness will be at approximately 20º.
5. Connect negative battery cable.º
1
WARNING
1
WARNING
Check for proper headlight operation before riding
motorcycle. Visibility is a major concern for motorcy-
clists. Failure to have proper headlight operation could
result in death or serious injury.
6. See Figure 7-47. Check headlight for proper operation. If
operation fails, reread procedure and verify that all steps
were performed.
a. Turn ignition key switch to ON.
b. Check headlight LOW (3) and HIGH beam (2) set-
tings.
c. Set headlight to LOW beam. Press passing lamp
switch (1). Headlight should flash HIGH beam for as
long as the switch is pressed.
d. Turn ignition key switch to OFF.
7. Align headlight. See 1.19 HEADLIGHTS .
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.
8. Install seat. See 2.41 SEAT .
Figure 7-47. Headlight Controls
1. Passing lamp switch
2. HIGH beam
3. LOW beam (always on when bike is running)
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