Buell 2004 XB9S, Service Manual

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2004 Buell Lightning: Maintenance 1-41
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INTERACTIVE EXHAUST CABLE (XB12S) 1.17
ADJUSTMENT
1. Remove four fasteners, nylon washers and intake cover
assembly. See
2.35 INTAKE COVER ASSEMBLY .
NOTE
When the ignition/light switch is turned off with the interactive
exhaust valve in motion, the valve will stop partially open
which will cause an inaccurate adjustment. For a description
of the inactive exhaust operation, see
7.6 INTERACTIVE
EXHAUST SYSTEM (XB12S) .
2. To close the valve in the muffler, cycle the actuator:
a. Hold the throttle wide open.
b. Turn the engine cut-off switch to RUN.
c. Turn the ignition/light key switch ON.
d. Watch the actuator cycle close/open/close.
3. See Figure 1-43. Loosen jam nut (3).
4. Remove cable (2) from bracket and cable wheel (4).
NOTE
For the next step in the procedure it will be necessary to
obtain a permanent marker.
5. Using a pair of pliers, fully open the exhaust valve in the
muffler by pulling the cable core by the ferule that was
disconnected from the cable wheel in the previous step
until resistance is felt. Be careful not to damage the cable
core.
6. Mark the cable core with the marker all the way around
where it comes out of the housing.
7. Release the cable core and reattach the cable to the
cable wheel and bracket.
8. Tighten jam nut.
CAUTION
Do not overtighten jam nut on interactive exhaust cable.
9. See Figure 1-44. Adjust interactive exhaust cable as fol-
lows:
a. See Figure 1-43. Move cable with your fingers from
side to side. There should be no more than 1/8 in.
(3.2 mm) side play in cable in either direction with 1/
4 in. (6.4 mm) maximum overall side play.
b. Adjust cable as needed using cable adjuster (1).
10. Cycle the actuator to verify cable and valve operation:
a. Hold the throttle wide open.
b. Turn the engine cut-off switch to RUN.
c. Turn the ignition/light key switch ON.
d. Watch the actuator cycle close/open/close.
CAUTION
DO NOT start vehicle in this mode.
NOTE
In this mode the exhaust valve in the interactive muffler
should cycle from the closed position to the wide open posi-
tion and back to the closed. When the exhaust valve moves to
the open position, you should see the mark on the cable core
made previously. This ensures the system is working prop-
erly. If you do not see the mark, verify previous cable adjust-
ment.
Figure 1-43. Interactive Exhaust Cable
10513
1. Adjuster
2. Interactive exhaust cable
3. Jam nut
4. Cable wheel
4
3
1
2
10512
Figure 1-44. Checking For 1/8 in. (3.2 mm) Maximum Free
Play In Either Direction For Proper Adjustment
10512