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Buell 2005 FIREBOLT, Service Manual

The Buell 2005 FIREBOLT Service Manual is a comprehensive guide that allows you to maintain and repair your motorcycle with ease. Download this manual for free from our website, ensuring you have the necessary instructions to efficiently service your Buell FIREBOLT and keep it running smoothly.

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2-66

2005 Buell Firebolt: Chassis

 

HOME

 

THROTTLE CONTROL

2.23

 

REMOVAL/DISASSEMBLY 

 

1.

See 

Figure 2-92.

 Loosen cable adjuster lock (thick disc)

(3) on each cable.

2.

Turn adjusters (thin disc) (3) in direction which will
shorten cable housings to minimum length.

3.

Remove fasteners (1) on right switch housing and sepa-
rate housing from handlebar.

4.

See 

Figure 2-93.

 Remove cables (2, 3) from notches in

front housing (4).

5.

Remove ferrules (6) from throttle (7).

6.

Remove airbox cover and base plate. See 

4.45 AIRBOX

. 

7.

Disconnect cables from throttle body manifold to remove.

8.

Cut cable straps and remove cables.

 

CLEANING AND INSPECTION

1

1

WARNING

1

WARNING

 

Compressed air can pierce the skin and cause injury.
Never use your hand to check for leaks or to determine
air flow rates. Wear safety glasses to shield your eyes
from flying dirt and debris. Failure to comply could result
in death or serious injury.

 

Clean all parts except cables in a non-flammable cleaning
solvent. Blow dry with compressed air. Replace cables if
frayed, kinked or bent.

 

ASSEMBLY/INSTALLATION

 

1.

Route cable as shown in 

D.1 HOSE AND WIRE ROUT-

ING

.

2.

Add cable straps as shown in the throttle cable routing in

D.1 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 2-92. 

Attach rear switch housing and position

housings on right handlebar by engaging locating pin on
front housing with hole in handlebar. Attach housings
with two fasteners, installing longer fastener on bottom.
Tighten to 25-33 

 

in-lbs 

 

(3-4 Nm).

8.

Adjust cables. See 

1.16 THROTTLE CABLE AND IDLE

SPEED ADJUSTMENT

.

9.

Install airbox assembly. See 

4.45 AIRBOX

.

 

Figure 2-92. Throttle Control Cables

Figure 2-93. Cable Connections

1.

Right switch housing fasteners

2.

Adjusters

3.

Cable adjuster lock

4.

Throttle control cable

5.

Idle control cable

8401

1

4

5

3

2

1.

Screw (short, top)

2.

Idle control cable

3.

Throttle control cable with molded end

4.

Front housing

5.

Screw (long, bottom)

6.

Ferrules

7.

Cable wheel

8.

Rear housing

9.

Locating pin

1

7098

4

8

7

5

3

2

6

9

Summary of Contents for 2005 FIREBOLT

Page 1: ... FIREBOLT MODELS SERVICE MANUAL Part Number 99493 05Y 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: ...4 1 9 Clutch 1 25 1 10 Drive Belt System 1 28 1 11 Primary Chain 1 31 1 12 Suspension Damping Adjustments 1 33 1 13 Steering Head Bearings 1 38 1 14 Spark Plugs 1 39 1 15 Air Cleaner Filter 1 41 1 16 Throttle Cable and Idle Speed Adjustment 1 43 1 17 Interactive Exhaust Cable XB12R 1 44 1 18 Ignition Timing 1 46 1 19 Headlights 1 48 1 20 Throttle Position Sensor TPS 1 50 1 21 Storage 1 51 1 22 Tro...

Page 3: ......

Page 4: ...ppropriate 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 wheneve...

Page 5: ...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 6: ... 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 7: ...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 8: ...y 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 to add oil and Harley Davidson oil is ...

Page 9: ...d idler X 1 Throttle brake and clutch con trols jiffy stand active muffler cable and active intake cable adj if equipped Check adjust and lubricate X X X X X X 1 Ignition gas cap locks lubricate X X X X X X Brake fluid Check levels and condition X X X X X X 1 2 Brake pads and discs Inspect for wear X X X X X X Brake calipers and master cylinders Inspect for leaks X X X X 1 2 Spark plugs Replace X ...

Page 10: ... tighten to 11 15 ft lbs 14 9 20 3 Nm Clutch adjustment Free play at adjuster screw clockwise 1 4 1 2 turn Free play at hand lever 1 16 1 8 in 1 6 3 2 mm Clutch inspection cover torque 84 108 in lbs 10 12 Nm Transmission lubricant Lubricant level SPORT TRANS FLUID Part No 98854 96 as required until fluid level is even with bottom of clutch diaphragm spring Tire condition and pressure Pressure for ...

Page 11: ...ark plugs Type 10R12A Gap 0 035 in 0 9 mm Torque 12 18 ft lbs 16 24 Nm Engine idle speed Idle speed 1050 1150 RPM Front fork oil Type HYDRAULIC FORK OIL TYPE E Part No 99884 80 4 6 in 118 mm from the top of the fork tube Battery Lubricant ELECTRICAL CONTACT LUBRICANT Part No 99861 02 1 oz Battery terminal torque 72 96 in lbs 8 11 Nm Table 1 2 Quick Reference Maintenance Chart ITEM SERVICED SPECIFI...

Page 12: ...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 13: ...death or serious injury 00064a 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 00019a BATTERY TESTING Voltmeter Test See Table 1 4 The voltmeter test provides a general indicator of battery condition Check the voltage o...

Page 14: ...e for cracks or leaks STORAGE 1WARNING 1WARNING Batteries contain sulfuric acid which could cause severe burns to eyes and skin Wear a protective face shield rubberized gloves and protective clothing when working with batteries KEEP BATTERIES AWAY FROM CHIL DREN 00063a CAUTION Do not allow battery to completely discharge The elec trolyte in a discharged battery will freeze The more dis charged a b...

Page 15: ...y terminals Use rec ommended torque values Over tightening battery termi nal bolts could result in damage to battery terminals 00216a 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 negat...

Page 16: ...il tank Doing so can result in oil carry over to the air cleaner leading to equipment damage and or equipment malfunction 00190a CAUTION Do not switch lubricant brands indiscriminately because some lubricants interact chemically when mixed Use of inferior lubricants can damage the engine 00184a Ride motorcycle for approximately 10 minutes to ensure the oil is hot and the engine is at normal operat...

Page 17: ...move 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 adapter until filt...

Page 18: ...etely DO NOT OVER TIGHTEN 6 Remove left side oil cooler scoop See 2 35 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 1...

Page 19: ...NG 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 fluid Earlier ...

Page 20: ...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 21: ...d 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 flow from bleeder valve and ...

Page 22: ...id 5 Slowly depress and release brake pedal several times to build up hydraulic pressure then hold brake pedal in the depressed position 6 While holding brake pedal in the depressed position open bleeder valve about 1 2 turn counterclockwise Brake fluid will flow from bleeder valve and through tub ing into clean container When brake pedal has moved 1 2 to 3 4 of its full range of travel close blee...

Page 23: ...ARNING 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 of clevis 4 b Turn rod adjust...

Page 24: ...n changing fluid Traction can be adversely affected which could result in loss of control of the motorcycle and death or serious injury 00047b See Figure 1 14 Check brake rotors for minimum thickness At the 1000 mile 1600 km service interval At every 5000 mi 8000 km service interval thereafter At every scheduled service interval 1 Measure rotor thickness Replace rotor if minimum thick ness is less...

Page 25: ...suitable tool such as a clean paint scraper until fully seated in bores Be careful not to dam age rotor 2 Install new inner side 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 cali...

Page 26: ...uch 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 LOCTITE 272 and tighten hanger pin to 11 14 ft lbs 14 9 ...

Page 27: ...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 bearings with compressed air can also cause a b...

Page 28: ...spec tion cover Remove clutch inspection cover with gasket from primary cover CAUTION Do not overfill the primary chaincase transmission with lubricant Overfilling can cause rough clutch engage ment incomplete disengagement clutch drag and or dif ficulty in finding neutral at engine idle 00199b CAUTION Make certain primary chaincase is filled with proper amount of lubricant with motorcycle upright...

Page 29: ...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 30: ...Gap between ferrule and bracket should be 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 8 See Figure 1 19 Install clutch inspection cover and new gasket using three fasteners and washers and tighten to 84 108 in lbs 10 12 Nm 9 Check clut...

Page 31: ...rockets are misaligned Outside surface for signs of stone puncture If cracks damage exists near edge of belt replace belt immedi ately Damage to center of belt will require belt replace ment eventually but when cracks extend to edge of belt belt failure is imminent Inside toothed portion of belt for exposed tensile cords normally covered by facing fabric This condition will result in belt failure ...

Page 32: ...amaged 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 NOTE The drive belt tension on a new belt will loosen after approxi mately 1000 mi 1600 km Worn sprocket Inspect replace sprocke...

Page 33: ... replace sprocket Clean and protect drive Inspect replace belt Excessive drive noise Worn damaged sprocket Inspect replace sprocket Missing damaged belt guards 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 belt Inspect rep...

Page 34: ... 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 engine ad...

Page 35: ...justment limits Replace parts as necessary See 6 2 PRI MARY COVER 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 10309a 1 Locknut 2 Adjusting screw 1 2 ...

Page 36: ...anges in Load Changes in the load carried requires changes in the preload setting s Carrying less weight than was used for setting up the suspension requires decreasing the amount of preload 1WARNING 1WARNING Do not exceed the motorcycle Gross Vehicle Weight Rat ing GVWR Exceeding the GVWR can affect stability and handling which could result in death or serious injury 00016a GVWR is the sum of the...

Page 37: ...nded to compensate for the varying fluid viscosity by readjusting the damping adjuster positions when operating outside the normal ambient temperature range of 65 95 F 18 35 C 1 Adjust suspension for rider weight Refer to Table 1 10 Reduce front and rear compression damping and rebound damping by turning adjuster counterclockwise 1 4 1 2 turn Table 1 10 Recommended Suspension Settings for Rider an...

Page 38: ...ition Refer to 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 10 Setting Front Fork Compression Damping 1 See F...

Page 39: ...uster counterclockwise to decrease pre load 1WARNING 1WARNING After installing seat pull upward on front of seat to be sure it is in locked position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070a 3 Install seat See 2 38 SEAT Setting Rear Shock Rebound Damping 1 See Figure 1 32 Using a screwdriver turn the slotted dial clockwise unti...

Page 40: ...r of the rider seat 3 See Figure 1 34 Using a screwdriver turn the slotted dial clockwise until it stops This is the maximum com pression damping setting 4 Then turn the dial counterclockwise the recommended amount specified in Table 1 10 5 Install seat See 2 38 SEAT Figure 1 33 Accessing Rear Shock Compression Adjuster Figure 1 34 Rear Shock Compression Adjustment 8415 8976 ...

Page 41: ...eering head resistance turn front wheel all the way to the right 6 See Figure 1 35 Hook a spring 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 ADJUSTMENT 7 When adjustment is co...

Page 42: ...p 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 heated plug...

Page 43: ...trode gap with a wire type 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 12 18 ft lbs 16 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...

Page 44: ...er cover from base plate 6 See Figure 1 40 Remove the filter element 1 from base plate 2 Inspect and replace if necessary CAUTION See Figure 1 40 Cover the velocity stack so nothing can drop into the motor CLEANING AND INSPECTION 1WARNING 1WARNING Do not use gasoline or solvents to clean filter element Flammable cleaning agents can cause an intake system fire which could result in death or serious...

Page 45: ...e cover assembly 5 Position fuel vent tube 2 in groove on top of air cleaner cover and connect to fuel vent valve 3 Secure vent tube to vent valve with new cable strap 6 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 in locked position While riding a l...

Page 46: ... cable housings to minimum length 4 Point front wheel straight ahead Twist throttle control grip to fully open position hold in position 5 Turn adjuster on throttle control cable until throttle cam stop touches stop plate Tighten jam nut on throttle con trol cable adjuster release throttle control grip 6 Turn handlebars fully to right Turn adjuster on idle con trol cable until end of cable housing...

Page 47: ...the housing 7 Release the cable core and reattach the cable to the cable wheel and bracket 8 Tighten jam nut CAUTION Do not overtighten jam nut on interactive exhaust cable 9 See Figure 1 45 Adjust interactive exhaust cable as fol lows a See Figure 1 44 Move cable with your fingers from side to side There should be no more than 1 8 in 3 18 mm sideplay in cable in either direction with 1 4 in 6 36 ...

Page 48: ... 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 46 Correct Cable Routing Behind Frame Lug 10514a 1 Interactive exhaust cable 2 Frame lug 2 1 ...

Page 49: ...s active 7 Turn or gently bump the flywheel in a 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 4...

Page 50: ...f timing is advanced mark appears on left side of window rotate timing plate counterclockwise 3 Check timing See CHECKING STATIC TIMING 4 See Figure 1 52 If timing is retarded mark appears on right side of window rotate timing plate clockwise 5 Recheck timing Figure 1 49 Timer Cover Figure 1 50 Cam Position Sensor Figure 1 51 Advanced Timing 8363 8391 b0964x1x b0963x1x ...

Page 51: ...le suspension slightly 5 Stand motorcycle upright with front fairing aimed straight forward 6 Check LOW beam right lens for alignment a See Figure 1 54 Turn ignition switch to IGN Set handlebar headlamp switch to LOW beam position b Turn engine stop switch to the run position c Check that the correct pattern of light is a double rectangular pattern and is aligned with the horizontal line as shown ...

Page 52: ...he left and the LOW Beam adjuster 2 is on the right underneath the front fairing If headlamp requires adjustment perform the following NOTE To lower beam turn adjuster clockwise To raise beam turn adjuster counterclockwise Figure 1 55 Headlamp Height Adjustment 8392 1 2 1 High beam adjuster left 2 Low beam adjuster right ...

Page 53: ...s 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 perform TPS zero NOTE When calibration is complete dialogue box will appear on Digital Tech screen with message display Command Sent Successfully Press OK 9 Turn id...

Page 54: ... all weight is off the tires 1WARNING 1WARNING Be sure that brake fluid or other lubricants do not con tact brake pads or discs Such contact can adversely affect braking ability which could cause loss of control resulting in death or serious injury 00290a 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...

Page 55: ...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 56: ...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 57: ...ake fades due to heat buildup 8 Insufficient brake 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 t...

Page 58: ... Suspension seems not 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 ...

Page 59: ...HOME NOTES ...

Page 60: ...2 18 Steering Head Bearings 2 55 2 19 Swingarm and Brace 2 58 2 20 Front and Rear Isolator 2 62 2 21 Frame 2 63 2 22 Rear Shock Absorber 2 64 2 23 Throttle Control 2 66 2 24 Clutch Control 2 67 2 25 Headlight Assembly and Support Bracket 2 71 2 26 Fairing Support Bracket 2 74 2 27 Handlebars 2 76 2 28 Exhaust System 2 78 2 29 Footpeg Heel Guard and Mount 2 81 2 30 Sprocket Cover 2 83 2 31 Fenders ...

Page 61: ......

Page 62: ...ight 460 204 GVWR 850 386 GAWR front 325 147 GAWR rear 525 238 Load capacity 400 181 Table 2 3 Weight Specifications XB9R WEIGHT U S MODELS LBS KG Wet weight 450 204 GVWR 850 386 GAWR front 325 147 GAWR rear 525 238 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 gallons 2 6 Oil tank wet for normal oil change 2 5...

Page 63: ... set rear 11 14 ft lbs 15 20 Nm page 2 42 Brake pin plug rear 22 26 in lbs 2 3 Nm page 2 42 Brake reservoir fastener rear 96 120 in lbs 11 14 Nm page 2 92 Caliper banjo bolt front 16 20 ft lbs 22 27 Nm metric page 2 31 Caliper banjo bolt rear 16 20 ft lbs 22 27 Nm page 2 40 Caliper bleeder valves 36 60 in lbs 4 7 Nm metric page 2 26 Caliper carrier rear 24 26 ft lbs 32 35 Nm page 2 19 Caliper fast...

Page 64: ... Hand lever pivot fastener 60 120 in lbs 9 14 Nm page 2 28 Handlebar clipon fastener left 24 26 ft lbs 33 35 Nm LOCTITE 272 page 2 76 Handlebar clipon fastener right 24 26 ft lbs 33 35 Nm LOCTITE 272 page 2 76 Headlight fasteners 20 25 in lbs 2 3 2 8 Nm page 2 72 Headlight support bracket pivot fasteners 72 96 in lbs 8 11 Nm page 2 73 Heel guard fasteners passen ger 48 72 in lbs 5 8 Nm page 2 82 H...

Page 65: ...bolt 22 24 ft lbs 30 32 5 Nm page 2 69 Shock mounting fastener lower 15 17 ft lbs 20 3 23 Nm page 2 65 Shock mounting fastener upper 49 51 ft lbs 66 69 Nm page 2 65 Shock reservoir clamp rear 120 144 in lbs 14 16 Nm page 2 92 Sidestand bracket fasteners 25 27 ft lbs 34 37 Nm page 2 98 Sidestand pivot bolt 18 20 ft lbs 24 27 Nm page 2 98 Sprocket cover fastener 12 36 in lbs 1 4 Nm page 2 83 Sprocke...

Page 66: ...le 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 See Table 2 7 Figure 2 1 Rim Markings 8423 Table 2 7 Tire Fitment Tubeless Cast Wheels WHEEL SIZE POSITION CONTOU...

Page 67: ...53450001 NOTE Always give the full Vehicle Identification Number located on the steering head when ordering parts or making any inquiry about your motorcycle Figure 2 2 Buell Vehicle Identification Number V I N Typical 4 MZ AX 12 J 5 3 400001 1 2 3 4 5 6 7 8 Table 2 8 Buell 2005 XB Models V I N Description ITEM DESCRIPTION POSSIBLE VALUES 1 Market destination 4 Domestic 5 International 2 Manufactu...

Page 68: ...e recommended air pressure Always balance the wheel after replacing a tire 11WARNING 1WARNING Do not inflate tire beyond maximum pressure as speci fied on sidewall Over inflated tires can blow out which could result in death or serious injury 00027a TROUBLESHOOTING See Figure 2 3 Check tire inflation pressure at least once each week At the same time inspect tire tread for punctures cuts breaks and...

Page 69: ... Harley Davidson replace ment tires 00090a At regular intervals of 5000 miles 8000 km or whenever handling irregularities are noted perform the recommended service checks See Table 2 9 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 9 Wheel Service CHECK FOR REMEDY Loose axles Tighten front axle See 2 5 F...

Page 70: ... 2 31 FEND ERS 3 See Figure 2 4 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 5 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 71: ...BEARING INSTALLER REMOVER HD 44060 4 See Figure 2 7 Insert the FRONT WHEEL BEARING REMOVER COLLET B 43993 7 into the wheel bearing until it fully seats against the bearing 5 Insert the ball bearing into the collet 6 See Figure 2 8 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 9 Place the bridge 1 against the whee...

Page 72: ...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 NOTE XB wheel bearings are designed as sealed bearings which are not intended to be disassembled serviced or cleaned with solvents 11W...

Page 73: ...r Part No HD 44060 with the smaller diameter toward the wheel hub Insert the forcing screw and backing plate into the wheel hub 2 See Figure 2 13 Sparingly apply EXTREME PRES SURE LUBRICANT Part No J 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 fro...

Page 74: ...tall a washer 4 Nice bearing 5 and nut 6 onto the forcing screw 3 NOTE See Figure 2 15 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 contacts the spacer 15 Remove the nut bearing washer FRONT BEARING INSTALLER Part No B 43993 10 and forcing sc...

Page 75: ...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 17 Front Wheel Assembly 1 Front axle 2 Wheel be...

Page 76: ...xle a Apply LOCTITE ANTI SEIZE LUBRICANT to axle b See Figure 2 19 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 19 Tighten the front axle pinch...

Page 77: ...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 Remove sprocket fasteners and washers Discard fasteners b Remove sprocket from wheel 2 Remove rear rotor a See Figure 2 22 Remove and discar...

Page 78: ...HOME Figure 2 22 Rear Wheel Assembly 1 Rotor mounting fastener 6 2 Brake rotor 3 Wheel bearing 4 Wheel spacer 5 Wheel 6 Sprocket 7 Sprocket fastener 8 Axle b0936x2x 1 3 5 4 3 2 6 7 8 ...

Page 79: ...Install sprocket a Position sprocket 6 on wheel 5 keeping lip of sprocket facing the inside b Install new sprocket fasteners 7 and washers tight ening to 35 37 ft lbs 48 50 Nm 5 Install rear rotor 2 a Position rear brake rotor 2 on wheel 5 b Install brake rotor 2 with new rotor mounting fas INSTALLATION 1 Center rear wheel in the swingarm at the same time slid ing the drive belt onto the rear spro...

Page 80: ... rotor to slide into the caliper Press on the brake pad from the outside of the caliper to straighten out the pad 11WARNING 1WARNING After repairing the brake system test brakes at low speed If brakes are not operating properly testing at high speeds can cause loss of control which could result in death or serious injury 00289a Figure 2 26 Rear Brake Caliper Carrier Fasteners 8348 ...

Page 81: ...fication shown in Table 2 10 Rim Radial Runout 1 See Figure 2 28 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 10 Table 2 10 Wheel Rim Runout RUNOUT IN MM Maximum lateral 0 040 1 02 Maximum ra...

Page 82: ...th Inadequate tread depth can cause an accident which could result in death or serious injury Buell front and rear tires are not the same Inter changing front and rear tires can cause tire failure which could result in death or serious injury 00026b REMOVAL 1 Remove wheel from motorcycle See 2 5 FRONT WHEEL or 2 6 REAR WHEEL 2 Deflate tire 3 See Figure 2 29 Loosen both tire beads from rim flange 1...

Page 83: ...ing a tire with the wrong rotation could result in death or serious injury Buell front and rear tires are not the same Inter changing front and rear tires can cause tire failure which could result in death or serious injury 00026a 1 Damaged or leaking valve stems must be replaced 2 Install and tighten fastener to 40 44 in lbs 4 5 4 9 Nm 3 Thoroughly lubricate rim flanges and both beads of tire wit...

Page 84: ... again for tire tread lateral runout Checking Tire Radial Runout 1 See Figure 2 34 Turn wheel on axle and measure tread radial runout 2 Check tire tread for appropriate runout specification See Table 2 11 If 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 check tire tread radi...

Page 85: ... oz 7 g at 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 sid...

Page 86: ...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 87: ...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 88: ... Do not use mineral based solvents such as gaso line or paint thinner which will deteriorate rubber parts even after assembly Deterioration of these components can cause brake failure which could result in death or serious injury 00291a 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 cloth Blow ou...

Page 89: ...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 90: ...t 3 6 Protect body work from brake fluid 7 See Figure 2 41 With the 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 A plugged or covered relief port can cause brake drag or lock up which could lead to loss of control resulting in death or serious injury 00288a 8 Verify p...

Page 91: ... banjo bolt seating surfaces will leak when reassembled Prevent damage to seating surfaces by carefully removing brake line components 3 See Figure 2 37 Remove master cylinder banjo bolt 12 metric and two copper washers 14 to disconnect brake line from master cylinder 4 Discard copper washers 4 See Figure 2 42 Remove caliper banjo bolt 5 metric two copper washers and wire form 3 to disconnect brak...

Page 92: ...e 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 4 Tighten p clamp with fastener 1 on lower triple clamp to 36 60 in lbs 4 7 Nm 5 See Figure 2 37 Tighten master cylinder banjo bol...

Page 93: ...t brake line at 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 caliper pad spring 2 and brake pads 2 Split caliper by removing caliper fasteners 3 3 See Figure 2 47 Remove and discard o rings 6 4 See Figure 2 46 Remove pistons using a BRAKE PIS...

Page 94: ...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 95: ...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 96: ... 7 Nm 2 Remove brake pedal See 2 9 BRAKE PEDAL 3 Remove heel guard See 2 29 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 38 SEAT Figure 2 48 Brake Bleeder Valve Rear Caliper Figure 2 49 Re...

Page 97: ...ount 10 See Figure 2 52 Detach remote reservoir a Remove top clamp 4 on hose connected to master cylinder b Remove fastener 2 to detach reservoir 1 from frame if necessary Figure 2 50 Brake Line Switch Connector Figure 2 51 Rear Master Cylinder Assembly 8442 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 98: ...tand 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 ASSEMBLY KIT 2 ...

Page 99: ...2 Tighten to 48 72 in lbs 5 4 8 1 Nm b Attach hose 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 29 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...

Page 100: ... 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 seating surfaces will leak when reassembled Prevent da...

Page 101: ...eel guard See 2 29 FOOTPEG HEEL GUARD AND MOUNT 6 Bleed brakes See BLEEDING BRAKES in 1 7 BRAKE SYSTEM MAINTENANCE 11WARNING 1WARNING Connect positive battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explo sion which could result in death or serious injury 00068a 7 Install negative battery cable and tighten to 72 96...

Page 102: ... 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 103: ...per brake operation could result in death or serious injury 00111a 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 piston must be pressed all ...

Page 104: ...jo bolt hydrau lic brake line and 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 After rep...

Page 105: ...ING ADJUSTMENTS for more information REMOVAL 1 Remove front fender See 2 31 FENDERS 2 Remove front wheel See 2 5 FRONT WHEEL 3 Remove caliper mounting fasteners See 2 12 FRONT BRAKE CALIPER 4 Loosen upper 1 and lower 3 fork clamp pinch fasten ers 5 Remove fork from upper fork clamp 2 6 See Figure 2 63 Slide the stopper ring up and over the top of the fork 7 See Figure 2 62 Remove fork from lower f...

Page 106: ...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 B 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 Fi...

Page 107: ...ure not to bind the outer fork tube on the tool 7 See Figure 2 68 Hold damper rod assembly 3 and remove fork cap 1 CAUTION Careful not to damage preload pins while holding damper rod assembly 8 Remove preload washer 4 and slider piston 5 9 See Figure 2 67 Uncompress fork and remove from FORK SPRING COMPRESING TOOL Figure 2 67 Fork Spring Compressing Tool HD 45966 b1145x1x Figure 2 68 Holding Dampe...

Page 108: ...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 109: ... 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 t...

Page 110: ...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 fork oil CAUTION The outer tube can...

Page 111: ...e 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 See Figure 2 71 Hold damper rod assembly 3 and install fork cap 1 on damper rod assembly 3 tightening to 22 30 ft lbs 30 40 Nm NOTE See Figure 2 68 Careful not to damage preload pins 2 while holding damper rod assembly...

Page 112: ...tion 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 1...

Page 113: ...HOME NOTES ...

Page 114: ...ding ignition switch fuse block and right handlebar switch wires See 7 3 IGNITION HEADLIGHT KEY SWITCH 7 Unplug the ignition switch See 7 3 IGNITION HEAD LIGHT KEY SWITCH 8 See Figure 2 75 Hold or brace the lower fork clamp and remove steering stem cap 1 9 Remove the upper fork clamp 4 10 Remove the lower fork clamp 8 11 Remove ignition switch See 7 3 IGNITION HEADLIGHT KEY SWITCH 12 If steering h...

Page 115: ...eering stem cap 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 can lead to loss of control which could result in death or serious injury 00124a 9 See Figure 2 74 Position both forks with same number alignment l...

Page 116: ...notches inside steering head stem bore upper bearing removed for clarity b Place a suitable tool in the notches of the steering stem bore and remove upper and lower steering head bearings NOTE Discard steering head bearings and replace with new Steer INSTALLATION NOTES Steering head bearings should be installed one at a time in order to ensure proper alignment of bearing in bore Use the new backin...

Page 117: ...tion lubricate the outside of the steering head bearings 2 See Figure 2 79 Sparingly apply EXTREME PRES SURE LUBRICANT Part No J 23444 A to the threads of the forcing screw 1 from the STEERING HEAD BEARING RACE INSTALLER Part No HD 39302 to prolong service life and ensure smooth operation Insert the forcing screw 1 through the STEERING HEAD BEARING INSTALLATION TOOL Part No B 45521 2 3 Place the W...

Page 118: ... steering head 8 Repeat this process for the lower bearing 9 Install forks front wheel and lower fork clamp steering stem as an assembly 10 Install upper fork clamp 11 Tighten steering stem capnut to 38 42 ft lbs 52 57 Nm 12 Use LOCTITE 272 on steering stem pinch fastener and tighten to 17 19 ft lbs 23 26 Nm 13 Install headlight assembly and support bracket See 2 25 HEADLIGHT ASSEMBLY AND SUPPORT ...

Page 119: ...eve belt ten sion first Removing swingarm brace without releasing tension will cause swingarm brace damage 1 Remove left side rider footpeg mount See 2 29 FOOT PEG 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 Figure 2 81 Rear Wheel Mounting Right Side 8420 2 1 A...

Page 120: ...el See 2 6 REAR WHEEL 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 too...

Page 121: ...o check for air leaks or to deter mine air flow rates 00061a 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 83 Install new shock mount bushings 3...

Page 122: ...48 52 ft lbs 65 70 Nm 6 Tighten rear axle pinch fastener 13 to 40 45 ft lbs 54 61 Nm 7 Install left and right side passenger footpeg mounts Tighten fasteners to 25 28 ft lbs 34 37 Nm See 2 29 FOOTPEG HEEL GUARD AND MOUNT 8 Install right side rider footpeg mount Tighten fasteners to 108 132 in lbs 12 15 Nm See 2 29 FOOTPEG HEEL GUARD AND MOUNT 9 Install heel guard See 2 29 FOOTPEG HEEL GUARD AND MO...

Page 123: ...ee 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 front isolator bolt and raising scissor jack to support engine 4 Tighten front isolator bolt 6 to 49 51 ft lbs 66 69 Nm 5 See Figure 2 85 Install clutc...

Page 124: ...MAIN WIRE HAR NESS 8 Remove rear isolator fastener See 2 20 FRONT AND REAR ISOLATORS 9 Lift and remove frame from the motorcycle 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 23 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...

Page 125: ... adjustments set the proper preload See 1 12 SUSPENSION DAMPING ADJUST MENTS Figure 2 89 Rear Shock Absorber Assembly b0940x2x 1 2 3 11 8 6 9 4 10 5 1 Shock remote reservoir clamp fastener 2 Shock remote reservoir clamp 3 Shock remote reservoir 4 Shock reservoir body 5 Upper shock mount fastener 6 Lower shock mount nut and washer 7 Lower shock mount 8 Lower shock mount sleeve 9 Lower shock mount f...

Page 126: ...unt sleeve 8 and tighten to 15 17 ft lbs 20 3 23 Nm 3 Feed rear shock reservoir through tail section D 1 HOSE AND WIRE ROUTING for correct routing a Loosely install reservoir in clamp b See Figure 2 91 Temporarily place upper body work onto tail section and adjust reservoir placement so dial aligns with bodywork c Tighten clamp on reservoir to 96 120 in lbs 11 14 Nm 4 See Figure 2 90 Install cable...

Page 127: ...pressed air Replace cables if frayed kinked or bent ASSEMBLY INSTALLATION 1 Route cable as shown in D 1 HOSE AND WIRE ROUT ING 2 Add cable straps as shown in the throttle cable routing in D 1 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...

Page 128: ...ngine 7 Remove cable strap securing clutch cable to voltage reg ulator wire 8 See Figure 2 95 Slide clutch cable adjuster boot 1 up to access clutch adjuster 2 9 Loosen clutch adjuster 2 to release tension from hand lever and clutch release mechanism 10 See Figure 2 96 Remove clutch cable ferrule 7 from hand lever 4 NOTE See D 1 HOSE AND WIRE ROUTING in Appendix D 11 Pull clutch cable down and out...

Page 129: ...ANISM 16 See Figure 2 99 Unscrew the cable fitting from the pri mary cover Remove clutch cable and fitting 17 Remove and discard oring on the clutch cable fitting Figure 2 97 Primary Cover and Shifter Assembly 1 Primary cover 2 Clutch inspection cover 3 Engine shift lever 4 Shift pedal assembly 5 Shift linkage assembly 6 Flange head bolt 7 Drain plug 3 1 4 5 6 2 7 b1169x2x Figure 2 98 Clutch Relea...

Page 130: ...primary cover See 6 3 CLUTCH RELEASE MECHANISM 4 See Figure 2 100 Install rubber washer and engine shift lever assembly 1 5 After applying LOCTITE 272 install flange bolt 5 and shift pedal to primary cover and tighten to 22 24 ft lbs 30 32 5Nm 6 After applying LOCTITE 272 red tighten engine shift lever pinch screw to 48 60 in lbs 5 4 6 8 Nm NOTE See D 1 HOSE AND WIRE ROUTING in Appendix D 7 Route ...

Page 131: ...ft lbs 33 9 36 6 Nm 15 Adjust clutch cable See 1 9 CLUTCH 16 Install wire form and clutch cable to front isolator and tighten fastener 17 Install cable strap to voltage regulator wire 11WARNING 1WARNING Connect positive battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explo sion which could result in death or seriou...

Page 132: ...T FAIRING WIND SHIELD AND MIRRORS 4 See Figure 2 102 Disconnect flasher 1 and bank angle sensor 2 Remove electronic control module fasteners 3 5 See Figure 2 104 Rotate headlamp support bracket a Loosen headlamp pivot fasteners 1 b Rotate headlight bracket 2 down 6 See Figure 2 103 Disconnect headlight connection 7 Disconnect and remove electronic control module See 4 30 ELECTRONIC CONTROL MODULE ...

Page 133: ...dlight support bracket 2 Tighten headlight fasteners 6 to 20 25 in lbs 2 3 2 8 Nm 2 Connect headlight bulb 8 connector white into wire harness 3 Connect black headlight connector 4 Install black rubber cover 4 5 See Figure 2 102 Install bank angle sensor connector case 2 Tighten to 12 36 in lbs 1 4 Nm 6 Install flasher 1 and tighten to 30 40 in lbs 3 5 Nm 1 Headlight pivot fasteners 2 Headlight su...

Page 134: ... support bracket b Tighten electronic control module fasteners 3 to 72 96 in lbs 8 11 Nm 8 See Figure 2 102 Connect flasher 1 and bank angle sensor 2 9 Install front fairing See 2 37 FRONT FAIRING WIND SHIELD AND MIRRORS 11WARNING 1WARNING Connect positive battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explo sion ...

Page 135: ...rs 4 Tightening to 16 18 ft lbs 22 26 Nm 3 Install p clamp 7 with p clamp fasteners and washers 8 4 Connect instrument cluster connector and install instru ment cluster Tightening to 36 48 in lbs 4 5 Nm See 7 18 INSTRUMENT MODULE 5 Install horn and tighten fasteners to 72 96 in lbs 8 10 Nm See 7 20 HORN 6 Install fuse block relay and p clamp tightening fasteners to 72 96 in lbs 8 11 Nm See 7 22 MA...

Page 136: ...ng Support Bracket Assembly 1 Jam nut 2 Washer 3 Rubber grommet 4 Fairing support bracket fasteners and washers 5 Fairing support bracket 6 Instrument cluster 7 P clamp 8 P clamp fastener and washers b0958x2x 1 2 3 6 5 4 7 8 ...

Page 137: ...nd clip on 3 has been removed from fork clamp 4 3 Remove clutch lever assembly See 2 24 CLUTCH CON TROL 4 Remove clip on endcap 1 INSTALLATION Right Clip on 1 Install right switch gear housing 2 Install right clip on into right fork clamp using LOCTITE 272 and tighten fastener to 24 26 ft lbs 33 35 Nm 3 Install front brake master cylinder Tighten but do not torque 4 Install throttle and grip onto ...

Page 138: ...HOME Figure 2 108 Handlebar Clip on Assembly left clip on shown b0945x2x 1 Endcap 2 Clip on 3 Upper fork clamp 4 Clip on fastener 3 1 2 3 4 ...

Page 139: ...2 110 Loosen Torca clamp 1 and remove muffler NOTE The muffler may be removed for replacement without remov ing the exhaust header Front Muffler Mount 1 Remove muffler 2 See Figure 2 109 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 Remove muffler 2 Drain oil See 1 ...

Page 140: ...ve muffler 4 Front muffler strap 5 Front muffler strap fastener 6 Front muffler mount 7 Front muffler mount fastener 8 Front muffler mount bushings 9 Interactive exhaust cable 10 Rear muffler bracket 11 Rear muffler bracket fasteners 2 2 6 10 11 Jacking point symbol shown on both sides of muffler 5 3 9 4 1 7 8 ...

Page 141: ...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 Always replace front muffler strap with a new strap when removed from sys tem 2 ...

Page 142: ...asteners 2 Tighten to 108 132 in lbs 12 15 Nm Install Heel Guard 1 See Figure 2 111 Position heel guard 3 onto footpeg mount 1 NOTE There is one long fastener which installs on the lower left side in order to secure the non California vent clamp 2 Install heel guard 3 with fasteners 4 Tighten to 72 96 in lbs 8 11 Nm Install Footpeg 1 See Figure 2 111 Install clip 5 2 Position footpeg 8 on to footp...

Page 143: ... 272 tighten fasteners 10 to 25 28 ft lbs 34 38 Nm Install Heel Guard 1 See Figure 2 112 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 lbs 5 8 Nm Install Footpeg 1 See Figure 2 112 Position footpeg 8 detent plate 6 ball 5 and spring 4 on to footpeg mount 3 2 Install ...

Page 144: ...2 114 Position sprocket cover 2 over front sprocket NOTE Apply LOCTITE 222 purple to long fastener 1 only 2 Install sprocket cover 2 using sprocket cover fasteners 1 3 and tighten all fasteners and washers 1 to 12 36 in lbs 1 4 Nm 3 Install chin fairing See 2 33 CHIN FAIRING Figure 2 113 Chin Fairing Assembly Right Rear Fasteners Figure 2 114 Sprocket Cover b0942x2x b0943a2x 1 Long fastener and wa...

Page 145: ...ighten to 12 36 in lbs 1 4 Nm REAR FENDER Removal 1 Remove rear wheel See 2 6 REAR WHEEL 2 See Figure 2 115 Remove fasteners and washers 4 securing the rear fender 3 to frame 3 Remove rear fender 3 Installation 1 See Figure 2 115 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 3 Install rear wheel See 2 6 REAR WHEEL Figure 2 115 Fr...

Page 146: ...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 147: ...re 2 116 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 ...

Page 148: ...from a Marson Thread SetterTM Tool Kit MODEL NO MAR39200HD 1 See Figure 2 117 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 on a...

Page 149: ... See Figure 2 118 Secure intake cover assembly 1 with fasteners and nylon washers 2 Tighten 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 in locked position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070a 4 Install seat See 2 38 ...

Page 150: ...nstallation 1 See Figure 2 119 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 2 119 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 2 119 Position oil cooler air scoop 2 2 A...

Page 151: ...rom subframe tail assembly 7 a Remove body work fasteners 2 b Disconnect passenger lock cable 6 by removing cable from seat lock plate 4 and ferrule from key lock 3 c Lift upper tail body work 1 off subframe tail assem bly 8 4 Remove passenger seat latch 14 from rear of subframe tail assembly 1 Upper tail body work 2 Upper tail body work fasteners 3 Passenger seat keylock 4 Passenger seat lock pla...

Page 152: ...tail assembly 7 a Remove lower body work 9 underneath subframe tail assembly by removing fasteners 10 b Remove trunk 11 13 See Figure 2 122 Disconnect main battery ground 1 and ground to wire harness 2 14 Remove main fuse case 3 from subframe tail assembly NOTE When removing the main fuse case from subframe tail assembly be very careful not to bend the subframe 15 See Figure 2 122 Cut cable strap ...

Page 153: ...nect 4 Install main fuse case 3 onto subframe tail assembly 5 Install main battery ground 1 and ground to wire har ness 2 to subframe tail assembly Tightening fastener to 72 96 in lbs 8 11 Nm 6 See Figure 2 121 Feed the rear shock reservoir 4 through second subframe tail assembly support 7 Install rear shock reservoir into shock reservoir clamp and install clamp on to subframe tail assembly Do not...

Page 154: ...nd tail light con nections See 7 14 TURN SIGNALS and 7 13 TAIL LAMP 20 Install passenger seat latch 14 from rear of subframe tail assembly and tighten to 60 96 in lbs 7 11 Nm 21 See Figure 2 120 Install upper body work onto subframe tail assembly a Connect passenger lock cable 6 by installing fer rule into lock lever b Starting on the left side of the subframe tail assem bly cover the lock cable a...

Page 155: ...N 1 See Figure 2 124 Position fairing 5 onto fairing support bracket and install turn signals 6 7 See 7 14 TURN SIGNALS 2 Install mirrors 2 with fasteners and tighten to 72 96 in lbs 8 11 Nm 3 Install two center 4 and four side windscreen fasteners 3 Figure 2 124 Front Fairing and Windscreen b0967x2x 1 Windshield 2 Mirrors 3 Side windshield fastener 4 Center windshield fastener 5 Front fairing 6 T...

Page 156: ... tab in slot Pull up on front of seat to verify tab slot engagement 11WARNING 1WARNING After installing seat pull upward on front of seat to be sure it is in locked position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070a 3 Pull up rear corners of seat and tighten two fasteners to 12 36 in lbs 1 4 Nm Pillion Seat 1 Install seat by sl...

Page 157: ...plate 6 tab 4 Position short tab of spring 5 into seat lock notch 5 Position long end of spring into the seat lock lever 4 6 Load the spring 5 by turning the seat lock lever 4 counterclockwise 1 4 turn 7 Once the spring is loaded install the seat lock lever 4 onto the lock aligning the lever to the square groove that is cast into the seat lock 7 8 Fasten the lock lever 4 to the seat lock 7 with th...

Page 158: ...ee Figure 2 130 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...

Page 159: ...stand 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 lb...

Page 160: ...der 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 Cooler 3 75 3 11 Oil Pressure Indicator Switch 3 77 3 12 Crankcase Breathing System 3 78 3 13 Oiling System 3 80 3 14 Oil Pump 3 81 3 15 Oil Filter Mount 3 84 3 16 Hydraulic Lifters 3 85 3 17 Gearcase Cover And Cam Gears 3 87 3 18 Crankcase 3 92 Table Of Contents ...

Page 161: ......

Page 162: ... 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 12 18 ft lbs 16 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 163: ...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 164: ...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 Flywheels at rim 0 000 0 010 in 0 00...

Page 165: ...ator bracket mounting fastener 49 51 ft lbs 66 69 Nm page 3 14 Front isolator bracket mounting fastener 49 51 ft lbs 66 69 Nm page 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 76 Oil cooler feed oil line 19 21 ft lbs 25 8 28...

Page 166: ... head bolts 135 155 in lbs 15 18 Nm Small fasteners 2 page 3 62 Rocker box to head bolts 135 155 in lbs 15 18 Nm Small fasteners 3 page 3 62 Rocker box to head bolts 18 22 ft lbs 24 30 Nm Large fasteners page 3 62 Sprocket cover fastener 12 36 in lbs 1 4 Nm page 3 18 Sprocket cover fastener 12 36 in lbs 1 4 Nm page 3 44 Stabilizer bracket fastener at oil cooler 120 144 in lbs 13 6 16 3 Nm page 3 7...

Page 167: ...rm bushings valve stems valve springs push 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 acti...

Page 168: ...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 169: ... of the vehicle 11WARNING 1WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 2 Remove seat and disconnect battery 3 Remove intake cover See 2 34 INTAKE COVER ASSEMBLY 4 Remove air filter See 1 15 AIR CLEANER FILTER 5 Remove air filter base plate See 4 45 AIRBOX NOTE The velocity stack has a clamp ring...

Page 170: ... 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 5 3 2 1 10647 4 ...

Page 171: ...Figure 3 3 Remove muffler a Remove front muffler strap b Remove rear muffler straps c Loosen Torca clamp and remove muffler Figure 3 3 Muffler and Mounting System XB9 Models 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 ...

Page 172: ... 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 Retainer and Adjuster Boot 1 Wire form retainer 2 Clutch cable ...

Page 173: ...unt center tie bar 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 Fastener...

Page 174: ... 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 175: ...olator bolt 1 through front isolator 2 and loosely thread into frame Do not tighten at this point 3 Install isolator mounting fasteners 3 and tighten to 49 51 ft lbs 66 69 Nm 4 Tighten front isolator bolt to 49 51 ft lbs 66 69 Nm 5 See Figure 3 6 Torque rear isolator bolt to 25 27 ft lbs 33 9 36 6 Nm 6 Install rear tie bar to frame and tighten to 25 27 ft lbs 33 9 36 6 Nm 7 Install center tie bar ...

Page 176: ...s oil Tighten feed oil line to 19 21 ft lbs 25 8 28 5 Nm at oil cooler 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 return oil line at crankcase and tighten to 15 17 ft lbs 20 3 23 Nm 15 L...

Page 177: ...OVAL under 7 6 INTERAC TIVE EXHAUST SYSTEM XB12 MODELS ONLY 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 muffler strap fastener 7 and tighten to 108 120 in lbs 12 2 13 6 Nm c Tighten torca clamp to 28 30 ft lbs 38 40 6 Nm 17 Tighten front muffler mou...

Page 178: ...Oxygen sensor 137 20 See Figure 3 14 Install the ignition coil and connect 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 10647 4 ...

Page 179: ...late and 29 Install sprocket cover and tighten fasteners and washers to 12 36 in lbs 1 4 Nm 30 Install chin fairing See 2 33 CHIN FAIRING 31 Install air scoops right and left sides See 2 35 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 Connect positive battery cable fi...

Page 180: ... start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 3 Remove seat and disconnect battery 4 Remove intake cover and airbox assembly 5 Remove throttle body velocity stack NOTES The XB9R and XB12R have a clamp ring securing veloc ity stack to the throttle body Install shop towel in entrance to throttle body to prevent objects from falling int...

Page 181: ... sensor 90 3 b Oxygen sensor 137 4 10 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 10647 4 ...

Page 182: ...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 Figure 3 18 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 Muffl...

Page 183: ... rider footrest and support plate also remove rear brake pedal assembly and remote reservoir 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 cooler 12 Cable i...

Page 184: ...1 See Figure 3 21 Remove sidestand assembly Figure 3 20 Clutch Cable Retaining Clamps 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 Bracket 5 Bracket fasteners 2 6 Leg 6 b0946c2x 1 2 3 4 5 ...

Page 185: ...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 186: ...4 See Figure 3 22 Remove center tie bar from engine 25 Remove rear tie bar from frame 26 Loosen rear isolator bolt 27 Remove front isolator bolt 28 Remove front isolator mount from engine 29 See Figure 3 23 Disconnect electrical components a Neutral switch 131 b Speedometer sensor 65 remove tie wrap c Cam position sensor 14 d Positive battery cable at starter e Starter solenoid 128 f Oil pressure ...

Page 187: ...ee Figure 3 27 Cut the two tie wraps 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 rear brake reservoir and hose 34 Lower engine with scissors lift all the way down 35 Move the engine assembly from under the main frame to the right side of the lift 36 Remove e...

Page 188: ...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 189: ...oute a 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 41 Remove support from under swingarm oil tank 42 Remove overhead support Fig...

Page 190: ...new fasteners Tighten 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 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 35 Center Tie Ba...

Page 191: ...haft pinch bolt to 17 19 ft lbs 23 25 8 Nm using LOCTITE 272 6 See Figure 3 40 Route transmission vent line up through left side of frame exiting under the rear master cylinder under the rider s seat Install two tie wraps 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 ...

Page 192: ...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 193: ...this point 11 Install isolator mounting fasteners 2 and tighten to 49 51 ft lbs 66 69 Nm 12 Tighten front isolator bolt to 49 51 ft lbs 66 69 Nm 13 See Figure 3 43 Torque rear isolator bolt to 49 51 ft lbs 66 4 69 1 Nm 14 Install rear tie bar to frame and tighten to 25 27 ft lbs 33 9 36 6 Nm 15 Install center tie bar to engine and tighten to 25 27 ft lbs 33 9 36 6 Nm CAUTION When reinstalling the ...

Page 194: ...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 195: ...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 Cable interactive exhaust 3 2 7 6 5 5 4 3 2 4 10 9 8710a 8709 10501 10 11 1 8 6 12 ...

Page 196: ... the return oil line first making sure to maintain the proper clearance 1 between the oil line and the rear muffler bracket Tighten oil line to 23 25 31 2 33 9 Nm 23 Arrange the feed line and the return line so that the dis tance between is within specifications 2 Torque the feed oil line to 24 26 ft lbs 32 5 35 2 Nm 24 Arrange the vent line and the feed line so that the dis tance between is withi...

Page 197: ...bs 29 8 32 5 Nm When the oil line has been properly torqued the orientation of the line should also be approximately 7 o clock 27 Torque the vent oil line at the gearcase cover to 12 13 ft lbs 16 3 17 6 Nm NOTE When torquing 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 torquing Figure 3 49 Approxi...

Page 198: ...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 199: ...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 30 Verify that the clutch cable and feed line have 1 8 1 4 in 3 175 6 35 mm clearance Figure 3 51 Oil Cooler Feed Oil Line Orient...

Page 200: ...case first 32 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 201: ...4 d Alternator 46 e Voltage regulator 77 f 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 ...

Page 202: ...VE EXHAUST SYSTEM XB12 MODELS ONLY for specific details on removal and installation of interactive components 34 See Figure 3 56 Pull clutch cable back up into the proper position a Connect clutch cable to handlebars and adjust to specifications b Install retaining clamps Figure 3 55 Correct Routing of Wiring Harnesses Figure 3 56 Clutch Cable Wire Form Retainer 10427 10502 ...

Page 203: ...8 Nm b Install front muffler strap fastener 7 and torque to 108 120 in lbs 12 2 13 6 Nm c Tighten Torca clamp to 28 30 ft lbs 38 40 6 Nm d Tighten front muffler mount to 22 25 ft lbs 29 8 33 9 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 Fr...

Page 204: ... cable strap on harness 4 38 Install the ignition coil 1 and spark plug wires and con nect 83 2 Tighten ignition coil fasteners to 120 144 in lbs 13 6 16 3 Nm Figure 3 58 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 10647 4 ...

Page 205: ...rt 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 33 CHIN FAIRING 50 Install air scoops right and left sides See 2 35 AIR SCOOPS 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 1W...

Page 206: ... and internal components must be removed before removing cylinder heads 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 207: ...e 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 and then disas semble 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 ...

Page 208: ... 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 valv...

Page 209: ...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 210: ...or dirt 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...

Page 211: ...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 212: ...e 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 springs for ...

Page 213: ... 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 214: ...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 215: ... sure to highlight all 3 angles Allow marker to dry before proceeding NOTES 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...

Page 216: ...of 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 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 needs...

Page 217: ...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 218: ... 3 Blow 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 t...

Page 219: ...rp 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 The XB Firebolt utilizes a single valve spring 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...

Page 220: ...y 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 PART...

Page 221: ...oil CAUTION The procedure 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 s...

Page 222: ... 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 3 4 5 6 7 8 11 12 13 14 15 16 17 26 24 22 21 20 23 25 9 10 b0960x3x 18 19 ...

Page 223: ...nd 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 bolts 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 ne...

Page 224: ...inder studs Discard 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 Wear safety glasses or goggles when removing or insta...

Page 225: ...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 226: ...shing clearance 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...

Page 227: ...rmines the speed at which it must be stroked up and down the bore to produce the desired cross hatch pattern CAUTION The angular cross hatch pattern ensures an even flow of oil onto the cylinder walls and promotes longer cylinder piston and ring life An Improper crosshatch pattern will result in insufficient oil retention and possible piston sei zure and or high oil consumption 4 Stopping frequent...

Page 228: ... 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 compression ring Install eith...

Page 229: ...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 230: ... 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 231: ...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 232: ...ot 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 Po...

Page 233: ...HOME NOTES ...

Page 234: ...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 235: ...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 236: ...tect finish IMPORTANT NOTE Dispose of oil in accordance with local regulations 2 Place a container under the motorcycle to catch excess oil 3 Remove clamp 3 from oil cooler oil lines 4 Loosen oil cooler return line 2 at oil cooler Do not dis connect 5 Loosen oil cooler feed line 1 at oil cooler Do not dis connect 6 Remove two fasteners 10 securing the oil cooler scoop Figure 3 111 Oil Cooler 1 Oil...

Page 237: ...rear fitting on the oil cooler and return oil line to the front fitting on the oil cooler Do not tighten 3 After the oil cooler is in place apply Loctite 272 to the two fasteners 6 and tighten to 120 144 in lbs 13 6 16 3 Nm 4 Apply Loctite 272 to the stabilizer bracket fastener 8 and tighten to 66 78 in lbs 7 5 8 8 Nm 5 Install oil cooler scoop and apply Loctite 272 to the two fasteners 10 and tig...

Page 238: ...l be more viscous i 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 pr...

Page 239: ... 4 located on top of the rocker boxes From the PCV valves the air enters the crankcase breather hoses 2 3 The crankcase breather hoses route through the air cleaner base plate 1 to the air box where it is directed inside the air filter element and back into the engine The oil mist collects and eventually returns to the crankcase through oil passageways in the cylinder head Figure 3 114 Reed Valve ...

Page 240: ...and break age Fasteners should be tightened to 30 40 in lbs 3 4 4 5 Nm CAUTION See Figure 3 117 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 3 116 Figure 3 116 Re...

Page 241: ...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 242: ...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 243: ...hers 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 Remove and discard retaining ring Remove thrust washer and gear shaft Figure 3 119 Oil Pump Hardware 1 Feed line connection 2 Cover TORX screw ...

Page 244: ...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 3 121 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 3 118 Place gerotor feed set over gear shaft 7 Place cover onto pump body Install ...

Page 245: ...air Never use your hand to check for air leaks or to deter mine air flow rates 00061a 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 3 122 Install oil pressure indicator switch 1 using OIL PRESSURE SENDING UNIT WRENCH Part No HD 41675 Tighten ...

Page 246: ... 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 Compressed air can pierce the skin and flying debris from compressed air could cause serious eye ...

Page 247: ...ghten anti rotation screws to 55 65 in lbs 6 7 Nm 5 See Figure 3 125 Install pushrod cover a Place new pushrod cover gasket over bottom of pushrod 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 lo...

Page 248: ... important to know and understand all inspection procedures and how components interact Figure 3 126 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 249: ...osition sensor and rotor from gearcase cover See 4 31 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 3 127 Remove cam gears 1 2 3 4 NOTE Nut is secured by LOCTITE 262 red on the nu...

Page 250: ...E The numbers identify the cam location function and the letter E indicates model year application Refer to Table 3 25 NOTE Prior to changing any cam gears check gear shaft fit within corresponding bushings Worn bushings can cause excessive backlash Bushing Inspection 1 Bushings are press fit in gearcase cover and crankcase Inspect each bushing against its corresponding cam gear shaft or pinion ge...

Page 251: ...nut to 19 21 ft lbs 26 29 Nm plus an additional 15º to 19º rotation 3 See Figure 3 126 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 XB9R uses V style timing marks on the front intake cam assembly Please note the V design Because of the larger diameter additio...

Page 252: ...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 16 HYDRAULIC LIFTERS 8 Install cam position sensor and rotor in...

Page 253: ...AD 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 7 CYLINDER AND PISTON 3 Remove oil pump See 3 14 OIL PUMP 4 Remove gearcase components See 3 17 GEARCASE COVER AND CAM GEARS 5 Remove primary cover and primary drive clutch compo nents See 6 2 PRIMA...

Page 254: ...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 3 134 Crankcase Fasteners D b1016x3x Indicates Bolt Pattern...

Page 255: ...ring 12 will remain on flywheel pinion shaft Remove retaining ring 13 and bearing can be slipped off pinion shaft Figure 3 136 Removing Flywheels from Left Crankcase 8622 Figure 3 137 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 sprocket sh...

Page 256: ...t Puller 6 Remove outer thrust washer 4 next to sprocket shaft bearing 6 7 See Figure 3 140 Remove sprocket shaft bearing retain ing ring from the inside of the left crankcase half 8 See Figure 3 141 Using CRANKCASE BEARING REMOVER INSTALLER with ADAPTER Part No B 45655 HD 42720 2 and HD 46663 press sprocket shaft bearing out of the left crankcase half NOTE The bearing presses to the inside There ...

Page 257: ... 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 258: ... race Table 3 30 Pinion Bearing Roller Specifications Figure 3 143 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 3 144 Bearing Roller OD ROLLER OD COLOR Largest Red Blu...

Page 259: ...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 260: ...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 3 145 Dimensions are shown for fabrication of tools used in pressing the outer race into or out of crankcase 7 The new outer race ...

Page 261: ...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 262: ... 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 263: ... left crankcase half from the inside NOTE Make sure that the bearing assembly bottoms against the machined shoulder in the left crankcase half 2 Install bearing retaining ring in left crankcase half 3 Install transmission See 6 14 TRANSMISSION INSTAL LATION Figure 3 150 Sprocket Shaft Bearing Assembly 7 1 3 4 6 b1046a3x 5 2 1 Spacer sprocket shaft 2 Retaining ring oil seal 3 Oil seal 4 Thrust wash...

Page 264: ...ngine oil b Slip bearing on pinion shaft c Install new retaining ring in groove of pinion shaft bearing inner race Figure 3 151 Sprocket Shaft Bearing Installation 8789 8792 8762 1 2 3 1 Shoulder 2 Crankcase bearing remover installer tool Part No B 45655 HD 42720 2 and HD 46663 3 Retaining ring Figure 3 152 Installing Flywheel Assembly with CRANKSHAFT GUIDE Part No HD 42326 Figure 3 153 Pinion Sha...

Page 265: ...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 3 154 Crankcase Fasteners D b1016x3x Indicates Bolt Pattern Location One Behind Shifter Mechanism ...

Page 266: ...oulder 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 14 OIL P...

Page 267: ...HOME NOTES ...

Page 268: ... 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 269: ... 107 4 40 Fuel Pump Late Model Year 4 113 4 41 Fuel Tank Vent Valve 4 121 4 42 Fuel Cap Retaining Ring 4 122 4 43 Throttle Body and Intake Manifold 4 123 4 44 Intake Leak Test 4 128 4 45 Airbox 4 130 4 46 Evaporative Emissions Control California Models 4 134 ...

Page 270: ...0 168 in lbs 13 6 19 Nm page 4 102 Fuel cap retaining ring fas teners 17 70 in lbs 1 9 7 9 Nm page 4 122 Fuel pump assembly ground screw 18 22 in lbs 2 0 2 5 Nm page 4 117 Fuel pump drain plug 84 108 in lbs 9 5 12 2 Nm page 4 107 Fuel pump drain plug 84 108 in lbs 9 5 12 2 Nm page 4 113 Fuel pump harness fas tener 18 22 in lbs 2 0 2 5 Nm page 4 111 Fuel pump harness fas tener 18 22 in lbs 2 0 2 5 ...

Page 271: ...level sensor retain ing screw 18 22 in lbs 2 0 2 5 Nm page 4 116 Oxygen sensor 40 45 ft lbs 54 61 Nm LOCTITE ANTI SEIZE page 4 101 Rear shock absorber reser voir clamp rear 10 12 ft lbs 13 6 16 3 Nm page 4 135 Throttle position sensor 13 23 in lbs 1 5 2 6 Nm LOCTITE THREADLOCKER 222 purple page 4 105 Timer plate studs 15 30 in lbs 2 3 Nm page 4 98 Upper tie bar 25 27 ft lbs 33 9 36 6 Nm page 4 102...

Page 272: ...er 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 maximum p...

Page 273: ...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 274: ...PROBLEMS 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 nosti...

Page 275: ...urn off 2 See Figure 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 functiona...

Page 276: ...oric 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 TROUBLE CODE...

Page 277: ...length 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 s...

Page 278: ... 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 279: ...eakout Box to corre sponding black ECM connector b Attach 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 10 Depress latches on each side of con n...

Page 280: ...to wiring harness between the suspect connections When diagnosing ECM connections a BREAKOUT BOX Part No HD 42682 may be used to simplify the procedure 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 11 Fluke 78...

Page 281: ...or 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 Check Part 1 of 2 1 Compare engine behavior to tables a Starts hard Se...

Page 282: ...odes 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 1203 s only 4 21 TROUBLE CODE 21 23 Front fuel injector 4 22 TROUBLE CODE...

Page 283: ...0 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 12 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch in fairing 11 ECM gray 12 place Deutsch in fairing 91A data link 4 place Deutsch beneath left side fairing ...

Page 284: ...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 7 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 285: ... to ground 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...

Page 286: ...tic Tips Check for the following conditions Check for open in BK Y wire Check for blown accessory fuse Diagnostic Notes The reference 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 14 Inspect connector 10 black for con tamination or corrosion If connection is good replace E...

Page 287: ...Fan IGN Acces Key Sw Lights ECM Spare Empty Empty O W BK Ignition Switch 33 To battery Electronic Control Module ECM Connector 10 Connector 11 Instrument Module 39 R BK W R Y R GY O W R R R Main Fuse Fuse Block Check Engine Lamp Accessory Fuse KeySwitch Fuse b1081b4x Top View R GY R GY Table 4 9 Wire Harness Connectors in Figure 4 15 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch in fa...

Page 288: ...CM power 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 betwee...

Page 289: ...onds It may then come back on for an eight second period for a stored error or remain on continuously current error DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Test 4 10 flow chart 1 See Figure 4 17 If the lamp goes off when the black ECM connector 10 is unplugged the BK Y wire is not shorted to ground Figure 4 16 Check Engine Lamp Typical Fi...

Page 290: ...an IGN Acces Key Sw Lights ECM Spare Empty Empty O W BK Ignition Switch 33 To battery Electronic Control Module ECM Connector 10 Connector 11 Instrument Module 39 R BK W R Y R GY O W R R R Main Fuse Fuse Block Check Engine Lamp Accessory Fuse KeySwitch Fuse b1081b4x Top View R GY R GY Table 4 10 Wire Harness Connectors in Figure 4 18 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch in fa...

Page 291: ... Check engine 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 YES NO Repair short to ground on BK Y wire between connector 39 and connector 10 Repair short to ground on BK Y wire between connector 39 and...

Page 292: ...Part No HD 42682 between harness and ECM See 4 6 BREAKOUT BOX 2 Check battery 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 19 Attach cable to SPARK PLUG TESTER Part No HD 26792 Clip tester to cylin der hea...

Page 293: ...a code 24 or 25 This condition is normal and does not by itself indicate a mal function Codes must be cleared if his condition occurs 7 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 gray pin probe and patch cord Figure 4 20 Ignition Coil Circuit Test 7863 Table 4 11 Wire Harness Connectors in Figure 4 21 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch in fairing 11 ECM gray 12 place D...

Page 294: ...ctronic Control Module ECM Connector 10 Connector 11 GY Cam Position Sensor 14 A GN W Y BE GY BE O BK W B C A A 3 1 2 B A To Rear Cylinder To Front Cylinder W Y GN GY Rear Injector 85 GY To Ignition Relay Y BE GY BE O GY GN GY Dyno Loop b1071b4x GY To Interactive muffler control XB12 Models R W 83B 83B 14A 14B 134B 134A B 84A 84B 85A 85B ...

Page 295: ...nate 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...

Page 296: ...t spark plug cable resistance See 4 15 MISFIRE Check coil by substituting one known to be good OR Check coil resistance See 4 32 IGNITION COIL YES Connect Breakout Box Check continuity between ignition coil Terminal A of connec tor 83 and Breakout Box BK Pin 7 Measure resistance between ignition coil Terminal C and ECM Pin 6 10B Resistance should be less than 1 0 ohm Is it NO Disconnect cam positi...

Page 297: ...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 tance between Terminal B and Connector 14B and Breakout Box GY Pin 3 Is resistance greater than 1 0 ohms Remove cam timer cover u...

Page 298: ...s not 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 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 299: ...p both fuel injec tors and coil Right Handlebar Switch 22 GY O GY Ignition Relay Ignition Fuse Key Switch Fuse Ignition Switch 33 Electronic Control Module ECM Connector 11 Connector 10 Relay Center Fuse Block R W BK R R R R Y BK BK W BK GY O W BK R BK GY GY To Battery R BK R BK GY O b1077a4x Top View Top View R BK R BK Key Switch Relay Table 4 12 Wire Harness Connectors in Figure 4 22 NO DESCRIPT...

Page 300: ...n relay Check 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 Is fuse 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 YES Check for 12 volts on right handlebar con ne...

Page 301: ... spill from bore when supply valve is loosened or removed Gasoline is extremely flammable and highly explosive which could result in death or serious injury Wipe up spilled fuel immediately and dispose of rags in a suitable manner 00277a 3 See Figure 4 24 Depress button 2 of fuel line connec tor and disconnect the fuel line 3 from throttle body inlet 1 4 See Figure 4 25 Attach FUEL PRESSURE GAUGE ...

Page 302: ... extremely flammable and highly explosive which could result in death or serious injury Wipe up spilled fuel immediately and dispose of rags in a suitable manner 00277a 10 See Figure 4 26 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 adapte...

Page 303: ...re Empty Empty Ignition Switch 33 LowFuel Lamp Instrument Module 39 Fuel Pump 86 R Y R Main Fuse 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 10 Connector 11 Right Handlebar Switch 22 b1082b4x R R W BK GY O GY O R BK BK R R BK Relay Center Fuse Block Top View Top View ...

Page 304: ... nal D on pump side of con 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 ...

Page 305: ...re 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 EARLY MODEL YEAR YES Locate and repair open on BN Y w...

Page 306: ...ION Idle 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 C...

Page 307: ...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 15 Replace cables not meeting specifications Reinstall and repeat procedure on other spark plug...

Page 308: ...tilock beneath right side of fairing 83 ignition coil 3 place Packard beneath airbox base Front Injector 84 Ignition Coil 83 W Y GN W BK W R W Electronic Control Module ECM Connector 10 Connector 11 GY Cam Position Sensor 14 A GN W Y BE GY BE O BK W B C A A 3 1 2 B B To Rear Cylinder To Front Cylinder W Y GN GY R W Rear Injector 85 GY To Ignition Relay Y BE GY BE O GY GN GY Dyno Loop b1071x4x ...

Page 309: ...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 310: ... 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 311: ...HOME NOTES ...

Page 312: ...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 313: ...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 17 Wire Harness Connectors in Figure 4 33 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch in fairing 11 ECM gray 12 place Deutsch in fairing 14 cam position sensor 3 place Deutsch under sprocket cover 88 throttle position sensor 3 place Packard rig...

Page 314: ...ine lamp come on 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 8...

Page 315: ...n in R W wire NO Check continuity between connector 88 Terminal B V Y wire and Pin 2 of connector 11 Continuity present YES 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 Locate and repair open in BK W wire NO YES Locate and repair short between R W and BK W wires Reconnect 14 NO Replace ECM See 4 30 ELE...

Page 316: ...ECM to detect an oxygen sensor failure Check for the following conditions Poor connection Inspect the ECM harness connector 11 fuel injector connectors 84 85 and oxygen sensor connector wiring for backed out terminals improper mat ing broken locks improperly formed or damaged termi nals poor terminal to wire connection and damaged harness Dirty stuck open injectors The motorcycle may run lean dirt...

Page 317: ...r 137 Electronic Control Module ECM Connector 10 Connector 11 V GY V GY 1 137A 137B Table 4 18 Wire Harness Connectors in Figure 4 36 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch in fairing 137 oxygen sensor 1 place Packard behind rear cylinder head ...

Page 318: ... of con nector 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 oxygen volt age approximately 0 5 volts YES NO Inspect V GY wire for shorts to voltage and repair Replace ECM See 4 30 ELECTRONIC CON...

Page 319: ...ck for 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 43 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 EARLY MODEL YEAR Clear codes and confirm proper operation with no check engine lamp Codes can...

Page 320: ... sensor 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 oxygen sensor Turn ignition ON and start engine Allow engine to reach operating tempera ture Does voltage quickly fluctuate between 0 1 0 8 volts Clear codes and confirm proper operation wi...

Page 321: ...he following conditions Poor connection 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 c...

Page 322: ...ic Control Module ECM Connector 10 Connector 11 PK Y 1 Engine Temperature Sensor Location b0801x4x 90A 90B REAR CYLINDER Table 4 20 Wire Harness Connectors in Figure 4 37 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch in fairing 90 engine temperature sensor 1 place bullet beneath airbox base ...

Page 323: ...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 324: ...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 325: ...ection 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 sor display will change Shifted sensor The temperature to resistance values table may be used to test the IAT sensor at various tem perature levels in order to...

Page 326: ... Lt 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 IAT Sensor 8380 P89B P89A Table 4 22 Wire Harness Connectors in Figure 4 38 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch in fairing 89 intake air temperature sensor 2 place Amp in airbox base ...

Page 327: ... 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 328: ...s 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 to ...

Page 329: ...e 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 excessive starter current draw Figure 4 39 Electrical Relays Figure 4 40 Fuse Blo...

Page 330: ...mpty Empty Right Handlebar Switch 22 GY O GY Ignition Relay Key Switch Relay Ignition Fuse Key Switch Fuse Ignition Switch 33 Main Fuse Electronic Control Module ECM Connector 11 Connector 10 Relay Center Fuse Block R R W BK R R R Y R BK BK BK W BK GY O W BK R BK GY GY BK LT GN R V R To Battery R BK R BK GY O b1083d4x R R Top View Top View ECM 10 Pin 1 also provides power to fuel pump both fuel in...

Page 331: ...ut 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 on i...

Page 332: ...n 0 5 volt YES NO Repair R wire or terminals Measure voltage drop between Battery Positive Terminal and R Y wire of 30 amp Main fuse with key ON Is voltage drop greater than 0 5 volt YES NO Replace main fuse Replace R Y wire between main 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 greater tha...

Page 333: ...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 334: ... 2 2 161B TN V W O 3 1 2 9 3 BRAKE HORN MUFFLER R BK 165A 165B O Electronic Control Module ECM Connector 10 Connector 11 b1073a4x Table 4 24 Wire Harness Connectors in Figure 4 44 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 335: ...ity 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 NO Disconnect cable to inter active valve Does valve arm move freely with...

Page 336: ...s ECM vehicle speed sensor 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 To prevent spray of fuel purge system of high pressure fuel before supply line is disconnected Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00275a 1 Purge fuel line...

Page 337: ...Rear Injector 85 Cam Position Sensor 14 Table 4 25 Wire Harness Connectors in Figure 4 47 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch in fairing 14 cam position sensor 3 place Deutsch under sprocket cover 84 front fuel injector 2 place Packard underneath airbox base 85 rear fuel injector 2 place Packard underneath airbox base ...

Page 338: ...2 W Y wire of front injector con nector 84 If CODE 32 measure resistance between Breakout Box Pin 8 Black and Terminal 2 GN GY wire of rear injector con nector 85 YES Check for loose or corroded terminals in harness Repair as necessary Replace injector See 4 43 THROTTLE BODY YES NO NO Go to Code 23 32 Test Part 2 of 2 YES NO Repair open or poor connection Insert test lamp at connector 84B CODE 23 ...

Page 339: ... 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 340: ... 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 35 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 341: ...Position Sensor A GN W Y BE GY BE O BK W B C 3 1 2 To Rear Cylinder To Front Cylinder R W GY Ignition Relay Y BE GY Dyno Loop b1072a4x 10A 83A 83B 14A 14B 11A 11B 10B 87 RELAY CENTER 4 Table 4 26 Wire Harness Connectors in Figure 4 50 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch under fairing 83 ignition coil 3 place Packard beneath airbox base ...

Page 342: ...at ignition relay Terminal 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...

Page 343: ...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 344: ... Switch 33 LowFuel Lamp Instrument Module 39 Fuel Pump 86 R Y R Main Fuse 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 10 Right Handlebar Switch 22 b1082g4x R R W BK GY O GY O R BK BK R R BK Relay Center Fuse Block Top View Top View Ignition Fuse Connector 11 Table 4 27 Wire Harness...

Page 345: ...Did check engine lamp come on YES NO Install original fuel pump 4 39 FUEL PUMP EARLY MODEL YEAR 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...

Page 346: ...nostic 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 18 INSTRUMENT MODULE Figure 4 53 Installed Breakout Box Figure 4 54 Instrument Module Connector 39 8427 1 ECM 2 Breakout box 1 2 8426 ...

Page 347: ... Mflr Fan IGN Acces Key Sw Lights ECM Spare Empty Empty R GY O W BK Ignition Switch 33 To battery Electronic Control Module ECM Connector 10 Connector 11 Instrument Module 39 R R Y R GY O W R R R Main Fuse Fuse Block R GY Accessory Fuse KeySwitch Fuse b1084c4x PK Top View Table 4 28 Wire Harness Connectors in Figure 4 55 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch in fairing 39 inst...

Page 348: ...nnector 10 Continuity 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 Se...

Page 349: ...et 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 Code 36 flow charts 1 Use HARNESS CONNEC...

Page 350: ... Acces Key Sw Lights ECM Spare Empty Empty Electronic Control Module ECM Connector 10 Connector 11 BK R Y Y BN BK O To battery R Main Fuse Fuse Block Cooling Fan Fuse Top View Y BN R Cooling Fan 97 BK O BK b1090x4x Y BN BK 97A 97B Table 4 30 Wire Harness Connectors in Figure 4 57 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch in fairing 97 cooling fan 2 place Multilock behind rear cylin...

Page 351: ... 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 asterisk Disregar...

Page 352: ...n 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 continuity bet...

Page 353: ...c 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 BREAKOUT BOX Part No HD 42682...

Page 354: ... LTGN GY R W 5 Volt Reference Lt GN GY BAS Signal BK W Sensor Ground Bank Angle Sensor 134 BK W R W LTGN GY b1112x4x Table 4 32 Wire Harness Connectors in Figure 4 60 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch in fairing 11 ECM gray 12 place Deutsch in fairing 14 cam position sensor 3 place Deutsch under sprocket cover 88 throttle position sensor 3 place Packard right side of engin...

Page 355: ...tage on Lt GY GN 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 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 to original...

Page 356: ...epair open in 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 engi...

Page 357: ... 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 358: ...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 61 Cam Position Sensor...

Page 359: ...rence 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 62 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch in fairing 11 ECM gray 12 place Deutsch in fairing 14 cam position sensor 3 place Deutsch under sprocket cover 88 throttle position sensor 3 place Packard right...

Page 360: ...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 361: ...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 362: ... 3 Disconnect ECM black connector 10 and gray connec tor 11 INSTALLATION 1 Attach ECM connectors 10 and 11 2 Locate ECM between fairing and headlight bracket 3 Install headlight bracket See 2 25 HEADLIGHT ASSEM BLY AND SUPPORT BRACKET 4 Install front fairing See 2 37 FRONT FAIRING WIND SHIELD AND MIRRORS 5 Re calibrate throttle position sensor using DIGITAL TECHNICIAN Part No HD 44750 Figure 4 63 ...

Page 363: ...CTION 1 Switched ignition 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 35 Pin Table for ECM Connector 11 Gray PIN FUNCTION 1 5 volt sensor power 2 Throttle position sensor 3 Camshaft position sensor 4 O...

Page 364: ...CTRICAL 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 timer bore ...

Page 365: ... 6 Terminal pin 7 Electronic control module ECM 8 Connector interactive exhaust system 9 Spark plug 2 10 Rear spark plug cable 11 Mounting fastener 12 Ignition coil 13 Front spark plug cable 14 Engine mount 15 Seal 16 Trigger rotor 17 Trigger rotor bolt 18 Cam position sensor 19 Inner cover 1 2 3 5 6 7 4 17 16 9 10 11 18 12 13 19 14 15 9 8 ...

Page 366: ... 1 B B B B 2 2 C C C C 3 3 1 1 1 1 1 1 1 2 2 2 2 2 2 2 DIODE COOLING FAN BRAKE HORN MUFFLER IGNITION ECM KEY SWITCH 1 90A ENGINE TEMP SENSOR 90B 131A 1 1 W TN V O 165A 165B ACTIVE MUFFLER SUB HARNESS TN V O W 2 1 3 ECM SENSOR POSITION THROTTLE 88B 88A 3 2 1 1 2 3 R W V Y BK W 161A GROUND V bat MUFFLER VALVE ACTUATOR MOTOR SENSOR POSITION DC CONTROL ELECTRONICS O TN V W BK 1 1 4 4 3 3 2 2 161B HALL...

Page 367: ...W and BK W wires of plug 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 4 64 Attach connector 3 2 7 Check ignition timing See 1 18 IGNITION TIMING 8 Tighten timer plate studs 4 to 15 30 in lbs 2 3 Nm 9...

Page 368: ... 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 resistan...

Page 369: ...l first 1 Connect spark plug cables to ignition coil 2 See Figure 4 71 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 35 AIR SCOOPS 6 Install Airbox See 4 45 AIRBOX 7 Install intake cover assembly See 2 34 INTAKE COVER ASSEMBLY 8 Connect nega...

Page 370: ... 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 73 Thread sensor into exhaust header Tighten sensor to 40 45 ft lbs 54 61 Nm 3 Install cooling fan See 4 38 COOLING FAN 4 Install shock absorber Se...

Page 371: ...ad 6 Slide rubber boot up ET sensor wire 7 Remove sensor from rear cylinder head using Snap on socket M3503B INSTALLATION CAUTION Do not pull on engine temperature sensor wiring Excess strain to sensor wiring will cause sensor damage 1 See Figure 4 76 Screw sensor into rear cylinder head NOTE In next step make sure wire is in cutout portion slot of socket to prevent damage 2 Secure sensor with Sna...

Page 372: ...ttery cable 2 Remove front fairing See 2 37 FRONT FAIRING WIND SHIELD AND MIRRORS 3 See Figure 4 78 Unplug bank angle sensor connector 134 4 Remove screws and washers to detach sensor from headlight bracket INSTALLATION 1 Position bank angle sensor on headlight bracket Make sure locating post on sensor engages hole in mounting tab 2 Install bank angle sensor to mounting tab with fasteners and new ...

Page 373: ... battery cable before proceeding 00048a 1 Disconnect negative battery cable 2 See Figure 4 79 Remove airbox cover filter Remove fasteners securing base See 4 45 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 IAT sensor connector 89 to wiring h...

Page 374: ... and washers Tighten to 12 14in lbs 1 4 1 6 Nm 4 See Figure 4 82 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 See Figure 4 80 For the XB12R the throttle position sensor is located on the opposite side of the throttle body...

Page 375: ...an 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 counter clockwise 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 R...

Page 376: ... 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 Stop the engine when refueling or servicing the fuel sys tem Do not smoke or allow open flame or sparks near gasoline Gasoline is extremely flammable and highly explosive which could...

Page 377: ...rs 1 6 See Figure 4 86 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 87 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 contact with...

Page 378: ... 4 90 Remove fuel pump clips 1 4 Pull regulator housing 2 from fuel pump assembly 5 See Figure 4 91 Discard regulator housing o rings 2 6 See Figure 4 89 Remove fuel filter hose from fitting 2 and remove fuel filter 1 7 Install new fuel filter 1 on fuel filter hose 8 Install new clamps on fuel filter hose 9 Install new fuel filter hose with 90 bend towards fit ting 2 10 See Figure 4 91 Install new...

Page 379: ... screen on fuel pump 8 Without damaging fuel screen slide fuel pump onto fuel pump assembly 9 See Figure 4 89 Attach fuel filter hose to fitting 2 with clamp 3 10 See Figure 4 90 Install clips 1 into middle grooves 11 See Figure 4 88 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 380: ...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 88 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 381: ...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 3 banjo fitting over fuel supply stud 4 Install new fastener Tighten to 84 108 in lbs 9 5 12 2 Nm 7 Fill tank w...

Page 382: ...l pump connector 1 86 Connector is 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 Stop the engine when refueling or servicing the fuel sys tem Do not smoke or allow open flame or sparks ...

Page 383: ...rs 5 6 See Figure 4 86 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 87 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 contact with...

Page 384: ... in place Spread the four clips and detach regulator 3 from regulator housing 4 3 Remove and discard O rings from regulator 4 Install new O rings on new regulator Press new regula tor into place 5 Install plastic retaining ring 6 Install fuel pump assembly See INSTALLATION in this section Figure 4 98 Fuel Pressure Regulator 10937a 1 Plastic retaining ring 2 Plastic retainers 3 Fuel pressure regula...

Page 385: ...sor 5 Install screw 8 securing sensor and tighten to 18 22 in lbs 2 0 2 5 Nm 6 Attach low fuel level sensor wire connector 10 7 Install fuel pump assembly See INSTALLATION in this section Figure 4 99 Fuel Pump Assembly 1 Fuel supply stud 2 Fuel pump assembly 3 O rings 4 Fuel screen 5 Fuel pump 6 Fuel pump connectors 7 Low fuel pressure regulator 8 Fastener 9 Fuel pressure regulator 10 Low fuel lev...

Page 386: ...0 Install regulator housing 3 and fuel pump 8 assembly 9 Install E clip 7 in bottom groove on shaft 10 Install ground fastener 12 and connect ground wires to bracket 9 and tighten to 18 22 in lbs 2 0 2 5 Nm 11 Connect electrical connectors 5 6 NOTE Fuel pump connectors are two different sizes to prevent incor rect installation 12 Route overflow hose 10 through guide in bracket 9 13 Install fuel pu...

Page 387: ...ll ground fastener 12 and con nect ground wires to bracket 9 and tighten to 18 22 in lbs 2 0 2 5 Nm 11 Connect fuel pump connectors 5 6 NOTE Fuel pump connectors are two different sizes to prevent incor rect installation 12 Route overflow hose 10 through guide in bracket 9 13 Install fuel pump assembly See INSTALLATION in this section Table 4 38 Fuel Pump Specifications SPECIFICATION DATA Pressure...

Page 388: ...rings with clean engine oil From inner side of fuel pump assembly push new wire harness into assembly 8 See Figure 4 100 Insert new fastener 12 through ground wire terminal and secure to bracket 9 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 on terminal to aid in seating wire 9 Install terminals into proper...

Page 389: ...o frame by tightening 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...

Page 390: ...nd o ring 2 from fuel tank frame 1 INSTALLATION 1 See Figure 4 106 Install new vent valve o ring 2 2 Install vent valve 3 into fuel tank frame Vent valve noz zle should be at approximately 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 ...

Page 391: ...w o ring 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 4 107 Fuel Pump Drain Screw swingarm removed for illust...

Page 392: ...oline a See Figure 4 109 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 remaining fuel from fuel line d Reconnect fuel pump connector 2 Label and detach throttle cables See 2 23 THROTTLE CON...

Page 393: ... 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 45mm 984 49mm 1203 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 2...

Page 394: ... in this section 2 Separate fuel rail assembly from throttle body a See Figure 4 114 Remove both injector clips 4 b Remove fuel rail fasteners 1 6 that hold the fuel rail to the throttle body and manifold c Separate fuel rail from injectors 2 5 by gently rock ing the fuel rail and pulling it away from the injectors 3 Remove fuel injectors 2 5 from manifold by gently rock ing and pulling it away fr...

Page 395: ...urple to threads of fuel rail fasteners 1 6 d Secure the fuel rail to the throttle body with fasten ers 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 34 INTAKE COVER ASSEMBLY 2 Remove airbox cover See 4 45 AIRBOX 3 Conduct test a Turn key ON for two seconds b...

Page 396: ... tighten all intake flange screws to 96 120 in lbs 10 8 13 6 Nm 4 Attach throttle cables See 2 23 THROTTLE CONTROL 5 Attach wiring a Injector cables are tagged F ront and R ear for ease of assembly Push connector halves together until latches click Grooves in female connector must align with the tabs in male housing b Connect throttle position sensor by pushing the con nector halves together Slots...

Page 397: ...ich heat shrink work is being performed Always keep hands away from tool tip area and heat shrink attachment To prevent 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 14oz propane cylinder HD 41417 Propane Enrichment Kit 12 in 304 mm long 1 4 in 6mm diameter copper tub ing Tester Assemb...

Page 398: ...erature 3 See Figure 4 117 Turn knob 5 counterclockwise to open propane bottle 6 Avoid directing heat toward any fuel system component Extreme heat can cause fuel ignition explosion resulting in death or serious injury Avoid directing heat toward any electrical system compo nent other than the connectors on which heat shrink work is being performed Always keep hands away from tool tip area and hea...

Page 399: ...er sealing ring 8 on velocity stack 7 f Remove baseplate from motorcycle INSPECTION 1 Inspect airbox Check for dirt torn filter material and gen eral 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 sensor and replace if faulty See 4 36 ...

Page 400: ... damage 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 1...

Page 401: ...EM XB12 MODELS ONLY 10 Install intake cover assembly See 2 34 INTAKE COVER ASSEMBLY 1WARNING 1WARNING After installing seat pull upward on front of seat to be sure it is in locked position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070a 11 Install seat See 2 38 SEAT Figure 4 122 Airbox Assembly 1 Airbox cover 2 Air filter 3 Airbox se...

Page 402: ... 3 Flat washer 4 Actuator interactive exhaust 5 Harness interactive exhaust 6 Cable bracket 7 Interactive exhaust cable 8 Upper isolator 9 Cover airbox 10 Filter element 11 Airbox seal 12 Intake snorkel 13 Shoulder screw 4 14 Baseplate assembly 15 Breather hoses front and rear 2 3 4 15 14 12 13 1 8 10 9 11 6 7 5 16 ...

Page 403: ...bustion in the engine TROUBLESHOOTING 1WARNING 1WARNING Keep evaporative emissions vent lines away from exhaust and engine Gasoline is extremely flammable and highly explosive which could result in death or seri ous injury 00266a The system has been designed to operate with a minimum of maintenance Check that all hoses are properly routed and connected and are not pinched or kinked REMOVAL Vent Va...

Page 404: ... 3 See Figure 4 126 Install reservoir mounting fasteners 2 Tighten fasteners to 120 144 in lbs 13 6 16 3 Nm 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 s...

Page 405: ...RNING 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 4 128 Emissions Hose Attachment California Models Only 10645 ...

Page 406: ...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 407: ......

Page 408: ...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 nut 60 85 in lbs 7 10 Nm page 5 19 Starter mounting bolts 13 20 ft lbs 18 27 Nm page 5 19 ...

Page 409: ...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 410: ...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 411: ...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 412: ...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 413: ...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 414: ...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 415: ... 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 416: ...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 417: ... Y BK TN LT GN R GY O TN Y BK BK GN 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 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 SWITCH WIRING DIAGRAM CONNECTING WI...

Page 418: ...STARTER CURRENT DRAW TEST Starter Current Draw Test NOTES 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 positiv...

Page 419: ...over See 2 30 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 S...

Page 420: ...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 421: ...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 422: ... 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 423: ...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 424: ...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 425: ...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 426: ...en nut to 60 85 in lbs 7 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 30 SPROCKET COVER 5 Install primary cover See 6 2 PRIMARY COVER 1WARNING 1WARNING Connect positive battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks ca...

Page 427: ...e housing mounting 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 428: ...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 429: ...HOME NOTES ...

Page 430: ... 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 Installation 6 48 6 16 Transmission Sprocket 6 49 Table Of Contents DRIVE TRANSMISSION 6 ...

Page 431: ......

Page 432: ... 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 155 Replace at 25 000 mi 40 000 km Table 6 3 Transmission ITEM NEW COMPONENTS XB9R NEW COMPONENTS XB12R 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 g...

Page 433: ...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 Magnetic drain plug 11 15 ft lbs 14 9 20 3 Nm metric page 6 5 Negative battery cable at bat tery terminal 72 96 in lbs 8 11 Nm page 6 6 Negative battery cable to ba...

Page 434: ...e TORX screws with washers and clutch inspection cover 10 See Figure 6 1 Remove clutch inspection cover 3 11 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 12 Remove screws which secure primary cover Remove cover and gasket 13 Discard gasket 14 Remove and discard shifter lever oil seal 15 C...

Page 435: ...bushing 3 Primary cover 4 Gasket 5 Clutch dove 6 Sems Screws 5 7 Inspection cover gasket 8 Cover inspection 9 Engine lever 10 Screw 11 Rubber shift lever pad 12 Shifter linkage assembly 13 Bolt 14 Flange bolt 15 Sleeve 16 Pedal bearing 17 Bolt 18 Shifter lever 19 Oil seal 20 Sems screw 21 Adjuster assembly 22 Chain adjustment nut 23 O ring 24 Drain plug 20 23 ...

Page 436: ...r and gasket onto left crankcase half using mounting bolts 4 See Figure 6 5 Tighten fasteners to 80 110 in lbs 9 12 4 Nm in sequence shown 5 See Figure 6 3 Install new shifter lever oil seal 6 See Figure 6 6 Fit coupling 2 over cable end 1 with rounded side inboard and the ramp connector button out board With retaining ring side of ramp assembly facing inward place hook of ramp 3 around coupling b...

Page 437: ... fairing See 2 33 CHIN FAIRING 11WARNING 1WARNING Connect positive battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explo sion which could result in death or serious injury 00068a 18 Connect negative battery cable to battery terminal Tighten fastener to 72 96 in lbs 8 11 Nm 11WARNING 1WARNING After installing seat p...

Page 438: ... 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 9 Inspect three balls of releas...

Page 439: ...to 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 Connect positive battery cable first If positive cable should contact ground with negative cable con nected the resulting spar...

Page 440: ...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 441: ...eat 11 Diaphragm spring separate spring for XB9R XB12R 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 sprock...

Page 442: ...ING TOOL Part No HD 38515 A against diaphragm spring c Install bearing and washer CAUTION See Figure 6 14 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 14 Remove pressure plate assembly a Place a wrench on the clutch spring forcing screw flats to prevent t...

Page 443: ... reassemble adjusting screw assembly in reverse order s 4 Install adjusting screw assembly into pressure plate a See Figure 6 37 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 15 Adjusting Screw Assembly 1 2 3 4 5 6 7 8 9 1 Retaining ring 2 Spring seat 3 Diaphragm Spring 4 Retaining...

Page 444: ...mm 4 Inspect the damper spring for cracks or distortion Install a new spring if either condition exists 5 See Figure 6 17 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 0 661 in 16 7...

Page 445: ...ng seat and snap ring Excessive compression of diaphragm spring could dam age clutch pressure plate c See Figure 6 22 Install SPRING COMPRESSING TOOL Part No HD 38515 A onto clutch hub against diaphragm spring d Place a wrench on the clutch spring forcing screw flats to prevent the forcing screw from turning e Turn compressing tool handle clockwise until dia phragm spring compresses just enough to...

Page 446: ...inal Tighten fastener to 76 96 in lbs 8 6 10 9 Nm 11WARNING 1WARNING After installing seat pull upward on front of seat to be sure it is in locked position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070a 11 Install seat See 2 38 SEAT Figure 6 22 Pressure Plate Assembly Figure 6 23 Clutch Adjusting Screw Assembly and Retaining Ring 62...

Page 447: ...CH 3 Remove primary cover See 6 2 PRIMARY COVER 4 Loosen engine sprocket a See Figure 6 24 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 16 Remove adjusting screw assembly a Remove large ...

Page 448: ...aring 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 26 Inspect the clutch shell compensating spring set 9 See Figure 6 27 Inspect clutch shell nee...

Page 449: ...aring 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 32 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 29 Clutch Shell Bearing Remover Insta...

Page 450: ...lutch assembly and primary chain as a unit into primary chaincase 5 See Figure 6 34 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 Figure 6 35 Washer must be installed with the word out facing the mainshaft...

Page 451: ... COVER 11 Adjust Clutch See 1 9 CLUTCH 12 Add SPORT TRANS FLUID See TRANSMISSION FLUID under 1 9 CLUTCH 11WARNING 1WARNING Connect positive battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explo sion which could result in death or serious injury 00068a 13 Connect negative battery cable to battery terminal Tighten fa...

Page 452: ...NING See 1 10 DRIVE BELT Figure 6 38 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...

Page 453: ...o 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 remove Figure 6 39 Chin Fai...

Page 454: ...ether 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 REMOVAL in 6 6 DRIVE BELT SYSTEM 8 See Figure 6 41 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 pinch fastene...

Page 455: ...ee Figure 6 45 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 30 SPROCKET COVER 4 Install chin fairing fasteners and tighten to 36 48 in lbs 4 5 Nm See 2 33...

Page 456: ...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 3rd Gear Countershaft Mainshaft Out 2nd Gear Countershaft Mainshaft In In 4th Gear Countershaft Mainshaft In Out 5th Gear Countershaft Mainshaft Out In b1068x6x ...

Page 457: ...t No HD 42310 HD 43646 or HD 43682 4 Disassemble top end See 3 6 CYLINDER HEAD 5 Disassemble gearcase See 3 17 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 47 Place transmission in 1st gear Remove countershaft TORX screw 1 and retention collar 2 9 See Figure 6 48 Place transmission...

Page 458: ...e shifter drum at the 12 o clock position for later reference 15 See Figure 6 53 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 49 Removing Shifter Shaft Assembly Figure 6 50 Shifter Shaft Assembly Figure 6 51 Rear Isolator Assembly 8617 1 Sh...

Page 459: ...t main bearing by hand No tools are required for this operation 18 See Figure 6 56 Remove the flywheel assembly from left crankcase half Figure 6 54 Crankcase Fasteners D b1016x3x Indicates Bolt Pattern Location 14 fasteners One Behind Shifter Mechanism Figure 6 55 Separating Crankcase Halves 8621 Figure 6 56 Removing Flywheels from Left Case Half 8636 ...

Page 460: ...hat each shifter fork be reinstalled in its original location 1 See Figure 6 57 Remove shifter fork shafts NOTE Carefully tap on alternate sides of the shaft using the pro vided slots 2 See Figure 6 58 Remove shifter drum and shifter forks 3 Remove mainshaft 2nd gear from mainshaft Figure 6 57 Removing Shifter Fork Shafts Figure 6 58 Transmission Assembly 1 Slots for removing the shifter fork shaf...

Page 461: ...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 462: ...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 61 Removing Transmission Assembly from Left Case Half 1 Arbor press 2 Transmission rem...

Page 463: ...ee Figure 6 62 As each component is removed place it on a clean surface in the exact order of removal Figure 6 62 Transmission Parts Identification b0948x6x Figure 6 63 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 464: ...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 465: ...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 seri ous injury 11WARNING 1WARNING Compressed a...

Page 466: ...ext 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 can also cause a bearing to fl...

Page 467: ... to accommodate the new style shifting fork and has a new part number 3 See Figure 6 68 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 retaining ring 8 next to mainshaft 3rd g...

Page 468: ...ning 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 countershaft 8 Locate countersha...

Page 469: ... 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 g...

Page 470: ... bearing 2 See Figure 6 74 Lubricate both main drive gear needle bearing assemblies and the mating surface of the main shaft with HARLEY DAVIDSON SPECIAL PURPOSE GREASE Part No 99857 97 3 See Figure 6 75 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...

Page 471: ...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 76 Main Drive Gear Assembly 1 Main drive gear 2 Needle bearing 2 3 Seal b1069x6x 2 3 1 Figure 6 77 Transmission Assembly Right...

Page 472: ...f case 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 77 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 e...

Page 473: ...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 474: ... 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 475: ...case 4 See Figure 6 84 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 476: ...y scribed line at the 6 o clock position This will place the shifter drum in the 4th gear position 3 See Figure 6 86 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 477: ...HOME Figure 6 87 Crankcase Fasteners D b1016x3x Indicates Bolt Pattern Location One Behind Shifter Mechanism ...

Page 478: ... at 6 o clock 4 Lubricate both main drive gear needle bearing assem blies and the mating surface of the mainshaft with HAR LEY DAVIDSON SPECIAL PURPOSE GREASE Part No 99857 97 5 See Figure 6 91 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 87 Tight...

Page 479: ...e half and release Ratchet arms should now be inside the end plate of the shifter drum contacting the shifter drum pins 3 See Figure 6 95 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 tight...

Page 480: ...8 See Figure 6 97 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 driv...

Page 481: ...f you cannot align lockplate and sprocket screw holes nut may be additionally tightened until screw holes align 9 See Figure 6 97 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 having to additi...

Page 482: ...6 DRIVE BELT SYSTEM 1CAUTION Never tighten rear axle with swingarm brace removed 17 See Figure 6 101 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 6 100 Anti Seize Lubricant Location b1036x2x Figure 6 101 Rear Wheel Mounting Right Side 842...

Page 483: ...HOME NOTES ...

Page 484: ... 10 Battery Cables 7 33 7 11 Battery 7 35 7 12 Headlight 7 42 7 13 Tail Lamp 7 44 7 14 Turn Signals 7 45 7 15 Turn Signal Flasher 7 48 7 16 Handlebar Switches 7 49 7 17 Speedometer Sensor 7 51 7 18 Instrument Module 7 53 7 19 Speedometer Performance Check 7 55 7 20 Horn 7 60 7 21 Neutral Indicator Switch 7 62 7 22 Main Fuse and Fuses 7 63 7 23 Main Wire Harness 7 64 7 24 Interactive Exhaust Harnes...

Page 485: ......

Page 486: ... 5 0 7 ohms Secondary winding 5500 7500 ohms Table 7 6 Electrical System Specifications ELECTRICAL SYSTEM AMPERES Main fuse 30 Ignition fuse 15 Light fuse 15 Accessory fuse 10 Brake horn active muffler fuse XB12R only 10 ECM fuse 10 Key switch fuse 15 Cooling fan fuse 10 Table 7 7 Specifications BULB CHART BULBS REQUIRED WATTS AMPS PART NUMBER Headlights Bulb H3 2 55 4 58 68918 98 Position lamp Eu...

Page 487: ... 1 4 4 0 Nm page 7 53 Main battery ground 48 72 in lbs 5 4 8 1 Nm page 7 66 Main battery ground 48 72 in lbs 5 4 8 1 Nm page 7 34 Negative battery cable at bat tery terminal 72 96 in lbs 8 11 Nm page 7 69 Neutral indicator switch 36 60 in lbs 4 6 8 Nm LOCTITE 243 blue page 7 61 Relay block mounting fasten ers 72 96 in lbs 8 1 10 8 Nm page 7 65 Rotor mounting fasteners 90 110 in lbs 10 12 Nm LOCTIT...

Page 488: ...ce As the vehicle warms up to operating temperature the fuel mix ture will lean and the spark advance will decrease On the XB12R an interactive exhaust system utilizes an actuator 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 eng...

Page 489: ...6 Terminal pin 7 Electronic control module ECM 8 Connector interactive exhaust system 9 Spark plug 2 10 Rear spark plug cable 11 Mounting fastener 12 Ignition coil 13 Front spark plug cable 14 Engine mount 15 Seal 16 Trigger rotor 17 Trigger rotor bolt 18 Cam position sensor 19 Inner cover 1 2 3 5 6 7 4 17 16 9 10 11 18 12 13 19 14 15 9 8 ...

Page 490: ...sition 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 See Table 7 9 Figure 7 2 Ignition Headlight Key Switch 8345 1 ON position 2 OFF position 3 PUSH DETENT 4 LOCK position 5 PARKING LIGHT position 6 Upper triple clamp 1 2 3 4 5 6 Table ...

Page 491: ...x cover See 2 34 INTAKE COVER ASSEMBLY 7 See Figure 7 4 Remove steering stem pinch fastener 2 8 Remove upper fork clamp pinch fasteners 1 9 See Figure 7 4 Hold or brace the lower fork clamp and remove steering stem cap 3 10 Remove the upper fork clamp 4 from forks 11 See Figure 7 5 Use Snap on Tamper Resistant T45 Torx driver Part No FTXR45E to remove ignition switch fas teners 3 securing ignition...

Page 492: ...step do not force ignition switch 4 into ignition switch body 2 If ignition switch does not easily slide into ignition 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 b1108x7x 1 B...

Page 493: ...ion switch fuse block and right handlebar switch wires 6 Install airbox assembly See 4 45 AIRBOX 7 See Figure 7 3 Attach cable straps to upper fork clamp a Install cable strap to the right of ignition switch securing right hand switch and brake line wires to upper fork clamp b Install cable strap to the left of ignition switch secur ing left hand switch and clutch cable wires to upper fork clamp 8...

Page 494: ...y fatal elec tric 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 Remov...

Page 495: ...k 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 environme...

Page 496: ...ngaging 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 Table 7 11 Starter Interlock Troubleshooting PROBLEM CHECK FOR CORRECTION Electric starter will not crank Battery problems See 7 11 BATTERY Inappropriate gear sel...

Page 497: ...rity TN LTGN Terminal 8 Terminal 2 Figure 7 12 Ohmmeter Diode Test Continuity Infinite ohms b0643x4x 1 2 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 2 6 7 10 87 87A 30 85 86 3 RELAY CENTER ISO ISO ISO KEY SW IGNITION START 19 20 21 22 23 24 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 11 Spare Diode Bk Hn Mflr Fan IGN Acces Key Sw Lights ECM Spare Empty Empty Neutral Switch TN LTG...

Page 498: ...ground at neutral switch terminal 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 Depress starter button Does Starter work Check for ground on TN Lt GN wire of Diode Ground present NO Neutral ...

Page 499: ...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 500: ...Unplug 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 CONTROL Figure 7 14 Clutch Switch b0393x7x 1 Clutch engaged switch open 2 Clut...

Page 501: ...ity 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 located on the left side of the vehicle behind the fairing See Ignition Relay under 7 5 STA...

Page 502: ...de using Starter 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 diode Figure 7 18 Fuse Block 10960 19 20 21 22 23 24 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 11 Spare Diode Bk Hn Mflr Fan IGN Acces Key Sw Lights ECM Spare Empty Empty b1165x4x ...

Page 503: ... to reduce 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 exhau...

Page 504: ...active Control System XB12 Models Only 1 Upper EVA isolator 2 Interactive exhaust cable 3 Harness with connector 161B 4 Interactive exhaust cable bracket 5 Actuator 6 Lower EVA Isolator 7 Air cleaner cover 2 4 6 7 3 8899 1 5 ...

Page 505: ...lay to interactive exhaust cable 6 loosen jam nut and remove cable from bracket on actuator 5 10 Remove interactive exhaust cable from cable 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...

Page 506: ... interactive exhaust harness to actuator 161B 6 Install upper isolator and route fuel vent line and install 7 Attach interactive exhaust cable to bracket on actuator and adjust See 1 17 INTERACTIVE EXHAUST CABLE XB12 MODELS ONLY 1WARNING 1WARNING Connect positive battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery expl...

Page 507: ...HOME NOTES ...

Page 508: ... stator which bolts to the engine crankcase Voltage Regulator See Figure 7 23 The voltage regulator is a series regulator The voltage regulator combines the functions of rectifying converting AC voltage to DC and regulating controlling volt age output TROUBLESHOOTING When the charging system fails to charge or does not charge at a satisfactory rate check the following Battery Check for a weak or d...

Page 509: ... 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 510: ...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 511: ...SOLENOID STARTER MOTOR 128A A B 46B 46A HD 3 PHASE STATOR REGULATOR VOLTAGE 77A 77B TO VOLTAGE REGULATOR 30A MAXIFUSE TO J FUSE ASSY 5A GRD2 STARTER BATTERY BK 2 1 1 4 4 3 3 2 2 2 1 1 R BK 2 1 R R Y BK MALE FEMALE bd0018xx BK R R Y BK 35B BK BK BK BK BK 35A ...

Page 512: ...efore connecting tester cables to battery terminals Connecting tester cables with load tester ON can cause a spark and battery explo sion which could result in death or serious injury 00252a 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 wiring at the connector 4...

Page 513: ... 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 24 INTERACTIVE EXHAUST HARNESS XB12 MODELS Disconnect from alter nator 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 ...

Page 514: ... 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 515: ...etic 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 24 INTERACTIVE EXHAUST HAR NESS XB12 MODELS 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 the proper ...

Page 516: ...sting 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 24 INTERACTIVE EXHAUST HARNESS XB12...

Page 517: ...Remove 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 24 INTERACTIVE EXHAUST HARNESS XB12 MOD ELS 3 Connect negative battery cable to battery terminal 1WARNING 1WARNI...

Page 518: ...ery cable from starter INSTALLATION 1 Clean cable connectors and battery terminals using a wire brush or sandpaper to remove any oxidation 1WARNING 1WARNING Connect positive battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explo sion which could result in death or serious injury 00068a CAUTION Connect the cables to ...

Page 519: ...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 520: ...agnesia vegetable 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 vehicl...

Page 521: ...Turn battery load tester OFF before connecting tester cables to battery terminals Connecting tester cables with load tester ON can cause a spark and battery explo sion which could result in death or serious injury 00252a 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 lo...

Page 522: ...rap 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 water 2 Clean cable connectors an...

Page 523: ... hotter than 110 F 43 C during charging discontinue charging and allow the battery to cool Overheating may result in plate distortion internal shorting dryout or other damage 1 Perform a voltmeter test to determine the state of charge See BATTERY TESTING If battery needs to be charged 1WARNING 1WARNING Remove battery from motorcycle before charging Elec trolyte leakage will damage motorcycle parts...

Page 524: ...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 525: ... CAUTION Do not over tighten bolts on battery terminals Use rec ommended torque values Over tightening battery termi nal bolts could result in damage to battery terminals 00216a 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 bat...

Page 526: ...ontinuously at a rate that depends on the ambient temperature 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...

Page 527: ...ch could cause death or serious injury disconnect negative battery cable before proceeding 00048a 1 Disconnect negative battery cable 1CAUTION Handle bulb carefully and wear eye protection Bulb con tains Halogen gas under pressure which if not handled carefully could cause serious eye injury 00062a CAUTION Never touch the quartz bulb Fingerprints will etch the glass and decrease bulb life Grab the...

Page 528: ... the headlight bulb connector 4 Connect negative battery cable 1WARNING 1WARNING Be sure that all lights and switches operate properly before operating motorcycle Low visibility of rider can result in death or serious injury 00316a 5 Check headlight 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 47 ...

Page 529: ...perate properly before operating motorcycle Low visibility of rider can result in death or serious injury 00316a 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 Pr...

Page 530: ...g 5 Rear 1 Remove seat See 2 38 SEAT 2 Remove tail frame upper body work See 2 36 SUB FRAME TAIL ASSEMBLY AND BODY WORK 3 See Figure 7 52 Disconnect bullet connectors on turn signal wires 4 See Figure 7 51 Remove fastener 6 and lockwasher 5 NOTE In next step reflector bracket 3 will be removed with turn signal 1 5 Remove turn signal from tail section 7 and license plate bracket 4 Figure 7 49 Front...

Page 531: ...HOME Figure 7 51 Rear Turn Signals 1 Turn signal 2 Turn signal bulb 3 Reflector bracket 4 License plate bracket 5 Washer 2 6 Fastener 2 7 Tail section 1 2 4 7 5 6 b1008a7x 3 ...

Page 532: ...nal fits into hole in reflector bracket and tab on reflector bracket fits into hole in license plate bracket 3 Attach turn signal using lockwasher 5 and fastener 6 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 52 1WARNING 1WARNING Be sure that all lights and switches operate properly before operating motorcycle Low visibility of ri...

Page 533: ...ND SHIELD AND MIRRORS 1WARNING 1WARNING Be sure that all lights and switches operate properly before operating motorcycle Low visibility of rider can result in death or serious injury 00316a 4 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 IGN b See Figure 7 54 Activate left turn signals using swit...

Page 534: ...om wiring harness 3 Detach brake switch connector 121 Left Side 1 Remove left switch housing mounting fasteners 2 Unplug the clutch switch 95 3 Access left handlebar switch connector 24 under fair ing Remove cable straps Detach connector 24 from wiring harness Figure 7 55 Right Handlebar Switch Connection 1 2 1 3 2 4 b1101x7x Right Handlebar Switch 22 Brake Switch 121 To starter relay GY GY O W BK...

Page 535: ...ront housing with hole in handle bar b Attach switch housing with three mounting fasteners and tighten to 25 33 in lbs 3 4 Nm 2 Connect clutch switch 95 3 Attach right handlebar switch connector 24 to wire har ness See D 1 HOSE AND WIRE ROUTING for wire rout ing information 1WARNING 1WARNING Be sure that all lights and switches operate properly before operating motorcycle Low visibility of rider c...

Page 536: ...cable strap 4 Figure 7 57 Speedometer Sensor 1 8741a 2 3 4 1 Fastener 2 Vehicle speed sensor 3 Starter 4 Cable strap 1 2 3 4 2 1 5A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 7 RELAY CENTER ISO ISO ISO KEY SW IGNITION START Spare Diode Bk Hn Mflr Fan IGN 15A 15A 10A 10A 10A 10A 15A 15A 10A Acces Key Sw Lights ECM Spare FUSE BLOCK J FUSE ...

Page 537: ...FFLER 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 CHECK ENGINE LAMP FUEL PUMP OUTPUT SYSTEM GROU...

Page 538: ...bracket 1 Bulb Replacement 1 Once the instrument module has been removed from the vehicle place face down on a work surface 2 Remove the nine fasteners securing the back of the module housing to the display and remove back cover CAUTION Do not turn display over Speedometer and Tachometer will fall out possibly causing damage to instruments 3 See Figure 7 61 Insert screwdriver blade into the slot o...

Page 539: ...ND SUPPORT BRACKET 5 Install negative battery cable 1WARNING 1WARNING After installing seat pull upward on front of seat to be sure it is in locked position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070a Install seat See 2 38 SEAT Figure 7 63 Instrument Module Connector 39 8426 Figure 7 64 Instrument Module b1009x7x 2 1 6 3 4 5 1 He...

Page 540: ...determining if speedometer replacement is necessary Speedometer Operation Test NOTE For information on the correct routing of vehicle speed sensor wiring see 7 24 INTERACTIVE EXHAUST HARNESS XB12 MODELS 1 See Figure 7 66 Locate the 3 place vehicle speed sen sor connector 65 under the sprocket cover See 2 30 SPROCKET COVER 2 Place speedometer tester power switch in the ON posi tion Place signal swi...

Page 541: ...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 67 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 542: ... 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 Go to Speedometer Test Chart 2A 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 ...

Page 543: ...tput 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 pre...

Page 544: ...d read 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 VSS NO 4 6 VDC is present but no flunct...

Page 545: ...en to 72 96 in lbs 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 in locked position While riding a loose seat can s...

Page 546: ...r 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 70 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 pr...

Page 547: ... or faulty wiring c After testing and repair connect wire lead to indica tor switch 4 Install sprocket cover See 2 30 SPROCKET COVER REMOVAL INSTALLATION 1 Verify that the ignition key switch is turned to OFF 2 Remove sprocket cover See 2 30 SPROCKET COVER NOTE If replacing neutral indicator switch wiring see 7 24 INTER ACTIVE EXHAUST HARNESS XB12 MODELS for correct wire routing 3 See Figure 7 72 ...

Page 548: ... 7 5 Amps Always investigate the cause of blown fuses before replacing them Main Fuse See Figure 7 75 The 30 Amp main fuse is located under the seat To disable the motorcycle s ignition system pull the main fuse up and out of the main fuse holder Figure 7 73 Fuse Block Figure 7 74 Fuse Block Figure 7 75 30 A Main Fuse Location 10960 19 20 21 22 23 24 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 11...

Page 549: ...t in death or serious injury 00049a 2 Unthread fastener and remove battery negative cable black from battery negative terminal 3 Pull back terminal cover boot 4 Unthread fastener and remove battery positive cable red from battery positive terminal 5 Disconnect positive battery cable from starter 6 Remove tail frame upper body work 2 36 SUBFRAME TAIL ASSEMBLY AND BODY WORK 7 See Figure 7 76 Disconn...

Page 550: ...sconnect a Flasher connector 30 b Bank angle sensor connector 134 c Electronic control module ECM 4 30 ELEC TRONIC CONTROL MODULE d Instrument module connector 39 e Horn connectors 122 f Ground terminals on front of steering head g Left switch housing connector 24 and right switch housing connector 22 h Clutch switch 95 from left switch housing i Front brake switch 121 from right switch housing j ...

Page 551: ... 3 ENGINE ROTATION FOR SERVICE 9 Install sprocket cover wiring See 7 25 SPROCKET COVER WIRING 10 Install oil pressure switch connector to oil pressure switch 11 See Figure 7 80 Install cable straps a Front cable strap 3 secures voltage regulator and oil pressure switch wiring b Middle cable strap 2 secures voltage regulator oil pressure switch and cam position sensor wiring c Rear cable strap 1 se...

Page 552: ...ke light switch connec tor 121 5 Install cable strap 4 24 Install main fuse case 3 25 Install main battery ground 1 and wire harness ground 2 Tighten fastener to 48 72 in lbs 5 4 8 1 Nm 26 See Figure 7 76 Connect tail harness connector 3 Attach cable strap 2 27 Install starter side of positive battery cable to starter 1WARNING 1WARNING Connect positive battery cable first If positive cable should ...

Page 553: ... 3 4 5 9 1 2 8 7 6 1 Cable strap 2 Left turn signal connectors 3 Data link 91 4 Left switch housing connector 24 5 Cable strap 6 Headlight connector 38 7 Right turn signal connectors 8 Cable strap 9 Right switch housing connector 22 10 Ignition switch connector 33 11 Cable strap ...

Page 554: ...nd cut as required 8 Pull actuator harness through frame 9 Move foam rubber isolator out of the way and disconnect connector 161B from actuator 10 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 XB12 MOD ELS ONLY b Remove interactive exhaust cable from cable wheel c Remove actuator Figure 7 83 Left Si...

Page 555: ...ound cable and actuator ground wire Tighten to 48 60 in lbs 5 4 6 7 Nm 1WARNING 1WARNING Connect positive battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explo sion which could result in death or serious injury 00068a 9 Connect negative battery cable to battery terminal Tighten fastener to 72 96 in lbs 8 11 Nm 10 I...

Page 556: ...stalled over oil pressure and side stand switch wiring 3 Connect stator connector 9 4 See Figure 7 88 Connect cam position sensor 14 1 Form a loop 2 as shown using wiring leading to cam position sensor 5 See Figure 7 89 Connect neutral switch connector 6 See Figure 7 90 Form a loop 6 as shown using neutral switch wiring Figure 7 87 Sprocket Cover Wiring Figure 7 88 Cam Position Sensor Wiring 10549...

Page 557: ... boss 2 10 Install cable strap 3 securing vehicle speed sensor wir ing to starter connector 128 wiring 11 Install cable strap 5 securing main harness wiring 12 Install cable strap 6 securing stator cam position sen sor and oil pressure switch wiring 13 Add cable strap 7 to secure cam position sensor and voltage regulator wiring Figure 7 89 Neutral Switch Connector 131 Figure 7 90 Neutral Switch Wi...

Page 558: ...BJECT 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 E ACTIVE INTAKE SYSTEM JAPAN ONLY E 1 Table Of Contents APPENDICES ...

Page 559: ......

Page 560: ... B 41174 2 Replacement Pad Part No B 42887 Brake Caliper Piston Remover Part No B 43721 Front Fork Seal Driver 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 ...

Page 561: ...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 562: ... bs npond 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 hslnsl...

Page 563: ...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 564: ...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 565: ...cing Screw Part No J 5586 Transmission Shaft Retaining Ring Pliers Part No HD 41609 Amp Terminal Crimp Tool 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 ...

Page 566: ...HOME Part No HD 41354 Speedometer Tester Part No HD 47248 Rocker Housing Wrench Part No HD 47250 Intake Manifold Wrench HD 47248 HD 47250 Part No HD 47258 Rocker Cover Wrench HD 47258 ...

Page 567: ...HOME NOTES ...

Page 568: ...hamber 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 NOTES 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 termin...

Page 569: ...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 570: ... 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 571: ... 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 the crimping sequence is complete Raise up locking bar and remove contact 6 Inspect the quality of the core and insulation cri...

Page 572: ...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 573: ...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 574: ...e 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 the...

Page 575: ... 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 576: ... 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 577: ...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 578: ...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 579: ... 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 Tools are avail able to install Packard...

Page 580: ...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 581: ...ring 31 left front turn signal 2 1 place bullet beneath left side of fairing 33 ignition switch 4 place Augat beneath right side of fairing 38 headlamp connector 4 place Amp beneath fairing 39 instrument module 20 place Multilock in fairing 46 stator 4 place Deutsch under sprocket cover 61 fuse and diode assembly spade terminals right side of fairing 62 relay assembly spade terminals left side of ...

Page 582: ...ilock under seat 122 horn spade terminals in fairing 128 starter solenoid spade terminals top of starter 131 neutral switch 1 place bullet under sprocket cover 134 bank angle sensor 6 place Sumitomo in fairing 137 oxygen sensor 1 place Packard behind rear cylinder head 164 Interactive exhaust circuit to ECM under seat 161 Interactive exhaust to solenoid under airbox cover Table B 2 Electrical Conn...

Page 583: ... 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 Starting and charging circuits B 22 Component circuits B 23 ...

Page 584: ... Y R BK BK BN Y BN Y GY GY TN Y R W R W W BK W BK R W R W GN W GN W BK W BK W R BK BK BE W O W GY V R BK LT GN R R W LT GN GY BK W V R BK R BK R BK R BK GN R BK R BK TN LT GN BK R GY GY O GY O BK W BK R BE 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 VEHICLE SPEED SENSOR INJE...

Page 585: ...B 18 2005 Buell Firebolt Electrical HOME 2005 XB Firebolt Main Harness 2005 XB Firebolt Main Harness ...

Page 586: ... 4 D D 4 4 4 A A A A 1 1 B B B B 2 2 C C C C 3 3 1 1 1 1 1 1 1 2 2 2 2 2 2 2 DIODE COOLING FAN BRAKE HORN MUFFLER IGNITION ECM KEY SWITCH 1 90A ENGINE TEMP SENSOR 90B 131A 1 1 W TN V O 165A 165B ACTIVE MUFFLER SUB HARNESS TN V O W 2 1 3 ECM SENSOR POSITION THROTTLE 88B 88A 3 2 1 1 2 3 R W V Y BK W 161A GROUND V bat MUFFLER VALVE ACTUATOR MOTOR SENSOR POSITION DC CONTROL ELECTRONICS O TN V W BK 1 1...

Page 587: ...B 20 2005 Buell Firebolt Electrical HOME 2005 XB Firebolt Engine Management Circuit 2005 XB Firebolt Engine Management Circuit ...

Page 588: ...Y R Y O O BN O W V R Y BK BE W O W V R BK R BK R BE 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 2 3 3 4 4 5 5 6 6 7 7 8 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 2 2 2 2 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 SWITCH WIRING DIAGRAM CONNECTING WIRE SEC...

Page 589: ...B 22 2005 Buell Firebolt Electrical HOME 2005 XB Firebolt Lighting Circuit 2005 XB Firebolt Lighting Circuit ...

Page 590: ...GN R BK 62B RELAY CENTER DIODE 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 CH...

Page 591: ...B 24 2005 Buell Firebolt Electrical HOME 2005 XB Firebolt Horn Instruments Circuit 2005 XB Firebolt Horn Instruments Circuit ...

Page 592: ...R BK R LOCK 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 1 2 2 DIODE IGNITION KEY SWITCH 131A 1 MALE FEMALE 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 SWIT...

Page 593: ...B 26 2005 Buell Firebolt Electrical HOME 2005 XB Firebolt Starting Circuit 2005 XB Firebolt Starting Circuit ...

Page 594: ...tarting Charging Circuit BATTERY CABLE SOLENOID STARTER MOTOR 128A A B 46B 46A HD 3 PHASE STATOR REGULATOR VOLTAGE 77A 77B TO VOLTAGE REGULATOR 30A MAXIFUSE TO J FUSE ASSY 5A GRD2 STARTER BATTERY BK 2 1 1 4 4 3 3 2 2 2 1 1 R BK 2 1 R R Y BK MALE FEMALE bd0018xx ...

Page 595: ...B 28 2005 Buell Firebolt Electrical HOME 2005 XB Firebolt Starting Charging Circuit 2005 XB Firebolt Starting Charging Circuit ...

Page 596: ... 7 W BK W Y BK Y BK W BK BE W BK BK BK O W HDI ONLY LAMPS POSITION O W BK W BK Y BN BK BE BK BK R Y O W Y BK V BK BE 86B REAR INJECTOR OIL PRESSURE SWITCH MUFFLER ACTUATOR SUB HARNESS Y0206 1AA TO MAIN HARNESS POSITION SENSOR MTR CONTROL ELECTRONICS MUFFLER VALVE ACTUATOR TAIL LAMP REAR TURNING LIGHTS RH TURN SIGNAL TAIL LIGHT 93A 93B 19A 19B 7B 18A 18B LH TURN SIGNAL TO MAIN HARNESS YH350 02A8 ST...

Page 597: ...B 30 2005 Buell Firebolt Electrical HOME 2005 XB Firebolt Component Circuits 2005 XB Firebolt Component Circuits ...

Page 598: ...4 567 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 ...

Page 599: ...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 600: ...2005 Buell Firebolt Appendix D D 1 HOME HOSE AND WIRE ROUTING D 1 Figure D 1 Front and Rear Brake Systems Right Side View b1114xax ...

Page 601: ...D 2 2005 Buell Firebolt Appendix D HOME Figure D 2 Rear Brake Systems Top View b1115xbx ...

Page 602: ...2005 Buell Firebolt Appendix D D 3 HOME Figure D 3 Rear Brake Systems Left Side View b1116xcx ...

Page 603: ...D 4 2005 Buell Firebolt Appendix D HOME Figure D 4 Evaporative Emissions Control California Models Top View Carbon canister b1117xax ...

Page 604: ...5 HOME Figure D 5 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 2 1 3 4 b1118xbx ...

Page 605: ...D 6 2005 Buell Firebolt Appendix D HOME Figure D 6 Wiring Harness Left Side View 1 Active intake solenoid Japan only 2 Intake air temperature sensor IAT 3 Fuel pump 3 2 b1119xdx To ECM 1 ...

Page 606: ...2005 Buell Firebolt Appendix D D 7 HOME Figure D 7 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 b1120xbx 1 ...

Page 607: ...ix D HOME Figure D 8 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 b1121xcx 4 1 ...

Page 608: ... D D 9 HOME Figure D 9 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 b1122xax 1 ...

Page 609: ...D 10 2005 Buell Firebolt Appendix D HOME Figure D 10 Oil Lines Bottom View 1 Vent line 2 Feed oil line 3 Return oil line b1123xbx 1 2 3 ...

Page 610: ...2005 Buell Firebolt Appendix D D 11 HOME Figure D 11 Clutch Throttle Cables and Interactive Exhaust System 1200 Only Right Side View b1124xax Exhaust valve actuator Muffler valve ...

Page 611: ...12 2005 Buell Firebolt Appendix D HOME Figure D 12 Clutch Throttle Seat Release Cables and Interactive Exhaust System 1200 Only Left Side View Cable seat lock b1125xbx Muffler valve Exhaust valve actuator ...

Page 612: ... D 13 Clutch Throttle Seat Release Cables and Active Intake System with Exhaust Valve Actuator 1200 Only Top View Cable seat lock TPS adjuster b1126xdxa Clip to functional airbox cover Exhaust valve actuator mounted on top of functional airbox cover ...

Page 613: ...HOME NOTES ...

Page 614: ...Using TEST CONNECTOR KIT Part No HD 41404 attach Brown pin probe and patch cord to 179 1 2 VERIFY SETTINGS 1 Prior to verifying the active intake system check the throttle position sensor TPS zero and adjust if neces sary See 1 20 THROTTLE POSITION SENSOR TPS 2 Leave Digital Technician attached to vehicle 3 In Digital Technician go to Active Intake test screen 4 Rotate throttle grip to wide open t...

Page 615: ...tle you should be able to move the solenoid shaft slightly inward until the shaft bottoms out This slight travel will be the retraction freeplay NOTE This freeplay is necessary for the solenoid to properly func tion Freeplay should be 1 32 in 0 79 mm or greater c If you have no travel in the shaft adjust cable hous ing 4 away from the solenoid bracket 3 until free play is achieved Figure E 1 Check...

Page 616: ... 32 in 0 79 mm or greater c If you have no travel in the shaft loosen jam nuts 2 and adjust cable housing 4 towards the solenoid bracket 3 until freeplay is achieved 4 See VERIFY SETTINGS Once freeplay has been set it will be necessary to verify settings and adjustments again If values are not between 10 4 10 9 degrees see Throttle Stop Screw in this section Figure E 2 Checking for Freeplay in the...

Page 617: ...ile reading the TPS on Digital Technician until setting is between the range of 10 4 to 10 9 a If the reading is below 10 4 adjust screw clockwise b If the reading is above 10 9 adjust screw counter clockwise 5 Reconfirm the TPS setting Repeat process if needed 6 Adjust active intake cable assembly See CABLE ADJUSTMENT 7 Verify active intake TPS settings 8 Install cosmetic intake cover assembly an...

Page 618: ...HOME Figure E 4 Active Intake System 1 1 2 2 J1 J3 J4 J2 11A 164A 179B 179A 10A 178A 178B GY O W GY 1 1 2 2 Active Intake Solenoid Control Signal ECM ...

Page 619: ...nt NO Measure resistance between connector 178A pin 1 and 179B pin 1 Continuity present NO NO Clean and repair connections Disconnect active solenoid connector 179B at ECM Measure resistance at pin 2 to chassis ground Resistance less than 10 000 ohms Repair short to voltage in GY O wire YES NO Repair open in GY O wire YES NO Repair short to ground in W GY wire Measure resistance between connector ...

Page 620: ...nnect battery voltage to 178B pin 2 of active intake solenoid Use HD 41404 brown pin and patch cable Hold throttle wide open Observe throttle plate and connect solenoid pin 1 to ground Does solenoid attempt to pull throttle almost closed NO Hold throttle wide open Energize active intake solenoid Does throttle close to an angle less than 11 degrees YES YES NO Replace ECM See CABLE ADJUSTMENT in thi...

Page 621: ...e assembly 10 see 4 45 AIRBOX CAUTION When installing the backing plate it is important to ensure that the active cable remains in the tower on the cable wheel on the throttle body If the cable comes out the cable will not work properly and will not be able to be adjusted NOTES When installing baseplate be sure to feed the electrical connector 1 through hole in baseplate first and then insert acti...

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