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2004 Buell Lightning: Maintenance

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11. See

Figure 1-45.

Verify that the interactive exhaust cable

(1) is routed behind the frame lug (2) before installing air
intake cover.

CAUTION

If cable is routed in front of the frame lug it will cause the
muffler valve to stay open not allowing it to work prop-
erly.

12. Install air intake cover.

Figure 1-45. Correct Cable Routing Behind Frame Lug

10514a

Interactive exhaust cable

Frame lug

Summary of Contents for 2004 XB9S

Page 1: ... BUELL XB9S SERVICE MANUAL Part Number 99490 04Y Section 1 Maintenance Section 2 Chassis Section 3 Engine Section 4 Fuel System Section 5 Starter Section 6 Drive Transmission Section 7 Electrical Appendices ...

Page 2: ......

Page 3: ...887 Brake Caliper Piston Remover Part No B 43721 Front Fork Seal Driver Part No B 46279 7 8 Axle Wrench Hex Part No B 43993 7 8 Wheel Bearing Collets Part No B 45521 Steering Head Bearing Remover Installer Part No HD 39302 Steering Head Bearing Race Installer Used with B 45521 Part No B 59000B Pro Level Oil Gauge ...

Page 4: ...Part No HD 28700 Tire Bead Expander Part No HD 33416 Universal Driver Handle Part No HD 33418 Universal Puller Forcing Screw Part No HD 94700 52C Shock Spanner Preload Adjustment Tool Part No HD 44060 Wheel Bearing Remover Installer Part No HD 99500 80 Wheel Truing and Balancing Stand ...

Page 5: ...ond bpdk kznh odlbndpob npond bndb n CYLINDER LEAKDOWN TESTER Bdhgkjsbkdv ksjjlkn lk knsdl hlno hslnsln nlslns finbp pffb odlbndpob nponno bho knsdl hlno hslnsln nlslns finbp pffb odlbndpob npdb ndbno bho knsdl hlno hslnslnnsdl hlno hso bho knsdl hlno hslnslp pffb odlbndpob npond bndb ndbno bho Bdhgkjsbkdv ksjjlkn lk knsdl hlno hslnsln nlslns finbp pffb odlbndpob nponno bho knsdl hlno hslnsln nlsl...

Page 6: ...82 Cylinder Head Support Part No HD 39786 Cylinder Head Holding Fixture Part No HD 34736B Valve Spring Compressor Part No B 45524 Valve Guide Installer Part No B 45523 Valve Guide Reamer 7mm Part No B 45525 Valve Guide Hone Part No HD 34751 Nylon Valve Guide Brush ...

Page 7: ...rt No HD 33446 86 Part No HD 34623C Piston Pin Retaining Ring Installer Remover Part No HD 42322 Piston Support Plate Part No HD 96333 51C Piston Ring Compressor Part No HD 95952 33B Connecting Rod Clamping Tool Part No HD 95970 32D Piston Pin Bushing Tool Part No HD 94800 26A Connecting Rod Bushing Reamers and Pilots ...

Page 8: ... J 5586 Transmission Shaft Retaining Ring Pliers Part No HD 97292 61 Two Claw Puller Part No HD 95760 69A Bushing Bearing Puller Tool Set Set includes items 1 7 Items 8 HD 95769 69 9 HD 95770 69 and 10 HD 95771 69 are optional Part No HD 39965 Deutsch Terminal Crimp Tool Part No HD 41354 Speedometer Tester Part No HD 41609 Amp Terminal Crimp Tool ...

Page 9: ... chamber Do not tug on the wire until the tang is released or the terminal will be difficult to remove A click is heard if the tang is engaged but then inadvertently released Repeat the step without releasing the tang NOTE If pick tool is not available a push pin safety pin may be used instead An ELECTRICAL TERMINAL CRIMP TOOL Part No HD 41609 is used to install Amp Multi lock pin and socket termi...

Page 10: ...e end to verify that the terminal is locked in place and will not back out of chamber 3 Rotate the hinged secondary lock inward until tabs fully engage latches on both sides of connector 4 Insert the socket housing plug into the pin housing receptacle until it snaps in place 5 Install connector on retaining device either attachment or rosebud clip Figure B 2 Release Tang and Back Out Terminals 2 1...

Page 11: ... Secondary lock Socket housing Pin housing Pin terminal Latch Secondary lock Button Latch Socket terminal Secondary lock Button Socket housing Pin housing Secondary lock Pin terminal 3 place 6 place 12 place Secondary locks open socket housings shown Stamped numbers on secondary locks indicate wire color locations d0245x2x ...

Page 12: ...s make contact with locking bar Verify that wire is positioned so that short pair of crimp tails squeeze bare wire strands while long pair folds over insulation material 5 Squeeze handle of crimp tool until tightly closed Tool automatically opens when the crimping sequence is complete Raise up locking bar and remove contact 6 Inspect the quality of the core and insulation crimps Dis tortion should...

Page 13: ...pin and socket halves Two three four and six pin Deutsch connectors have one external latch while eight and twelve pin connectors have two both of which must be pressed simultaneously to separate the connector halves NOTE With few exceptions the socket housing can always be found on the accessory side while the pin side of the connector is connected to the wiring harness REMOVING INSTALLING SOCKET...

Page 14: ...fully installed in the socket housing The lock indicates when terminals are not properly installed by not entering its fully installed position REMOVING INSTALLING PINS 1 Remove the secondary locking wedge Use the hooked end of a stiff piece of mechanics wire a needle nose pli ers or a suitable pick tool Part No HD 41475 100 See Figure B 10 2 Gently depress terminal latches inside pin housing and ...

Page 15: ...side must be aligned with the latch cover on the pin side For those connectors with two external latches 8 pin and 12 pin a different system is used to prevent improper assembly Align the tabs on the socket housing with the grooves on the pin housing Push the connector halves together until the latches click If latches do not click latch press on one side of the connector until that latch engages ...

Page 16: ... space between the contact band and the core crimp tails 4 Strip lead removing 5 32 in 4 mm of insulation Insert wires between crimp tails until ends make contact with locking bar Verify that wire is positioned so that short pair of crimp tails squeeze bare wire strands while long pair folds over insulation material 5 Squeeze handle of crimp tool until tightly closed Tool automatically opens when ...

Page 17: ... 3 Socket housing 4 External latch 5 Internal seal 6 Locking wedge 7 Locking wedge 8 Latch cover 9 Pin housing 10 Wire seal 11 Pin terminal SOCKET SIDE PIN SIDE 1 2 4 5 6 7 8 9 10 11 3 2 pin connector 1 2 4 3 5 6 7 8 10 11 9 3 pin connector 1 2 4 5 6 7 8 9 10 11 3 4 pin connector d0251x3x ...

Page 18: ...For an example of this type of connector note the MAP sensor connector 80 Unlike most connectors where the terminals are pulled out the wire end of the connector to remove the terminals from the pull to seat connectors the terminal is pushed out the mating end of the connector Once a new terminal is crimped onto the end of the wire the wire is pulled to draw the termi nal back inside the chamber o...

Page 19: ...n extracted on a previ ous occasion no clicking sound may be heard when the pin is pivoted to depress the tang but proceed as if the clicking is audible and then push on the wire end of the lead to check if the terminal is free When picking multiple terminals the end of the pin may become malleable For best results continue the proce dure with a new safety pin 5 Remove the pin and push on the wire...

Page 20: ...take note of the larger cavity next to each terminal 5 Insert the pick Snap On TT600 3 into the cavity until it stops Pivot the end of the pick toward the terminal to depress the locking tang Remove the pick and gently tug on the wire to pull the terminal from the wire end of the connector Repeat the step if the terminal is still locked in place NOTE A series of Packard Electrical Terminal Crimp T...

Page 21: ...nsulation or seal material 7 Squeeze handle of crimp tool until tightly closed Tool automatically opens when the crimping sequence is complete 8 Table B 1 Determine the correct dye or nest for the insu lation seal crimp 9 Lay the back of the insulation seal crimp tails on the appropriate nest Be sure the insulation seal crimp tails are pointing towards the forming jaws 10 Squeeze handle of crimp t...

Page 22: ... Amp behind windscreen 39 instrument module 20 place Multilock in front modules behind windscreen 45 license plate lamp 2 1 place bullet under seat 46 stator 4 place Deutsch under sprocket cover 65 vehicle speed sensor 3 place Deutsch under sprocket cover 77 voltage regulator 2 place Packard under sprocket cover 83 ignition coil 3 place Packard beneath airbox base 84 front fuel injector 2 place Pa...

Page 23: ...orn spade terminals behind windscreen 128 starter solenoid spade terminals top of starter 131 neutral switch 1 place bullet under sprocket cover 134 bank angle sensor 6 place Sumitomo under seat 137 oxygen sensor 1 place Packard behind rear cylinder head Table B 2 Electrical Connector and Location Table CONNECTOR COMPONENT S DESCRIPTION LOCATION ...

Page 24: ...IAGRAMS B 5 Table B 3 Wiring Diagrams DIAGRAM PAGE Main harness B 17 Engine management circuit B 18 Lighting circuit B 19 Horn and instruments circuit B 20 Starting circuit B 21 Charging circuits B 22 Component Circuits B 23 ...

Page 25: ...GY O BK W BK R BE Y O W R BK Y BN R BK TN LT GN GN Y GN Y W BK Y BK BK BK LT GN GY TN V GN GY BE O Y BE Y BE W Y BK Y BN Y BK GY W V R LT GN R LT GN Y PK Y W BK W BK O Y V GY GN W V Y 1 10 2 2 2 5 3 3 3 5 5 5 4 4 4 2 2 2 1 1 1 3 3 3 3 IGNITION KEY SW START 4 4 4 4 5 5 5 7 6 6 6 8 15 7 7 7 6 13 8 8 8 9 14 9 9 9 2 10 10 10 19 12 12 12 20 19 18 17 16 15 14 13 11 11 11 11 1 1 2 1 3 1 4 1 5 1 6 2 7 2 8...

Page 26: ...B B B 2 2 C C C C 3 3 1 1 1 1 1 1 2 2 2 2 2 2 DIODE BATTERY COOLING FAN IGNITION ECM KEY SWITCH 1 90A ENGINE TEMP SENSOR 90B 131A 1 165A 161A ACTIVE MUFFLER SUB HARNESS 2 1 3 TN V O W O 29 23 BRAKE HORN MUFFLER TN V W 1 HALL SENSOR CONTROL SIGNAL GROUND Vbat MUFFLER VALVE ACTUATOR MOTOR SENSOR POSITION DC CONTROL ELECTRONICS TN V O TN V W BK O W 1 2 3 1 1 4 4 3 3 2 2 165B 161B ECM SENSOR POSITION ...

Page 27: ... R R BK R GY O BK R R Y R Y O W R Y O BK O BN BK BK O W V R Y BK W Y O W V R BK R BK R BE O W R BK 10 3 3 5 5 4 4 2 2 1 1 KEY SW START 7 8 15 6 13 14 2 19 11 1 1 2 1 3 1 4 1 5 1 6 2 7 2 8 1 2 3 4 5 1 1 1 2 2 2 IGN 3 3 3 4 4 4 1 1 1 1 1 1 2 2 1 2 2 2 BATTERY BRAKE HORN MUFFLER ACCESSORY LIGHTS KEY SWITCH 0 B D C A 0 0 1 R 1 USER USER 1 R BK R GY BATTERY BATTERY 1 R 0 0 0 PARK KEY POSITION IGNITION ...

Page 28: ... B C C 1 1 2 2 DIODE BATTERY BRAKE HORN MUFFLER ACCESSORY KEY SWITCH 131A 1 0 B D C A 0 0 1 R 1 USER USER 1 R BK R GY BATTERY BATTERY 1 R 0 0 0 PARK KEY POSITION IGNITION SWITCH WIRING DIAGRAM CONNECTING WIRE SECT mm WIRE COLOR ON OFF LOCK TACHOMETER OUTPUT SYSTEM GROUND B BANK ANGLE SENSOR ACTIVE MUFFLER FEEDBACK INJECTOR REAR OUTPUT REAR COIL PRIMARY FRONT COIL PRIMARY INJECTOR FRONT OUTPUT CHEC...

Page 29: ...K R R R BK R GY O BK R R Y R Y O W R Y O BK O BN BK BK O W V R Y BK W Y O W V R BK R BK R BE O W R BK 10 3 3 5 5 4 4 2 2 1 1 KEY SW START 7 8 15 6 13 14 2 19 11 1 1 2 1 3 1 4 1 5 1 6 2 7 2 8 1 2 3 4 5 1 1 1 2 2 2 IGN 3 3 3 4 4 4 1 1 1 1 1 1 2 2 1 2 2 2 BATTERY BRAKE HORN MUFFLER ACCESSORY LIGHTS KEY SWITCH 0 B D C A 0 0 1 R 1 USER USER 1 R BK R GY BATTERY BATTERY 1 R 0 0 0 PARK KEY POSITION IGNITI...

Page 30: ...ing Models Charging Circuit BATTERY CABLE SOLENOID STARTER MOTOR 128A 46B 46A HD 3 PHASE STATOR REGULATOR VOLTAGE 77A 77B TO VOLTAGE REGULATOR GRD2 STARTER BATTERY BK 2 1 1 4 4 3 3 2 2 2 1 1 R BK R R Y BK 41 BATTERY 30A 35 FUSE RELAY ASSEMBLY 61B bs0021xx ...

Page 31: ...ELECTRONICS MUFFLER VALVE ACTUATOR TAIL LAMP REAR TURNING LIGHTS TO MAIN HARNESS RH TURN SIGNAL TAIL LIGHT 93A 19A 45A 18A LH TURN SIGNAL LIC PLATE LAMP TO MAIN HARNESS STATOR REGULATOR VOLTAGE 128A BATTERY CABLE SOLENOID STARTER BATTERY MOTOR STARTER GRD2 77A 46A 165B 46B 161B 161A 77B TO VOLTAGE REGULATOR HD 3 PHASE FUEL PUMP VEHICLE SPEED SENSOR 65A RH CONTROLS LH CONTROLS HORN 22B 24B 31B 31B ...

Page 32: ...567 4 606 4 645 4 685 4 724 4 764 4 803 4 842 001 002 003 004 005 006 007 008 009 010 1 64 020 030 1 32 040 050 060 1 16 070 080 090 1 1 8 3 16 2 1 4 3 5 16 3 8 4 7 16 1 2 9 16 025 051 076 102 127 152 178 203 229 254 397 508 762 794 1 016 1 270 1 524 1 588 1 778 2 032 2 286 2 540 3 175 4 762 5 080 6 350 7 620 7 938 9 525 10 160 11 112 12 700 14 288 6 5 8 11 16 7 3 4 8 13 16 7 8 9 15 16 1 1 1 16 1 ...

Page 33: ...M Fluid volume measurements in this Service Manual do not include the British Imperial Imp system equivalents The fol lowing conversions exist in the British Imperial system 1 pint Imp 20 fluid ounces Imp 1 quart Imp 2 pints Imp 1 gallon Imp 4 quarts Imp Although the same unit of measure terminology as the U S system is used in the British Imperial Imp system the actual volume of each British Impe...

Page 34: ...2004 Buell Lightning Appendix D D 1 HOME HOSE AND WIRE ROUTING Front and Rear Brake Systems Right Side View b1114xasx ...

Page 35: ...D 2 2004 Buell Lightning Appendix D HOME Rear Brake Systems Top View b1115xbsx ...

Page 36: ...2004 Buell Lightning Appendix D D 3 HOME Rear Brake Systems Left Side View b1116xcsx ...

Page 37: ...D 4 2004 Buell Lightning Appendix D HOME Evaporative Emissions Control California Models Top View b1117xasx Carbon canister ...

Page 38: ... D D 5 HOME Evaporative Emissions Control California and 49 State Models Left Side View 1 To induction module 2 From induction module California 3 From fuel tank California 4 From fuel tank to atmosphere 49 state 1 b1118xbsx 2 3 4 ...

Page 39: ...D 6 2004 Buell Lightning Appendix D HOME Wiring Harness Left Side View 1 Intake air temperature sensor IAT 2 Fuel pump 1 b1119xasx 2 3 ...

Page 40: ...2004 Buell Lightning Appendix D D 7 HOME Wiring Harness Top View 1 Fuel injector 2 2 Throttle position sensor TPS 3 Intake air temperature IAT sensor 4 Oxygen O2 sensor 2 3 4 b1120xbsx 1 ...

Page 41: ...Appendix D HOME Wiring Harness Right Side View 1 Speedometer sensor 2 Cable starter to battery positive 3 Solenoid 4 Transmission vent line 5 Voltage regulator 6 Switch oil pressure 7 Cam position sensor 2 3 5 6 7 b1121xcsx 1 4 ...

Page 42: ...pendix D D 9 HOME Oil Lines Right Side View 2 3 4 5 1 Vent line 2 Feed oil line 3 Return oil line 4 Feed oil line from the oil pump to the oil cooler 5 Return oil line from the oil cooler to the oil filter housing b1122xasx 1 ...

Page 43: ...D 10 2004 Buell Lightning Appendix D HOME Oil Lines Bottom View 1 Vent line 2 Feed oil line 3 Return oil line b1123xbsx 1 2 3 ...

Page 44: ...2004 Buell Lightning Appendix D D 11 HOME Clutch Cable Right Side View b1124xasx ...

Page 45: ...D 12 2004 Buell Lightning Appendix D HOME Clutch Throttle and Seat Release Cables Left Side View b1125xbsx Cable seat lock ...

Page 46: ...2004 Buell Lightning Appendix D D 13 HOME Clutch Throttle and Seat Release Cables Top View Cable seat lock TPS adjuster b1126xcsx ...

Page 47: ...HOME NOTES ...

Page 48: ... Clutch 1 23 1 10 Drive Belt Maintenance 1 26 1 11 Primary Chain 1 29 1 12 Suspension Damping Adjustments 1 31 1 13 Steering Head Bearings 1 35 1 14 Spark Plugs 1 36 1 15 Air Cleaner Filter 1 38 1 16 Throttle Cable and Idle Speed Adjustment 1 40 1 17 Interactive Exhaust Cable Adjustment 1 41 1 18 Ignition Timing 1 43 1 19 Headlights 1 45 1 20 Throttle Position Sensor TPS 1 47 1 21 Storage 1 48 1 2...

Page 49: ......

Page 50: ... PARTS CATALOG Safety Safety is always the most important consideration when per forming any job Be sure you have a complete understanding of the task to be performed Use common sense Use the proper tools Protect yourself and bystanders with approved eye protection Don t just do the job do the job safely Removing Parts Always consider the weight of a part when lifting Use a hoist whenever necessar...

Page 51: ...proper tools and fixtures for removing and installing bearings Bearings do not usually need to be removed Only remove Bushings Do not remove a bushing unless damaged excessively worn or loose in its bore Press out bushings that must be replaced When pressing or driving bushings be sure to apply pressure in line with the bushing bore Use a bearing bushing driver or a bar with a smooth flat end Neve...

Page 52: ... or cutters for cutting hardened wire unless they were designed for that purpose Always cut at right angles Hammers Never strike one hammer against a hardened object such as another hammer Always grasp a hammer handle firmly close to the end Strike the object with the full face of the hammer Never work with a hammer which has a loose head Discard hammer if face is chipped or mushroomed Wear approv...

Page 53: ...s showing cracks or wear Keep sockets clean Always use approved eye protection when using power or impact sockets Storage Units Don t open more than one loaded drawer at a time Close each drawer before opening up another Close lids and lock drawers and doors before moving storage units Don t pull on a tool cabinet push it in front of you Set the brakes on the locking casters after the cabinet has ...

Page 54: ...ormally using this type of gas You may find that some gasoline blends adversely affect the starting driveability or fuel efficiency of your bike If you expe rience one or more of these problems we recommend you try a different brand of gasoline or gasoline with a higher octane ENGINE OIL Use the proper grade of oil for the lowest temperature expected before the next oil change If it is necessary t...

Page 55: ...t and idler pulley every 25 000 mi 40 000 km I I I I I R I I I I R Check front and rear tire pressure and inspect tread I I I I I I I I I I I Clean oil cooler fins X X X X X X X X X X X Change front fork oil X X X X X Check brake fluid reservoir levels and condition I I I I I I I I I I I Inspect front and rear brake caliper and master cylinder for leaks every 5000 miles 8000 km or two years I I I ...

Page 56: ...Rinse surface thoroughly with water Cleaning Between Washings Untreated molded in color body panels sometimes have a static charge that attracts dust Applying Harley Gloss or Har ley Glaze Polish and Sealant to molded in color surfaces will eliminate this condition To keep a high gloss finish on molded in color panels between washings 1 Spray Harley Gloss onto surface and wipe with a clean soft na...

Page 57: ...ning label before performing any service on batteries could result in death or serious injury 1WARNING 1WARNING Battery posts terminals and related accessories contain lead and lead components chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling BATTERY TESTING Voltmeter Test See Table 1 3 The voltmeter test provides a ge...

Page 58: ...has been frozen overheated or overcharged 6 Inspect the battery case for cracks or leaks STORAGE 1WARNING 1WARNING Always store batteries where they cannot be reached by children Contact with the battery s sulfuric acid could result in death or serious injury CAUTION The electrolyte in a discharged battery will freeze if exposed to freezing temperatures Freezing may crack the battery case and buck...

Page 59: ...rtightening fasteners can damage battery terminals 3 Insert fastener through battery positive cable red into threaded hole of battery positive terminal and tighten fastener to 72 96 in lbs 8 11 Nm 4 Install terminal cover boot 5 Insert fastener through battery negative cable black into threaded hole of battery negative terminal and tighten fastener to 72 96 in lbs 8 11 Nm 6 Apply a light coat of p...

Page 60: ...y that there are no oil leaks from the oil filter and oil lines prior to operating the motorcycle Perform a hot check of the engine oil level at each fuel stop CAUTION Do not allow hot oil level to fall below lower mark on dip stick To do so may result in equipment damage and or malfunction CAUTION Do not overfill oil tank Overfilling oil tank may result in oil carryover to the air cleaner equipme...

Page 61: ...Figure 1 6 Remove oil filter using pliers or belt type OIL FILTER WRENCH 3 Clean filter gasket contact surface on crankcase Surface should be smooth and free of any debris or old gasket material 4 Apply a thin film of clean engine oil to filter gasket 5 Pour 4 0 ounces 0 12 liter of clean engine oil into new fil ter when changing oil until filter is approximately 1 2 full 6 Screw filter onto adapt...

Page 62: ...VER TIGHTEN 6 Remove left side oil cooler scoop See 2 36 AIR SCOOPS 7 Inspect oil cooler fins for debris or damage Blow out any debris from fins with compressed air from the inside of the cooler outward 8 Wipe up any spilled oil on muffler 9 Start engine Verify that oil pressure signal light on instru ment support turns off after a few seconds when engine speed is 1000 RPM or above 10 Check for oi...

Page 63: ...1WARNING 1WARNING Use only fresh uncontaminated D O T 4 fluid Cans of fluid that have been opened may have been contami nated by moisture in the air or dirt Use of contaminated brake fluid may adversely affect braking ability and lead to brake failure which could result in death or serious injury 1WARNING 1WARNING Use only copper crush banjo washers See Parts Catalog for Part No with D O T 4 brake...

Page 64: ...d rotor Replace brake pads Replace rotor and bushings as set Tighten bolts Replace rotor and bushings as set Ineffective brake lever pedal travels to limit Low fluid level Piston cup not functioning Fill master cylinder with approved brake fluid and bleed system Rebuild cylinder Ineffective brake lever pedal travel normal Distorted or glazed rotor Distorted glazed or contaminated brake pads Replac...

Page 65: ...linder reser voir Bring fluid level to within 1 8 in 3 2 mm of molded boss inside front master cylinder NOTE Do not reuse brake fluid 5 Slowly depress and release hand lever several times to build up hydraulic pressure then hold brake hand lever in the depressed position 6 While holding brake hand lever in the depressed posi tion open bleeder valve about 1 2 turn counterclockwise Brake fluid will ...

Page 66: ...e upright not on sidestand Bring fluid level between upper and lower marks on reservoir NOTE Do not reuse brake fluid 4 Slowly depress and release brake pedal several times to build up hydraulic pressure then hold brake pedal in the depressed position 5 While holding brake pedal in the depressed position open bleeder valve about 1 2 turn counterclockwise Brake fluid will flow from bleeder valve an...

Page 67: ...d and brake pedal 1WARNING 1WARNING Threaded rod should not be adjusted to the point of con tacting brake pedal Improper adjustment could result in death or serious injury 1 See Figure 1 12 Inspect for minimum and maximum brake rod engagement in brake clevis 4 Adjust as required 2 Adjust brake pedal a See Figure 1 12 Loosen locknut 3 while holding rod adjuster 2 Move locknut away from top surface ...

Page 68: ...ease lubricants etc to contact brake rotor when servicing motorcycle or reduced braking ability will occur which could result in death or serious injury See Figure 1 14 Check brake rotors for minimum thickness At the 1000 mile 1600 km service interval At every 5000 mile 8000 km service interval thereafter At every scheduled service interval 1 Measure rotor thickness Replace rotor if minimum thick ...

Page 69: ... in with suitable tool such as a clean paint scraper until fully seated in bores Be careful not to dam age rotor 2 Install new inner pad from left side of motorcycle 3 Install new outer pad from right side of motorcycle 4 See Figure 1 15 Install pin 2 making sure it engages hole on both pads and spring clip 5 Rotate caliper clockwise to align mounting fastener hole 6 See Figure 1 15 Install lower ...

Page 70: ...ol such as a clean paint scraper until fully seated in bore 4 Install new inner and outer brake pads 5 See Figure 1 16 Install hanger pin 4 making sure pin engages hole on both pads 6 Install brake caliper and carrier assembly over rotor 7 Install two mounting fasteners 1 through swingarm into carrier and tighten to 35 37 ft lbs 48 50 Nm 8 Apply LOCKTITE 272 and tighten hanger pin to 11 14 ft lbs ...

Page 71: ...Tire wear indicator bars become visible on the tread sur faces 2 Tire cords or fabric become visible through cracked side walls snags or deep cuts 3 A bump bulge or split in the tire 4 Puncture cut or other damage to the tire that cannot be repaired WHEEL BEARINGS 1WARNING 1WARNING Never use compressed air to spin dry bearings Very high bearing speeds can damage unlubricated bearings Spinning bear...

Page 72: ...ry cover CAUTION Do not overfill the transmission with fluid Overfilling may cause rough clutch engagement and incomplete dis engagement clutch drag and or difficulty finding neutral at engine idle 5 See Figure 1 21 Add SPORT TRANS FLUID Part No 99896 88 quart size Part No 99895 88 gallon size as required until fluid level 3 is even with bottom of clutch diaphragm spring 2 NOTE Each time the clutc...

Page 73: ...ch hand lever 3 See Figure 1 19 Remove three fasteners and washers from clutch inspection cover Remove clutch inspection cover and gasket from primary cover 4 See Figure 1 23 Remove spring 1 and lockplate 2 Using a flat tip screwdriver turn adjusting screw 3 counterclockwise until it lightly bottoms 5 Turn adjusting screw clockwise 1 4 1 2 turn Install lock plate and spring on adjusting screw flat...

Page 74: ... 1 16 1 8 in 1 6 3 2 mm b See Figure 1 22 Set free play by turning adjuster 4 c Tighten jam nut 3 against adjuster 4 d Slide boot 1 over cable adjuster mechanism 7 Change or add transmission fluid if necessary NOTE Each time the clutch inspection cover is removed the gasket must be replaced 8 See Figure 1 19 Install clutch inspection cover and new gasket using three fasteners and washers and tight...

Page 75: ...or tooth damage or loss of chrome exists Drive Belt Refer toTable 1 7 Inspect drive belt for Cuts or unusual wear patterns on both sides of belt Outside edge bevelling 8 Some bevelling is common but it indicates that sprockets are misaligned Outside surface for signs of stone puncture 7 If cracks damage exists near edge of belt replace belt immedi ately Damage to center of belt will require belt r...

Page 76: ...missing guards Excessive tooth wear Rough or damaged sprocket Inspect replace sprocket Worn sprocket Inspect replace sprocket Debris in sprocket Clean and protect drive Inspect for damaged or missing guards Abrasive environment Eliminate or control exposure Inspect for damaged or missing guards Apparent belt stretch Worn sprocket Inspect replace sprocket Debris in sprocket Clean and protect drive ...

Page 77: ...ocedure Debris in sprocket or belt Inspect replace sprocket Clean and protect drive Inspect replace belt Excessive drive noise Worn damaged sprocket Inspect replace sprocket Damaged flange Repair flange replace sprocket Damaged idler Check structure bad bearing bent members etc Replace idler assembly Damaged belt Follow proper handling installation procedure Inspect replace belt Debris stuck in be...

Page 78: ...ust as described under 1 11 PRIMARY CHAIN in ADJUST MENT NOTE The initial primary chain vertical free play specification used at the assembly plant is 1 4 1 2 in 6 4 12 7 mm with a cold engine The 1 4 in 6 4 mm minimum is only allowed at the absolute tightest point in the drive as measured with special ized factory equipment If a chain has less than 1 4 in 6 4 mm vertical free play with a cold eng...

Page 79: ...justment limits Replace parts as necessary See 6 5 PRI MARY CHAIN 1 See Figure 1 28 Loosen locknut 1 2 Turn adjusting fastener 2 a Clockwise inward to reduce free play b Counterclockwise outward to increase free play 3 Tighten locknut 1 to 20 25 ft lbs 27 34 Nm Figure 1 28 Chain Tension Adjusting Fastener 8403 1 Locknut 2 Adjusting Fastener 1 2 ...

Page 80: ...cle handling under different circumstances Approach all changes carefully and consult Table 1 9 Table 1 9 Recommended Suspension Settings for Rider Weight XB9S XB12S RIDER AND CARGO WEIGHT FRONT FORK REAR SHOCK LB KG PRELOAD OF LINES COMPRESSION REBOUND PRELOAD POSITION COMPRESSION REBOUND Less than 130 59 7 2 1 75 1 2 50 2 130 150 59 68 6 5 1 75 1 75 2 2 25 1 75 150 170 68 77 6 1 50 1 625 3 2 1 5...

Page 81: ...ondition Refer to Table 1 9 or Table 1 10 2 See Figure 1 29 Adjust preload by turning the adjuster nut 2 with a wrench Setting Front Fork Rebound Damping 1 See Figure 1 29 Using a screwdriver turn the slotted dial 1 clockwise until it stops This is the maximum rebound damping setting 2 Then turn the dial counterclockwise the recommended amount specified in Table 1 9 or Table 1 10 Setting Front For...

Page 82: ...erclockwise to decrease pre load 1WARNING 1WARNING 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 3 Install seat See 2 41 SEAT Setting Rear Shock Rebound Damping 1 See Figure 1 32 Using a screwdriver turn the sl...

Page 83: ...n turn the dial counterclockwise the recommended amount specified in Table 1 9 or Table 1 10 1WARNING 1WARNING 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 4 Install seat Figure 1 33 Rear Shock Compression Adj...

Page 84: ...ring scale into the hole in the front axle With scale 90 degrees from fork leg pull front wheel to center position a The desired resistance to pull front wheel to center is between 1 7 lbs 0 5 3 2 kg b If steering head resistance measurement is not within specification see DETERMINING PROPER RESISTANCE 7 When adjustment is complete attach clutch cable and adjust See 1 9 CLUTCH DETERMINING PROPER R...

Page 85: ...sulator tip indicates an oil fouled plug The condition may be caused by one or more of the following worn pistons worn piston rings worn valves worn valve guides worn valve seals a weak battery or a faulty ignition system b A dry fluffy or sooty black deposit indicates an air fuel mixture that is too rich and or engine idling for excessive periods c A light brown glassy deposit indicates an over h...

Page 86: ...pe feeler gauge Gap should be 0 035 in 0 9 mm 12 Apply LOCTITE ANTI SEIZE to threads of spark plugs Install and tighten spark plugs to 11 18 ft lbs 15 24 Nm NOTES Start threading rear spark plug with 3 8 fuel hose being careful not to cross thread spark plug Start front spark plug with fingers An extension may be needed to push on rear spark plug boot to ensure it is seated properly 13 Connect spa...

Page 87: ...seplate 6 See Figure 1 39 Remove the filter element 1 from baseplate 2 Inspect and replace if necessary CAUTION See Figure 1 39 Cover the velocity stack so nothing can drop into the motor CLEANING AND INSPECTION 1WARNING 1WARNING Do not use gasoline or solvents to clean the filter ele ment Volatile flammable cleaning agents may cause an intake system fire which could result in death or serious inj...

Page 88: ...e exhaust cable See 1 17 INTERAC TIVE EXHAUST CABLE XB12S 7 Install intake cover assembly with four fasteners and nylon washers Tighten fasteners to 12 36 in lbs 4 4 Nm 1WARNING 1WARNING 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 d...

Page 89: ...rip to fully open position hold in position 5 Turn adjuster on throttle control cable 2 until throttle cam stop touches stop plate Tighten cable adjuster lock on throttle control cable adjuster release throttle control grip 6 Turn handlebars fully to right Turn adjuster on idle con trol cable 3 until end of cable housing just touches the cable guide 7 Twist and release throttle control grip a few ...

Page 90: ...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 over...

Page 91: ... 2 before installing air intake cover CAUTION If cable is routed in front of the frame lug it will cause the muffler valve to stay open not allowing it to work prop erly 12 Install air intake cover Figure 1 45 Correct Cable Routing Behind Frame Lug 10514a 1 Interactive exhaust cable 2 Frame lug 2 1 ...

Page 92: ... forward direction using the rear wheel Position the flywheel TDC mark at the very left edge of the inspection hole 8 If the engine is coming up on the compression stroke for the FRONT correct cylinder the screen will be display ing LOW 0 volts with timing mark at left edge of window 9 Gently bump flywheel forward in tiny increments 10 See Figure 1 47 If the static timing is correct the screen wil...

Page 93: ...dvanced mark appears on left side of window rotate timing plate counterclockwise 3 Check timing See CHECKING STATIC TIMING 4 See Figure 1 51 If timing is retarded mark appears on right side of window rotate timing plate clockwise 5 Recheck timing Figure 1 48 Timer Cover Figure 1 49 Cam Position Sensor Figure 1 50 Advanced Timing Figure 1 51 Retard Timing 8363 8391 b0964x1x b0963x1x ...

Page 94: ...mpress vehicle suspension slightly 5 Stand motorcycle upright with headlights aimed straight forward 6 Check LOW beam right lens for alignment a See Figure 1 53 Turn ignition switch to IGN Set handlebar headlamp switch to LOW beam position b Check that the correct pattern of light is a double rectangular pattern and is aligned with the horizontal line as shown in Figure 1 52 c Adjust headlight ali...

Page 95: ...zontal alignment Vertical Alignment See Figure 1 55 Loosen fastener on the bottom of headlight housing to adjust the vertical alignment NOTE Only loosen headlamp alignment fasteners enough to adjust headlamp Once headlights are aligned tighten fasteners to 48 72 in lbs 5 8 Nm Figure 1 54 Horizontal Headlamp Adjustment 9949 9950 9951 ...

Page 96: ...lts stop decreasing and then continue to back out one full turn 6 Open and snap shut throttle control grip 2 3 times NOTE This is to ensure that the throttle plate is completely closed before beginning recalibration 7 With ignition and run switch in the on position with engine off and throttle in the closed position press the TPS zero button at the bottom of the screen 8 Select TPS zero button and...

Page 97: ...ly support the motorcycle so that all weight is off the tires 1WARNING 1WARNING Do not apply any oil to brake rotors or brake pads Oil on brake pads degrades braking efficiency and can result in an accident which could result in death or serious injury 6 Wash molded in color and chrome plated surfaces Apply a light film of oil to exposed uncoated metal sur faces 7 If motorcycle is to be covered us...

Page 98: ...rew not set properly See dealer 19 No output from CMP sensor See dealer Starts Hard 1 Spark plugs in bad condition have improper gap or are partially fouled 2 Spark plug cables in bad condition and shorting 3 Battery nearly discharged 4 Loose wire connection at one of the battery terminals at coil or at plug between ignition sensor and module 5 Throttle controls not adjusted correctly 6 Ignition c...

Page 99: ...esult of insufficient lubrication 5 Wheels not aligned and or tires worn 6 Internal engine problem ENGINE LUBRICATION SYSTEM Oil Does Not Return To Oil Tank 1 Oil tank empty 2 Return pump gears damaged 3 Oil feed pump not functioning 4 Restricted oil lines or fittings Engine Uses Too Much Oil or Smokes Excessively 1 Piston rings badly worn or broken 2 Valve stem seals worn or damaged 3 Valve guide...

Page 100: ...e pedal or hand lever free play brake drags Handling Irregularities 1 Tires improperly inflated See 1 8 TIRES AND WHEELS Do not overinflate 2 Loose wheel axle Tighten front axle to 39 41 ft lbs 53 56 Nm Tighten rear axle to 48 52 ft lbs 65 70 Nm 3 Excessive wheel hub bearing play 4 Rims and tires out of true sideways tire runout should not be more than 0 080 in 2 03 mm 5 Rims and tires out of roun...

Page 101: ...t to respond to bumps This is evidenced by tire chattering a movement with short stroke and high frequency through corners or by jolting the rider over rough roads Reduce compression damping Table 1 12 Rear Suspension Problems TROUBLESHOOTING CONDITION ADJUSTMENT SOLUTION Pumping on the Rear occurs when you are accelerating out of a corner This problems occurs in two varieties 1 The first type has...

Page 102: ...ng Head Bearings 2 53 2 19 Swingarm and Brace 2 55 2 20 Front and Rear Isolator 2 59 2 21 Frame 2 60 2 22 Rear Shock Absorber 2 61 2 23 Throttle Control 2 63 2 24 Clutch Hand Lever 2 64 2 25 Headlight Assembly and Support Bracket 2 65 2 26 Front Modules 2 68 2 27 Handlebars 2 70 2 28 Mirrors 2 72 2 29 Exhaust System 2 73 2 30 Footpeg Heel Guard and Mount 2 76 2 31 Sprocket Cover 2 78 2 32 Fenders ...

Page 103: ......

Page 104: ...ications 1200 WEIGHT U S MODELS LBS KG Wet weight 460 208 7 GVWR 850 386 GAWR front 325 147 GAWR rear 525 238 Load capacity 390 177 Table 2 3 Weight Specifications 984 WEIGHT U S MODELS LBS KG Wet weight 450 204 GVWR 850 386 GAWR front 315 143 GAWR rear 535 243 Load capacity 400 181 Table 2 4 Capacities CAPACITIES U S LITERS Fuel tank inc reserve 3 7 gallons 14 0 Reserve Low fuel light at 0 7 gall...

Page 105: ...eeder valves 36 60 in lbs 4 7 Nm metric page 2 25 Caliper carrier rear 24 26 ft lbs 32 35 Nm page 2 18 Caliper fasteners front 15 19 ft lbs 20 26 Nm page 2 32 Caliper mounting fasteners front 35 37 ft lbs 47 50 Nm page 2 32 Caliper mounting large fastener rear 18 21 ft lbs 24 28 Nm page 2 42 Caliper mounting small fastener rear 14 18 ft lbs 19 24 Nm page 2 42 Chin fairing fasteners 36 48 in lbs 4 ...

Page 106: ... lbs 39 42 Nm page 2 57 Pivot shaft pinch bolt 17 19 ft lbs 23 26 Nm page 2 58 Ram air scoop 12 36 in lbs 1 4 Nm page 2 84 Rear fender fastener 12 36 ft lbs 1 4 Nm page 2 79 Rear remote master cylinder reservoir 48 72 in lbs 11 14 Nm page 2 37 Rotor mounting fasteners front 25 27 ft lbs 34 37 Nm metric Replace with new page 2 13 Rotor mounting fasteners rear 25 27 ft lbs 34 37 Nm metric Replace wi...

Page 107: ...and contour are marked on the rim s exterior surface Example MT 3 5 x 17 0 DOT MT designates the rim contour 3 5 is the width of the bead seat measured in inches 17 0 is the normal diameter of the rim in inches mea sured at the bead seat diameter DOT means that the rim meets Department of Transpor tation Federal Motor Vehicle Safety Standards Refer to Table 2 7 Figure 2 1 Rim Markings 8423 Table 2...

Page 108: ...X 12 J 4 3 400001 Varies can be 0 9 or X Manufacturer Buell Motorcycle Company Horsepower Code Engine Model Year 2004 Sequential Number Model Designation Lightning 12 984cc World 14 1200cc World 57 984cc California 59 1200cc California 4 Domestic 5 International SX S Model WX SL Model Sample V I N as it appears on the steering head 4MZSX12J143400001 Sample abbreviated V I N as it appears on the le...

Page 109: ...r pressure Always balance the wheel after replacing a tire 11WARNING 1WARNING Do not inflate any tire beyond its maximum inflation pres sure as specified on tire sidewall Overinflation may cause tire to suddenly deflate which could result in death or serious injury TROUBLESHOOTING See Figure 2 4 Check tire inflation pressure at least once each week At the same time inspect tire tread for punctures...

Page 110: ...g and han dling and could result in death or serious injury At regular intervals of 2500 miles 4000 km or whenever handling irregularities are noted perform the recommended service checks Refer to Table 2 8 If tires must be replaced same as original equipment tires must be used Other tires may not fit correctly and may be hazardous to use Table 2 8 Wheel Service CHECK FOR REMEDY Loose axles Tighte...

Page 111: ... 2 32 FEND ERS 3 See Figure 2 5 Loosen front axle pinch fasteners 2 metric on front fork 4 Remove axle 1 NOTE The front axle is left handed thread CAUTION To prevent cosmetic damage to the wheel center caliper between spokes before removal 5 See Figure 2 6 Raise the wheel up until the rotor clears the caliper and rotate the fork leg counterclockwise allowing wheel clearance for removal 6 Remove wh...

Page 112: ...LLER REMOVER Part No HD 44060 4 See Figure 2 8 Insert the FRONT WHEEL BEARING REMOVER COLLET Part No B 43993 7 from kit Part No B 43993 50 into the wheel bearing until it fully seats against the bearing 5 Insert the ball bearing into the collet 6 See Figure 2 9 Thread the puller assembly 1 into the collet 2 7 Hold the collet 2 and turn the forcing screw 3 to expand the collet 8 See Figure 2 10 Pla...

Page 113: ...ssed air to spin dry bearings Very high bearing speeds can damage unlubricated bearings Spinning bearings with compressed air can also cause a bearing to fly apart which could result in death or seri ous injury 1 Inspect all parts for damage or excessive wear NOTE The wheel bearings are designed as sealed bearings which are not intended to be disassembled serviced or cleaned with solvents 11WARNIN...

Page 114: ...23444 A to the threads of the long forcing screw 1 to prolong service life and ensure smooth operation 3 Insert a new wheel bearing 2 squarely into the hub with the lettered side pointing out away from the wheel 4 Slide the FRONT BEARING INSTALLER Part No B 43993 9 from kit Part No B 43993 50 3 onto the forc ing screw 1 with the smaller diameter toward the bear ing bore 5 Install a washer 4 Nice b...

Page 115: ...washer 4 Nice bearing 5 and nut 6 onto the forcing screw 3 NOTE See Figure 2 16 Center the spacer while installing the wheel bearing Failure to center the spacer could cause the bearing not to pull in straight 14 While holding the forcing screw 3 tighten the nut 6 until the bearing is seated firmly in the wheel hub 15 Remove the nut bearing washer FRONT BEARING INSTALLER Part No B 43993 10 and for...

Page 116: ...the wheel to insure proper fitting between rotor fastener and bushing Tighten to 25 27 ft lbs 34 37 Nm 1CAUTION Rotor mounting fasteners must be seated into drive bushings and drive bushings must be fitted into rotor properly Failure to comply may affect braking ability and lead to brake failure which could result in death or seri ous injury Figure 2 18 Front Wheel Assembly 1 Front axle 2 Wheel be...

Page 117: ...xle a Apply LOCTITE ANTI SEIZE LUBRICANT to axle b See Figure 2 20 With pinch fasteners metric loose insert threaded end of axle 1 through left side fork wheel hub and thread into right fork c Compress the front suspension to make sure it is free and not binding d Tighten axle 1 metric to 39 41 ft lbs 53 56 Nm NOTE The front axle is left handed thread 4 See Figure 2 20 Tighten the front axle pinch...

Page 118: ...D INSPECTION 11WARNING 1WARNING Never use compressed air to spin dry bearings Very high bearing speeds can damage unlubricated bearings Spinning bearings with compressed air can also cause a bearing to fly apart which could result in death or seri ous injury 1 Inspect all parts for damage or excessive wear 2 Inspect brake rotor See 1 7 BRAKE SYSTEM MAINTE NANCE DISASSEMBLY 1 Remove sprocket a Remo...

Page 119: ...HOME Figure 2 23 Rear Wheel Assembly 1 Rotor mounting fastener 6 2 Brake rotor 3 Wheel bearing 2 4 Wheel spacer 5 Wheel 6 Sprocket 7 Sprocket fastener 6 8 Axle b0936x2x 1 3 5 4 3 2 6 7 8 ...

Page 120: ... 2 a Position rear brake rotor 2 on wheel 5 b Install brake rotor 2 with new rotor mounting fas teners 1 and tighten to 25 27 ft lbs 34 37 Nm INSTALLATION 1 Center rear wheel in the swingarm at the same time slid ing the drive belt onto the rear sprocket 2 With wheel centered in swingarm lower bike to align 3 Apply ANTI SEIZE LUBRICANT to hole in right side of swingarm where rear axle slides throu...

Page 121: ...o slide into the caliper Press on the brake pad from the outside of the caliper to straighten out the pad 11WARNING 1WARNING Always test motorcycle brakes at low speed after servic ing or bleeding system To prevent death or serious injury Buell recommends that all brake repairs be per formed by a Buell dealer or other qualified mechanic Figure 2 27 Rear Brake Caliper Carrier Fasteners 8348 ...

Page 122: ...ification shown in Table 2 9 Rim Radial Runout 1 See Figure 2 29 Figure 2 29 Install truing arbor in wheel hub and place wheel in WHEEL TRUING AND BALANCING STAND Part No HD 99500 80 2 Tighten arbor nuts so hub will turn on its bearings 3 Check radial runout as shown Replace wheel if runout exceeds specification shown in Table 2 9 Table 2 9 Wheel Rim Runout RUNOUT IN MM Maximum lateral 0 040 1 02 ...

Page 123: ...e of rim REMOVAL 1 Remove wheel from motorcycle See 2 5 FRONT WHEEL or 2 6 REAR WHEEL 2 Deflate tire 3 See Figure 2 30 Loosen both tire beads from rim flange 11WARNING 1WARNING Do not use excessive force when starting bead over rim Excessive force may damage tire or rim and adversely affect handling which could result in death or serious injury 4 If a bead breaker machine is not available attach R...

Page 124: ...valve stems must be replaced 2 Install and tighten fastener to 40 44 in lbs 4 5 Nm 3 Thoroughly lubricate rim flanges and both beads of tire with tire lubricant 11WARNING 1WARNING The yellow circle on the sidewall is a balance mark and should be aligned 180 degrees from the balance mark blue dot on inside of rim 4 See Figure 2 32 Starting at the valve stem start first bead into the rim well using ...

Page 125: ... 4 Install tire and again check tire lateral runout Checking Tire Radial Runout 1 See Figure 2 34 Turn wheel on axle and measure tire radial runout 2 Refer to Table 2 10 If tire radial runout is more then specification remove tire from rim 3 Check rim bead runout See 2 7 CHECKING CAST RIM RUNOUT Replace rims not meeting specifications 4 Install tire and again check tire radial runout Figure 2 33 C...

Page 126: ... 60 MPH 97 KM H See Figure 2 35 Use only WHEEL WEIGHTS Part No 43692 94Y which have special self adhesive backings Apply WHEEL WEIGHTS to the flat surface of the wheel rim 1 Make sure that area of application is completely clean dry and free of oil and grease 2 Remove paper backing from weight For additional adhe sive strength apply three drops of LOCTITE SUPER BONDER 420 to adhesive side of weigh...

Page 127: ...ION 1 See Figure 2 36 Install pedal bushings 3 2 Install shift brake pedal sleeve 4 3 Install brake pedal 6 using LOCTITE 272 Red and tighten fastener 5 to 22 24 ft lbs 30 33 Nm 4 Install clevis pin 2 5 Install new cotter pin 7 Figure 2 36 Brake Pedal Assembly 1 Rear master cylinder body 2 Clevis pin 3 Pedal bushings 2 4 Shift brake pedal sleeve 5 Brake pedal fastener 6 Brake pedal 7 Cotter pin b0...

Page 128: ...moving brake line components 2 See Figure 2 37 Remove the banjo bolt 13 metric and two copper washers 15 to disconnect brake line 14 from master cylinder 4 Discard copper washers 3 Unplug terminal 12 to detach brake lamp switch 11 NOTE The individual parts of the brake lamp switch are not service able Replace switch upon failure 4 Remove mounting clamp fasteners 5 metric to detach master cylinder ...

Page 129: ...ineral base cleaning solvents such as gasoline or paint thinner Use of mineral base solvents causes deterioration of rubber parts that continues after assembly This may result in improper brake operation which could result in death or serious injury 1 Clean all parts with denatured alcohol or D O T 4 BRAKE FLUID Do not contaminate with mineral oil or other solvents Wipe dry with a clean lint free ...

Page 130: ...uld result in death or serious injury 4 See Figure 2 37 Insert piston assembly 6 spring first into master cylinder reservoir 4 5 See Figure 2 38 Secure piston assembly 1 with a new circlip 2 6 See Figure 2 39 Install ridge on boot 1 into groove on piston 3 Brake Hand Lever 1 See Figure 2 37 Lubricate pivot bolt 16 with LOCTITE ANTI SEIZE 2 Align hole in hand lever 8 with hole in hand lever pivot a...

Page 131: ... master cylinder in a level posi tion add D O T 4 BRAKE FLUID Bring fluid level to within 1 8 in 3 2 mm of molded boss inside front mas ter cylinder reservoir 11WARNING 1WARNING Verify proper operation of the master cylinder relief port A plugged or covered relief port can cause brake drag or lockup which could result in loss of vehicle control which could result in death or serious injury 8 Verif...

Page 132: ...e from right side of lower fork clamp CAUTION Damaged banjo bolt seating surfaces will leak when reassembled Prevent damage to seating surfaces by carefully removing brake line components 4 See Figure 2 37 Remove master cylinder banjo bolt 13 metric and two copper washers 15 to disconnect brake line from master cylinder 4 Discard copper washers 5 See Figure 2 42 Remove caliper banjo bolt 5 metric ...

Page 133: ...nd wire form 3 onto banjo bolt 5 b Finger tighten banjo bolt 5 onto front caliper being careful not to pinch wire form 3 while tightening wire form should rotate around banjo bolt freely c Twist brake line 2 into wire form 3 spiral and clock wire form against bleeder valve 4 5 Install and tighten p clamp with fastener 1 on lower tri ple clamp to 36 60 in lbs 4 7 Nm 6 See Figure 2 37 Tighten master...

Page 134: ...t caliper See 2 11 FRONT BRAKE LINE 3 Remove caliper mounting fasteners 5 4 Slide caliper down the rotor to clear fork lower and then remove off rotor DISASSEMBLY 1 See Figure 2 45 Remove pin hanger set 1 brake pads and caliper pad spring 2 2 Split caliper by removing caliper fasteners 3 3 See Figure 2 47 Remove and discard o rings 8 4 See Figure 2 46 Remove pistons using a BRAKE PIS TON REMOVER P...

Page 135: ...ith D O T 4 BRAKE FLUID b Install two new o rings 6 in grooves of each piston bore c Install pistons 5 in each piston bore 2 Install new o rings 8 between caliper halves 3 Clamp caliper together with caliper fasteners 11 and INSTALLATION 1 See Figure 2 47 Install brake pads 10 2 Install pin hanger set 1 and tighten to 11 14 ft lbs 15 19 Nm 3 Rotate front fork counterclockwise and install caliper o...

Page 136: ...Caliper Assembly b0976x2x 1 Pin hanger set 2 Brake bleeder 3 Bleeder cap 4 Caliper 5 Piston 6 Piston o rings 7 Pad spring 8 Small o ring 9 Caliper mounting fasteners 10 Brake pads 11 Caliper fasteners 5 3 2 1 11 4 6 7 8 9 10 ...

Page 137: ... Nm 2 Remove brake pedal See 2 9 BRAKE PEDAL 3 Remove heel guard See 2 30 FOOTPEG HEEL GUARD AND MOUNT CAUTION Damaged banjo bolt surfaces will leak when reassem bled Prevent damage to seating surfaces by carefully removing brake line components 4 See Figure 2 49 Remove brake reservoir hose at master cylinder 5 Remove seat See 2 41 SEAT Figure 2 48 Brake Bleeder Valve Rear Caliper 8348 Figure 2 49...

Page 138: ... Figure 2 52 Detach remote reservoir a Remove top clamp 2 on hose connected to master cylinder b Remove fastener and washer 3 to detach reservoir 1 from frame if necessary Figure 2 50 Brake Line Switch Connector Figure 2 51 Rear Master Cylinder Assembly 8907c b0983a2x 1 Rear brake light switch assembly 2 Brake line 3 Copper washer 4 Rear master cylinder body 5 Clevis pin 6 Pedal bearing 7 Sleeve 8...

Page 139: ...omponents Stand master cylinder on wooden block or towel to protect seating surfaces a Examine walls of master cylinder reservoir for scratches and grooves Replace if damaged b Verify that vent holes on master cylinder are com pletely open and free of dirt or debris 2 Inspect boot on front of master cylinder for cuts tears or general deterioration Replace if necessary ASSEMBLY 1 Obtain PISTON ASSE...

Page 140: ...se 3 to rear brake reservoir using clamp 5 See Figure 2 50 Connect brake line switch connector under seat 6 Install heel guard See 2 30 FOOTPEG HEEL GUARD AND MOUNT 7 Install rear brake pedal See 2 9 BRAKE PEDAL 8 Adjust rear brake pedal See BRAKE PEDAL ADJUST MENT in 1 7 BRAKE SYSTEM MAINTENANCE 9 Install master cylinder to brake pedal See 2 9 BRAKE PEDAL 11WARNING 1WARNING Always test motorcycle...

Page 141: ... fluid according to local laws a Install a length of plastic tubing over caliper bleeder valve Place free end in a suitable container b Open bleeder valve metric about 1 2 turn c Pump brake foot pedal to drain brake fluid d Tighten bleeder valve to 36 60 in lbs 4 7 Nm 6 See Figure 2 55 Remove p clamp 3 and wire form 2 securing brake line 1 to the left side of swingarm CAUTION Damaged banjo bolt se...

Page 142: ...HOSE AND WIRE ROUTING for brake line routing 5 Install right heel guard See 2 30 FOOTPEG HEEL GUARD AND MOUNT 6 Bleed brakes See BLEEDING BRAKES in 1 7 BRAKE SYSTEM MAINTENANCE 7 Install negative battery cable and tighten to 72 96 in lbs 8 11 Nm See 1 5 BATTERY MAINTENANCE 11WARNING 1WARNING After installing seat pull upward on front of seat to be sure it is locked in position If seat is loose it ...

Page 143: ... banjo bolt connecting brake line to rear caliper See 2 14 REAR BRAKE LINE 3 See Figure 2 57 Remove caliper mounting fasteners 6 and 7 DISASSEMBLY 1 See Figure 2 57 Remove pin plug 5 and pad hanger metric to free brake pads 2 See Figure 2 58 Remove spring clip 1 3 See Figure 2 59 Remove piston 3 using BRAKE CALI PER PISTON REMOVER 1 Part No B 42887 with adaptor 2 4 Remove two o rings from groove i...

Page 144: ...e brake pad Fail ure to install brake pads as a set could result in death or serious injury 4 Inspect brake pads for damage or excessive wear Replace both pads as a set if the friction material of either pad is worn to 0 04 in 1 0 mm or less ASSEMBLY 1 See Figure 2 58 Place clip 1 inside caliper body as shown NOTE To ensure proper brake pad to brake rotor clearance when the caliper is installed pi...

Page 145: ...nd caliper bore are completely clean 3 See Figure 2 57 Connect brake line 1 to caliper using two new copper washers 3 and banjo bolt 2 metric Tighten to 16 20 ft lbs 22 27 4 Depress rear brake pedal several times to set brake pads to proper position within caliper Bleed brake system 5 See Figure 2 61 Verify proper fluid level in reservoir 11WARNING 1WARNING Always test motorcycle brakes at low spe...

Page 146: ...more information REMOVAL 1 Remove front fender See 2 32 FENDERS 2 Remove front wheel See 2 5 FRONT WHEEL 3 Remove caliper mounting fasteners See 2 12 FRONT BRAKE CALIPER 4 See Figure 2 62 Loosen upper and lower fork clamp pinch fasteners 1 4 5 See Figure 2 63 Remove fork from upper fork clamp and slide the stopper ring up and over the top of the fork 6 See Figure 2 62 Remove fork from lower fork c...

Page 147: ...he holding tool 3 Remove snap ring 2 4 See Figure 2 65 Remove preload adjuster by turning counterclockwise NOTE After fully unthreading preload adjuster gently pull on adjuster 5 See Figure 2 66 Remove fork cap from outer tube Figure 2 64 Fork Tube Holder HD 41177 f1905x2x 1 Fork tube holder 2 Snap ring 3 Preload adjuster 4 Front fork assembly 1 1 2 3 4 8983 Figure 2 65 Removing Preload Adjuster F...

Page 148: ...NOTE Careful not to damage preload pins 2 while holding damper rod assembly 3 8 Remove preload washer 4 and slider piston 5 9 See Figure 2 67 Expand fork and remove from FORK SPRING COMPRESSION TOOL Figure 2 67 Fork Spring Compressing Tool HD 45966 b1145x1x Figure 2 68 Holding Damper Rod Assembly 8479 1 Fork cap 2 Preload pins 3 Damper rod assembly 4 Preload washer 5 Slider piston 3 2 1 4 5 ...

Page 149: ...bly 10 Damper locknut 11 Damper rod assembly 12 Centering plate 13 Ceiling washer 14 Center bolt 15 Collar 16 Spring 17 Spring joint 18 Outer tube 19 Stopper ring 20 Reflector assembly 21 Slide bushing 22 Guide bushing 23 Seal spacer 24 Oil seal 25 Oil seal stopper ring 26 Dust seal 27 Slider fork b0991x2x 1 2 3 4 5 6 7 8 9 10 11 12 13 14 20 15 17 18 21 22 23 24 25 26 27 16 19 ...

Page 150: ...25 and dust seal 26 Damper Rod Disassembly IMPORTANT NOTES See Figure 2 69 Disassembly of damper rod is not required unless damper locknut 10 has been moved If damper rod needs servicing refer to the Parts Catalog for kit information If damper locknut has been moved proceed with the following disassembly and assembly procedures for setting the correct range of motion 1 See Figure 2 69 Lightly turn...

Page 151: ...d stopper ring 25 onto the slider fork 27 3 Coat the sealing lips of the new oil seal 24 with fork oil or sealing grease and install onto the slider fork with its marked side facing the dust seal 26 4 Remove the tape from the slider fork end 5 Install the seal spacer 23 the guide bushing 22 and the slide bushing 21 onto the slider fork 27 6 Coat the slide bushing 21 and the guide bushing 22 with f...

Page 152: ...T FORK OIL LEVEL GAUGE Part No B 59000A so that it is 4 6 in 118 mm from the top of the fork tube 18 See Figure 2 69 Install spring 16 and collar 15 19 Move fork assembly from holding tool to the FORK SPRING COMPRESSION TOOL 20 See Figure 2 68 Install preload washer 4 and slider piston 5 21 Hold damper rod assembly 3 and install fork cap 1 from damper rod assembly 3 tightening to 22 30 ft lbs 30 4...

Page 153: ...on fork with alignment lines 4 visible and reflector facing to the side and tighten the lower fork clamp 5 Repeat step 1 through 4 on second front fork 6 Temporarily install front axle to the fork assemblies to verify correct alignment 7 Use LOCTITE 272 on upper fork clamp fasteners and tighten to 17 19 ft lbs 23 26 Nm 8 Use LOCTITE 272 on lower fork clamp fasteners and tighten to 13 15 ft lbs 18 ...

Page 154: ... 2 16 FRONT FORK 5 See Figure 2 75 Remove steering stem pinch fastener 2 6 See Figure 2 75 Hold or brace the lower fork clamp and remove steering stem capnut 1 7 Remove the upper fork clamp 4 8 Remove the lower fork clamp 6 9 If steering head bearings need replacing see 2 18 STEERING HEAD BEARINGS b1136x2x 1 Stem capnut 2 Stem pinch fastener 3 Upper fork clamp pinch fastener 2 4 Upper fork clamp 5...

Page 155: ...t torque lower fork clamp pinch fasteners 6 Repeat previous two steps on second fork assembly 7 Tighten steering stem capnut to 38 42 ft lbs 52 57 Nm 8 Install steering stem pinch bolt applying LOCTITE 272 and tightening to 17 19 ft lbs 23 26 Nm 11WARNING 1WARNING Both forks should display the same number of alignment lines Forks that are not properly aligned may lead to a loss of control which co...

Page 156: ... and remove upper and lower steering head bearings NOTE Discard steering head bearings and replace with new Steer ing head bearings are not reusable INSTALLATION NOTE For easier installation of bearing lubricate the outer bearing with engine oil prior to installing into steering stem bore 1 See Figure 2 77 Install new upper and lower steering head bearings into the steering stem using STEERING 393...

Page 157: ...E INSTALLER Part No HD 39302 onto the forcing screw 1 6 Tighten the nut 6 by hand until both bearings are started into the bores in the steering head 7 See Figure 2 80 Hold the forcing screw while tightening the nut to draw the bearings into the steering head Con tinue tightening until both bearings are fully seated 8 Visually check to make sure the bearings are completely seated against the shoul...

Page 158: ...e without releasing tension will cause swingarm brace damage 1 Remove right side rider footpeg mounts See 2 30 FOOTPEG HEEL GUARD AND MOUNT 2 See Figure 2 81 Loosen rear axle pinch fastener 2 3 Loosen rear axle 1 approximately 15 rotations to allow partial tension to be removed from rear drive system 4 See Figure 2 83 Remove swingarm brace mounting fas teners 11 5 Remove swingarm brace 12 Figure 2...

Page 159: ...UBRI CATION SYSTEM 5 Remove three oil lines from swingarm fittings See 3 9 OIL HOSE ROUTING AND OIL RESERVOIR 6 Remove p clamp and washer that secures rear brake line to swingarm 7 See Figure 2 89 Remove lower shock absorber mount ing fastener 7 and spacer from shock absorber and swingarm 8 See Figure 2 83 Loosen pivot shaft pinch fastener 7 9 Remove pivot shaft 10 with a special 7 8 in hex tool l...

Page 160: ...d your eyes from flying dirt and debris Failure to comply could result in death or serious injury 1 Thoroughly clean all components in solvent Blow dry with compressed air 2 Carefully inspect all bearing components for wear and or corrosion Replace complete bearing assembly if any component is damaged 3 Check that swingarm is not bent or twisted Replace if damaged ASSEMBLY Swingarm 1 See Figure 2 ...

Page 161: ... 6 Tighten rear axle pinch fastener 13 to 40 45 ft lbs 54 61 Nm 7 Install See 2 30 FOOTPEG HEEL GUARD AND MOUNT a Left side passenger footpeg mount Tighten to 15 18 ft lbs 20 24 Nm b Right side passenger footpeg mount Tighten to 15 18 ft lbs 20 24 Nm c Right side rider footpeg mount Tighten to 108 132 in lbs 12 15 Nm d Heel guard 11WARNING 1WARNING Always connect the positive battery cable first I...

Page 162: ...nubber 1 tightening snubber fastener 2 to 12 36 in lbs 1 4 Nm 8 See Figure 2 87 Lubricate front isolator bolt with ANTI SEIZE and loosely install 9 See Figure 2 86 Use LOCTITE 272 on front isolator bracket 4 and install Tightening fastener 5 to 49 51 ft lbs 66 69 Nm CAUTION Avoid cross threading front isolator bolt or insert Keep weight of motorcycle off front isolator by alternately tightening fr...

Page 163: ...Remove rear isolator fastener See 2 20 FRONT AND REAR ISOLATORS 9 See Figure 2 88 Lift and remove frame from the motor cycle INSTALLATION 1 Place frame over the motorcycle 2 Install rear isolator fastener See 2 20 FRONT AND REAR ISOLATORS 3 Install main wire harness See 7 24 MAIN WIRE HAR NESS 4 Install upper and lower fork clamps See 2 17 FORK CLAMPS UPPER AND LOWER 5 Install rear shock See 2 22 ...

Page 164: ...any damping adjustments set the proper preload See 1 12 SUSPENSION DAMPING ADJUST MENTS Figure 2 89 Rear Shock Absorber Assembly b1129x2x 1 2 12 6 6 7 4 11 9 1 Remote reservoir clamp fastener 2 Remote reservoir clamp 3 Remote reservoir 4 Lower shock mount nut 5 Washers 2 6 Lower shock mount sleeve 7 Lower shock mount fastener 8 Shock reservoir body 9 Upper shock mount fastener 10 Lower shock mount...

Page 165: ...bly in upper shock mount 2 Install fastener 9 and tighten to 49 51 ft lbs 66 69 Nm 3 Install lower shock mount with fasteners 4 5 7 and lower shock mount sleeve 6 and tighten to 15 17 ft lbs 20 3 23 Nm 4 Install rear shock reservoir through reservoir clamp and tighten clamp on reservoir to 96 120 in lbs 11 14 Nm NOTE Verify compression dial is facing up See Figure 2 90 11WARNING 1WARNING Always co...

Page 166: ... frayed kinked or bent ASSEMBLY INSTALLATION 1 Route cable as shown in HOSE AND WIRE ROUTING 2 Add cable straps as shown in the throttle cable routing in HOSE AND WIRE ROUTING 3 Install throttle grip and position ferrules 6 into cable wheel 7 4 Insert idle control into front switch housing 5 Slide switch housing over throttle 6 Insert throttle cable into front switch housing 7 See Figure 2 91 Atta...

Page 167: ...igure 2 94 Slide hand lever clutch clamp 2 over left handlebar Loosely tighten hand lever pinch fastener and nut 3 2 Connect safety interlock connector and switch 5 3 Install safety interlock switch 5 with fastener 6 tighten ing to 7 10 in lbs 0 8 1 0 Nm NOTE Apply small amount of LOCTITE ANTI SEIZE LUBRICANT to bolt 3 4 Install clutch hand lever 4 in hand lever clamp 2 and tighten hand lever pinc...

Page 168: ...2 95 Disconnect headlight connector 38 5 6 Remove female connector from headlight support bracket by sliding connector upward and off of attach ment clip 7 Remove headlight assembly a Remove both upper headlight assembly fasteners 6 b Remove lower fastener not shown c Remove headlight assembly 7 from headlight sup port bracket 9 8 Remove remaining two fasteners 8 securing headlight support bracket...

Page 169: ...nto back of headlight housing 4 NOTE The tab on the base of the headlight bulb should rest between the two tabs located at the top of the hole on the back of the headlight assembly 2 Install bulb holders 2 3 Connect wiring harness 5 to headlight bulbs 3 and install rubber boots 1 and install position bulb socket 6 between the headlights For proper alignment of rubber boots see 7 12 HEADLIGHT 1 Boo...

Page 170: ...connect the positive battery cable first If the pos itive 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 10 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 11WARNING 1WARNING After installing seat pu...

Page 171: ...ure 2 99 Remove the left front module 10 See Figure 2 98 Remove the final fastener and the right front module INSTALLATION 1 See Figure 2 98 Install right front module leaving single fastener loose 2 After installing the left front module and aligning with holes in upper triple clamp tighten previously installed single fastener to 12 14 ft lbs 16 3 19 Nm 3 Attach front brake line p clamp to rear o...

Page 172: ... Fastener and Brake Line P Clamp Fastener 8998 Figure 2 99 Fairing Support Bracket Assembly b1149x2x 1 Left and right front module 2 Right front module overlaps left front module 3 Right front module 4 Left front module 1 2 3 4 b1148x2x ...

Page 173: ... clamp in position and thread the four screws in place after applying Loctite 272 Red c Tighten both front screws to 10 12 ft lbs 14 16 Nm d Then tighten both rear screws 2 10 12 ft lbs 14 16 3 Install clutch hand control See 2 24 CLUTCH HAND LEVER 4 Install left switch housing See 7 17 HANDLEBAR SWITCHES 5 Check control wire routings See HOSE AND WIRE ROUTING a Route right hand control wires betw...

Page 174: ...HOME Figure 2 100 Handlebar Assembly b0945x2x 1 Endcap 2 2 Handlebar 3 Handlebar clamp 4 Clamp fasteners 4 5 Left hand grip 1 5 2 3 4 1 ...

Page 175: ...3 and remove from bracket 4 INSTALLATION 1 Install mount 3 onto bracket 4 and tighten to 20 22 ft lbs 27 1 29 8 Nm NOTE Before tightening adjuster nut position mirrors for rider 2 Install mirror 1 and tighten adjuster to 115 130 in lbs 13 14 7 Nm 1 Mirror 2 Adjuster nut 3 Mount 4 Bracket 1 1 2 3 2 3 4 9990 b1154x2x ...

Page 176: ... ing the exhaust header Front Muffler Mount 1 Remove muffler NOTE For details on removal of components on XB12S with interac tive exhaust systems see REMOVAL under 7 6 INTERAC TIVE EXHAUST SYSTEM XB12S 2 See Figure 2 102 Remove front muffler mount fastener 7 3 Remove strap 4 from front muffler mount 6 4 Remove front muffler mount bushings 8 by punching out with suitable tool Rear Muffler Bracket 1...

Page 177: ...active muffler 4 Front muffler strap 5 Front muffler strap fastener 6 Front muffler mount 7 Front strap fastener 8 Front muffler mount bushings 9 Interactive exhaust cable 10 Rear muffler bracket 11 Rear muffler bracket fasteners 2 2 6 8 10 11 1 Jacking point symbol shown on both sides of muffler 7 5 3 9 4 ...

Page 178: ...eed for silicone or graphite tape during assembly To ensure sealing integrity of muffler clamps and prevent the possibility of leakage Buell recommends that muffler clamp assemblies be discarded and replaced each time they are removed 1 Install muffler and new Torca clamp onto header NOTE If necessary use a fiber hammer to fit muffler on header 11WARNING 1WARNING Never reuse front muffler strap Al...

Page 179: ...04 Position footpeg mount 1 2 Install footpeg mount with fasteners 2 Tighten to 108 132 in lbs 12 15 Nm Install Heel Guard 1 See Figure 2 104 Position heel guard 3 onto footpeg mount 1 2 Install heel guard 3 with fasteners 4 Tighten to 72 96 in lbs 8 11 Nm Install Footpeg 1 See Figure 2 104 Install clip 5 2 Position footpeg 8 on to footpeg mount 1 3 Install footpeg pin 9 Install Wear Peg 1 See Fig...

Page 180: ...nt 3 onto tail section 2 Apply LOCTITE 272 Red to footpeg mount fasteners 10 install and tighten to 25 28 ft lbs 34 38 Nm 3 Install jam nut 11 and tighten to 48 72 in lbs 5 4 8 1 Nm Install Heel Guard 1 See Figure 2 105 Position heel guard 2 onto footpeg mounts 3 2 Install heel guard 2 a Apply WD40 lubricant to the heel guard fasteners before installing b Tighten heel guard fasteners to 48 72 in l...

Page 181: ... 2 107 Position sprocket cover 2 over front sprocket NOTE Apply LOCTITE 222 purple to the long fastener 1 only 2 Install sprocket cover 2 using sprocket cover fasteners 1 3 and tighten all fasteners and washers 1 3 to 12 36 in lbs 1 4 Nm 3 Install chin fairing See 2 34 CHIN FAIRING Figure 2 106 Chin Fairing Assembly Right Rear Fasteners Figure 2 107 Sprocket Cover b0942x2x b0943a2x 1 Long fastener...

Page 182: ... and washers 2 and tighten to 12 36 in lbs 1 4 Nm REAR FENDER Removal 1 Remove rear wheel See 2 6 REAR WHEEL 2 See Figure 2 108 Remove fasteners and washers 4 securing the rear fender 3 to frame 3 Remove rear fender 3 Installation 1 See Figure 2 108 Align rear fender 3 to frame 2 Install rear fender 3 with fasteners and washers 4 Tighten to 12 15 in lbs 1 1 7 Nm Figure 2 108 Front and Rear Fender ...

Page 183: ...ing tension will cause swingarm brace damage 6 Remove swingarm brace by removing fasteners See 2 19 SWINGARM AND BRACE 7 Remove upper belt guard 1 by removing fasteners from swingarm brace INSTALLATION 1 Install upper belt guard 1 to swingarm brace tightening fasteners to 12 36 in lbs 1 4 Nm 2 Install swingarm brace and tighten swingarm brace fas teners to 25 27 ft lbs 34 37 Nm See 2 19 SWINGARM A...

Page 184: ...e 2 109 Belt Guard Assembly b1064a2x 1 Upper belt guard 2 Upper belt guard fasteners 3 3 Lower belt guard fasteners 3 4 Lower belt guard 5 Sprocket cover 6 Sprocket cover fasteners 2 short 1 long 2 5 6 1 4 3 6 6 ...

Page 185: ...om a Marson Thread SetterTM Tool Kit MODEL NO MAR39200HD 1 See Figure 2 110 Position chin fairing 5 and install with right side fasteners and washers 6 2 Align left section 3 and install with left side fasteners and washers 4 3 Turn wheel full right or left for easier access to center fas teners 4 Align center section 1 and install with center section fasteners and washers 2 Use LOCTITE 272 red on...

Page 186: ...he remaining fasteners and nylon washers 2 Tighten all fasteners to 12 36 in lbs 1 4 Nm NOTE Front screws go in at a slight angle 11WARNING 1WARNING 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 4 Install seat ...

Page 187: ...oop 6 Installation 1 See Figure 2 112 Position engine shroud air scoop 6 2 Install engine shroud air scoop 6 with three fasteners 5 Tighten to 12 36 in lbs 1 4 Nm OIL COOLER AIR SCOOP Removal 1 See Figure 2 112 On left side of bike locate oil cooler air scoop 2 2 Remove two oil cooler air scoop fasteners 1 3 Remove oil cooler air scoop 2 Installation 1 See Figure 2 112 Position oil cooler air scoo...

Page 188: ... from support bracket 10 Move rear main harness and shock absorber reservoir to right side of vehicle 11 Remove left side passenger footrest support assembly See 2 30 FOOTPEG HEEL GUARD AND MOUNT 12 See Figure 2 113 Remove the following fasteners Left front trunk pan to left side tail section 14 Left rear tail section to center tail section 15 Left tail section to main frame fuel tank assembly 13 ...

Page 189: ...e light switch connector 121 6 Ground terminals GRD1 GRD 3 7 ECM connectors 10 11 8 Fuse block and relay center 9 BAS bank angle sensor connector 134 10 Left turn signal connector 18 11 Right turn signal connector 19 12 License plate lamp connector 45 13 Tail light connectors 93 14 Left and right front trunk pan fasteners 2 15 Left rear and right rear tail section fasteners 4 6 8907 5 10 14 14 15 ...

Page 190: ...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...

Page 191: ...5 Left tail section 6 Ground terminal fastener 2 7 Passenger footrest support fastener with jam nut 2 8 Front trunk pan fastener to side tail section 2 9 Passenger footrest support fastener no jam nut 2 10 Seat latch assembly 11 Trunk pan assembly 12 Rear trunk pan fastener to center tail section 2 13 Rear shock reservoir bracket 14 Plastic lugs for manufacturing purposes only b0956x2x 2 3 4 9 8 7...

Page 192: ...eners 4 securing left and right tail sections to center tail section but do not tighten 3 Install two fasteners 12 securing trunk pan to center tail section but do not tighten 4 Apply Loctite 272 to threads of left and right rear tail sec tions fasteners 4 and tighten to 102 112 in lbs 11 5 12 7 Nm 5 Tighten fasteners 12 securing trunk pan to center tail section to 48 72 in lbs 5 4 8 1 Nm 6 See Fi...

Page 193: ... 2 115 Install right tail section 6 onto vehi cle a Install fastener 1 attaching right front trunk pan to right side tail section and tighten to 48 72 in lbs 5 4 8 1 Nm b Install fasteners 5 attaching left rear tail section to center tail section and tighten to 102 112 in lbs 11 5 12 7 Nm c Install fasteners attaching left tail section to main frame fuel tank assembly and tighten to 21 23 ft lbs 2...

Page 194: ... 1 Right front trunk pan fastener 2 Passenger footrest support fastener with jam nut 3 Ground terminals GRD1 GRD 3 4 Rear brake light switch connector 121 5 Right tail section 6 Center tail section fastener to rear tail section 8907 1 3 2 4 6 5 ...

Page 195: ... 1 See Figure 2 116 Remove four windscreen fasteners 3 2 Remove windscreen 4 INSTALLATION 1 See Figure 2 116 Position windscreen 4 onto left and right front modules 2 5 2 Install four fasteners 3 and tighten to 10 12 in lbs 1 1 1 4 Nm b1153x2x 1 Headlight mounting bracket 2 Left front module 3 Windscreen fastener 4 4 Windscreen 5 Right front module 2 4 5 1 3 3 ...

Page 196: ...seat 1 INSTALLATION 11WARNING 1WARNING 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 1 Install seat 1 by sliding locating tab 4 on front under side of seat into opening 5 on trunk pan 2 Align rear tab 2 with la...

Page 197: ...ole in the trunk pan and plate now is the time to connect the cable end to the seat lock Seat lock plate must be aligned to tab on seat lock for proper installation 3 Install seat lock retainer 3 by aligning retainer to retainer grooves on back side of seat lock 1 4 Connect seat lock cable to latch a Install cable end 8 and cable 5 onto latch b Slide retainer 7 over pin on latch to lock cable end ...

Page 198: ...HOME 1 Seat lock 2 Plate 3 Retainer 4 Cable end 5 Cable 6 Latch screw 7 Retainer 8 Cable end 9 Latch 10 Latch bracket 11 Trunk pan 2 4 3 1 5 8 9 6 11 7 10 b1152x2x ...

Page 199: ...igure 2 120 Remove fasteners 4 securing side stand bracket 3 to frame 3 Remove sidestand DISASSEMBLY NOTE Sidestand assembly does not have to be removed from motorcycle in order to remove sidestand leg 1 Remove two fasteners from the left side of chin fairing 2 Remove sidestand leg 1 a Retract sidestand leg b Remove sidestand spring 8 and spring extension plate 4 using SNAP ON SPRING TOOL Part No ...

Page 200: ...nd pivot bolt 3 tightening to 18 20 ft lbs 24 27 Nm d Retract sidestand leg e Install spring extension plate 4 and sidestand spring 2 using SNAP ON SPRING TOOL Part No HE 52B NOTE Extension plate should curve away from primary chain adjust ment screw to allow for clearance around adjustment screw INSTALLATION 1 Install sidestand to frame tightening the sidestand bracket fasteners to 25 27 ft lbs 3...

Page 201: ...HOME NOTES ...

Page 202: ...9 3 6 Cylinder Head 3 45 3 7 Cylinder and Piston 3 63 3 8 Lubrication System 3 73 3 9 Oil Hose Routing and Oil Reservoir 3 74 3 10 Oil Pressure Indicator Switch 3 75 3 11 Crankcase Breathing System 3 76 3 12 Oiling System 3 78 3 13 Oil Pump 3 79 3 14 Oil Filter Mount 3 82 3 15 Hydraulic Lifters 3 83 3 16 Gearcase Cover and Cam Gears 3 85 3 17 Crankcase 3 90 Table Of Contents ...

Page 203: ......

Page 204: ... Regular idle 1050 1150 RPM Spark plug size 12 mm Spark plug type Harley Davidson No 10R12A Spark plug gap 0 035 in 0 8890 mm Spark plug torque 11 18 ft lbs 15 24 Nm Table 3 3 Valve and Valve Seat Specifications VALVE NEW COMPONENTS SERVICE WEAR LIMITS Fit in guide Exhaust 0 001 0 003 in 0 0254 0 0762 mm 0 0038 in 0 1016 mm Intake 0 001 0 003 in 0 0254 0 0762 mm 0 0038 in 0 0889 mm Seat width 0 04...

Page 205: ...8 mm Pin fit loose at room temperature 0 00005 0 00045 in 0 00127 0 01143 mm 0 00100 in 0 02540 mm Table 3 7 Cylinder Head Specifications CYLINDER HEAD NEW COMPONENTS SERVICE WEAR LIMITS Valve guide in head tight 0 0033 0 0020 in 0 0838 0 0508 mm Valve seat in head tight 0 0035 0 0010 in 0 0889 0 0254 mm Head gasket surface flatness 0 006 in total 0 152 mm total 0 006 in total 0 152 mm total Table...

Page 206: ...2 Gearcase Specifications GEARCASE NEW COMPONENTS SERVICE WEAR LIMITS Cam gear shaft in bushing loose 0 0007 0 0022 in 0 0178 0 0559 mm 0 003 in 0 076 mm Cam gear shaft end play min 0 005 0 024 in 0 127 0 610 mm 0 025 in 0 635 mm Intake cam gear shaft end play min 0 006 0 024 in 0 152 0 610 mm 0 040 in 1 016 mm Table 3 13 Flywheel Specifications FLYWHEEL NEW COMPONENTS SERVICE WEAR LIMITS Runout F...

Page 207: ... Front isolator bracket mounting fastener 49 51 ft lbs 66 4 69 1 Nm page 3 14 3 32 Front muffler strap fastener 108 120 in lbs 12 2 13 6 Nm page 3 16 Gearcase cover screws 80 110 in lbs 9 12 Nm Special pattern to tighten page 3 91 Oil cooler feed oil line at oil cooler 19 21 ft lbs 26 28 Nm page 3 39 Oil cooler feed oil line at pump 22 24 ft lbs 29 8 32 5 Nm page 3 15 Oil cooler return oil line at...

Page 208: ...rge fasteners page 3 63 Sprocket cover fastener 12 36 in lbs 1 4 Nm page 3 18 3 44 Swingarm pivot shaft pinch bolt 17 19 ft lbs 23 25 8 Nm page 3 30 Swingarm pivot shaft 24 26 ft lbs 32 5 35 2 Nm page 3 30 Torca clamp 40 45 ft lbs 54 2 61 Nm page 3 16 V bracket to main frame 120 144 in lbs 13 6 16 3 Nm page 3 14 3 32 Vent oil line at gearcase cover 12 13 ft lbs 16 3 17 6 Nm page 3 36 Vent oil line...

Page 209: ...ush rods and tappets Cylinder wall piston piston pin timing gears bushings and main bearings are lubricated by oil spray thrown off connecting rods and crankshaft and by oil draining from each rocker box through an internal drain passage in each cylinder and each tappet guide Oil is transferred to the teeth of all the cam gears by way of the gear meshing action The oil scavenging section of the pu...

Page 210: ...rk plug and remove spark plug 3 Remove air cleaner and set induction module throttle plate in wide open position 4 Remove timing inspection plug from crankcase 5 The piston in cylinder being tested must be at top dead center of compression stroke during test 6 To keep engine from turning over when air pressure is applied to cylinder engage transmission in fifth gear and lock the rear brake 7 Follo...

Page 211: ... the left side of the vehicle 11WARNING 1WARNING To protect against shock and accidental start up of vehi cle disconnect the negative battery cable before pro ceeding Inadequate safety precautions could result in death or serious injury 2 Remove seat and disconnect battery 3 Remove intake cover See 2 35 INTAKE COVER ASSEMBLY 4 Remove air filter See 1 15 AIR CLEANER FILTER 5 Remove air filter base ...

Page 212: ... the following sensors a Temperature sensor 3 90 b Oxygen sensor 4 137 Figure 3 2 Electrical Connections and Throttle Cables Typical 1 Ignition coil 2 Coil connection 83 3 Cylinder head temperature sensor connection 90 4 Oxygen sensor connection 137 5 Throttle cables 8708 3 4 5 2 1 ...

Page 213: ... a Remove front muffler strap 8 b Remove rear muffler straps 13 c Loosen Torca clamp 1 and remove muffler 14 d Loosen front muffler mount 2 Figure 3 3 Muffler and Mounting System 1 Torca clamp 2 Front muffler mount 3 Front muffler mount fastener 1 4 Front muffler mount bushings 2 5 Front muffler mount washer 1 6 Front muffler mount nut 1 7 Front muffler strap fastener 8 Front muffler strap 9 Rear ...

Page 214: ...lutch cable adjuster boot 2 up to access clutch adjuster c Loosen clutch adjuster to release tension from hand lever d Remove clutch cable ferrule from hand lever Figure 3 4 Oil Line Connections at Oil Cooler 1 Feed oil line from oil pump to oil cooler 2 Return oil line for oil cooler to crankcase 8711 1 2 Figure 3 5 Clutch Cable Wire form and Adjuster Boot 1 Wire form 2 Clutch cable adjuster boot...

Page 215: ...ar mount 11 Fasteners for center tie bar mount 2 12 Washers for center tie bar mount 2 13 Center tie bar assembly 14 Fasteners for center tie bar assembly 2 15 Washers for center tie bar assembly 2 16 Negative battery cable 17 Rear isolator assembly 18 Fasteners for rear isolator assembly 4 19 Washers for rear isolator assembly 4 20 Bolt 21 Rear tie bar assembly 22 Fasteners for rear tie bar assem...

Page 216: ... tie bar from V bracket only e Unbolt V bracket from main frame and remove from left side 23 Remove center tie bar from engine 24 See Figure 3 7 Remove rear tie bar from frame only 25 Loosen rear isolator bolt DO NOT REMOVE 26 See Figure 3 8 Remove front isolator bolt 1 27 Remove front isolator mount 2 from engine 28 Rotate engine down Figure 3 7 Rear Isolator Bolt and Rear Tie Bar 1 Rear isolator...

Page 217: ...lator 2 and loosely thread into frame Do not tighten at this point 3 See Figure 3 10 Install isolator mounting fasteners 3 and tighten to 49 51 ft lbs 66 4 69 1 Nm 4 Tighten front isolator bolt to 49 51 ft lbs 66 4 69 1 Nm 5 See Figure 3 6 Torque rear isolator bolt to 25 27 ft lbs 33 9 36 6 Nm 6 See Figure 3 6 Install rear tie bar to frame and tighten to 25 27 ft lbs 33 9 36 6 Nm 7 See Figure 3 6 ...

Page 218: ...5 8 28 5 Nm at oil cooler making sure to center the oil line between the oil sending switch and the return oil line fitting on the crankcase 13 Verify that the clutch cable and feed line have a clear ance of 1 8 1 4 in 3 175 6 35 mm between them NOTE When installing the oil cooler return oil line it is necessary to install the end at the crankcase first 14 See Figure 3 12 Install the oil cooler re...

Page 219: ... contact idler pulley bracket 16 See Figure 3 13 Install muffler with new Torca clamp but do not tighten a Install rear muffler straps and alternately tighten rear strap fasteners 6 to 48 60 in lbs 5 4 6 8 Nm b Install front new muffler strap and fastener 3 4 and tighten to 108 120 in lbs 12 2 13 6 Nm c Tighten Torca clamp to 40 45 ft lbs 54 2 61 Nm 17 Tighten front muffler mount to 22 25 ft lbs 2...

Page 220: ...Oxygen sensor 4 137 20 See Figure 3 14 Install the ignition coil and connect 2 83 and tighten fasteners to 120 144 in lbs 13 6 16 3 Nm Figure 3 14 Electrical Connections and Throttle Cables Typical 1 Ignition coil 2 Coil connection 83 3 Cylinder head temperature sensor connection 90 4 Oxygen sensor connection 137 5 Throttle cables 5 3 2 1 8708 4 ...

Page 221: ...tall sprocket cover and tighten fasteners and washers 30 Install chin fairing See 2 34 CHIN FAIRING 31 Install air scoops right and left sides See 2 36 AIR SCOOPS 32 Connect fuel pump NOTE The connection for fuel pump is just above the pump located at the rear of the fuel tank on the left side of the vehicle 11WARNING 1WARNING Always connect positive battery cable first If the positive cable shoul...

Page 222: ...ainst shock and accidental start up of vehi cle disconnect the negative battery cable before pro ceeding Inadequate safety precautions could result in death or serious injury 3 Remove seat and disconnect battery 4 Remove intake cover and air filter See 2 35 INTAKE COVER ASSEMBLY 5 Remove throttle body velocity stack NOTES The XB12S has a clamp ring securing velocity stack to the throttle body The ...

Page 223: ...erature sensor 3 90 b Oxygen sensor 4 137 12 Disconnect throttle cables from induction module throttle body Figure 3 17 Electrical Connections and Throttle Cables Typical 1 Ignition coil 2 Coil connection 83 3 Cylinder head temperature sensor connection 90 4 Oxygen sensor connection 137 5 Throttle cables 5 3 2 1 8708 4 ...

Page 224: ...ve muffler a Remove front muffler strap fastener 7 Front strap will not be removed b Alternately loosen rear strap fasteners 12 and remove rear muffler straps c Loosen Torca clamp and remove muffler d Loosen front muffler mount Figure 3 18 Muffler and Mounting System 1 Torca clamp 2 Front muffler mount 3 Screw 1 4 Bushings 2 5 Flat washer 1 6 Nut 1 7 Front muffler strap fastener 8 Front muffler st...

Page 225: ...support plate also remove rear brake pedal assembly and remote reservoir and secure towards rear of vehicle Figure 3 19 Oil Lines and Connections 1 Swingarm Oil reservoir 2 Vent oil line 3 Feed oil line 4 Return oil line 5 Feed oil line from oil pump to oil cooler 6 Feed oil line from oil cooler to crankcase 7 Oil tank drain plug 8 Oil Filter 9 Front muffler mount 10 Rear muffler bracket 11 Oil co...

Page 226: ... clutch cable ferrule from hand lever 23 See Figure 3 21 Remove sidestand assembly Figure 3 20 Clutch Cable Wire Form Retainer Retaining Clamp and Adjuster Boot 1 Wire form retainer 2 Clutch cable adjuster boot 3 Lower retaining clamp 1 2 3 10502 Figure 3 21 Sidestand Assembly Extended 10310 1 Pivot bolt 2 Spring extension plate 3 Spring post 4 Sidestand bracket 5 Sidestand bracket fasteners 2 6 S...

Page 227: ...r tie bar mount 11 Fasteners for center tie bar mount 2 12 Washers for center tie bar mount 2 13 Center tie bar assembly 14 Fasteners for center tie bar assembly 2 15 Washers for center tie bar assembly 2 16 Negative battery cable 17 Rear isolator assembly 18 Fasteners for rear isolator assembly 4 19 Washers for rear isolator assembly 4 20 Bolt 21 Rear tie bar assembly 22 Fasteners for rear tie ba...

Page 228: ...e front tie bar from V bracket e Unbolt V bracket from main frame and remove from left side 26 See Figure 3 20 Remove front tie bar from engine along with lower retaining clamp 27 See Figure 3 22 Remove center tie bar from engine 28 Remove rear tie bar from frame 29 Loosen rear isolator bolt 30 Remove front isolator bolt 31 Remove front isolator mount from engine 32 See Figure 3 23 Disconnect elec...

Page 229: ...3 27 Cut the cable strap holding transmis sion vent line and pull vent line out of frame leaving it attached to engine NOTE The transmission vent line runs up the left side of the frame and exits underneath the left rear side of the intake cover assembly 37 Lower engine with scissors lift all the way down 38 Move the engine assembly from under the main frame to the right side of the lift 39 Remove...

Page 230: ...3 28 Center tie bar mount c See Figure 3 29 Swingarm pivot shaft pinch bolt threaded insert d See Figure 3 30 Aluminum bushings from front exhaust mount e Timer cover Figure 3 28 Center Tie Bar Mount Figure 3 29 Removing Threaded Insert 8725 8724 8729 Figure 3 30 Front Exhaust Mount Bushings 2 piece Left Side Right Side 8718 8727 ...

Page 231: ...ratcheting tie down through the swingarm bear ings up over the main frame through the top stabilizer area back down to the ratchet mechanism and secure swingarm to main frame NOTE See Figure 3 33 This allows the vehicle to remain together as a rolling chassis and to be removed from the lift and stored if necessary 44 Remove support from under swingarm oil tank 45 Remove overhead support Figure 3 3...

Page 232: ...ten to 25 27 ft lbs 33 9 36 6 Nm 2 Install the following items on the engine assembly as required a Shifter assembly b See Figure 3 35 Center tie bar mount 25 27 ft lbs 33 9 36 6 Nm c See Figure 3 36 Apply LOCTITE 242 blue and install swingarm pivot shaft pinch bolt threaded insert d See Figure 3 37 Aluminum bushings from front exhaust mount Figure 3 34 Rear Isolator and Mounting Hardware Figure 3...

Page 233: ...to 17 19 ft lbs 23 25 8 Nm using LOCTITE 272 red 6 See Figure 3 40 Route transmission vent line up through left side of frame exiting under the left rear side of the intake cover assembly Install cable strap to secure transmission vent line in place Inspect vent line to verify space between vent line and rear exhaust NOTE See Figure 3 41 At this point it is necessary to support main frame with ove...

Page 234: ...r 11 Fasteners for center tie bar mount 2 12 Washers for center tie bar mount 2 13 Tie bar assembly center 14 Fasteners for center tie bar assembly 2 15 Washers for center tie bar assembly 2 16 Cable negative battery 17 Isolator assembly rear 18 Fasteners for rear isolator assembly 4 19 Washers for rear isolator assembly 4 20 Bolt rear isolator 21 Tie bar assembly rear 22 Fasteners for rear tie ba...

Page 235: ...into frame Do not tighten at this point 11 Install isolator mounting fasteners 2 and tighten to 49 51 ft lbs 66 4 69 1 Nm 12 See Figure 3 43 Torque rear isolator bolt to Rear 25 27 ft lbs 33 9 36 6 Nm 13 Install rear tie bar to frame and tighten to 25 27 ft lbs 33 9 36 6 Nm 14 Install center tie bar to engine and tighten to 25 27 ft lbs 33 9 36 6 Nm CAUTION When reinstalling the tie bar first moun...

Page 236: ...install muffler mounts first in order to properly install oil lines CAUTION At this point it will be necessary to install the oil lines It is important to follow this procedure to ensure correct orientation of oil lines in order to establish the proper clearances needed between the oil lines and varied com ponents on the vehicle Figure 3 46 Muffler Mounting System Rear muffler mount Front muffler ...

Page 237: ...l line 4 Return oil line 5 Feed oil line from oil pump to oil cooler 6 Feed oil line from oil cooler to crankcase 7 Oil tank drain plug 8 Oil Filter 9 Front muffler mount 10 Rear muffler bracket 11 Oil cooler 12 Interactive exhaust cable 3 2 7 6 5 5 4 3 2 4 10 9 8710a 8709 10501 10 11 1 8 6 12 ...

Page 238: ... 48 Tighten the return oil line first making sure to maintain the proper clearance between the oil line and the rear muffler bracket 23 25 ft lbs 31 2 33 9 Nm 22 Tighten the feed oil line next making sure the distance between the feed line and the return line is within specifi cations 24 26 ft lbs 32 5 35 2 Nm 23 Tighten the vent oil line next making sure the distance between the vent line and the...

Page 239: ...mp fit ting to 22 24 ft lbs 29 8 32 5 Nm When the oil line has been properly torqued the orientation of the line should 26 Tighten the vent oil line at the gearcase cover to 12 13 ft lbs 16 3 17 6 Nm NOTE When tightening the vent line verify that the line does not twist down towards the muffler but remains horizontal and aligned with the feed and return lines after tightening Figure 3 49 Approxima...

Page 240: ...erify that both black plastic oil line clamps are parallel to the crankcases and there is a clearance of 5 16 in 7 9375 mm between the bottom of the crankcases and the oil lines NOTE The 5 16 in clearance is between the crankcase and the steel oil line as shown Not between the crankcase and the Figure 3 50 Clamp Orientation and Oil Line Spacing 5 16 8764 8766a ...

Page 241: ...ine fittings CAUTION See Figure 3 51 It is important to maintain an orientation of approximately 2 o clock with the rigid part of the feed oil line running to the oil cooler Also be aware of the 1 8 1 4 3 175 6 35 mm clearance specified between the feed oil line and the clutch cable at the front of the crankcase Figure 3 51 Oil Cooler Feed Oil Line Orientation Approximately 2 O Clock and Oil LIne ...

Page 242: ...case first 30 Install the oil cooler return oil line at crankcase and tighten to 15 17 ft lbs 20 3 23 Nm Lightly coat the threads of the oil cooler fitting with clean H D 20W50 engine oil Wipe off any excess oil Tighten return oil line to 19 21 ft lbs 25 8 28 5 Nm at oil cooler NOTE See Figure 3 53 The orientation of the oil cooler return oil line where it enters the crankcase should be at approxi...

Page 243: ... Positive battery cable at starter g Starter solenoid 128 h Oil pressure switch 120 Figure 3 54 Electrical Connections 1 Neutral switch 131 2 Speedometer sensor connection 65 3 Cam position sensor connection 14 4 Alternator connection 46 5 Voltage regulator connection 77 6 Cable interactive exhaust 4 5 3 8717a 1 2 6 Figure 3 55 Correct Routing of Wiring Harnesses and Interactive Muffler Cable 1042...

Page 244: ...ACTIVE EXHAUST SYSTEM XB12S 32 See Figure 3 56 Pull clutch cable back up into the proper position a Connect clutch cable to handlebars and adjust to specifications See 3 1 SPECIFICATIONS b Install upper retaining clamp Figure 3 56 Clutch Cable Wire Form Retainer 10502 ...

Page 245: ...moved from sys tem NOTE For XB12Ss with interactive exhaust system see 7 6 INTER ACTIVE EXHAUST SYSTEM XB12S Figure 3 57 Muffler and Mounting System 1 Clamp Torca 2 Muffler mount front 3 Screw front muffler mount 1 4 Bushings front muffler mount 2 5 Flat washer front muffler mount 1 6 Nut front muffler mount 1 7 Front muffler strap fastener 8 Muffler strap front 9 Muffler bracket rear 10 Screw rea...

Page 246: ... mount 2 to 22 55 ft lbs 29 8 33 9 Nm 34 See Figure 3 58 Connect throttle cables to induction module throttle body 35 Connect the following sensors a Temperature sensor 90 b Oxygen sensor 137 Install cable wrap on har ness 36 See Figure 3 58 Install the ignition coil and spark plug wires and connect 83s Tighten ignition coil fasteners to 120 144 in lbs 13 6 16 3 Nm Figure 3 58 Electrical Connectio...

Page 247: ...s and torque to 108 132 in lbs 12 20 14 91 Nm NOTE When re installing the right side rider footrest and support plate also install rear brake pedal assembly and remote res ervoir 48 Install sprocket cover and tighten fasteners and washers to 12 36 in lbs 1 4 Nm 49 Install chin fairing See 2 34 CHIN FAIRING 50 Install air scoops right and left sides See 2 36 AIR SCOOPS NOTE The connection for fuel ...

Page 248: ...hardened parts Do not re use fiber cover seals Engine damage may result 1 Crankcase breather 2 Grommet 3 Screw 4 4 Washer 4 5 Gasket 4 6 Rocker cover top 7 Bolt 3 8 Washer 3 9 Gasket inner 10 Gasket lower 11 Rocker arm shafts 12 Bolt 2 13 washer 2 14 Rocker cover lower 15 Rocker arm 2 16 Bushing rocker arm 4 17 Gasket lower rocker cover 18 Hydraulic lifter 19 Screw tappet anti rotation 2 20 Gasket...

Page 249: ...lieve valve spring pressure on the lower rocker box 7 See Figure 3 60 Remove lower rocker cover NOTE Remove lower rocker box as an assembly then disassemble as required CAUTION Mark rocker arm shafts for reassembly in their original positions Valve train components must be reinstalled in their original positions to prevent accelerated wear and increased valve train noise 8 See Figure 3 62 Remove r...

Page 250: ...TOOL Part No HD 34736B in vise 2 See Figure 3 64 Compress valve spring with VALVE SPRING COMPRESSOR 3 See Figure 3 65 Remove valve keepers upper collar and valve spring Mark valve keepers for reassembly in their original locations 4 Use a fine tooth file to remove any burrs on the valve stem at the keeper groove 5 Mark valve to ensure that it will be reassembled in the same head Remove valve valve...

Page 251: ...retainer 4 Upper valve spring collar 5 Valve spring 6 Valve seal and lower valve spring collar assembly 7 Valve guide intake exhaust 2 8 Cylinder head 9 Exhaust port stud 10 Cylinder head gasket 11 Cylinder O ring 4 12 Cylinder insert 13 Cylinder w piston rings 14 Cylinder base gasket 15 Cylinder base stud 16 Exhaust valve 17 Exhaust valve seat ...

Page 252: ... with compressed air 2 Soak cylinder head in an aluminum compatible cleaner solvent to loosen carbon deposits 3 Wash all parts in non flammable solvent followed by a thorough washing with hot soapy water Blow out oil passages in head Be sure they are free of sludge and carbon particles Remove loosened carbon from valve head and stem using a wire wheel Never use a file or other hardened tool which ...

Page 253: ...sure rocker arm bushing inner diameter 4 Check the measurements obtained in Steps 5 6 against the SERVICE WEAR LIMITS Repair or replace parts exceeding limits 5 Assemble rocker arms and rocker arm shafts into lower rocker cover 6 Check end play of rocker arm with feeler gauge 7 Replace rocker arm or lower cover or both if end play exceeds 0 025 in 0 635 mm Figure 3 67 Measuring Rocker Arm Shaft Di...

Page 254: ...eat surface must be flush with or below the head surface See 3 1 SPECIFICATIONS for valve Valve Guides 1 Clean valve guides by lightly honing with VALVE GUIDE HONE Part No HD 34723 2 Scrub guides with VALVE GUIDE BRUSH Part No HD 34751 and hot soapy water Measure valve stem outer diameter and valve guide inner diameter Check mea surements against 3 1 SPECIFICATIONS Valve Springs 1 Inspect valve sp...

Page 255: ... side of rocker arm press out bushing and tap using a discarded rocker arm shaft 2 Press replacement bushing into rocker arm flush with arm end and split portion of bushing towards top of arm 3 Using remaining old bushing as a pilot line ream new bushing with ROCKER ARM BUSHING REAMER Part No HD 94804 57 4 Repeat for other end of rocker arm Figure 3 73 Replacing Rocker Arm Bushings 8732 8733 8734 ...

Page 256: ...point the correct guide height has been reached 5 Ream guides to final size or within 0 0010 in 0 0254 mm of final size using VALVE GUIDE REAMER Part No B 45523 Use REAMER LUBRICANT Part No HD 39964 or liberal amounts of suitable cutting oil to prevent reamer chatter NOTE The hone is not intended to remove material 6 Apply the proper surface finish to the valve guide bores using the VALVE GUIDE HO...

Page 257: ...ure to highlight all 3 angles Allow marker to dry before proceeding NOTE Always ensure cutter blades and cutter pilot are clean before beginning the cutting process The correct clean ing brush is supplied with the Neway tool set Also ensure the inside of the valve guide is clean by using Kent Moore cleaning brush Part No HD 34751 6 Choose the cutter pilot that fits properly into the valve guide ho...

Page 258: ...f the 46 angle and the width is at least 0 062 in 1 575 mm pro ceed to the next step 12 Select the proper 60 cutter and gently slide the cutter down the cutter pilot to the valve seat 13 Remove just enough material to provide an even valve seat width of 0 040 0 062 in 1 016 1 575 mm 14 Remove cutter pilot and wash head thoroughly and dry completely 15 Repeat the process on any valve seat that need...

Page 259: ...retainer 4 Upper valve spring collar 5 Valve spring 6 Valve seal and lower valve spring collar assembly 7 Valve guide intake exhaust 2 8 Cylinder head 9 Exhaust port stud 10 Cylinder head gasket 11 Cylinder O ring 4 12 Cylinder insert 13 Cylinder w piston rings 14 Cylinder base gasket 15 Cylinder base stud 16 Exhaust valve 17 Exhaust valve seat ...

Page 260: ...dry with compressed air 4 Apply a liberal amount of engine oil to the valve stem 5 See Figure 3 78 Insert valve into valve guide and bottom valve on valve seat 6 See Figure 3 79 Place a protective sleeve over the valve stem keeper groove CAUTION Failure to use a protective sleeve on the valve stem keeper groove when installing the valve stem seal and collar assembly will result in damage to the se...

Page 261: ...wise sharp edges on keeper groove will damage seal 8 Install valve spring and upper collar 9 See Figure 3 82 Compress spring with VALVE SPRING COMPRESSOR Part No HD 34736B NOTE A single valve spring is used for each valve The inner and outer springs are combined into one tapered spring that is progressively wound 10 Insert valve keepers into upper collar making sure they engage grooves in valve st...

Page 262: ...ify push rod color coding length and respective push rod positions in engine Place intake and exhaust push rods onto seat at top of tappet CAUTION After head s have been installed do not turn engine over until both push rods can be turned with fingers Other wise damage to push rods or rocker arms may result Figure 3 83 Push Rod Locations Table 3 20 Push Rod Selection POSITION COLOR CODES LENGTH PA...

Page 263: ...dure for tightening the head screws is critical to proper distribution of pressure over gasket area It prevents gasket leaks stud failure and head and cylin der distortion Always tighten in sequence shown 6 Start the cylinder head screws onto the cylinder studs two short bolts on the left side of the engine two long bolts on the right 7 See Figure 3 85 For each cylinder head start with screw numbe...

Page 264: ... lower 11 Rocker arm shafts 12 Bolt 2 13 Washer 2 14 Rocker cover lower 15 Rocker arm 2 16 Bushing rocker arm 4 17 Gasket lower rocker cover 18 Hydraulic lifter 19 Screw tappet anti rotation 2 20 Gasket push rod cover 21 Push rod cover 22 Screw 4 23 O ring push rod cover 2 24 Push rod 25 Washer 4 26 Bolt 4 1 2 4 6 7 8 12 13 14 15 16 17 24 22 21 20 25 9 10 b0960x3x 18 19 26 23 3 5 11 ...

Page 265: ...and torque specifications are listed in Table 3 21 a Tighten bolts 1 to 18 22 ft lbs 24 30 Nm b Tighten bolts 2 to 135 155 in lbs 15 18 Nm c Tighten screws 3 to 135 155 in lbs 15 18 Nm 11 See Figure 3 87 Install upper rocker covers a Place a new inner gaskets on lower rocker box assemblies b Place a new lower gaskets on lower rocker cover c Install upper rocker cover using screws with washers and ...

Page 266: ...rd cyl inder base gasket CAUTION With cylinder removed be careful not to bend the cylin der studs The slightest bend could cause a stress riser and lead to stud failure 7 Install a 6 in 152 mm length of 1 2 in 12 7 mm ID plastic or rubber hose over each cylinder stud This will protect the studs and the piston 11WARNING 1WARNING Retaining rings are highly compressed in the ring groove and may fly o...

Page 267: ...he bore during removal Remove circlip from claw and discard NOTES It is not necessary to remove both piston pin circlips dur ing piston removal Leave the second circlip in the pin bore Since the piston pin is a loose fit in the piston the pin will easily slide out The pin has tapered ends to help seat the round retaining rings NOTE See Figure 3 91 The arrow at the top of pistons must always point ...

Page 268: ...earance exceeds 0 00200 in 0 05080 mm replace worn parts 6 Clean piston pin retaining ring grooves 7 Examine piston and cylinder for cracks burnt spots grooves and gouges 8 Check connecting rod for up and down play in lower bearings When up and down play is detected lower bearing should be refitted This requires removing and disassembling engine crankcase Checking Gasket Surface CAUTION If cylinde...

Page 269: ... which the tool rotates determines the speed at which it must be stroked up and down the bore to produce the desired cross hatch pattern 4 Starting at the bottom of the cylinder move the deglazing tool up and down the entire length of the cylinder bore for 10 to 12 complete strokes NOTE Stop to examine the cylinder bore and or take measure ments A precise 60 cross hatch pattern in the piston trave...

Page 270: ... See Table 3 23 NOTES The same piston may be used if cylinder bore was not changed unless it is scuffed or grooved If re using pis ton replace piston rings and hone the cylinder walls with a No 240 grit flexible hone to facilitate ring seating Piston ring sets must be properly fitted to piston and cyl inder Ring sets are available to fit standard and oversize pistons Figure 3 95 Piston Rings 1 Top...

Page 271: ...end gaps of adjacent rings are a minimum of 90 apart Ring gaps are not to be within 10 of the thrust face centerline 4 See Figure 3 99 Check for proper side clearance with thickness gauge as shown See 3 1 SPECIFICATIONS NOTE If the ring grooves are clean and the side play is still not cor rect replace the rings the piston or both Figure 3 97 Installing Piston Rings Transmission Shaft Retaining Rin...

Page 272: ... was for removal of the bushing 7 Clean up and size bushing to 0 0010 0 0005 in 0 0254 0 0127 mm undersize using REAMER Part No HD 94800 26A Sizing bushing with less than 0 00125 in 0 03175 mm clearance can result in a bushing loosening and or seized pin in rod 8 Hone bushing to final size using WRIST PIN BUSHING HONE Part No HD 35102 Use a liberal amount of honing oil to prevent damage to hone or...

Page 273: ...een installed and then removed for any reason A loosely installed ring will come out of the piston groove and damage cylinder and piston beyond repair 4 See Figure 3 106 Install new piston pin retaining rings 1 using PISTON PIN RETAINING RING INSTALLER 2 Part No HD 34623C Place new retaining ring on tool with gap pointing up NOTE Make sure the ring groove is clean Ring must be fully seated in the ...

Page 274: ... bump the studs or crankcase 9 See Figure 3 109 Compress the piston rings using PIS TON RING COMPRESSOR Part No HD 96333 51C 10 Install cylinder over piston 11 Remove PISTON RING COMPRESSOR 12 Assemble and install cylinder head See 3 6 CYLINDER HEAD 13 Install assembled engine See 3 4 STRIPPING MOTOR CYCLE FOR ENGINE SERVICE Figure 3 107 Ring End Gap Position Figure 3 108 Piston Support Plate Posi...

Page 275: ...HOME NOTES ...

Page 276: ...tion in a gasoline engine produces water vapor and carbon dioxide along with other gases and particu lates When first starting and warming an engine some of the water vapor that gets into the engine crankcase condenses to form liquid water If the engine is driven long enough to thor oughly warm the crankcase most of this liquid water is again vaporized and exhausted through the crankcase breather ...

Page 277: ...he crankcases The feed line then exits the oil cooler and connects to the oil filter housing on the right front side of the crankcases The vent hose continues upward from under the vehicle to connect to an elbow fitting at the rear of the gearcase cover Figure 3 110 Oil Lines and Connections 1 Swingarm Oil reservoir 2 Vent oil line 3 Feed oil line 4 Return oil line 5 Feed oil line from oil pump to...

Page 278: ... e thicker When an engine is operated at high speeds the volume of oil circulated through the oiling system increases resulting in higher oil pressure As engine speed is reduced the volume of oil pumped is also reduced resulting in lower oil pressure To check oil pressure use OIL PRESSURE GAUGE Part No HD 96921 52B and OIL PRESSURE GAUGE ADAPTER Part No HD 96940 58 Remove oil pressure indicator sw...

Page 279: ...4 located on top of the rocker boxes From the PCV valves the air enters the crankcase breather hoses 2 3 The crank case breather hoses route through the air cleaner base plate 1 to the air box where it is directed inside the air filter ele ment and back into the engine The oil mist collects and eventually returns to the crankcase through oil passageways in the cylinder head Figure 3 112 Reed Valve...

Page 280: ...and break age Fasteners should be tightened to 30 40 in lbs 3 4 4 5 Nm CAUTION See Figure 3 115 When replacing the reed valve it is extremely important to ensure that both edges of the reed valve stop 1 and the reed valve 2 are properly aligned to prevent premature failure of the reed valve When replacing the reed valve it is not necessary to replace the reed block See Figure 3 114 Figure 3 114 Re...

Page 281: ...d through the crank pin to properly lubricate the rod bearing assembly 11 Oil flow then continues through the gearcase cover to the main feed galley at the top of the gearcase cover Drilled passages in the crankcase intersect the main feed galley and carry oil to all hydraulic lifters and piston jets 12 Oil flows up passages in the push rods to the rocker arm shafts and bushings 13 The valve stems...

Page 282: ...d by the gerotor scavenge set back to the oil reservoir The oil pump seldom needs servicing Before you disassem ble an oil pump suspected of not producing adequate oil pres sure be sure that all possible related malfunctions have been eliminated 1 Make sure all oil line connections are tight and that lines are not pinched or damaged 2 Check level and condition of oil in reservoir swingarm Pressure...

Page 283: ...ers only Pump will drop with screws removed Discard mounting gasket 6 Remove cover TORX screws 2 Lift cover off body 7 Remove and discard O ring 8 Slide both pieces of gerotor feed set separator plate and both pieces of gerotor scavenge set off gear shaft 9 Remove and discard retaining ring Remove thrust washer and gear shaft Figure 3 117 Oil Pump Hardware 1 Feed line connection 2 Cover TORX screw...

Page 284: ...in shaft 2 Insert inner gerotor of the gerotor scavenge set over gear shaft 3 Place outer gerotor over inner gerotor to complete scav enge set 4 See Figure 3 119 Install gerotor separator plate by lining up slots on perimeter with tabs inside oil pump body 5 Install a new O ring into groove in pump body 6 See Figure 3 116 Place gerotor feed set over gear shaft 7 Place cover onto pump body Install ...

Page 285: ...ke ade quate safety precautions could result in death or serious injury Thoroughly clean all parts in cleaning solvent Blow out holes and passages using compressed air ASSEMBLY NOTE Use TEFLON PIPE SEALANT or HYLOMAR on all fittings installed to oil filter mount 1 See Figure 3 120 Install oil pressure indicator switch 1 using OIL PRESSURE SENDING UNIT WRENCH Part No HD 41675 Tighten to 50 70 in lb...

Page 286: ...crews b Remove push rod covers c Remove gaskets and o rings Discard parts 5 Remove valve hydraulic lifters a Remove anti rotation screws b Remove lifters from crankcase bore using a thin bladed screwdriver Mark the location and orienta tion front back of each lifter CLEANING AND INSPECTION 11WARNING 1WARNING Low pressure compressed air can blow debris into your face and eyes Always wear eye protec...

Page 287: ...n anti rotation screws to 55 65 in lbs 6 7 Nm 5 See Figure 3 123 Install push rod cover a Place new push rod cover gasket over bottom of push rod cover b Position push rod cover onto crankcase c Install screws through holes in push rod cover into tapped holes in crankcase Tighten screws evenly to 30 40 in lbs 3 5 Nm d Place new o rings on top of push rod cover 6 Install push rods cylinder head low...

Page 288: ... important to know and understand all inspection procedures and how components interact Figure 3 124 Gearcase Cover Cam Assembly b0980x3x 1 Screw 7 2 Seal 3 Fitting oil vent line 4 Gear Cover 5 Gear cover gasket 6 Bushing outer intake camshaft gear 7 E Cam gear set 8 Right crankcase half 9 Dowel pin 10 Bushing inner camshaft gear 4 11 Bushing outer camshaft gear 3 12 Key 13 Oil pump drive gear 14 ...

Page 289: ...tion sensor and rotor from gearcase cover See 4 17 CAM POSITION SENSOR AND ROTOR 7 Place a pan under gearcase to collect oil Remove cover screws Carefully remove gearcase cover Discard old gasket NOTE If cover does not come loose on removal of screws tap lightly with a plastic hammer Never pry cover off 8 See Figure 3 125 Remove cam gears 1 2 3 4 NOTE Nut is secured by LOCTITE 262 red on the nut t...

Page 290: ...umbers identify the cam location function and the letter E indicates model year application NOTE Prior to changing any cam gears check gear shaft fit within corresponding bushings Worn bushings can cause excessive Bushing Inspection 1 Bushings are press fit in gearcase cover and crankcase Inspect each bushing against its corresponding cam gear shaft or pinion gear shaft Refer to Table 3 26 NOTE If...

Page 291: ...ut to 19 21 ft lbs 26 29 Nm plus an additional 15º to 19º rotation 3 See Figure 3 124 Liberally apply engine oil to bushings shafts and gears Install all cam gears into bushings of right crankcase half properly aligning timing marks of cam gears and pinion gear NOTES The XB9S uses new style timing marks on the front intake cam assembly Please note the V design Because of the larger diameter additi...

Page 292: ...blade screwdriver c Measure gap between bushing in crankcase half and cam gear shaft thrust face shoulder using a feeler gauge This is cam gear end play d Compare cam gear end play measurements with the SERVICE WEAR LIMITS Make repairs as required if end play does not meet specifications 7 Install hydraulic lifters and push rods See 3 15 HYDRAULIC LIFTERS 8 Install cam position sensor and rotor in...

Page 293: ... HEAD CAUTION After removing cylinders install plastic or rubber hose over cylinder studs Lifting or moving crankcase by grasping studs will cause cylinder stud damage 2 Remove cylinders and pistons See 3 6 CYLINDER HEAD 3 Remove oil pump See 3 13 OIL PUMP 4 Remove gearcase components See 3 16 GEARCASE COVER AND CAM GEARS 5 Remove primary cover and primary drive clutch compo nents See 6 2 PRIMARY ...

Page 294: ...Gasket is part of the piston jet assembly Gasket not sold sep arately 1 Install new piston oil jet assemblies in right crankcase 2 Apply LOCTITE Low Strength Threadlocker 222 purple to threads of TORX screws 3 With the jet pointed upward install TORX screws to secure piston jet to crankcase Tighten screws to 25 35 in lbs 2 8 4 0 Nm Figure 3 132 Crankcase Fasteners D b1016x3x Indicates Bolt Pattern...

Page 295: ...ing 12 will remain on flywheel pinion shaft Remove retaining ring 13 and bearing can be slipped off pinion shaft Figure 3 134 Removing Flywheels from Left Crankcase 8622 Figure 3 135 Crankcase and Flywheel Assembly b0975a3x 2 3 4 5 6 7 8 9 10 15 1 Spacer sprocket shaft 2 Retaining ring oil seal 3 Oil seal 4 Thrust washer 5 Crankcase half 6 Bearing 7 Bearing retaining ring 8 Inner race left main be...

Page 296: ...y Dent Puller 6 Remove outer thrust washer 4 next to left main bearing 6 7 See Figure 3 138 Remove left main bearing retaining ring from the inside of the left crankcase half 8 See Figure 3 139 Using CRANKCASE BEARING REMOVER INSTALLER with ADAPTER Part No B 45655 HD 42720 2 and HD 46663 press left main bearing out of the left crankcase half NOTE The bearing presses to the inside There is a should...

Page 297: ... based on the largest measured outside diameter OD of the inner race and the smallest measured inside diameter ID of the outer race crankcase bushing A running clear ance of 0 0002 0 0008 in 0 0051 0 0203 mm is established during crankcase set or flywheel assembly replacement and engine rebuild Table 3 28 Pinion Shaft Inner Race Paint Dot Specifications Table 3 27 Pinion Shaft Bearing Service Wear...

Page 298: ... race Table 3 30 Pinion Bearing Roller Specifications Figure 3 141 Pinion Shaft Outer Race OUTER RACE ID CLASS NO STAMPED NO 1 5646 1 5648 in 39 7408 39 7459 mm 1 1 1 5648 1 5650 in 39 7459 39 7510 mm 2 2 1 5650 1 5652 in 39 7510 39 7561 mm 3 3 a0134x3x 1 Inside diameter ID 2 Outer race 3 Right crankcase half 4 Stamped class no 1 2 3 4 Figure 3 142 Bearing Roller OD ROLLER OD COLOR Largest Red Blu...

Page 299: ...een 1 5658 1 5660 in 39 771 39 776 mm Red Blue White Gray Green 1 5656 1 5658 in 39 766 39 771 mm Red Blue White Gray Green 1 5654 1 5656 in 39 761 39 766 mm Red Blue White Gray Green 1 5652 1 5654 in 39 756 39 761 mm Red Blue White Gray Green 3 1 5650 1 5652 in 39 751 39 756 mm Red Blue White Gray Green 2 1 5648 1 5650 in 39 746 39 751 mm Blue White Gray Green 1 1 5646 1 5648 in 39 741 39 746 mm ...

Page 300: ...continue lapping until specifications are met c If all specifications are met continue at Step 7 to remove and size inner race 5 Press the outer race from the right crankcase 6 Press new outer race into crankcase flush with inside edge of cast in insert NOTE See Figure 3 143 Dimensions are shown for fabrication of tools used in pressing the outer race into or out of crankcase 7 The new outer race ...

Page 301: ...ywheel refurbishing program as outlined in Tech Tip 38 Always use the smallest outer race ID measurement and the largest OD inner race measurement when selecting bearings 10 The following example illustrates how to determine the required inner race OD a See Table 3 31 For example purposes suppose the smallest outer race ID measurement is 1 5651 in 39 754 mm This requires an inner race OD range of ...

Page 302: ... a condition where hole is larger at ends than it is in the center 4 Withdraw arbor far enough to coat lightly with 220 grit lapping compound Do not apply a heavy coat 5 Reposition lap in bushing and turn handle at moderate hand speed Work lap back and forth in bushing as it is revolved to avoid grooving and tapering 6 At frequent intervals remove lap from crankcase wash and inspect bushing Lappin...

Page 303: ...eft crank case half from the inside NOTE Make sure that the bearing assembly bottoms against the machined shoulder in the left crankcase half 2 Install new bearing retaining ring in left crankcase half 3 Install transmission See 6 14 TRANSMISSION INSTAL LATION Figure 3 148 Left Main Bearing Assembly 7 1 3 4 6 b1046a3x 5 2 1 Spacer sprocket shaft 2 Retaining ring oil seal 3 Oil seal 4 Thrust washer...

Page 304: ... bearing on pinion shaft c Install new retaining ring in groove of pinion shaft bearing inner race Figure 3 149 Left Main Bearing Installation 8789 8792 8762 1 2 3 1 Shoulder for bearing to press against 2 Crankcase bearing remover installer tool Part No B 45655 HD 42720 2 and HD 46663 3 Bearing retaining ring Figure 3 150 Installing Flywheel Assembly with CRANKSHAFT GUIDE Part No HD 42326 Figure ...

Page 305: ...t faces b Slide outer race in right crankcase over pinion shaft and bearing assembly c Tighten fasteners to 15 19 ft lbs 20 26 Nm NOTE According to manufacturing there is no torque sequence to follow when tightening crankcase fasteners Figure 3 152 Crankcase Fasteners D b1016x3x Indicates Bolt Pattern Location One Behind Shifter Mechanism ...

Page 306: ...ave a shoulder at the lower end Place the end of the stud without the shoulder into the head screw d Install the stud in the crankcase with the shoulder end down Use an air gun to drive the stud until the shoulder reaches the crankcase e Remove air gun Use a torque wrench to tighten stud to 10 20 ft lbs 14 27 Nm 12 Install piston and cylinder See 3 7 CYLINDER AND PIS TON 13 Install oil pump See 3 ...

Page 307: ...HOME NOTES ...

Page 308: ... 38 4 16 Trouble Code 11 4 43 4 17 Trouble Code 13 4 47 4 18 Trouble Code 14 4 52 4 19 Trouble Code 15 4 56 4 20 Trouble Code 16 4 60 4 21 Trouble Code 21 4 64 4 22 Trouble Codes 23 and 32 4 67 4 23 Trouble Codes 24 and 25 4 71 4 24 Trouble Code 33 4 74 4 25 Trouble Code 35 4 77 4 26 Trouble Code 36 4 80 4 27 Trouble Code 44 4 84 4 28 Trouble Codes 52 53 54 and 55 4 88 4 29 Trouble Code 56 4 89 4 ...

Page 309: ...uel Pump 4 108 4 40 Fuel Tank Vent Valve 4 114 4 41 Fuel Cap Retaining Ring 4 115 4 42 Throttle Body and Intake Manifold 4 116 4 43 Intake Leak Test 4 122 4 44 Airbox 4 124 4 45 Evaporative Emissions Control California Models 4 128 ...

Page 310: ...4 103 Fuel cap retaining ring fasteners 17 70 in lbs 1 9 7 9 Nm page 4 115 Fuel pump drain plug 84 108 in lbs 9 5 12 2 Nm page 4 108 Fuel pump harness fastener 18 22 in lbs 2 0 2 5 Nm page 4 112 Fuel pump screws 48 51 in lbs 5 4 5 8 Nm page 4 113 Fuel pump wire harness fastener 18 22 in lbs 2 0 2 5 Nm page 4 112 Fuel rail fasteners 24 28 in lbs 2 7 3 2 Nm LOCTITE 222 purple page 4 119 4 120 Fuel s...

Page 311: ...HOME NOTES ...

Page 312: ...hamber muffler The engine ECM monitors engine speed and throttle position while activating the valve See 7 6 INTERACTIVE EXHAUST GENERAL The Buell DDFI operates both as an open and closed loop system which allows it to adjust for all possible operating con ditions During open loop operation the system utilizes pro grammed fuel and spark maps in the ECM which provide ease of cold starting and maxim...

Page 313: ...N GY Y BE W Y LT GN R V GY PK Y BK BK BK W LT GN Y R W GY Tachometer G2 G10 G7 G9 G4 G11 G12 B2 B11 B5 B4 B12 B10 B6 B7 B1 Instrument Module V R BK Y BK GN W Electronic Control Module ECM one 12 place black connector 10 one 12 place gray connector 11 one 1 place connector 165 1203cc onlyº GY GY GY GY GY B8 Y R Y R B3 BE O G1 G3 G6 BK O To cooling fan fuse Rear To IGN relay V Y BK W BK W BK W 165 I...

Page 314: ...MS NOTE The most sophisticated method of resolving problems involves using a computer based diagnostic package called DIGITAL TECHNICIAN Part No HD 44750 To resolve system problems five basic steps are involved In order of occurrence they are 1 Check for trouble codes by observing check engine lamp See 4 4 CHECKING FOR TROUBLE CODES 2 Retrieve trouble codes using check engine lamp diag nostics See...

Page 315: ... 4 5 After lamp turns off after being illumi nated for the first four second period one of three situa tions may occur a The lamp remains off This indicates there are no current fault conditions or stored functional trouble codes currently detected by the ECM b The lamp stays off for only four seconds and then comes back on for an eight second period This indi cates a functional error code is stor...

Page 316: ...t historic trouble codes may also be present whenever the system indicates the existence of a current fault See 4 4 CHECKING FOR TROUBLE CODES if multiple trouble codes are found Functional Trouble codes 52 through 56 are considered to be functional codes They indicate an internal problem with the ECM trou ble codes 52 through 55 or with the camshaft sensor timing trouble code 56 RETRIEVING TROUBL...

Page 317: ...ength of time the lamp is illuminated and the length of time in which it is off are each about 1 second in duration 4 The second digit follows a Following transmission of the first digit there is another 2 second pause in which the lamp is off b The lamp will then flash one or more times to indi cate the second digit of the trouble code Count the number of times the lamp flashes to retrieve the se...

Page 318: ... wire on Pins 1 and 2 of the data link connector However if the jumper wire is removed with the engine running the check engine lamp will continue to flash trouble codes To stop check engine lamp from flashing codes turn engine stop switch OFF CLEARING CODES After correcting system problems clear trouble codes If the Digital Technician Part No HD 44750 is not available per form 50 start and run cy...

Page 319: ...tach black connector from the wiring harness to black connector on Breakout Box 4 Attach Breakout Box to gray connector 11 a Attach gray connector from Breakout Box to corre sponding gray ECM connector b Attach gray connector from the wiring harness to gray connector on Breakout Box REMOVAL 1 See Figure 4 9 Depress latches on each side of connec tors 10 black and 11 gray 2 Detach Breakout Box conn...

Page 320: ...to wiring harness between the suspect connections When diagnosing ECM connections a BREAKOUT BOX Part No HD 42682 may be used to simplify the proce dure See 4 6 BREAKOUT BOX 2 Set DVOM to read voltage changes 3 Start motorcycle engine and run at idle 4 Shake or wiggle harness to detect intermittents If inter mittents are present radical voltage changes will register on the DVOM Figure 4 10 Fluke 7...

Page 321: ...e received using a jumper wire on Pins 1 and 2 of the data link connector However if the jumper wire is removed with the engine running the check engine lamp will continue to flash trouble codes To stop check engine lamp from flashing codes turn engine stop switch OFF Diagnostic Notes The reference numbers below correlate with the circled num bers on the diagnostic check flow charts See Diagnostic...

Page 322: ...uble Codes and Fault Conditions CODE NO FAULT CONDITION RELEVANT TOPIC 11 Throttle position sensor 4 16 TROUBLE CODE 11 13 Oxygen sensor 4 17 TROUBLE CODE 13 14 Engine temperature sensor 4 18 TROUBLE CODE 14 15 Intake air temperature sensor 4 19 TROUBLE CODE 15 16 Battery voltage 4 20 TROUBLE CODE 16 21 Interactive muffler control 4 21 TROUBLE CODE 21 23 Front fuel injector 4 22 TROUBLE CODES 23 A...

Page 323: ...ector 10 Connector 11 LTGN R GY BK BK V R Data Link 91A b1080a4x To IGN relay Table 4 8 Wire Harness Connectors in Figure 4 11 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under seat 11 ECM gray 12 place Deutsch under seat 91A data link 4 place Deutsch under seat ...

Page 324: ...P ON CONTINUOUSLY NO Does engine start YES See 4 11 ENGINE CRANKS BUT WILL NOT START NO YES NO Are any trouble codes displayed YES NO Refer to applicable trouble code flow chart Start with lowest trouble code All diagnostic codes are listed on page 4 13 in Table 4 7 YES Go to Diagnostic Check Part 2 of 2 Refer to diagnostic tips in related trouble code chart even if no code is set 1 STOP Does chec...

Page 325: ...round Test the four data link connector terminals against their ECM connector pins for continuity Continuity present in all four circumstances DATA LINK TERMINAL ECM TERMINAL Pin Wire Color Pin Connector 1 Lt GN R 11 11B 2 BK 11 10B 3 V R 12 11B 4 GY 1 10B NO Repair short to ground YES YES Inspect terminals for damage or repair opens as necessary NO 2 2 Replace ECM See 4 30 ELECTRONIC CONTROL MODU...

Page 326: ...erence numbers below correlate with the circled num bers on the Test 4 9 flow chart 1 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 black pin probe and patch cord 2 See Figure 4 13 Inspect connector 10 black 3 for contamination or corrosion If connection is good replace ECM See 4 30 ELECTRONIC CONTROL MOD ULE 3 Check continuity between instrument connector 39 Pin 7 and ECM connector 10 black 3 p...

Page 327: ...CM Spare Empty Battery 22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 26 21 R GY O W BK Ignition Switch 33 Electronic Control Module ECM Connector 10 Connector 11 Instrument Module 39 R BK Y R GY O W R R Fuse Block Relay Center Check Engine Lamp R GY Accessory Fuse KeySwitch Fuse b1081a4x Top View Battery Fuse R R Y To Battery Table 4 10 Wire Harness Connectors in Figure 4 14 NO DESCRIPTION...

Page 328: ... Refer to 4 12 NO ECM POWER NO Refer to 4 11 ENGINE CRANKS BUT WILL NOT START for no start condition and then return to 4 9 CHECK ENGINE LAMP NOT ILLUMI NATED AT KEY ON to resolve no engine check lamp YES NO Disconnect instruments connector 39 Remove BK Y wire from connector 39 and ground it Reconnect connector 39 Check engine lamp ON YES Repair open or short to voltage on BK Y wire between connec...

Page 329: ...lamp should go off for four seconds It may then come back on for an eight second period for a stored error or remain on continuously current error DIAGNOSTICS Diagnostic Notes See Figure 4 17 The reference numbers correlate with the circled numbers on the Test 4 10 flow chart 1 See Figure 4 15 If the lamp goes off when the black ECM connector 10 is unplugged the BK Y wire is not shorted to ground ...

Page 330: ...ghts ECM Spare Empty Battery 22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 26 21 R GY O W BK Ignition Switch 33 Electronic Control Module ECM Connector 10 Connector 11 Instrument Module 39 R BK Y R GY O W R R Fuse Block Check Engine Lamp R GY Accessory Fuse KeySwitch Fuse b1081a4x Top View Battery Fuse R R Y To Battery Table 4 11 Wire Harness Connectors in Figure 4 17 NO DESCRIPTION TYPE L...

Page 331: ...lamp function OK Check for trouble codes See 4 4 CHECKING FOR TROUBLE CODES With ignition key switch OFF reconnect black ECM connector 10 With ignition key switch ON verify that there is NOT a 4 second lamp OFF period Is there a lamp OFF period Repair short to ground on BK Y wire between connector 39 and connector 10 Replace ECM See 4 30 ELECTRONIC CONTROL MODULE 7150 7165 ...

Page 332: ...ttery condition Perform a voltage test and recharge if below 12 80 volts Check battery connections and perform load test Replace the battery if necessary 3 Remove spark plug cable from spark plug a Visually check condition of plug b See Figure 4 18 Attach cable to SPARK PLUG TESTER Part No HD 26792 Clip tester to cylin der head bolt c While cranking starter look for spark Repeat proce dure on othe...

Page 333: ... code 24 or 25 This condition is normal and does not by itself indicate a mal function Codes must be cleared if this condition occurs 7 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 gray pin probe and patch cord Figure 4 19 Ignition Coil Circuit Test 10561 Table 4 12 Wire Harness Connectors in Figure 4 20 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under seat 11 ECM gray 12 place ...

Page 334: ... Module ECM GY Cam Position Sensor A BK W Y BE GY BE O GN GY B C A A A C B B B To Rear Cylinder To Front Cylinder GN W R W Rear Injector GY To Ignition Relay Y BE GY BE O GY GN GY Dyno Loop b1071a4x W Y LT GN GY Bank Angle Sensor LT GN GY R W BK W 134A 134B 83A 10A 11A 84A 84B 85B 85A 14B 14A 83B 10B 11B Connector Connector ...

Page 335: ...te NO No pump response but light OK See 4 13 FUEL PRESSURE TEST NO Pump OK but no light See 4 9 CHECK ENGINE LAMP NOT ILLUMI NATED AT KEY ON YES Install Fuel Pressure Gauge See 4 13 FUEL PRES SURE TEST While cranking engine for more than two seconds to ensure proper system operation verify that pressure rises to 49 51 PSI 338 352 kPa Adequate pressure NO Incorrect pressure See 4 13 FUEL PRESSURE T...

Page 336: ...nector 14B Is 5 volts present YES Poor connection at connector 10B 83 or open in harness between coil and ECM Repair open NO With ignition OFF measure resistance between connector 14 Terminal A and Breakout Box GY Pin 1 Also between connector 14 Terminal C BK W wire and ECM Pin 7 on connector 11B Is resistance greater than 1 0 ohm NO Go to Test 4 11 Part 3 of 3 YES YES Repair open circuit NO Check...

Page 337: ...ify any loose connects engine misfires or stalls Any found YES Pinion gear key failure loose rotor cup or other mechanical failure NO Replace cam position sensor See 4 31 CAM POSITION SENSOR AND ROTOR NO Repair YES NO Disconnect connector 14 Measure resis tance between Terminal B and Connector 14B and Breakout Box GY Pin 3 Is resistance greater than 1 0 ohms Remove cam timer cover using 1 8 in dri...

Page 338: ...established the ECM will not receive power If the ECM does not appear to be receiving power check the ground sources A blown ignition fuse or ECM fuse can also disable the ECM DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Test 4 12 flow chart 1 Connect BREAKOUT BOX Part No HD 42682 to ECM See 4 6 BREAKOUT BOX ...

Page 339: ...ion Relay Key Switch Relay Ignition Fuse KeySwitch Fuse Ignition Switch Battery Fuse Electronic Control Module ECM Connector Connector R R W BK R R R R BK BK BK W BK GY O W BK R BK GY GY GY BK LT GN R V R To Battery R BK R BK GY O b1077c4x ECM 10 Pin 1 also provides power to fuel pump both fuel injectors and coil Fuse Block Relay Center Top View 33B 33A 10B 11B 11A 10A 22A 22B Data Link R Y BK Tab...

Page 340: ... for 12 volts on ignition relay Terminal 86 W BK Voltage present Repair open on GY O wire between connector 22 and ignition relay NO Check ignition fuse and ECM fuse Are fuses OK YES Replace ECM See 4 30 ELECTRONIC CONTROL MODULE YES Attach Breakout Box HD 42682 to ECM Check for 12 volts on ECM connector 10 Pin 1 and Pin 2 Voltage present Replace fuse s as needed YES Check for 12 volts on right ha...

Page 341: ...g fuel from fuel line 1WARNING 1WARNING A small amount of gasoline will drain from the valve when the gauge is installed Thoroughly wipe up any spilt fuel immediately Dispose of rags in a suitable manner Gasoline is extremely flammable and highly explosive Inadequate safety precautions could result in death or serious injury 3 See Figure 4 23 Depress button 2 of fuel line connec tor and disconnect...

Page 342: ...el immediately Dispose of rags in a suitable manner Gasoline is extremely flammable and highly explosive Inadequate safety precautions could result in death or serious injury 10 See Figure 4 25 Turn engine off Detach pressure gauge 4 from adapter 1 a Open the air bleed petcock 5 to relieve fuel system pressure and purge the pressure gauge of gasoline b Remove pressure gauge from adapter 11 Detach ...

Page 343: ...y Sw Lights ECM Spare Empty Battery Ignition Switch LowFuel Lamp Instrument Module Fuel Pump R Y R To Battery Ignition Relay Key Switch Relay W BK GY O W BK GY O Ignition Fuse Key Switch Fuse R R R BK BK BK Y R GY O R BK BK BN Y GY GY Electronic Control Module ECM Connector Connector Right Handlebar Switch b1082c4x R R W BK GY O GY O R BK BK R R BK Battery Fuse Fuse Block Relay Center Top View 33A...

Page 344: ...n nector 89 during first two seconds after key ON Is volt age greater than 1 VDC Check for restricted pump inlet screen Is screen restricted NO Move negative probe to GY wire on Terminal 87 of ignition relay Measure voltage during first two seconds after key ON Is voltage greater than 1 VDC YES Locate and repair poor connection between ignition relay and fuel pump NO Move negative probe to GY O wi...

Page 345: ...e BN Y wire at 86A during the first two seconds after key ON Does test lamp light YES NO Connect Breakout Box HD 42682 to ECM Check continuity between 86A Ter minal C BN Y wire and ECM connector 10 black Termi nal 3 Is continuity present Inspect fuel pump wiring Is wiring OK YES NO Repair fuel pump wiring NO Replace fuel pump assembly See 4 39 FUEL PUMP YES Locate and repair open on BN Y wire NO R...

Page 346: ... adjuster is located near the engine and could be extremely hot Use suggested tool for adjusting the idle speed Failure to comply could result in minor or moder ate injury The idle speed should be adjusted when the engine is at nor mal operating temperature NOTE An idle speed too low can cause poor throttle response An idle speed too high can cause a slow return to idle See 1 16 THROTTLE CABLE AND...

Page 347: ...on leads e Reinstall and repeat procedure on other spark plug cable 2 Perform spark plug cable resistance test a Remove spark plug cable from spark plug and igni tion coil See 7 4 SPARK PLUG CABLES b Using an ohmmeter touch probes to terminals on each end plug wire c Compare resistance values to Table 4 16 Replace cables not meeting specifications Reinstall and repeat procedure on other spark plug...

Page 348: ...e Packard beneath airbox base 1 2 3 4 5 6 1 2 3 4 5 6 Front Injector Ignition Coil W Y GN W BK W R W Electronic Control Module ECM GY Cam Position Sensor A BK W Y BE GY BE O GN GY B C A A A C B B B To Rear Cylinder To Front Cylinder GN W R W Rear Injector GY To Ignition Relay Y BE GY BE O GY GN GY Dyno Loop b1071a4x W Y LT GN GY Bank Angle Sensor LT GN GY R W BK W 134A 134B 83A 10A 11A 84A 84B 85B...

Page 349: ...for faulty plug wire connections and wire boots for carbon tracking Are wires OK YES Check for Faulty worn or cracked spark plug s Plug fouling due to engine mechanical fault Faulty or poor connection at plug NO Replace faulty wires YES Coils should be free of carbon tracking Are they NO Replace ignition coil YES Switch coil with unit known to be good Perform spark test Did spark jump gap during e...

Page 350: ... GY Voltage should alternate between 0 and 5 volts while cranking Does it YES With engine running wiggle cam position sensor and wires to iden tify any loose connects engine misfires or stalls Any found YES Pinion gear key failure loose rotor cup or other mechanical failure NO Replace cam position sensor See 4 31 CAM POSITION SENSOR AND ROTOR NO Repair YES NO Disconnect connector 14 Measure resis ...

Page 351: ...HOME NOTES ...

Page 352: ...proper mating broken locks improperly formed or damaged terminals poor terminal to wire connection and damaged harness Perform 4 7 WIGGLE TEST to locate intermittents If connections and harness check out OK monitor TP sen sor voltage using DVOM while moving related connec tors and wiring harness If the failure is induced the DVOM display will change TP sensor scaling Observe the TP sensor voltage ...

Page 353: ...ference Lt GN GY BAS Signal BK W Sensor Ground Bank Angle Sensor BK W R W LTGN GY b1112a4x 10B 11B 10A 11A 88B 88A 134A 134B 14A 14B Table 4 18 Wire Harness Connectors in Figure 4 32 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under seat 11 ECM gray 12 place Deutsch under seat 14 cam position sensor 3 place Deutsch under sprocket cover 88 throttle position sensor 3 place Packard rig...

Page 354: ...n and set CODE 11 NO System now OK YES Install original TP sensor and replace ECM 4 30 ELECTRONIC CON TROL MODULE Road test again to verify YES Connect Breakout Box if not already connected Disconnect TP sensor connector 88 and ECM connector 11 Measure voltage at Pin 2 and Pin 7 Does voltage measure 5 0 volts NO Go to Code 11 Test Part 2 of 2 STOP YES Reconnect TP sensor connector 88 Measure TP se...

Page 355: ...W wire NO Check continuity between connector 88 Terminal B V Y wire and Pin 2 of connector 11 Continuity present YES 7615 Locate and repair open in V Y wire NO Check continuity between con nector 88 Terminal C BK W and Pin 7 of connector 11 Continuity present YES 7580 Locate and repair open in BK W wire NO YES 7610 Locate and repair short between R W and BK W wires Reconnect 14 NO Replace ECM See ...

Page 356: ...PM for the ECM to detect an O2 sensor failure Check for the following conditions Poor connection Inspect the ECM harness connector 11 fuel injector connectors 84 85 and O2 sensor con nector wiring for backed out terminals improper mating broken locks improperly formed or damaged terminals poor terminal to wire connection and damaged harness Dirty stuck open injectors The motorcycle may run lean di...

Page 357: ...1 137B 137A Electronic Control Module ECM Connector Connector 10B 10A 11B 11A b1135x4x Table 4 19 Wire Harness Connectors in Figure 4 35 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch under seat 137 oxygen sensor 1 place Packard behind rear cylinder head ...

Page 358: ...ctor 11 gray Turn ignition ON and start engine Engine must be on and running to read O2 sensor values Observe O2 voltage Is it approximately 0 5 volts Install Breakout Box HD 42682 leaving harness side connector 11 disconnected from the Breakout Box Is the O2 voltage approximately 0 5 volts YES NO Inspect V GY wire for shorts to voltage and repair Replace ECM See 4 30 ELECTRONIC CONTROL MODULE Go ...

Page 359: ... air leaks at induction module Air leak present YES Replace fuel line or filter NO Fuel injectors may be dirty See Fuel Injectors under 4 42 THROTTLE BODY YES Repair Go to Code 13 Test Part 3 of 3 STOP YES Repair low pres sure problem See 4 13 FUEL PRES SURE TEST Replace fuel pump See 4 39 FUEL PUMP 7661 7664 7897 7663 7667 7668 Clear codes and confirm proper operation with no check engine lamp Co...

Page 360: ...or and replace ECM 4 30 ELECTRONIC CONTROL MODULE Road test again to verify YES See Code 13 Test Part 2 of 3 for slow or no change NO Continued from Code 13 Test Part 2 of 3 Turn ignition OFF and reconnect O2 sensor Turn ignition ON and start engine Allow engine to reach operating temperature Does voltage quickly fluctuate between 0 1 0 8 volts 7668 7672 7659 Clear codes and confirm proper operati...

Page 361: ...nection Inspect ECM harness connector 11 for backed out terminals improper mating broken locks improperly formed or damaged terminals poor terminal to wire connection and damaged harness Shifted sensor The temperature to resistance values table may be used to test the ET sensor at various tem perature levels in order to evaluate the possibility of a shifted out of calibration sensor which may resu...

Page 362: ...re Sensor PK Y Electronic Control Module ECM Connector Connector PK Y 1 90A 90B 10B 10A 11B 11A Table 4 21 Wire Harness Connectors in Figure 4 37 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch under seat 90 engine temperature sensor 1 place bullet beneath airbox base ...

Page 363: ... the resistance between Pin 9 of 11 and Pin 2 of 10 and Pin 11 of 10 on Breakout Box Is it greater than 1 0 megaohm NO Examine PK Y wire in harness for open circuit and repair YES NO Examine harness for short to ground and repair At some point in the flow chart you may be instructed to jump directly to the box marked by an asterisk Dis regard the asterisk but not the instruction box if your normal...

Page 364: ...s connect ECM connector 11 Mea sure resistance between ECM Pin 9 of 11 and Pin 2 of 10 Is resistance less than 1 ohm Unplug ECM leaving Breakout Box connected at vehicle harness Measure voltage between ECM Pin 9 of 11 and Pin 2 of 10 on Breakout Box Is the voltage 0 volts Install original ET sensor replace ECM 4 30 ELEC TRONIC CONTROL MODULE and road test YES System OK Repair short to ground on PK...

Page 365: ...re connection and damaged harness Perform 4 7 WIGGLE TEST to locate intermittents If connections and harness check out OK check intake air temperature reading while moving related connectors and wiring harness If the failure is induced the IAT sen Shifted sensor The temperature to resistance values table may be used to test the IAT sensor at various tem perature levels in order to evaluate the pos...

Page 366: ... GN Y Intake Air Temperature Sensor 89 Lt GN Y 5 volt reference and sensor signal BK W sensor ground 1 2 BK W Lt GN Y P89B P89A 10B 10A 11B 11A Table 4 23 Wire Harness Connectors in Figure 4 39 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch under seat 89 intake air temperature sensor 2 place Amp in airbox base ...

Page 367: ... road test Did check engine lamp come on and set only CODE 15 With IAT sensor disconnected dis connect ECM connector 11 Mea sure resistance between ECM Pin 10 of 11 and Pins 2 and 11 of 10 Is resistance less than 1 megaohm Unplug ECM leaving Breakout Box connected at vehicle harness Measure voltage between ECM Pin 10 of 11 and Pin 2 of 10 on Breakout Box Is the voltage 0 volts Install original IAT...

Page 368: ...ins 10 and 7 of connector 11 on Breakout Box Is it greater than 1 0 megaohm NO Examine BK W wire in harness for open circuit and repair YES Using a DVOM measure the resistance between ECM Pin 10 of connector 11 on Breakout Box and ground Is it greater than 1 0 megaohm NO Examine Lt GN Y wire and BK W wire in harness for short between these two circuits and repair YES NO Examine harness for short t...

Page 369: ...gulator DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Code 16 flow charts 1 The ECM is monitoring voltage at ECM connector 10 black Terminal 1 Connect BREAKOUT BOX Part No HD 42682 to ECM See 4 6 BREAKOUT BOX 2 This checks for voltage drops in the ECM power circuit If a significant voltage drop is not present condition may be caused by excessiv...

Page 370: ...ey Sw Lights ECM Spare Empty Battery Right Handlebar Switch GY O GY Ignition Relay Key Switch Relay Ignition Fuse Key Switch Fuse Ignition Switch Electronic Control Module ECM Connector Connector R R W BK R R R Y R BK BK W BK GY O W BK R BK BK LT GN R V R To Battery R BK R BK GY O b1083c4x R R Battery Fuse Fuse Block Relay Center Top View 10A 33A 33B 11A 11B 10B 22B 22A ECM 10 Pin 1 also provides ...

Page 371: ...akout Box with key ON Is voltage drop greater than 0 5 volt System OK YES NO Check for excessive starter cur rent draw See 5 6 STARTER SYSTEM TESTING Measure voltage drop between Battery Positive Terminal and Terminal 87 on ignition relay with key ON Is voltage drop greater than 0 5 volt NO Replace ignition relay 1 2 YES Measure voltage drop between Battery Positive Terminal and GY O Terminal 30 o...

Page 372: ... 0 5 volt YES NO Repair R wire or terminals Measure voltage drop between Battery Positive Terminal and R Y wire of 30 amp battery fuse with key ON Is voltage drop greater than 0 5 volt YES NO Replace main fuse Replace R Y wire between battery fuse and battery YES Measure voltage drop between Battery Positive Terminal and R BK wire Terminal on 15 amp ignition fuse with key ON Is voltage drop greate...

Page 373: ...k circuit Mechanical fault in the actuator valve or cable Electrical fault in the actuator circuit Electrical fault in the actuator feedback circuit Diagnostic Notes The reference numbers below correlate with the circled num bers on the Code 21 flow charts 1 Using TEST CONNECTOR KIT Part No HD 41404 attach red probe and patch cord to 164B 1 2 2 Using TEST CONNECTOR KIT Part No HD 41404 use gray ma...

Page 374: ... 2 161B TN V W O 3 1 2 9 3 COOLING FAN BRAKE HORN MUFFLER R BK 165A 165B O Electronic Control Module ECM Connector 10 Connector 11 b1073a4x Table 4 25 Wire Harness Connectors in Figure 4 43 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under seat 161 Interactive muffler actuator 4 place Deutsch under air cleaner 164 ECM 1 place Amp under seat 165 sub harness 3 place Packard beneath ai...

Page 375: ...ontinuity present 2 NO Locate and repair open on BK wire YES a Ignition on Run Stop in Run position 12V present at pin 1 161B NO Locate and repair open on O wire between fuse and 161B YES Check for continuity between 164B and 161B pin 3 Continuity present NO Locate and repair open on W wire Locate and repair open on TN V wire 161B Using pliers gently pull on cable to interactive muffler actuator C...

Page 376: ...s ECM and fuel pump DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Code 23 32 flow charts 1WARNING 1WARNING The gasoline in the fuel supply line downstream of the fuel pump is under high pressure 49 psi 338 kPa To avoid an uncontrolled discharge or spray of gasoline always purge the system of high pressure gas before servicing the fuel system Ga...

Page 377: ...ector 11 b1073a4x Table 4 26 Wire Harness Connectors in Figure 4 46 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under seat 161 Interactive muffler actuator 4 place Deutsch under air cleaner 164 ECM 1 place Amp under seat 165 sub harness 3 place Packard beneath airbox base ...

Page 378: ...tor 84 If CODE 32 measure resistance between ECM Pin 8 of 10 GN GY wire and Terminal 2 of rear injector connector 85 Is resistance less than 0 5 ohm YES Check for loose or corroded terminals in harness Repair as necessary Replace injector See 4 42 THROTTLE BODY YES NO NO Go to Code 23 32 Test Part 2 of 2 YES NO Repair open or poor connection Using Breakout Box check with test lamp between ECM 10 P...

Page 379: ... and Terminal 2 W Y for Code 23 or GN GY for Code 32 wire at injector connector Is resistance less than 0 5 ohm With DVOM still attached perform 4 7 WIGGLE TEST to locate intermittents Repair as necessary Find and repair connection or open wire YES NO Check for multiple codes See 4 4 CHECKING FOR TROUBLE CODES Clear codes and confirm proper operation with no check engine lamp Codes can be cleared ...

Page 380: ... the Code 24 25 flow charts 1 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 purple pin probes and patch cord 2 Connect BREAKOUT BOX Part No HD 42682 to ECM See 4 6 BREAKOUT BOX 3 See Figure 4 34 Plug IGNITION COIL CIRCUIT TEST ADAPTER Part No HD 44687 and FUEL INJECTOR TEST LAMP Part NO 34730 2C INTO Breakout Box Note that cranking the engine with test lamp in place of the ignition coil can some...

Page 381: ... Position Sensor A GN W Y BE GY BE O BK W B C A C B To Rear Cylinder To Front Cylinder R W GY Ignition Relay Y BE GY BE O Dyno Loop b1072a4x 10A 83A 83B 14A 14B 11A 11B 10B RELAY CENTER Table 4 27 Wire Harness Connectors in Figure 4 49 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under seat 83 ignition coil 3 place Packard beneath airbox base ...

Page 382: ...al 4 Pin 4 in Relay Center after key is turned ON Should be equivalent to battery voltage Is it YES Repair open wire or connection on GY wire NO Check for multiple codes See 4 4 CHECKING FOR TROUBLE CODES Measure resistance at Breakout Box between ECM and coil terminals as follows Resistance should be less than 0 5 ohms Is it Trouble Code Coil Terminal Breakout Box Terminal 24 Front A BE O 7 BK 25...

Page 383: ...or is not running Fuel pump motor stalls or spins without providing fuel pressure DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Code 33 flow chart 1 Connect BREAKOUT BOX Part No HD 42682 to ECM See 4 6 BREAKOUT BOX 2 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 red pin probe and patch cord 3 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 gr...

Page 384: ...y Ignition Switch LowFuel Lamp Instrument Module Fuel Pump R Y R To Battery Ignition Relay Key Switch Relay W BK GY O W BK GY O Key Switch Fuse R R R BK BK BK Y R GY O R BK BK BN Y GY GY Electronic Control Module ECM Connector Connector Right Handlebar Switch b1082c4x R R W BK GY O GY O R BK BK R R BK Battery Fuse Fuse Block Relay Center Top View 86A 10B 10A 11A 11B 86B 39A 39B 22A 22B 33A 33B Ign...

Page 385: ...ngine lamp come on and set only CODE 33 YES NO Install original fuel pump 4 39 FUEL PUMP and replace ECM 4 30 ELECTRONIC CONTROL MODULE System OK Fuel pump on continuously NO Check continuity of BN Y wire between 10 Pin 3 and Pin C of 86 Continuity present YES Repair open NO Check continuity of GY wire from ignition relay Terminal 87 to Pin D of 86 Continuity present YES Repair open NO NO 1 2 3 3 ...

Page 386: ...tic Notes The reference numbers below correlate with the circled num bers on the Code 35 flow chart 1 Connect BREAKOUT BOX Part No HD 42682 to ECM See 4 6 BREAKOUT BOX 2 Replace instrument module See 7 19 INSTRUMENT MODULE Figure 4 52 Installed Breakout Box Figure 4 53 Instrument Module Connector 39 1 Breakout box 2 ECM 2 1 8890 8893 8894 ...

Page 387: ... Acces Key Sw Lights ECM Spare Empty Battery O W BK Ignition Switch 33B To battery Electronic Control Module ECM Connector Connector Instrument Module R R Y R GY O W R R Fuse Block R GY Accessory Fuse KeySwitch Fuse b1084b4x PK Top View R GY R Battery Fuse 33A 39A 39B 10A 10B 11A 11B O W O W Table 4 29 Wire Harness Connectors in Figure 4 54 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsc...

Page 388: ...ontinuity present Locate and repair short on PK wire to ground YES Plug in 10 Connect voltmeter across Pin 12 and Pin 11 at Breakout Box 10 Start engine and let motor idle Is voltage approximately 4 0 6 0 volts NO Reconnect 39 Locate intermittents using 4 7 WIGGLE TEST Intermit tents found YES Replace ECM See 4 30 ELECTRONIC CON TROL MODULE NO Repair YES NO Replace instrument module See 7 19 INSTR...

Page 389: ...g Fan Specifications This code can also set if fan blade does not spin blocked fan blade when fan is commanded on and battery voltage is applied to fan Cooling Fan Low Voltage This code will set when the ignition key is ON and the ECM does not sense voltage at pin 6 of ECM terminal 11 gray connector DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the...

Page 390: ... IGN Acces Key Sw Lights ECM Spare Empty Battery Electronic Control Module ECM Connector Connector BK Y BN BK O To battery R Battery Fuse Top View Y BN R Cooling Fan BK O BK b1090b4x Y BN BK Fuse Block Cooling Fan Fuse 97B 97A 10A 10B 11A 11B Table 4 31 Wire Harness Connectors in Figure 4 56 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch under seat 97 cooling fan 2 place Multilock behin...

Page 391: ...y connector 11 Turn IGN ON Measure volts at pin 9 of Breakout Box Is voltage greater than 1 3 volts YES 2 Does cooling fan run continuously NO YES NO See 4 18 TROUBLE CODE 14 engine temperature sen sor Turn IGN switch ON Does fan run continuously YES Defective ECM or ECM connection NO System ok At some point in the flow chart you may be instructed to jump directly to a the box with the bold asteri...

Page 392: ... ground in Y BN wire Is there an obstruction preventing fan from rotating YES Remove obstruction preventing fan rotation NO Disconnect fan harness at fan Use ohmmeter to mea sure resistance between Y BN terminal and BK terminal of fan connector 97A Resistance greater than 1 Check for continuity between pin 6 gray of Breakout Box and BK O wire of fan connector 97A Continuity present Check for conti...

Page 393: ... between sensor and elec tronic control module Failed sensor If this code occurs the engine may stop running The engine may still be restarted and ridden to the dealership for repair DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Code 44 flow charts 1 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 gray pin probes and patch cord 2 Connect BREAKO...

Page 394: ...ence Lt GN GY BAS Signal BK W Sensor Ground Bank Angle Sensor BK W R W LTGN GY b1112a4x 14A 11A 11B 10A 10B 14B 134B 134A 88B 88A Table 4 33 Wire Harness Connectors in Figure 4 59 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under seat 11 ECM gray 12 place Deutsch under seat 14 cam position sensor 3 place Deutsch under sprocket cover 88 throttle position sensor 3 place Packard right ...

Page 395: ...N wire 4 75 5 25 volts Measure voltage between Socket 4 R W and Socket 6 BK W Is voltage 4 6 volts 11 13 volts 0 volts Go to Code 44 Test Part 2 of 2 YES Is bank angle sensor correctly installed NO Repair open in R W wire between 134 and harness YES Are ferrous metals located within 0 25 in 6 4 mm of sides face or top of bank angle sensor NO Install properly See 4 35 BANK ANGLE SENSOR YES Return t...

Page 396: ...n Lt GN GY wire YES Check continuity to ground for Socket 6 BK W and connector 11 Pin 7 Is continuity present NO Repair open in ground wire YES Check continuity to ground for Socket 5 Lt GN GY and connector 134 Is continuity present NO Replace ECM See 4 30 ELECTRONIC CONTROL MODULE YES Repair short to ground on Lt GN GY wire 2 Clear codes and confirm proper operation with no check engine lamp Code...

Page 397: ... 28 GENERAL ECM Failure All of the following codes indicate a failure which requires replacement of the ECM See 4 30 ELECTRONIC CONTROL MODULE Code 52 RAM failure Code 53 ROM failure Code 54 EE PROM failure Code 55 Microprocessor failure ...

Page 398: ...ntinue to run not run normally or stop running altogether DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Code 56 flow charts 1 Connect BREAKOUT BOX Part No HD 42682 to ECM See 4 6 BREAKOUT BOX 2 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 black pin probes and patch cord 3 See 4 31 CAM POSITION SENSOR AND ROTOR Figure 4 60 Cam Position Sensor...

Page 399: ...tion sensor 3 place Packard right side of engine between cylinders 134 bank angle sensor 6 place Sumitomo under seat A B C C B A Throttle Position Sensor R W V Y BK W R W BK W GN W Cam Position Sensor R W 5 Volt Reference V Y TP Sensor Signal BK W Sensor Ground R W V Y GN W BK W Electronic Control Module ECM Connector Connector LTGN GY R W 5 Volt Reference Lt GN GY BAS Signal BK W Sensor Ground Ba...

Page 400: ...n A on 14 and Pin 1 on 11 Continuity present Disconnect harness side connector 11B GY from Breakout Box Measure voltage between Pin 1 and Pin 7 of connector 11 Voltage present NO Repair open in R W wire between connectors 11 and 14 NO Repair open in BK W wire between connectors 11 and 14 YES YES 12 volts Locate and repair R W wire short to voltage Locate and repair R W wire short to ground YES 5 v...

Page 401: ...IGGLE TEST and repair intermittent YES NO Repair Remove timing cover and cam position sensor Observe rotor cup while cranking engine Does rotor turn YES Check rotor for damage Is rotor loose or damaged NO Is rotor attached properly YES Remove gearcase cover and inspect for damage NO Repair YES Replace rotor and retest NO Replace cam position sensor and clear code Retest Prob lem still exist YES In...

Page 402: ...ING 1WARNING Always connect the positive battery cable first If the pos itive 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 68 3 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 4 Connect negative ba...

Page 403: ...gnition 2 System ground A module 3 Fuel pump 4 Check engine lamp 5 Injector front 6 Front coil primary 7 Rear coil primary 8 Injector rear 9 Interactive muffler control feedback 10 Bank angle sensor input 11 System ground B coil 12 Tachometer Table 4 36 Pin Table for ECM Connector 11 Gray PIN FUNCTION 1 5 volt sensor power 2 Throttle position sensor 3 Camshaft position sensor 4 Oxygen sensor 5 Mem...

Page 404: ... DEUTSCH ELECTRICAL CONNECTORS under B 1 AMP MULTILOCK ELECTRICAL CONNEC TORS 7 Remove timer cover a Drill off heads of outer timer cover pop rivets 1 using a 3 8 in drill bit b Tap remaining rivet shafts inboard through holes in timer cover 2 and inner cover 20 c Remove timer cover Remove inner cover screws 3 and inner cover 20 d Carefully remove any remaining pieces of rivets from gearcase cover...

Page 405: ...n 7 Electronic control module ECM 8 Connector interactive exhaust system 9 Spark plug 2 10 Rear spark plug cable 11 Mounting fastener 12 Wireform cable guide 13 Ignition coil 14 Front spark plug cable 15 Engine mount 16 Seal 17 Trigger rotor 18 Trigger rotor bolt 19 Cam position sensor 20 Inner cover 1 2 3 5 6 7 4 18 17 9 10 11 19 13 12 14 20 15 16 9 8 ...

Page 406: ... 1 1 1 1 2 2 2 2 2 2 DIODE BATTERY COOLING FAN IGNITION ECM KEY SWITCH 1 90A ENGINE TEMP SENSOR 90B 131A 1 165A 161A ACTIVE MUFFLER SUB HARNESS 2 1 3 TN V O W O 29 23 BRAKE HORN MUFFLER TN V W 1 HALL SENSOR CONTROL SIGNAL GROUND V bat MUFFLER VALVE ACTUATOR MOTOR SENSOR POSITION DC CONTROL ELECTRONICS TN V O TN V W BK O W 1 2 3 1 1 4 4 3 3 2 2 165B 161B ECM SENSOR POSITION THROTTLE 88B 88A 3 2 1 1...

Page 407: ...ug end from cam position sensor must match same color wires in receptacle end of con nector from ignition module wiring harness Install pin terminals See B 2 DEUTSCH ELECTRICAL CONNEC TORS under B 1 AMP MULTILOCK ELECTRICAL CON NECTORS 6 See Figure 7 66 Attach connector 14 6 7 Check ignition timing See 1 18 IGNITION TIMING 8 Tighten timer plate studs 4 to 15 30 in lbs 2 3 Nm 9 Install inner cover ...

Page 408: ...resistance is not within nor mal operating range Test Results 1 A low resistance value indicates a short in the coil wind ing Replace coil 2 A high resistance value might indicate that there is some corrosion oxidation of the coil terminals Clean the termi nals and repeat resistance test If resistance is still high after cleaning terminals replace coil 3 An infinite ohms or no continuity resistanc...

Page 409: ...bles to ignition coil first 1 Connect spark plug cables to ignition coil 2 See Figure 4 70 Attach coil to frame with fasteners 2 Tighten to 120 144 in lbs 13 6 16 3 Nm 3 Attach front and rear spark plug cables to ignition coil posts 4 Attach connector 3 83 5 Install ram air scoop assembly See 2 36 AIR SCOOPS 6 Install airbox See 4 44 AIRBOX 7 Install intake cover assembly See 2 35 INTAKE COVER ASS...

Page 410: ... 4 73 Remove cable straps 2 Unplug 1 place connector 137 1 7 Remove oxygen sensor from exhaust header using Snap on Part No YA8875 INSTALLATION 1 Apply LOCTITE ANTI SEIZE LUBRICANT to threads of sensor Make sure anti seize is marked as safe for use with O2 sensors 2 See Figure 4 72 Thread sensor into exhaust header Tighten sensor to 40 45 ft lbs 54 61 Nm 3 Install cooling fan See 4 38 COOLING FAN ...

Page 411: ...s could result in death or serious injury 48 1 Disconnect negative battery cable 2 Remove intake cover assembly See 2 35 INTAKE COVER ASSEMBLY 3 Remove airbox See 4 44 AIRBOX 4 See Figure 4 76 Remove right upper tie bar fastener 2 Rotate tie bar to provide access to sensor CAUTION Do not pull on engine temperature sensor wiring Excess strain to sensor wiring will cause sensor damage 5 Unplug 1 pla...

Page 412: ...ET sensor to 120 168 in lbs 13 6 19 Nm NOTE Orient the rubber boot so the flat on the boot is towards the left side of the motorcycle 3 Push rubber boot down sensor wire towards cylinder head until it seats in hole on top of ET sensor 4 See Figure 4 76 Connect ET sensor 1 place connector 90 to wiring harness 5 Install right upper tie bar fastener 2 Tighten fastener to 25 27 ft lbs 33 9 36 6 Nm 6 I...

Page 413: ...34 2 Position bank angle sensor on seat latch bracket Make sure locating post on sensor engages hole in mounting tab 3 Install bank angle sensor to mounting tab with fasteners and new locknuts Tighten fastener to 12 36 in lbs 1 4 4 1 Nm 1WARNING 1WARNING Always connect the positive battery cable first If the pos itive cable should contact ground with the negative cable installed the resulting spar...

Page 414: ...dequate safety precautions could result in death or serious injury 48 1 Disconnect negative battery cable 2 See Figure 4 78 Remove airbox cover and filter Remove fasteners securing base See 4 44 AIRBOX 3 Raise base and pull IAT sensor from sensor grommet 4 Disconnect connector 89 from intake air temperature sensor 5 Inspect sensor grommet for damage and replace as required INSTALLATION 1 Connect I...

Page 415: ...nsor prior to installation 3 Attach TP sensor with both fasteners and washers Tighten to 16 20 in lbs 1 8 2 3 Nm 4 See Figure 4 81 Attach throttle position sensor connec tor 88 Slots on female connector 88B must fully engage tabs on male connector housing 88A NOTE Throttle position sensor can only be calibrated using DIGITAL TECHNICIAN Part No HD 44750 5 Calibrate throttle position sensor Figure 4...

Page 416: ...connector 97 NOTES When installing cooling fan 3 be sure wiring transmis sion vent hose and fuel line are routed through notch 2 in fan body On California models both fuel tank and canister vent hoses are routed through notch in fan body 2 Install fan and rotate counterclockwise into position 3 Install cooling fan fasteners Tighten to 12 36 in lbs 1 4 4 1 Nm 4 Install shock absorber See 2 22 REAR ...

Page 417: ...located inside the left rear portion of the fuel tank frame b With the motorcycle in neutral start the engine and allow vehicle to run c When the engine stalls press the starter button for 3 seconds to remove any remaining fuel from fuel line 1WARNING 1WARNING An open flame or spark may cause a fuel tank explosion if all traces of fuel are not purged from the tank Use extreme caution when servicin...

Page 418: ...ump fasteners 5 6 See Figure 4 85 Assemble fuel pump puller a Thread nut 3 onto bolt 4 b Slide washer 2 onto bolt c Insert bolt assembly into hole in main body 1 7 See Figure 4 86 Place the main body of the fuel pump puller over the fuel pump assembly 8 Thread bolt into the threaded hole in the center of the fuel pump assembly until snug 9 Thread the nut down the shaft of the bolt until it makes c...

Page 419: ... clamps 3 7 3 See Figure 4 89 Remove fuel pump clips 1 4 Pull regulator housing 2 from fuel pump assembly 5 See Figure 4 90 Discard regulator housing o rings 2 6 See Figure 4 88 Remove fuel filter hose from fitting 2 and remove fuel filter 1 7 Install new clamps on fuel filter hose 8 Install new fuel filter hose with 90 bend towards fit ting 2 9 See Figure 4 90 Install new regulator housing o ring...

Page 420: ... screen on fuel pump 8 Without damaging fuel screen slide fuel pump onto fuel pump assembly 9 See Figure 4 88 Attach fuel filter hose to fitting 2 with clamp 3 10 See Figure 4 89 Install clips 1 into middle grooves 11 See Figure 4 87 Connect low fuel level sensor wiring 11 12 Connect fuel pump connectors 10 Connectors are two different sizes 13 Install fuel pump assembly See INSTALLATION in this s...

Page 421: ...ly push wire harness through assembly 10 Lubricate new o rings with clean engine oil From inner side of fuel pump assembly push new wire harness into assembly 11 See Figure 4 87 Insert new fastener 5 through ground wire terminal and secure to fuel pump assembly Tighten to 18 22 in lbs 2 0 2 5 Nm NOTE After installing terminals pull slightly on wire to make sure it is seated If necessary bend tab o...

Page 422: ...ning screws Final tighten screws to 48 51 in lbs 5 4 5 8 Nm 1WARNING 1WARNING Do NOT overtighten fuel fitting nuts Overtightening fas teners may result in excessive compression of sealing components and fuel leakage which could result in death or serious injury 6 Install fuel supply line banjo fitting 2 over fuel supply stud 3 Install new fastener Tighten to 84 108 in lbs 9 5 12 2 Nm 7 Fill tank w...

Page 423: ...ely the 7 00 position 3 Install bracket over vent valve Slot in bracket should line up with notch in valve 4 Loosely install vent valve fasteners 5 5 Tighten fasteners to 39 41 in lbs 4 4 4 6 Nm 6 Connect fuel tank vent line to vent valve 7 Install airbox See 4 44 AIRBOX 8 Install intake cover assembly See 2 35 INTAKE COVER ASSEMBLY 9 Connect negative battery cable Tighten battery terminal hardwar...

Page 424: ... 2 with thin film of clean engine oil 2 Place o ring into groove in underside of fuel cap retaining ring 3 NOTE Be sure o ring remains in groove of fuel cap retaining ring during installation 3 Insert fuel cap retaining ring into fuel filler neck 4 Install fasteners 4 Tighten to 17 70 in lbs 1 9 7 9 Nm 5 Install fuel filler cap Figure 4 96 Fuel Pump Drain Screw swingarm removed for illustration Fi...

Page 425: ...quate safety precautions could result in death or serious injury 1 Purge the fuel supply line of high pressure gasoline a See Figure 4 98 Disconnect the 4 place fuel pump connector 86 Connector is located on the left side above the fuel pump b With the motorcycle in neutral start the engine and allow vehicle to run c When the engine stalls press the starter button for 3 seconds to remove any remai...

Page 426: ...ail fastener 2 4 Fuel rail 5 Throttle position sensor 6 Throttle position sensor fastener 2 7 Washer 8 Velocity stack 9 Throttle body 10 Velocity stack fastener 2 11 Ring seal 12 Intake manifold 13 Intake flange fastener 2 14 Intake flange 2 15 Intake seal 2 16 Intake flange fastener 2 b1034x4x 6 8 11 1 2 12 16 13 14 10 4 3 7 15 5 ...

Page 427: ...tor rear 8 Screw 2 9 Washer flat 2 10 Throttle position sensor 11 Clamp wire spring 49mm 12 Velocity stack 49mm 13 Throttle body manifold assembly 14 Throttle lever assembly 15 Nylock 16 Cable Bracket 17 Screw 2 18 Spring idle adjuster 19 Idle adjuster 20 Bolt 2 21 Bolt 2 22 Mounting flange intake 1 front 1 rear 23 Seal intake manifold 2 8 5 2 3 1 4 5 1 7 4 6 9 11 12 13 15 16 17 18 19 21 22 23 14 ...

Page 428: ...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 th...

Page 429: ... 6 d Secure the fuel rail to the throttle body and manifold with fasteners Tighten to 24 28 in lbs 2 7 3 2 Nm 7 Snap the injector clips 4 over the flange on the fuel rail outlet and into the top grove in the injector Testing 1 Remove intake cover assembly See 2 35 INTAKE COVER ASSEMBLY 2 Remove airbox cover See 4 44 AIRBOX 3 Conduct test a Turn key ON for two seconds b Turn key OFF for two seconds...

Page 430: ...20 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 t...

Page 431: ... false readings keep airbox cover installed when performing test Do not direct propane into air scoop false readings will result LEAK TESTER Parts List Standard 14 oz propane cylinder SNAP ON YA7148 Propane Enrichment Kit 12 in 304 mm long 1 4 in 6 mm diameter copper tub ing Tester Assembly 1 Cut rubber hose from kit to 18 in 457 mm in length 2 See Figure 4 106 Flatten one end of copper tube to fo...

Page 432: ...heat sparks and flame Keep container closed Use only with ade quate ventilation NOTE Do not direct propane stream toward front of engine If pro pane enters air scoop a false reading will be obtained 4 See Figure 4 108 Aim nozzle toward possible sources of leak such as fuel injectors and intake tract 5 See Figure 4 107 Push valve 4 to release propane Tone of engine will change when propane enters s...

Page 433: ...y disengaging baseplate from rubber sealing ring 8 on velocity stack 7 f Remove baseplate from motorcycle INSPECTION 1 Inspect air cleaner Check for dirt torn filter material and general condition Replace if necessary 2 Inspect inside of backing plate and cover Remove any dirt or debris 3 Inspect condition of velocity stack and velocity stack sealing ring If torn or damaged replace 4 Inspect IAT s...

Page 434: ...e to sensor may occur 3 Insert longer breather hose into right baseplate grommet from underside 4 Attach shorter breather hose onto crankcase breather located on top of rear cylinder 5 Carefully lower baseplate into mounting position Ensure rubber sealing ring on velocity stack completely engages baseplate Baseplate should be sandwiched between upper and lower rubber sealing rings Figure 4 111 Bas...

Page 435: ...nstall intake cover assembly See 2 35 INTAKE COVER ASSEMBLY 1WARNING 1WARNING 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 70 11 Install seat See 2 41 SEAT Figure 4 112 Airbox Typical XB9S 1 Airbox cover 2 Air...

Page 436: ...t washer 4 Actuator interactive exhaust 5 Harness interactive exhaust 6 Cable bracket 7 Interactive exhaust cable 8 Upper isolator 9 Cover air cleaner 10 Filter element 11 Air cleaner seal 12 Intake snorkel 13 Shoulder screw 4 14 Base plate assembly 15 Breather hoses front and rear 2 3 4 15 14 12 13 1 8 10 9 11 6 7 5 16 ...

Page 437: ...ugh the canister vent hose These vapors pass through the throttle body manifold and are burned as part of normal combustion in the engine TROUBLESHOOTING 1WARNING 1WARNING Verify that the evaporative emissions system hoses do not contact hot exhaust or engine parts The hoses con tain flammable vapors that can be ignited if damaged which could result in death or serious injury The system has been d...

Page 438: ...Figure 4 116 Slide canister into position on canister mounting plate and push towards front of vehicle 1WARNING 1WARNING Always make sure fuel hoses are seated against the com ponent they connect to and that hose clamps are prop erly tightened and positioned on straight section of fitting and not on the fitting barb Failure to comply may result in fuel leakage which could result in death or seri o...

Page 439: ...ING 1WARNING Always make sure fuel hoses are seated against the com ponent they connect to and that hose clamps are prop erly tightened and positioned on straight section of fitting and not on the fitting barb Failure to comply may result in fuel leakage which could result in death or seri ous injury Figure 4 117 Emissions Hose Attachment California Models Only 8756 ...

Page 440: ...Electric Starter System 5 2 5 3 Starting System Diagnosis 5 4 5 4 Starter Activation Circuits 5 8 5 5 Diagnostics Troubleshooting 5 9 5 6 Starter System Testing 5 11 5 7 Starter 5 12 5 8 Starter Solenoid 5 21 Table Of Contents ELECTRIC STARTER 5 ...

Page 441: ......

Page 442: ...4 V Stall torque 8 ft lbs 11 Nm min 2 4 V Table 5 2 Service Wear Specifications SERVICE WEAR LIMITS IN MM Brush length minimum 0 433 11 0 Commutator diameter minimum 1 141 28 981 ITEM TORQUE NOTES Battery terminal fasteners 72 96 in lbs 8 11 Nm page 5 19 Starter battery positive cable 60 85 in lbs 7 10 Nm page 5 19 Starter mounting bolts 13 20 ft lbs 18 27 Nm page 5 19 ...

Page 443: ...ctivated and battery current flows into the pull in winding 10 and the hold in winding 11 to ground The magnetic forces of the pull in and hold in windings in the solenoid push the plunger 7 causing it to shift to the left This action engages the pinion gear 1 with the clutch ring gear 13 At the same time the main solenoid contacts 8 are closed so battery current flows directly through the field w...

Page 444: ...iring diagram Starting circuit see wiring diagram 1 Pinion gear 2 Idler gear 3 Field winding 4 Armature 5 Brush 6 Ball bearing 7 Solenoid plunger 8 Main solenoid contacts 9 Battery 10 Pull in winding 11 Hold in winding 12 Overrunning clutch 13 Clutch ring gear Starter at moment starter switch is closed Starter during cranking ...

Page 445: ...1x5x STARTER RUNS ON YES 5822 Check battery using visual inspection voltage test and load test Check connections at battery and starter components Is system operational STARTER SPINS BUT DOES NOT ENGAGE YES STARTER STALLS OR SPINS TOO SLOWLY YES Check for audible clicking noise NO Solenoid clicks See Starter Test 2 Solenoid Clicks Relay clicks See Starter Test 3 Relay Clicks Nothing clicks See Sta...

Page 446: ...NO Repair connection between battery and starter YES Clean ground connections YES Repair or replace solenoid contacts NO 5824 5845 5824 NO Go to Starter Test 3 Relay Clicks Begin with box marked with bold asterisk STOP 1 1 2 1 1 Does starter motor turn if jumped YES Test for voltage at solenoid relay terminal on starter Is 12V present when starter button is pressed Test for voltage to relay Is 12V...

Page 447: ...nnector 22 Battery voltage present with starter button pressed NO Substitute good relay or test relay YES NO Substitute good starter relay or test relay YES Check for battery voltage to starter button W BK wire at connector 22 Battery voltage present NO Repair wiring from starter button to relay YES Repair wiring to starter button NO Replace right han dlebar switchgear YES 5831 5816 5831 Inspect S...

Page 448: ...s from battery positive to starter motor terminal Crank engine Voltage greater than 1 volt NO Repair connection between battery and starter YES Repair or replace solenoid contacts NO Perform voltage drop tests between battery negative and starter studs or bolts Voltage greater than 1 volt Clean ground connections YES Perform starter motor current draw test on vehicle Perform starter motor free dra...

Page 449: ... 1A 150A 20A 20A 0 1A 150A 15A 0 1A 0 1A 0 1A 0 1A 0 1A 0 1A 0 1A VDC ITEM A IDEAL CLOSED CIRCUIT GROUND CIRCUIT OPEN CIRCUIT b0157a5x OV VDC 12V OV ITEM B ITEM C ITEM D 1 Battery 2 Main fuse 30 A 3 Key switch fuse 4 Key switch 5 Run Stop switch 6 Ignition relay used for junction purposes only 7 Ignition fuse 8 Key switch relay 9 Start switch 10 Start relay 11 Solenoid 12 Starter VDC 6 12 11 3 7 8...

Page 450: ...n the meter 6 Typically a good circuit will drop less than 1 volt 7 If the voltage drop is greater back track through the con nections until the source of the potential difference is found The benefit of doing it this way is speed a Readings aren t as sensitive to real battery voltage b Readings show the actual voltage dropped not just the presence of voltage c This tests the system as it is actua...

Page 451: ...GY O R R BK R LOCK R Y BK TN LT GN R GY O TN Y BK BK GN R R Y TN Y R BK R BK R BK GN R BK TN LT GN BK R GY O GY O BK W BK R R BK TN LT GN W BK 10 5 3 3 3 5 5 5 4 4 4 2 2 2 1 1 1 3 IGNITION KEY SW START 4 7 8 15 6 13 9 14 2 19 11 1 1 1 2 2 2 IGN 3 3 3 4 4 4 1 1 2 DIODE BATTERY IGNITION KEY SWITCH 131A 1 0 B D C A 0 0 1 R 1 USER USER 1 R BK R GY BATTERY BATTERY 1 R 0 0 0 PARK KEY POSITION IGNITION S...

Page 452: ...Engine temperature should be stable and at room tem perature Battery should be fully charged See Figure 5 7 Check starter current draw with an induction ammeter before disconnecting battery Proceed as follows 1 Verify that transmission is in neutral Disconnect spark plug wires from spark plug terminals 2 Clamp induction ammeter over positive battery cable next to starter 3 With ignition key switch...

Page 453: ...er See 2 31 SPROCKET COVER NOTE A ball hex driver may be required to gain access to the starter mounting bolts 5 See Figure 5 8 Remove two starter mounting bolts and washers 1 6 See Figure 5 9 Remove fastener with washer 1 met ric a Remove protective boot b Remove positive battery cable ring terminal 2 c Detach solenoid wire 3 7 Remove starter and gasket from the gearcase cover side Figure 5 8 Sta...

Page 454: ...blem with engine or primary drive Starter Solenoid NOTE Do not disassemble solenoid Before testing disconnect field wire from motor terminal as shown in Figure 5 11 CAUTION Each test should be performed for only 3 5 seconds to prevent damage to solenoid NOTE The solenoid Pull in Hold in and Return tests must be per formed together in one continuous operation Conduct all three tests one after the o...

Page 455: ...inion does not remain in pull in position replace the solenoid Solenoid Return Test 1 See Figure 5 13 With test leads still connected in the manner specified at the end of the previous SOLENOID HOLD IN TEST disconnect solenoid relay terminal positive battery post test lead C at either end 2 Observe starter pinion a If starter pinion returns to its original position sole noid is working properly b ...

Page 456: ... 141 in 28 981 mm c Check armature bearings Replace if necessary CAUTION Do not use sandpaper or emery cloth to remove burrs on commutator Otherwise abrasive grit may remain on commutator segments this could lead to excessive brush wear Use only the recommended crocus cloth NOTE See Figure 5 17 If an undercutting machine is not available undercutting can be done satisfactorily using a thin hacksaw...

Page 457: ...Mica must not be left with a thin edge next to segments RIGHT WAY Mica Undercutting mica with piece of hacksaw blade WRONG WAY Starting groove in mica with 3 cornered file Mica must be cut away clean between segments b0136x5x Mica Segments Segments ...

Page 458: ...y commutator segment 1 b Touch the other probe to the armature core 2 c There should be no continuity infinite ohms If there is continuity then the armature is grounded Replace grounded armatures 11 See Figure 5 20 Check for OPEN ARMATURE with an ohmmeter or continuity tester a Check for continuity between all commutator seg ments 1 b There should be continuity 0 ohms at all test points No continu...

Page 459: ...f there is no continuity at either brush then the field coil s are open and the field frame must be replaced 14 See Figure 5 23 Test BRUSH HOLDER INSULATION with an ohmmeter or continuity tester a Touch one probe to holder plate 1 b Touch the other probe to each of the positive insu lated brush holders 2 c There should be no continuity infinite ohms If there is continuity at either brush holder re...

Page 460: ... 10 Nm d Replace protective boot 3 See Figure 5 26 Install both starter mounting bolts and washers Tighten to 13 20 ft lbs 18 27 Nm 4 Install sprocket cover See 2 31 SPROCKET COVER 5 Install primary cover See 6 2 PRIMARY COVER 1WARNING 1WARNING Always connect the positive battery cable first If the pos itive cable should contact ground with the negative cable installed the resulting sparks may cau...

Page 461: ...ing bolt 10 Drive housing 11 Solenoid housing 12 Drive assembly Overrunning clutch 13 Idler gear 14 Idler gear roller 5 15 Idler gear Bearing cage 16 O ring 17 Return spring 18 Ball 19 Gasket 20 Washer 2 21 Mounting bolt 2 22 Field wire 23 O ring 2 24 Field wire nut with washer metric b0004a5x 21 20 19 10 16 12 18 11 9 15 13 14 17 8 6 8 23 1 23 4 24 22 2 3 5 7 ...

Page 462: ...linder con taining a movable plunger DISASSEMBLY 1 See Figure 5 28 Remove screws 1 and clip 2 2 Remove cover 3 and gasket 4 Discard gasket 3 Remove plunger 5 from solenoid housing 6 ASSEMBLY 1 See Figure 5 28 Replace wire connection hardware as necessary 2 Install plunger 5 in solenoid housing 6 3 Install new gasket 4 onto cover 3 4 Position cover with gasket onto solenoid housing Install clip 2 a...

Page 463: ...HOME NOTES ...

Page 464: ...ission 6 25 6 8 Case Disassembly For Transmission Removal 6 26 6 9 Transmission Disassembly 6 29 6 10 Transmission Assembly 6 36 6 11 Main Drive Gear 6 38 6 12 Transmission Right Case Bearings 6 41 6 13 Transmission Left Case Bearings 6 43 6 14 Transmission Installation 6 44 6 15 Shifter Shaft 6 48 6 16 Transmission Sprocket 6 49 Table Of Contents DRIVE TRANSMISSION 6 ...

Page 465: ......

Page 466: ...at 25 000 mi 40 000 km Rear wheel sprocket number of teeth 65 Inspect at 25 000 mi 40 000 km Secondary drive belt number of teeth 128 Replace at 25 000 mi 40 000 km Table 6 3 Transmission ITEM NEW COMPONENTS 984 NEW COMPONENTS 1200 Primary drive transmission lubricant capacity approximately Approximately 32 fl oz 946 ml Overall gear ratios First gear low 10 85 9 71 Second gear 7 47 6 67 Third gear...

Page 467: ...rs 15 19 ft lbs 20 3 25 Nm LOCTITE 262 red page 6 47 Engine sprocket nut 190 210 ft lbs 257 6 284 7 Nm page 6 19 Front sprocket cover fasteners 12 36 in lbs 1 4 4 0 Nm page 6 23 Idler pulley wheel fastener 20 23 ft lbs 27 1 31 2 Nm page 6 24 Negative battery cable at battery terminal 72 96 in lbs 8 11 Nm page 6 6 6 8 Primary cover fasteners 80 110 in lbs 9 12 4 Nm Follow torque sequence page 6 6 P...

Page 468: ...ise to remove tension on primary chain 8 Remove three TORX screws with washers and clutch inspection cover 10 See Figure 6 2 Remove the outer ramp and hook 1 from the cable end 3 and coupling 2 Remove cable end from slot in coupling See 6 3 CLUTCH RELEASE MECHANISM 11 Remove screws which secure primary cover Remove cover and gasket 12 Discard gasket 13 Remove and discard shifter lever oil seal 14 ...

Page 469: ...y cover 4 Gasket 5 Cover 6 Sems screw 5 7 Inspection cover gasket 8 Inspection cover 9 Lever 10 Screw 11 Rubber shift lever pad 12 Linkage assembly 13 Shifter linkage assembly bolt 14 Flange head bolt 15 Shift brake lever sleeve 16 Pedal bearing 2 17 Bolt 18 Shifter lever 19 Oil seal 20 Sems screw 14 21 Adjuster assembly 22 Chain adjustment nut 23 O ring 24 Drain plug 20 23 ...

Page 470: ...of shoe Slide shoe over plate until plate is against closed blind side of shoe 5 Position adjuster inside primary cover 4 with closed side of shoe against cover Thread adjuster screw 2 all the way into tapped boss at bottom of primary cover 6 At outside of cover thread locknut 3 onto adjuster screw with nylon sealing surface toward cover A 1 4 inch allen wrench may be inserted into end of adjuster...

Page 471: ...nd three TORX screws with washers Tighten screws in a crosswise pattern to 84 108 in lbs 9 5 12 2 Nm 12 Install rubber washer and shifter lever assembly 2 13 After applying LOCTITE 272 red tighten engine lever pinch screw 3 to 48 60 in lbs 5 4 6 8 Nm 14 Install left footpeg support bracket See 2 30 FOOTPEG HEEL GUARD AND MOUNT 15 Install chin fairing See 2 34 CHIN FAIRING 11WARNING 1WARNING Always...

Page 472: ...sting screw is turned ramp assembly moves forward Unscrew nut 6 from end of adjusting screw 7 Remove hook of ramp from cable end coupling 10 Remove cable end from slot in coupling 8 Remove and discard retaining ring from ramp assembly to separate inner and outer halves Remove three balls from ramp sockets CLEANING AND INSPECTION 1 Thoroughly clean all parts in cleaning solvent 2 See Figure 6 6 Ins...

Page 473: ...s tance is felt c Adjust clutch release mechanism See 6 3 CLUTCH RELEASE MECHANISM d Fit nut hex into recess of outer ramp e Install clutch adjusting lockplate and spring 4 Install clutch inspection cover and new gasket with three TORX screws with washers Tighten in a crosswise pat tern to 84 108 in lbs 9 5 12 2 Nm 5 Adjust clutch cable See 1 9 CLUTCH 11WARNING 1WARNING Always connect positive bat...

Page 474: ...r from the engine will be transmitted to the rear wheel When the clutch is disengaged clutch lever pulled to left han dlebar grip the pressure plate is pulled outward by clutch cable action against the diaphragm spring thereby com pressing the diaphragm spring With the pressure plate retracted strong inward force no longer squeezes the clutch plates together The fiber plates are now free to rotate...

Page 475: ...at 11 Diaphragm spring separate spring for XB9S XB12S 12 Retaining ring 13 Release plate 14 Retaining ring 15 Bearing 16 Adjusting screw 17 Pressure plate 18 Friction plate paper 7 19 Steel plate 7 20 Friction plate narrow 21 Damper spring 22 Damper spring seat 23 Mainshaft nut 24 Washer 25 Clutch hub 26 Inner thrust washer 27 Needle bearing Inner race 28 Needle bearing 29 Clutch shell and sprocke...

Page 476: ...ridge of SPRING COMPRESSING TOOL Part No HD 38515 A against diaphragm spring c Install bearing and washer CAUTION See Figure 6 11 Turn compressing tool handle only the amount required to release spring seat and remove snap ring Excessive compression of diaphragm spring could damage clutch pressure plate 5 See Figure 6 11 Remove pressure plate assembly a Place a wrench on the clutch spring forcing ...

Page 477: ... reassemble adjusting screw assembly in reverse order s 4 Install adjusting screw assembly into pressure plate a See Figure 6 34 Align two tabs on perimeter of release plate with corresponding recesses 3 in pressure plate b Secure the adjusting screw assembly with new retaining ring Figure 6 12 Adjusting Screw Assembly 1 2 3 4 5 6 7 8 9 1 Retaining ring 2 Spring seat 3 Diaphragm Spring 4 Retaining...

Page 478: ...006 in 0 15 mm 4 Inspect the damper spring for cracks or distortion Install a new spring if either condition exists 5 See Figure 6 14 Check fiber plates for thickness a Wipe the lubricant from the eight fiber plates 7 reg ular and 1 narrow and stack them on top of each other b Measure the thickness of the eight stacked fiber plates with a dial caliper or micrometer The mini mum thickness must be 0...

Page 479: ...ring seat and snap ring Excessive compression of diaphragm spring could damage clutch pressure plate b See Figure 6 19 Install SPRING COMPRESSING TOOL Part No HD 38515 A onto clutch hub against diaphragm spring c Place a wrench on the clutch spring forcing screw flats to prevent the forcing screw from turning d Turn compressing tool handle clockwise until dia phragm spring compresses just enough t...

Page 480: ...Tighten fastener to 60 96 in lbs 6 8 10 9 Nm 11WARNING 1WARNING Pull up on seat to verify that it is properly secured front and rear A loose seat may shift during vehicle operation and startle the rider possibly causing loss of vehicle control resulting in death or serious injury 11 Install seat See 2 41 SEAT Figure 6 19 Pressure Plate Assembly Figure 6 20 Clutch Adjusting Screw Assembly and Retai...

Page 481: ...ION FLUID under 1 9 CLUTCH 3 Remove primary cover See 6 2 PRIMARY COVER 4 Loosen engine sprocket a See Figure 6 21 Install SPROCKET LOCKING LINK Part No HD 38362 b Remove the engine sprocket nut c Loosen but do not remove engine sprocket If neces sary use the slotted portion of TWO CLAW PULLER Part No HD 97292 61 and two bolts to loosen the engine sprocket 5 See Figure 6 13 Remove adjusting screw ...

Page 482: ...ing release plate and adjusting screw See ADJUSTING SCREW DISASSEMBLY ASSEMBLY under 6 4 CLUTCH 6 Remove clutch hub from clutch shell Inspect primary chain sprocket and the starter ring gear on the clutch shell 7 Inspect slots that mate with the clutch plates on both clutch shell and hub 8 See Figure 6 23 Inspect the clutch shell compensating spring set 9 See Figure 6 24 Inspect clutch shell needl...

Page 483: ...26 4 Place new needle bearing onto installer end of tool and insert the bearing guide to prevent the bearing from fall ing off during installation and to align bearing with clutch shell 5 See Figure 6 29 Place clutch shell on support blocks with sprocket side facing up 6 Press bearing into clutch shell until tool bottoms on the shell This will be the correct installed height Figure 6 26 Clutch She...

Page 484: ... 4 is installed on trans mission shaft 4 Install the engine sprocket clutch assembly and primary chain as a unit into primary chaincase 5 See Figure 6 31 Install the engine sprocket nut a Install SPROCKET LOCKING LINK Part No HD 38362 b Apply two or three drops of LOCTITE 262 red onto threads of sprocket shaft c Install engine sprocket nut Tighten to 190 210 ft lbs 257 6 284 7 Nm CAUTION See Figur...

Page 485: ...1 9 CLUTCH 12 Add SPORT TRANS FLUID See TRANSMISSION FLUID under 1 9 CLUTCH 11WARNING 1WARNING 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 13 Connect negative battery cable to battery terminal Tighten fastener to 60 96 in lb...

Page 486: ... 10 DRIVE BELT Figure 6 35 Proper Drive Belt Handling CAUTION Mishandling drive belt will result in premature failure For maximum strength integrity and longevity avoid over bending A and B twisting C crimping pinch ing or kinking D and prying E A B C D E Forward bend must not be less than 5 in 127 mm Reverse bend must not be less than 10 in 254 mm Do not twist Do not crimp pinch or kink Do not pr...

Page 487: ...allow partial tension to be removed from rear drive system 7 Remove idler pulley assembly by removing nuts and washers See IDLER PULLEY REMOVAL in 6 6 DRIVE BELT SYSTEM 8 Remove swingarm brace See 2 19 SWINGARM AND BRACE 1CAUTION When removing or installing belt do not bend or twist belt partially slide belt onto sprocket and roll wheel or belt damage will occur 9 Slide belt from sprocket and remo...

Page 488: ...e together until belt teeth are fully seated in rear sprocket 7 While keeping tension on lower belt install idler pulley assembly tightening washers and nuts to 33 35 ft lbs 45 47 Nm See IDLER PULLEY INSTALLATION in 6 6 DRIVE BELT SYSTEM 8 See Figure 6 38 Tighten rear axle 1 to 23 27 ft lbs 31 2 36 6 Nm back off two full turns and then retighten to 48 52 ft lbs 65 1 70 5 Nm 9 Tighten rear axle pin...

Page 489: ...ee Figure 6 42 Install new or existing pulley wheel 1 if removed and tighten washer and nut 2 wheel fas tener 6 to 20 23 ft lbs 27 1 31 2 Nm 2 Slide idler pulley bracket 4 washer and nuts 5 on to studs 3 and tighten to 33 35 ft lbs 45 47 Nm See DRIVE BELT INSTALLATION 3 Install front sprocket cover See 2 31 SPROCKET COVER 4 Install chin fairing fasteners and tighten to 36 48 in lbs 4 5 Nm See 2 34...

Page 490: ...e crankcase 4 1 3 2 5 4 1 3 2 5 4 1 3 2 5 4 1 3 2 5 4 1 3 2 5 4 1 3 2 5 Neutral Power flow Sliding member Countershaft Mainshaft Out 1st Gear Countershaft Mainshaft In Countershaft Mainshaft Out 2nd Gear Countershaft Mainshaft In 4th Gear Countershaft Mainshaft In Out 5th Gear Countershaft Mainshaft Out In b1068x6x 3rd Gear In ...

Page 491: ...t No HD 42310 HD 43646 or HD 43682 4 Disassemble top end See 3 6 CYLINDER HEAD 5 Disassemble gearcase See 3 16 GEARCASE COVER AND CAM GEARS 6 Remove primary cover See 6 2 PRIMARY COVER 7 Remove clutch assembly primary chain and engine sprocket See 6 4 CLUTCH 8 See Figure 6 44 Place transmission in 1st gear Remove countershaft TORX screw 1 and retention collar 2 9 See Figure 6 45 Place transmission...

Page 492: ...he shifter drum at the 12 o clock position for later reference 15 See Figure 6 50 Place transmission in 4th gear The scribed line should now be at the 6 o clock position NOTE Transmission can be easily shifted by rotating the mainshaft and shifter drum at the same time by hand Figure 6 46 Removing Shifter Shaft Assembly Figure 6 47 Shifter Shaft Assembly Figure 6 48 Rear Isolator Assembly 8617 1 S...

Page 493: ...t main bearing by hand No tools are required for this operation 18 See Figure 6 53 Remove the flywheel assembly from left crankcase half Figure 6 51 Crankcase Fasteners D b1016x3x Indicates Bolt Pattern Location 14 fasteners One Behind Shifter Mechanism Figure 6 52 Separating Crankcase Halves 8621 Figure 6 53 Removing Flywheels from Left Case Half 8636 ...

Page 494: ...hat each shifter fork be reinstalled in its original location 1 See Figure 6 54 Remove shifter fork shafts NOTE Carefully tap on alternate sides of the shaft using the pro vided slots 2 See Figure 6 55 Remove shifter drum and shifter forks 3 Remove mainshaft 2nd gear from mainshaft Figure 6 54 Removing Shifter Fork Shafts Figure 6 55 Transmission Assembly 1 Slots for removing the shifter fork shaf...

Page 495: ...th 9 Fork assembly shifter 4th 10 Pin shifter stop 11 Spring shifter return 12 Spring extension 13 Shifter lever assembly 14 Lever engine 15 Bolt engine lever 16 Bearing shift lever assembly 2 17 Shift lever 18 Bolt linkage assembly 19 Sleeve shift brake lever 20 Bolt shift lever 21 Pad rubber shift lever 22 Linkage assembly shifter 23 Bolt linkage assembly 5 16 6 3 8 2 1 4 4 9 7 13 12 11 10 15 14...

Page 496: ...trans mission assembly 4 from engine stand a Place crankcase half 3 and transmission assembly 4 on arbor press 1 and support transmission assembly on parallel supports 5 b Press transmission assembly using TRANSMIS SION REMOVER 2 Part No B 43895 1 to remove transmission assembly from crankcase half c Remove crankcase from press Figure 6 58 Removing Transmission Assembly from Left Case Half 1 Arbor...

Page 497: ...ee Figure 6 59 As each component is removed place it on a clean surface in the exact order of removal Figure 6 59 Transmission Parts Identification b0948x6x Figure 6 60 Transmission Assembly Right Crankcase Half 1 Bearing Inner 2 Fifth gear mainshaft 3 Bearing Outer 4 Oil seal 5 Right crankcase half 6 Ball bearing 7 Retaining ring 8 Quad seal 9 Spacer 10 Oil seal 11 Bearing closed end shifter drum...

Page 498: ...g 7 10 First gear mainshaft 11 Third gear mainshaft 12 Second gear mainshaft 13 Spacer 14 Fourth gear countershaft 15 First gear countershaft 16 Countershaft 17 Third gear countershaft 18 Second gear countershaft 19 Fifth gear countershaft 20 Bearing 21 Retaining ring 22 Countershaft retainer 23 Screw b1014x6x 14 13 3 2 1 20 21 22 23 9 8 9 19 18 6 8 9 17 16 9 8 15 6 12 9 8 11 6 8 9 10 9 8 7 6 5 4 ...

Page 499: ... 3 Slide thrust washer 8 off end of mainshaft 4 Expand retaining ring 7 which is next to mainshaft 1st gear 6 and slide off end of shaft 5 Remove mainshaft 1st gear 6 6 Expand retaining ring 5 and remove Cleaning And Inspection 11WARNING 1WARNING Never use compressed air to spin dry bearings Spin ning bearings with compressed air can also cause a bearing to fly apart which could result in death or...

Page 500: ...and retaining ring 10 located next to countershaft 1st gear 11 Remove retaining ring 10 and thrust washer 11 a Slide countershaft 1st gear 13 off end of shaft b Remove split bearing 12 4 Remove thrust washer 14 Expand remaining retaining ring 15 and slide off countershaft Cleaning And Inspection 11WARNING 1WARNING Never use compressed air to spin dry bearings Spin ning bearings with compressed air...

Page 501: ...aft first gear Part No 35762 89A to accommodate the new style shifting fork and has a new part number 3 See Figure 6 65 Install new retaining ring 3 a Install thrust washer 4 onto mainshaft b Install split bearing 5 onto mainshaft c Install mainshaft 3rd gear 6 onto shaft over bearing 5 3rd gear is installed with shifting lugs away from 1st gear mainshaft 4 Install thrust washer 7 and new retainin...

Page 502: ... 1st gear 3 6 Install new retaining ring 8 on countershaft Position new retaining ring in the second ring groove from the end Install thrust washer 9 next to retaining ring 8 Install split bearing 10 in seat next to washer 9 5 Install countershaft 2nd gear 11 with the locking dogs facing countershaft 3rd gear 7 6 Install countershaft 5th gear 12 on countershaft 7 Install new retaining ring 13 on c...

Page 503: ...d 5th gear 3 CAUTION When removing the main drive gear the gear is pressed out against the resistance of the bearing inner race Without any support at the inner race the bearing is destroyed Whenever the main drive gear is removed the main drive gear bearing will also have to be replaced 7 At outside of case place driver 4 and thrust washer 5 over end of bolt 2 Install and tighten nut 6 until 5th ...

Page 504: ...8 001 7 239 mm c Press in the inner bearing to a depth of 0 080 in 2 032 mm INSTALLATION 1 Replace main drive gear bearing 2 See Figure 6 71 Use MAIN DRIVE GEAR REMOVER AND INSTALLER Part No HD 35316 A for assembly a Take bolt 2 and place washer 5 followed by main drive gear 4 over end of bolt b From inside of case insert bolt and main drive gear through inner race of ball bearing c Insert threade...

Page 505: ...MAIN DRIVE GEAR SEAL INSTALLER Part No HD 41496 to gently tap seal into bore of case until the outside of seal is flush with outer edge of bore NOTE It is acceptable to recess seal to about 0 030 in 0 762 mm below outer edge of bore Seal will be controlled by tool Figure 6 72 Main Drive Gear Assembly 1 Main drive gear 2 Needle bearing 2 3 Seal b1069x6x 2 3 1 Figure 6 73 Transmission Assembly Right...

Page 506: ...e install beveled retaining ring in groove inside bearing bore with beveled side facing outside of case 4 Lubricate bearing with SPORT TRANS FLUID Countershaft Needle Bearing 1 Find a suitable bearing driver 1 1 4 in 31 75 mm in diameter 2 See Figure 6 73 From the outside of the case place the needle bearing open end first next to the bearing bore Hold the driver squarely against the closed end of...

Page 507: ...g 7 10 First gear mainshaft 11 Third gear mainshaft 12 Second gear mainshaft 13 Spacer 14 Fourth gear countershaft 15 First gear countershaft 16 Countershaft 17 Third gear countershaft 18 Second gear countershaft 19 Fifth gear countershaft 20 Bearing 21 Retaining ring 22 Countershaft retainer 23 Screw b1014x6x 14 13 3 2 1 20 21 22 23 9 8 9 19 18 6 8 9 17 16 9 8 15 6 12 9 8 11 6 8 9 10 9 8 7 6 5 4 ...

Page 508: ... either side INSTALLATION Mainshaft and Countershaft Bearings 1 Place crankcase on press with inside surface of crank case downward 2 Lay bearing squarely over bore with printed side of bear ing upward Place a pressing tool slightly smaller than outside diameter of bearing against outer race Press bearing into bore until bearing bottoms against shoulder 3 Install new retaining ring with beveled si...

Page 509: ...case 4 See Figure 6 80 Press crankcase onto transmission assembly into until it bottoms out 5 Remove COUNTERSHAFT GUIDE ADAPTER Part No B 43985 4 6 Remove transmission assembly and left crankcase half from fixture 7 Re install transmission assembly and left crankcase half in engine stand 8 Install mainshaft 2nd gear with shifter fork groove towards mainshaft 3rd gear 9 Install shifter forks shafts...

Page 510: ...y scribed line at the 6 o clock position This will place the shifter drum in the 4th gear position 3 See Figure 6 82 Place the 3rd and 5th gear shifter fork on the appropriate mainshaft sliding gear and install the shifter fork shaft through the two installed shifter forks and into the left case half 4 Install the 1st and 2nd gear shifter fork on the appropri ate countershaft sliding gear and inst...

Page 511: ...HOME Figure 6 83 Crankcase Fasteners D b1016x3x Indicates Bolt Pattern Location One Behind Shifter Mechanism ...

Page 512: ...smission in the 4th gear position The scribed line on the shifting drum should be at 6 o clock 4 See Figure 6 87 Assemble crankcase halves together a Apply a thin coat of DOW CORNING SILASTIC 732 clear sealant to crankcase joint faces b Apply several drops of LOCTITE 262 red to last few threads c See Figure 6 83 Tighten 5 16 in fasteners to 15 19 ft lbs 20 3 25 Nm Figure 6 84 Installing Flywheel A...

Page 513: ...and release Ratchet arms should now be inside the end plate of the shifter drum contacting the shifter drum pins 3 See Figure 6 91 Position retention collar 2 next to end of countershaft with beveled side facing outward a Apply several drops of LOCTITE 243 blue to last few threads b Insert screw 1 through retention collar 2 and thread into end of shaft c Place transmission in gear and tighten TORX...

Page 514: ...gure 6 93 Place transmission in first gear Remove two socket head screws 1 and lockplate 2 CAUTION Transmission sprocket nut has left hand threads Turn nut clockwise to loosen and remove from main drive gear shaft 9 Remove transmission sprocket nut 3 from main drive gear 5 using MAINSHAFT LOCKNUT WRENCH Part No HD 94660 37B Use an air impact wrench for best results 10 Remove secondary drive belt f...

Page 515: ...icle opera tion If you cannot align lockplate and sprocket screw holes nut may be additionally tightened until screw holes align 9 See Figure 6 93 Install lockplate over nut so that two of lockplate s four drilled holes diagonally opposite align with sprocket s two tapped holes NOTE The lockplate has four screw holes and can be turned to either side so you should be able to find a position without...

Page 516: ... 6 6 DRIVE BELT SYSTEM 1CAUTION Never tighten rear axle with swingarm brace removed 17 See Figure 6 97 Tighten rear axle 1 to 23 27 ft lbs 31 2 36 6 Nm back off two full turns and then retighten to 48 52 ft lbs 65 1 70 5 Nm 18 Tighten pinch fastener 2 on right side of swingarm to 40 45 ft lbs 54 61 Nm Figure 2 96 Anti Seize Lubricant Location b1036x2x Figure 6 97 Rear Wheel Mounting Right Side 842...

Page 517: ...HOME NOTES ...

Page 518: ...3 7 11 Battery 7 35 7 12 Headlight 7 42 7 13 Tail Lamp 7 45 7 14 License Plate Lamp Assembly 7 46 7 15 Turn Signals 7 47 7 16 Turn Signal Flasher 7 50 7 17 Handlebar Switches 7 51 7 18 Speedometer Sensor 7 54 7 19 Instrument Module 7 55 7 20 Speedometer Performance Check 7 56 7 21 Horn 7 61 7 22 Neutral Indicator Switch 7 63 7 23 Main Fuse and Fuses 7 64 7 24 Main Wire Harness 7 65 7 25 Interactiv...

Page 519: ......

Page 520: ...ohms Table 7 6 Electrical System Specifications ELECTRICAL SYSTEM AMPERES Battery fuse 30 Ignition fuse 15 Light fuse 15 Accessory fuse 7 5 Brake horn active muffler fuse XB12S only 15 ECM fuse 7 5 Key switch fuse 15 Cooling fan fuse 7 5 Table 7 7 Specifications BULB CHART BULBS REQUIRED WATTS AMPS PART NUMBER Headlights Bulb H7 2 55 4 58 Y0148 1AD Position lamp European models only 1 5 0 37 53436...

Page 521: ... page 7 9 Intrument module fastener 12 36 in lbs 1 4 4 0 Nm page 7 55 Main battery ground 48 72 in lbs 5 4 8 1 Nm page 7 34 Negative battery cable at battery terminal 72 96 in lbs 8 11 Nm page 7 73 Neutral indicator switch 36 60 in lbs 4 6 8 Nm LOCTITE 243 blue page 7 63 Rotor mounting fasteners 90 110 in lbs 10 12 Nm LOCTITE 243 blue page 7 31 Spark plugs 11 18 ft lbs 15 24 Nm page 7 1 Stator TOR...

Page 522: ...gher degree of spark advance As the vehicle warms up to operating temperature the fuel mix On the XB12S an interactive exhaust system utilizes an actu ator valve in the muffler which is connected to a servo motor via a cable The valve position automatically adjusts to enhance engine performance Cooling fan actuation is controlled by the ECM With key ON fan turns on when engine cylinder head temper...

Page 523: ...n 7 Electronic control module ECM 8 Connector interactive exhaust system 9 Spark plug 2 10 Rear spark plug cable 11 Mounting fastener 12 Wireform cable guide 13 Ignition coil 14 Front spark plug cable 15 Engine mount 16 Seal 17 Trigger rotor 18 Trigger rotor bolt 19 Cam position sensor 20 Inner cover 1 2 3 5 6 7 4 18 17 9 10 11 19 13 12 14 20 15 16 9 8 ...

Page 524: ...th the LOCK and P positions The P position is located counter clockwise from the LOCK position and allows the rider to remove the key while leaving the lights on When the key is placed in the P position several indicator markers are or can be activated Refer to Table 7 9 Figure 7 2 Ignition Headlight Key Switch 1 ON position 2 OFF position 3 PUSH DETENT 4 LOCK position 5 PARKING LIGHT position 6 L...

Page 525: ... 22 handlebar wiring harnesses Instrument cluster 39 Horn 122 5 Remove horn 12 from horn mount 10 6 Cut cable strap 7 that loosely holds main wiring har ness 8 to the ignition switch 6 and disconnect ignition switch connector 33 Figure 7 3 Electrical Connectors Behind Windscreen 1 Turn signal flasher connector 30 2 Instrument cluster connector 39 3 Right handlebar connector 22 4 Left handlebar con...

Page 526: ...g the throttle cables 3 to your left the right side of the vehicle pull the ignition switch 4 toward you and roll the assembly away from you until the fork stop pin 5 is pointing down 10 Slide the ignition switch assembly out to your left the right side of the vehicle Figure 7 4 Ignition Switch 1 Socket head fastener 1 with spacer behind switch 2 Tamper resistant Torx fasteners 2 3 Throttle cables...

Page 527: ...on switch body rotate slot in ignition switch body with screw driver until proper installation can be achieved 2 Mate ignition switch to ignition switch body 3 Install ignition switch body fasteners 1 Tighten to 12 36 in lbs 1 4 4 0 Nm Figure 7 5 Ignition Switch Assembly b1132x7x 1 Body fastener 2 2 Body 3 Spacer 4 Housing 5 Ignition switch 6 Socket head fastener 7 Tamper resistant Torx fasteners ...

Page 528: ...iring har ness and the ignition switch 1WARNING 1WARNING 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 resulting in personal injury 8 Install negative battery cable to battery terminal Tighten fastener to 60 96 in lbs 6 8 10 8 Nm 1WARNING 1WARNING DO NOT modify the igniti...

Page 529: ...ric shock from the ignition system which could result in death or serious injury CAUTION When disconnecting each spark plug cable from its spark plug terminal always grasp and pull on the rubber boot at the end of the cable assembly as close as possi ble to the spark plug terminal Do not pull on the cable portion itself Pulling on the cable will damage the cable s carbon core 1 Remove airbox assem...

Page 530: ...plug boot See Figure 7 10 When assembling the spark plug boots onto the spark plugs make sure the boot is slid all the way down over the spark plug insulator The gap should not exceed 1 8 in 3 2 mm For spark plug information see 1 14 SPARK PLUGS 1 Connect spark plug cables to ignition coil and spark plugs Fasten boots caps securely Tight connections provide the necessary moisture proof environment...

Page 531: ...gaging the clutch and grounding through the clutch lever switch Once the starter circuit is grounded and the starter button pushed the starter relay can be energized The energized relay then permits the starter motor to crank the engine I Table 7 11 Starter Interlock Troubleshooting PROBLEM CHECK FOR CORRECTION Electric starter will not crank Battery problems See 7 11 BATTERY Inappropriate gear se...

Page 532: ...TGN Terminal 40 Terminal 34 Figure 7 12 Ohmmeter Diode Test Continuity Infinite ohms b0643x4x 1 2 21 22 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 2 6 7 10 87 87A 30 85 86 23 RELAY CENTER ISO ISO ISO KEY SW IGNITION START 39 40 41 42 43 44 33 34 35 36 37 38 21 22 23 24 25 26 28 29 30 31 32 27 Spare Diode Bk Hn Mflr Fan IGN Acces Key Sw Lights ECM Spare Empty Battery Neutral Swi...

Page 533: ...erminal Ground present Check for ground at TN Y wire on Diode Ground present YES Diode installed backwards Reverse polarity Replace diode YES Repair open on TN Y wire between neutral switch and Diode Replace neutral switch NO NO NO NO 5060 5061 5062 5063 5064 1 2 YES Depress starter button Does Starter work NO Select diode test function on multimeter See Figure 7 11 and 7 13 Place red lead on term...

Page 534: ...f clutch switch connector 95 Ground present YES Repair open on TN GN wire between connector 95 and starter relay NO Replace clutch switch Check for ground on BK wire of connector 95 Ground present NO Repair open on BK wire between connector 95 and ground 5073 5074 5075 YES Depress starter button Does Starter work NO System OK ...

Page 535: ...nplug the 2 place clutch switch connector 95 2 Test the switch using an ohmmeter a With clutch engaged 1 switch open the switch should show ohms infinite ohms b With clutch disengaged 2 switch closed the switch should show 0 ohms or little resistance 3 Replace the assembly with a new switch if necessary See 2 24 CLUTCH HAND LEVER Figure 7 14 Clutch Switch b0393x7x 1 Clutch engaged switch open 2 Cl...

Page 536: ...ty between the 30 and 87 termi nals A good relay shows continuity continuity tester lamp on or a zero ohm reading on the ohmmeter A malfunctioning relay will not show continuity and must be replaced 4 Replace the relay with a new relay if necessary Key Switch Relay See Figure 7 15 The key switch relay 1 is under the seat See Ignition Relay under 7 5 STARTER INTERLOCK for test ing procedure Battery...

Page 537: ...er Test flow charts under DIAG NOSTICS 3 Replace the diode by pulling it straight out Ensure it is installed in the correct direction Figure 7 17 Fuse Block contains diodes Figure 7 18 Fuse Blocks 8892 39 40 41 42 43 44 33 34 35 36 37 38 21 22 23 24 25 26 28 29 30 31 32 27 Spare Diode Bk Hn Mflr Fan IGN Acces Key Sw Lights ECM Spare Empty Battery b1166x4x ...

Page 538: ...educe back pressure so the engine can gain RPM quickly The exhaust enters 2 the muffler and flows 3 through the open valve 1 into chamber C 7 and then exits 8 2 In the mid range the valve is closed to increase acceler ation torque The exhaust flows 4 through chamber A around to chamber B and then through chamber C and exits 3 At high RPM the valve opens again to maximize horse power The exhaust en...

Page 539: ...HOME Figure 7 20 Interactive Control System XB12S 1 Isolator EVA upper 2 Cable 3 Harness with connector 161B 4 Cable bracket 5 Actuator 6 Isolator EVA lower 7 Air cleaner cover 6 7 3 b0064 1 2 4 5 ...

Page 540: ...able wheel on actuator 11 Remove actuator 12 Remove tree fastener securing interactive exhaust cable to inside of muffler bracket on right side NOTE It is necessary to remove interactive exhaust cable from muf fler with muffler only partially removed 13 Loosen jam nut and remove interactive exhaust cable from bracket on muffler 14 Remove interactive exhaust cable from cable wheel on muffler NOTE T...

Page 541: ...tuator 161B 6 Install upper isolator and route fuel vent line and install 7 Attach interactive exhaust cable to bracket and cable wheel on actuator and adjust See 1 17 INTERACTIVE EXHAUST CABLE XB12S 1WARNING 1WARNING 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 resultin...

Page 542: ...ich bolts to the engine crankcase Voltage Regulator See Figure 7 23 The voltage regulator is a series regulator with shunt control The voltage regulator combines the func tions of rectifying converting AC voltage to DC and regulat ing controlling voltage output TROUBLESHOOTING When the charging system fails to charge or does not charge at a satisfactory rate check the following Battery Check for a...

Page 543: ... 5308 Isolate damaged component or wiring FAIL PASS 5310 Isolate damaged wiring or excessive accessories Perform Milliampere Draw Test If applicable Perform Total Current Draw Test Record measurement NOTE Whenever a charging system component fails a test and is replaced re test the system to be sure the problem has been corrected Inspect regulator See Voltage Regulator Inspection FAIL Correct as r...

Page 544: ...was not operated for a long period 5316 Replace regulator From Test 7 7 Part 1 of 2 Perform Current and Voltage Output Test Record measurement and compare with Total Current Draw Test before proceeding FAIL PASS Perform AC Output Check 5312 Replace stator FAIL PASS Replace regulator Perform Current and Voltage Output Test Inspect rotor FAIL Replace rotor PASS Replace stator FAIL Damaged or slippin...

Page 545: ...NOID STARTER MOTOR 128A 46B 46A HD 3 PHASE STATOR REGULATOR VOLTAGE 77A 77B TO VOLTAGE REGULATOR GRD2 STARTER BATTERY BK 2 1 1 4 4 3 3 2 2 2 1 1 R BK R R Y BK 41 BATTERY 30A 35 FUSE RELAY ASSEMBLY 61B bs0021ax Battery Fuse BK BK R R Y BK 35B BK BK BK BK BK 35A ...

Page 546: ...r OFF before connect ing tester cables to the battery terminals Connecting tester cables with the load tester ON could cause a spark resulting in a battery explosion which could result in death or serious injury 1 See Figure 7 27 To check for this condition place load tester induction pickup or current probe pickup over bat tery negative cable 2 Disconnect stator wiring from voltage regulator wiri...

Page 547: ...or is not functioning prop erly Stator Check 1 Turn ignition key switch to OFF 2 See Figure 7 29 Connect an ohmmeter a Locate voltage regulator connector 46 under sprocket cover See 7 26 SPROCKET COVER WIR ING Disconnect from alternator stator wiring b Insert one ohmmeter lead into a stator socket c Attach the other lead to a suitable ground 3 Test for continuity with ohmmeter set on the RX1 scale...

Page 548: ... AC approximately 16 20 volts per 1000 RPM d Repeat test across stator sockets 2 3 and 1 3 2 Compare test results to specifications a If the output is below specifications charging prob lem could be a faulty rotor or stator b If output is good charging problem might be faulty regulator rectifier Replace as required 3 Check the output again as described under CURRENT AND VOLTAGE OUTPUT TEST on page...

Page 549: ...y is due in part to the magnetic force of the permanent rotor magnets Stator 1 See Figure 7 34 Disconnect stator wiring 4 from volt age regulator wiring at connector 5 46 under sprocket cover See 7 26 SPROCKET COVER WIRING 2 Remove cable straps holding stator wire to wire harness CAUTION Stator TORX screws contain a thread locking compound Do not reuse existing screws Always use new screws with th...

Page 550: ...reuse existing screws Always use new screws with the proper thread locking compound Loss of torque on TORX fasteners could result in alternator damage 3 Position stator 2 on left crankcase half Secure stator using four new TORX screws 1 Tighten TORX screws to 30 40 in lbs 3 4 Nm 4 Route stator wiring 4 behind rear cylinder and in front of transmission breather hose See 7 26 SPROCKET COVER WIRING f...

Page 551: ...ove fasteners 5 and voltage regulator 4 from bracket 3 INSTALLATION 1 See Figure 7 37 Attach new voltage regulator 4 to bracket 3 Tighten new fasteners 5 to 48 60 in lbs 5 4 6 8 Nm 2 Connect stator connector 46 1 and voltage regulator connector 77 2 located under sprocket cover See 7 26 SPROCKET COVER WIRING 3 Connect negative battery cable to battery terminal 1WARNING 1WARNING After installing se...

Page 552: ...52 4 mm above the point where it enters the main harness bundle NOTE This is to allow a splice to be made for the new positive cable to be installed INSTALLATION 1 Clean cable connectors and battery terminals using a wire brush or sandpaper to remove any oxidation 1WARNING 1WARNING Always connect positive battery cable first If the positive cable should contact ground with the negative cable insta...

Page 553: ...ten fastener to 60 85 in lbs 7 10 Nm b See Figure 7 39 Attach negative cable to frame Tighten to 48 72 in lbs 5 4 8 1 Nm 4 Apply light coat of petroleum jelly or corrosion retardant material to both battery terminals Figure 7 40 Positive Battery Cable Protective Boot Not Shown 8742 1 Fastener with washer 2 Positive battery cable 1 2 ...

Page 554: ...getable oil or beaten eggs Call doctor immediately Eyes Flush with water get immediate medical attention Figure 7 41 Battery Warning Label Location M A D E I N U S A HARLEY D AVID SON M ILW AUKEE W I 53201 M ADE IN U S A WAR RAN TY AN DAD JU ST MEN TPO LICY Thisba tte ry willbe replac ed witho ut ch arge iffoun dto be de fectivein materialsor workm an sh ip 12 mon thsfrom da te of vehiclepu rcha s...

Page 555: ...ter OFF before connect ing the tester cables to the battery terminals Connecting tester cables with the load tester ON could cause a spark resulting in a battery explosion which could result in death or serious injury 3 Connect tester leads to battery posts and place induction pickup over negative black cable See Figure 7 44 CAUTION To avoid load tester and or battery damage do not leave the load ...

Page 556: ... terminal 4 Unhook battery strap from frame 5 Remove battery CLEANING AND INSPECTION 1 Battery top must be clean and dry Dirt and electrolyte on top of the battery can cause battery to self discharge Clean battery top with a solution of baking soda sodium bicarbonate and water 5 teaspoons baking soda per quart or liter of water When the solution stops bubbling rinse off the battery with clean wate...

Page 557: ...C during charging discontinue charging and allow the battery to cool Overheating may result in plate distortion internal shorting dryout or 1 Perform a voltmeter test to determine the state of charge See BATTERY TESTING If battery needs to be charged proceed to step 2 CAUTION Always remove the battery from the motorcycle before charging Accidental electrolyte leakage will damage motorcycle parts 2...

Page 558: ...s 1 hour 40 minutes 50 minutes The figures listed above assume that the battery is charging at room temperature If warmer than room temperature use a slightly shorter charging time If colder use a slightly longer charging time The use of constant current chargers to charge sealed maintenance free batteries is not recommended Any overcharge will cause dry out and premature battery failure If a cons...

Page 559: ...esult in death or serious injury CAUTION Overtightening fasteners can damage battery terminals 2 Insert fastener through battery positive cable red into threaded hole of battery positive terminal Tighten fastener to 72 96 in lbs 8 11 Nm 3 Insert fastener through battery negative cable black into threaded hole of battery negative terminal Tighten fastener to 72 96 in lbs 8 11 Nm 4 Apply a light coa...

Page 560: ...e and the battery s state of charge Batteries discharge at a faster rate at higher ambient temperatures To reduce the self discharge rate store battery in a cool not freezing dry place See Fig ure 7 45 Charge the battery every month if stored at temperatures below 60 F 16 C Charge the battery more frequently if stored in a warm area above 60 F 16 C NOTE The H D Battery Tender Automatic Battery Cha...

Page 561: ...mbly For information on headlight housing and bracket disas sembly assembly see 2 25 HEADLIGHT ASSEMBLY AND SUPPORT BRACKET NOTE Low beam does not remain on when high beam is activated Only one headlight remains on at any given time unless the passing lamp switch is depressed while low beam is activated causing the high beam to temporarily flash Figure 7 46 Headlight Assembly Rear View 3 4 1 Headl...

Page 562: ...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 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 housin...

Page 563: ...HOME Figure 7 48 Headlight Housing 20º Alignment Marks for Rubber Boot Wiring Harness Guides or Spigots 10525 10526 ...

Page 564: ...sult in death or serious injury 3 Check tail lamp for proper operation If operation fails reread procedure and verify that all steps were per formed a Turn ignition key switch to ON b Check for tail lamp illumination c Squeeze front brake hand lever Check for brake lamp illumination Release front brake hand lever d Press rear brake pedal Check for brake lamp illumi nation Release rear brake pedal ...

Page 565: ...p assembly to tail section using washers and jam nuts 1 and tighten to 12 36 in lbs 1 4 4 1 Nm c Attach the two connectors 45 from license plate lamp harness 2 to main harness 2 Check lamp for proper operation If operation fails reread procedure and verify that all steps were per formed a Turn ignition key switch to ON b Check for license plate lamp illumination c Turn ignition key switch to OFF 1...

Page 566: ...e 7 52 Disconnect bullet connectors on turn signal wires 3 See Figure 7 53 Remove jam nut and lockwasher 2 from inside of front module 3 4 Pull bullet connectors and wiring through hole in front module 3 and remove turn signal 1 Figure 7 52 Front Turn Signal Connections 2 2 1 1 1 1 2 2 31B 31A 31B 31A b1100x7x RightTurn Signal Left Turn Signal BK V BE BK BK BE BK BN 1 Turn signal 2 2 Jam nut and l...

Page 567: ...rn signal 1 4 Remove turn signal from center tail section 5 Figure 7 54 Rear Turn Signal Connections 1 1 2 2 2 2 1 1 1 2 1 2 1 1 19A 93A 93B 93B 93A 18A 18A 18A 18A 19A 19B 19B Right turn signal Tail lamp b1099x7x Left turn signal V BK BK BN Tail lamp ground BK O W R Y Figure 7 55 Rear Turn Signals 1 Turn signal 2 2 Turn signal bulb 3 Reflector bracket 4 Jam nut and lockwasher 2 5 Center tail sect...

Page 568: ... Attach turn signal using lockwasher and fastener 4 Tighten fastener to 25 28 in lbs 2 8 3 2 Nm 4 Attach bullet connectors on turn signal wires as shown in Figure 7 57 1WARNING 1WARNING Check for proper turn signal operation before riding motorcycle Visibility is a major concern for motorcy clists Failure to have proper turn signal operation could result in death or serious injury 5 Check turn sig...

Page 569: ...le Visibility is a major concern for motorcy clists Failure to have proper turn signal operation could result in death or serious injury 3 Check turn signals for proper operation If operation fails reread procedure and verify that all steps were per formed a Turn ignition key switch to ON b See Figure 7 59 Activate left turn signals using switch on left handlebar Front and rear left turn sig nals ...

Page 570: ...ch switch 95 3 Access left handlebar switch connector 24 under wind screen Remove cable straps Detach connector 24 from wiring harness Figure 7 60 Right Handlebar Switch Connection 1 2 1 3 2 4 Right Handlebar Switch Brake Switch To starter relay GY Fused power GY O W BK W BK W BK W BK BK R BK R O O R Y R Y To stoplight From Ign relay To Ign relay From Ign relay 121A 121B 22A 22B 2 8 7 6 5 4 3 1 2 ...

Page 571: ...lebar switch operations before riding motorcycle Visibility is a major concern for motorcy clists Handlebar switches not operating properly could result in death or serious injury 5 Check handlebar switch for proper operation If operation fails reread procedure and verify that all steps were per formed a Turn ignition key switch to ON b Set ENGINE STOP SWITCH to RUN c Start motorcycle d Turn ignit...

Page 572: ...operly could result in death or serious injury 4 Check handlebar switch for proper operation If operation fails reread procedure and verify that all steps were per formed a Turn ignition key switch to ON b Check headlight LOW and HIGH beam settings c Set headlight to LOW beam Press passing lamp switch Headlight should flash HIGH beam for as long as the switch is pressed d Check left and right turn...

Page 573: ...arter 4 Strain relief 4 Figure 7 65 Vehicle Speed Sensor Wiring 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 24 25 26 27 28 29 30 31 32 33 34 34 35 36 37 38 39 40 41 42 43 44 23 1 9 10 8 2 20 18 12 17 6 7 16 15 14 19 13 11 5 4 3 Ignition Start Key Sw 39 40 41 42 43 44 33 34 35 36 37 38 21 22 23 24 25 26 28 29 30 31 32 27 Spare Diode Bk Hn Mflr Fan IGN Acces Key Sw Lights ECM Sp...

Page 574: ...shers 4 6 Pull instrument module 2 from front support module 1 INSTALLATION 1 See Figure 7 68 Place instrument module 2 into posi tion in front support module 1 2 Install washers 4 and fasteners 5 Tighten fasteners to 12 36 in lbs 1 4 4 1 Nm 3 See Figure 7 67 Connect instrument module connector 39 4 Install windscreen See 2 40 WINDSCREEN 1WARNING 1WARNING After installing seat pull upward on front...

Page 575: ...ssist in determining if speedometer replacement is necessary Speedometer Operation Test NOTE For information on the correct routing of vehicle speed sensor wiring see 7 26 SPROCKET COVER WIRING 1 See Figure 7 70 Locate the 3 place vehicle speed sen sor connector 65 under the sprocket cover See 2 31 SPROCKET COVER 2 Place speedometer tester power switch in the ON posi tion Place signal switch in th...

Page 576: ...4 or 6 c If testing HI range press 7 or 9 Speedometer Sensor Test If the speedometer is inoperative but backlighting and odom eter work the speedometer sensor may not be working See Figure 7 71 Fabricate a test harness using the following parts This harness can also be used to test the tachometer Two Deutsch 3 place socket housings Part No 72113 94BK and six socket terminals Part No 72191 94 Deuts...

Page 577: ... odometer modes Turn ignition ON Does odometer display consist of correct numbers YES Verify trip display consists of correct numbers Are correct numbers displayed NO YES 6020 6020 STOP NO 6020 Press reset for 5 sec onds Does trip odome ter reset to zero NO 6020 Replace instrument module Replace instrument module Replace instrument module Go to Speedometer Test Chart 2A ...

Page 578: ... Output erratic YES Repair as necessary NO Replace instrument module NO Bad connection found Repair con nector or harness DIAGNOSTIC NOTES Low battery voltage on speedometer tester may cause inaccurate test results Make sure speedometer tester battery is fully charged If necessary remove vehicle speed sensor and check for accumulation of debris If debris is not present replace sensor If debris is ...

Page 579: ...4 6 VDC when gear tooth absent and 0 1 VDC when gear tooth present Does it NO Check for open wires Wires OK YES Replace instrument module NO Repair wires YES Check instrument module power O W wire and ground terminal BK wire voltage at back of instrument module Test voltage while shaking harness Does voltage fluctuate NO 4 6 VDC is not present Replace instrument module NO 4 6 VDC is present but no...

Page 580: ... 8 1 10 8 Nm 3 Check horn operation If horn does not sound or fails to function satisfactorily see TROUBLESHOOTING a Turn ignition key switch ON b Press horn switch to activate horn c Turn ignition key switch OFF 4 Install negative battery cable 1WARNING 1WARNING 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 op...

Page 581: ...and BK ground wires from terminal clips b Connect voltmeter positive lead to Y BK wire c Connect voltmeter negative lead to ground d Turn ignition key switch ON 3 See Figure 7 74 Depress horn switch and observe volt meter reading a If battery voltage is present horn or horn grounding is faulty If horn is faulty replace unit as an assembly The horn is not repairable b If battery voltage is not pres...

Page 582: ... indicator lamps or faulty wiring c After testing and repair connect wire lead to indica tor switch 4 Install sprocket cover See 2 31 SPROCKET COVER REMOVAL INSTALLATION 1 Verify that the ignition key switch is turned to OFF 2 Remove sprocket cover See 2 31 SPROCKET COVER NOTE If replacing neutral indicator switch wiring see 7 26 SPROCKET COVER WIRING for correct wire routing 3 See Figure 7 76 Rem...

Page 583: ... amps Always investigate the cause of blown fuses before replacing them Battery Fuse See Figure 7 78 The 30 amp battery fuse is located under the seat To disable the motorcycle s ignition system pull the battery fuse up and out of the fuse block Figure 7 77 Fuse Block 39 40 41 42 43 44 33 34 35 36 37 38 21 22 23 24 25 26 28 29 30 31 32 27 Spare Diode Bk Hn Mflr Fan IGN Acces Key Sw Lights ECM Spar...

Page 584: ...r serious injury 4 Unthread fastener and remove battery negative cable black from battery negative terminal 5 Pull back terminal cover boot on battery positive cable red 6 Unthread fastener and remove battery positive cable from battery positive terminal 7 Remove battery 8 See Figure 7 79 Disconnect positive battery cable from starter 9 See Figure 7 80 Disconnect Wire harness ground GRD 2 Rear bra...

Page 585: ...y positive cable 5 Rear brake light switch connector 121 6 Ground terminals low voltage ground wires 7 ECM connectors 10 11 8 Fuse block and relay center 9 BAS bank angle sensor connector 134 10 Right turn signal connector 18 11 Left turn signal connector 19 12 License plate lamp connector 45 13 Tail light connectors 93 14 Interactive exhaust connector 165B XB12S only 6 8907 5 10 14 ...

Page 586: ...intake air temperature sensor 89 See 4 22 INTAKE AIR TEMPERATURE SENSOR 19 Disconnect throttle position sensor 88 See 4 23 THROTTLE POSITION SENSOR 20 Disconnect fuel line at fuel rail 21 Remove spark plug wires 22 Remove any remaining cable straps and clamps secur ing wire harness and remove harness from front of vehi cle 23 Pull the main harness out through the rear of the frame fuel tank assemb...

Page 587: ...holder to left inside portion of frame using new plastic tree fasteners 5 On XB12S be sure to route the interactive exhaust cable behind the harness strap with main harness NOTE Fuel line is installed under engine connector portion of wire harness 6 See Figure 7 82 Install clamp over portion of harness that leads to engine connectors Install clamp as shown using new plastic tree fastener 7 See Fig...

Page 588: ... and tighten fasteners to 12 36 in lbs 1 4 4 1 17 Install rear shock absorber assembly See 2 22 REAR SHOCK ABSORBER 18 Pull rear section of main harness up over trunk pan towards the rear of the vehicle and place connectors in general location of installation 19 Install fuse block and relay center on support bracket 20 See Figure 7 85 Connect Ground terminals on right side tail section GRD 1 GRD 3...

Page 589: ...und cable 4 Battery positive cable 5 Rear brake light switch connector 121 6 Ground terminals low voltage ground wires 7 ECM connectors 10 11 164 XB12S only 8 Fuse block and relay center 9 BAS bank angle sensor connector 134 10 Right turn signal connector 18 11 Left turn signal connector 19 12 License plate lamp connector 45 13 Tail light connectors 93 6 8907 5 10 ...

Page 590: ...stalled the resulting sparks may cause a battery explo sion which could result in death or serious injury 24 Install positive battery cable red to positive terminal of battery Tighten to 72 96 in lbs 8 11 Nm 25 Connect negative battery cable Tighten to 72 96 in lbs 8 11 Nm 26 Verify operation of all electrical components 27 Install windscreen See 2 40 WINDSCREEN 1WARNING 1WARNING After installing ...

Page 591: ...l actuator harness through frame 8 Move foam rubber isolator out of the way and disconnect connector 161B from actuator 9 If removing actuator a Add free play to interactive exhaust cable loosen jam nut and remove cable from bracket See 7 6 INTERACTIVE EXHAUST SYSTEM XB12S b Remove interactive exhaust cable from cable wheel c Remove actuator Figure 7 87 Harness and Cable Routing Figure 7 88 Exhaus...

Page 592: ...nd wire Tighten to 48 60 in lbs 5 4 6 7 Nm 8 Mate connectors 10 11 1 2 and 164 to ICM 1WARNING 1WARNING 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 9 Connect negative battery cable to battery terminal Tighten fastener to 72 ...

Page 593: ...stalled over oil pressure wiring 2 Connect stator connector 9 3 See Figure 7 92 Connect cam position sensor 14 1 Form a loop 2 as shown using wiring leading to cam position sensor Figure 7 91 Sprocket Cover Wiring Figure 7 92 Cam Position Sensor Wiring 8748b 1 Voltage regulator connector 77 2 Cam position sensor connector 14 3 Neutral switch connector 131 approximate location 4 Neutral switch loca...

Page 594: ...ed behind other wires in harness at sprocket cover boss 2 9 Install cable strap 3 securing vehicle speed sensor wir ing to starter connector 128 wiring 10 Install cable strap 5 securing main harness wiring 11 Install cable strap 6 securing stator cam position sen sor and oil pressure switch wiring 12 Add cable strap 7 to secure cam position sensor and voltage regulator wiring Figure 7 93 Neutral S...

Page 595: ...HOME NOTES ...

Page 596: ...SUBJECT PAGE NO APPENDIX A TOOLS A 1 APPENDIX B WIRING B 1 APPENDIX C METRIC CONVERSIONS C 1 APPENDIX D HOSE AND WIRE ROUTING D 1 APPENDIX Table Of Contents ...

Page 597: ......

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Buell 2004 XB9S, Service Manual

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Summary of Contents for 2004 XB9S

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