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Buell 2007 FIREBOLT Service Manual Download Page 1

 

2007 BUELL FIREBOLT MODELS

 

SERVICE MANUAL

 

Part Number 99493-07Y

 

Section 1: Maintenance

Section 2: Chassis

Section 3: Engine

Section 4: Fuel System

Section 5: Starter

Section 6: Drive/Transmission

Section 7: Electrical

Appendices

Summary of Contents for 2007 FIREBOLT

Page 1: ... FIREBOLT MODELS SERVICE MANUAL Part Number 99493 07Y 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: ...art No HD 28431 B Black Light Fluorescent Additive Use with HD HD 25070 HD 26792 HD 28431 6 Fluorescent Additive 6 1 oz bottles HD 28431 22 Fluorescent Additive 1 22 oz container HD 28431B Part No HD 33223 1 Cylinder Compression Gauges Part No HD 33416 Universal Driver Handle Part No HD 33418 Universal Puller Forcing Screw h33223 HD33416 h33418 ...

Page 3: ...No HD34736 B Valve Spring Compressor Part No HD 34751 Nylon Valve Guide Brush h33446 b1001a3x h34726B h34751 Part No HD 34902 B Mainshaft Primary Bearing Race Remover And Installer Part No HD 35102 Wrist Pin Bushing Hone 20 mm Part No HD 35316 C Main Drive Gear Remover Installer and Main Drive Gear Bearing Installer Part No HD 35457 Black Light Leak Detector h34902b h35102 HD 35316C h35457 ...

Page 4: ...hso bho knsdl hlno hslnslp pffb odlbndpob npond bndb ndbno bho Bdhgkjsbkdv ksjjlkn lk knsdl hlno hslnsln nlslns finbp pffb odlbndpob nponno bho knsdl hlno hslnsln nlslns finbp pklhb odlbndpob npdb ndbno bho knsdl hlno hslnslnnsdl hlno hso bho bs npond bpdk kznh odlbndpob npond bndb ndbno bho Bdhgkjsbkdv ksjjlkn lk knsdl hlno hslnsln nlslns finbp pffb odlbndpob nponno bho knsdl hlno hslnsln nlslns ...

Page 5: ...rt No HD 39782 A Cylinder Head Support Stand Part No HD 39786 Cylinder Head Holding Fixture HD 39565 HD39617 h39782 h39786 Part No HD 39964 Reamer Lubricant Cool Tool Part No HD 39965 Deutsch Terminal Crimp Tool Part No HD 39969 Ultra Torch UT 100 Part No HD 39978 Fluke 78 Multimeter DVOM F HD39964 HD39965 HD 39969 HD39978 ...

Page 6: ...lamp Pliers Part No HD 41155 VHS Tape Storage Rack Part No HD 41177 Fork Tube Holder HD 41025 A HD 41137 HD41155 2 b41177 94 Part No HD 41185 Hose Cutting Tool Part No HD 41334 RPM Inductive Pickup Part No HD 41354 Speedometer Tester Part No HD 41404 Harness Connector Test Kit HD 41185 HD39617 h41354 HD41404 ...

Page 7: ...rt No HD 41475 100 Deutsch Connector Pick Tool Part No HD 41496 Main Drive Gear Seal Installer HD 41417 h41475 h41475 100 HD41496 Part No HD 41609 Amp Multi Lock Crimper Part No B 41623 B Oil Line Remover Part No HD 41675 Oil Pressure Sending Unit Wrench Part No HD 42310 Engine Transmission Stand HD39965 B41623 HD41675 h42310a ...

Page 8: ...o HD 42320 A Piston Pin Extractor Part No HD 42322 Piston Support Plate h42310 150a h42311a h42320a h42322 Part No HD 42326 A Crankshaft Guide Part No HD 42376 Battery Load Tester Part No B 42887 Brake Caliper Piston Remover Part No HD 43646 A Rolling Engine Stand h42326 600 200 Made in USA PP 9606 0001 h42376a b42887 h43646a ...

Page 9: ...river Part No B43982 Transmission Locking Tool Part No HD 43984 Crankshaft Locking Tool h43682 10a b43721 b 43982 hd43984 Part No B 43987 Engine Cradle Part No B 43993 Wheel Bearing Collets Part No HD 44060 Wheel Bearing Remover Installer Part No HD 44067 A Oil Filter Wrench b43987a B 43993a hd44060 hd44067b ...

Page 10: ...st Adapter Part No HD 44720 TSSM Adapter Cable h44358bc h44567 h44687 HD44720a Part No HD 44750 P29 Panasonic Toughbook touch screen and HD 44750 P50 Panasonic Toughbook non touch screen Part No B 45520 Gear Detente Assembly Aid Part No B 45521 Steering Head Bearing Remover Installer Part No B 45522 Fuel Pressure Gauge Adapter HD 44750 b45520 b45521 B 45522a ...

Page 11: ...45524 Valve Guide Installer Part No B 45525 Valve Guide Hone Part No B 45657 Fuel Pump Puller B 45523 B 45524 B 45525 b45657 Part No B 45676 Sprocket Shaft Seal Installer Part No HD 45830 Techlink Kit Part No HD 45835 Road Test Kit Part No B 45847 Cross Plate B 45676 hd45830a HD45835a B43983 ...

Page 12: ... Bearing Remover Part No HD 45928 Terminal Crimper Part No HD 45929 Terminal Remover h45907 b45926 HD45928 HD4529 Part No HD 45966 Front Fork Compressor Part No B 46279 7 8 Axle Wrench Hex Part No HD 46283 Primary Drive Locking Tool Part No HD 46285 Transmission Assembly Fixture HD45996a B 46279 HD 46283 HD 46285 ...

Page 13: ...Penlight Part No HD 47184 Leak Detector Flashlight Part No HD 47187 Technician Pen Light HD 46288 HD 47183 HD 47184 HD 47187 Part No HD 47188 Technician Flex Light Part No HD 47248 Rocker Housing Wrench Part No HD 47250 Intake Manifold Wrench Part No HD 47258 Rocker Cover Wrench HD 41788 HD 47248 HD 47250 HD 47258 ...

Page 14: ... Conductance and Electrical System Analyzer Part No J 5586 Transmission Shaft Retaining Ring Pliers HD 47855 HD 48030a HD 48053A J 5586A Part No B 59000 B Oil Level Gauge Part No HD 94660 37B Mainshaft Locknut Wrench Part No HD 94804 57 Rocker Arm Bushing Reamer Part No HD 95635 46 All Purpose Claw Puller use with HD 95637 46A 0 0 0 0 0 1 2 3 4 5 60 mL HD59000B HD 94660 37B h94804 57 HD 95635 46 ...

Page 15: ...Items 6 HD 95769 69 7 HD 95770 69 and 8 HD 95771 69 are optional Part No HD 95952 33C Connecting Rod Clamping Tool Part No HD 95970 32D Piston Pin Bushing Tool h95637 46A h95760 69B h95952 33C h95920 32D Part No HD 96333 51E Piston Ring Compressing Tool Part No HD 96550 36B Valve Lapping Tool Part No HD 96796 Valve Spring Test Fixture Part No HD 96921 52B h96333 51C h96550 36A 96796 47 h96921 52C ...

Page 16: ...2007 Buell Firebolt Appendix A A 15 HOME Part No HD97097 65B Hose Clamp Pliers Part No HD 99500 80 Wheel Truing Balancing Stand h97081a HD99500 80a ...

Page 17: ...A 16 2007 Buell Firebolt Appendix A HOME NOTES ...

Page 18: ...ll terminal from chamber Do not tug on the wire until the tang is released or the terminal will be difficult to remove A click is heard if the tang is engaged but then inadvertently released Repeat the step without releasing the tang 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...

Page 19: ...Gently tug on wire 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 ...

Page 20: ... 1 Socket terminal 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 21: ...mp 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 crimps ...

Page 22: ...n to separate the 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...

Page 23: ...all terminals are 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 insid...

Page 24: ...on the socket side must be aligned with the latch cover on the pin side For those connectors with two external latches 8 pin and 12 pin a different system is used to prevent improper assembly Align the tabs on the socket housing with the grooves on the pin housing Push the connector halves together until the latches click If latches do not click latch press on one side of the connector until that ...

Page 25: ...its snugly in the 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 automati...

Page 26: ...minal 2 Wire seal 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 27: ...nside the chamber 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 in...

Page 28: ...nals that have been 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 an...

Page 29: ...ger cavity next to each terminal 5 Insert the pick Snap On TT600 3 into the cavity until it stops Pivot the end of the pick toward the terminal to depress the locking tang Remove the pick and gently tug on the wire to pull the terminal from the wire end of the connector Repeat the step if the terminal is still locked in place NOTE A series of Packard Electrical Terminal Crimp Tools are avail able ...

Page 30: ... pair folds over insulation 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...

Page 31: ...iring 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 32: ...spade terminal 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 161 Interactive exhaust to actuator 4 place Amp under air cleaner cover 164 Interactive exhaust circuit to ECM spade terminal under seat 165 Interactive exhaust subharness to main harness 3 place Deutsch u...

Page 33: ...TO WIRING DIAGRAMS B 5 Table B 3 Wiring Diagrams DIAGRAM PAGE Main harness B 17 Engine management circuit B 19 Lighting circuit B 21 Horn and instruments circuit B 23 Starting circuit B 25 Starting and charging circuits B 27 Component circuits B 29 ...

Page 34: ... 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 INJECTOR REAR OUTPUT 5V SENSOR POWER 0 0 0 1 R 1...

Page 35: ...B 18 2007 Buell Firebolt Electrical HOME 2007 XB Firebolt Main Harness 2007 XB Firebolt Main Harness ...

Page 36: ... 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 SENSOR CONTROL SIGNAL TN V W O 3 1 ...

Page 37: ...B 20 2007 Buell Firebolt Electrical HOME 2007 XB Firebolt Engine Management Circuit 2007 XB Firebolt Engine Management Circuit ...

Page 38: ... Y BK BE W O W V R BK R BK R BE BE O W R BK 10 87 87A 30 85 86 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 2 4 3 1 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 L...

Page 39: ...B 22 2007 Buell Firebolt Electrical HOME 2007 XB Firebolt Lighting Circuit 2007 XB Firebolt Lighting Circuit ...

Page 40: ...ENTER DIODE BRAKE HORN MUFFLER ACCESSORY KEY SWITCH 131A 1 0 2 4 3 1 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 FUE...

Page 41: ...B 24 2007 Buell Firebolt Electrical HOME 2007 XB Firebolt Horn Instruments Circuit 2007 XB Firebolt Horn Instruments Circuit ...

Page 42: ...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 87 87A 30 85 86 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 2 4 3 1 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 ...

Page 43: ...B 26 2007 Buell Firebolt Electrical HOME 2007 XB Firebolt Starting Circuit 2007 XB Firebolt Starting Circuit ...

Page 44: ...Charging Circuit bd0018xx 128A A B 46B 46A 77A 77B 30A 5A GRD2 BK 2 1 1 4 4 3 3 2 2 2 1 1 R BK 2 1 R R Y BK BK R R Y BK BK BK BK BK Battery Cable Starter Motor Battery To J Fuse Assembly To Voltage Regulator Voltage Regulator Male Female Stator H D 3 Phase Maxifuse BK ...

Page 45: ...B 28 2007 Buell Firebolt Electrical HOME 2007 XB Firebolt Starting Charging Circuit 2007 XB Firebolt Starting Charging Circuit ...

Page 46: ... 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 47: ...B 30 2007 Buell Firebolt Electrical HOME 2007 XB Firebolt Component Circuits 2007 XB Firebolt Component Circuits ...

Page 48: ...4 449 4 488 4 527 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...

Page 49: ...ISH IMPERIAL SYSTEM 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...

Page 50: ...2007 Buell Firebolt Appendix D D 1 HOME HOSE AND WIRE ROUTING D 1 Figure D 1 Front and Rear Brake Systems Right Side View b1114xaxf ...

Page 51: ...D 2 2007 Buell Firebolt Appendix D HOME Figure D 2 Rear Brake Systems Top View b1115abxf ...

Page 52: ...2007 Buell Firebolt Appendix D D 3 HOME Figure D 3 Rear Brake Systems Left Side View b1116acxf ...

Page 53: ...D 4 2007 Buell Firebolt Appendix D HOME Figure D 4 Evaporative Emissions Control California Models Top View Carbon canister b1117aaxf ...

Page 54: ... 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 b1118abxf ...

Page 55: ...D 6 2007 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 b1119xcxf To ECM 1 ...

Page 56: ...2007 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 b1120abxf 1 ...

Page 57: ...x 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 6 b1121xdsxu 1 4 5 7 ...

Page 58: ...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 b1122xbsxf 1 ...

Page 59: ...D 10 2007 Buell Firebolt Appendix D HOME Figure D 10 Oil Lines Bottom View 1 Vent line 2 Feed oil line 3 Return oil line b1123xcsxf 1 2 3 ...

Page 60: ...2007 Buell Firebolt Appendix D D 11 HOME Figure D 11 Clutch Throttle Cables and Interactive Exhaust System 1200 Only Right Side View b1124xbxf Exhaust valve actuator Muffler valve ...

Page 61: ...2 2007 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 b1125xcxaf Muffler valve Exhaust valve actuator ...

Page 62: ...Clutch Throttle Seat Release Cables and Active Intake System with Exhaust Valve Actuator 1200 Only Top View Cable seat lock TPS adjuster b1126xdxaf Clip to functional air cleaner cover Exhaust valve actuator mounted on top of functional air cleaner cover ...

Page 63: ...2007 Buell Firebolt Appendix D D 14 HOME NOTES ...

Page 64: ...Code 22 flow charts 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...

Page 65: ...ing off the throttle 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...

Page 66: ...which should be 1 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 fo...

Page 67: ...just stop screw while 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...

Page 68: ...2007 Buell Firebolt Appendix E E 5 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 b1171xex ...

Page 69: ...ery voltage present 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 b...

Page 70: ...olenoid NO YES Connect 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 ...

Page 71: ...nstalling baseplate assembly 10 see 4 44 AIR CLEANER ASSEMBLY NOTE 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 basepla...

Page 72: ... 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 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 Troubleshoot...

Page 73: ......

Page 74: ...e Use the proper tools Protect yourself and bystanders with approved eye protection Don t just do the job do the job safely Removing Parts Always consider the weight of a part when lifting Use a hoist whenever necessary Do not lift heavy parts by hand A hoist and adjustable lifting beam or sling are needed to remove some parts The lengths of chains or cables from the hoist to the part should be eq...

Page 75: ...nstall bearings with numbered side facing out Always use the proper tools and fixtures for removing and installing bearings Bearings do not usually need to be removed Only remove bearings if necessary 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...

Page 76: ...tting hardened wire unless they were designed for that purpose Always cut at right angles Don t use any prybar as a chisel punch or hammer 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 ch...

Page 77: ...hes Replace sockets 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 afte...

Page 78: ...u may find that some gasoline blends adversely affect the starting driveability or fuel efficiency of your bike If you expe rience one or more of these problems we recommend you try a different brand of gasoline or gasoline with a higher octane rating 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 David...

Page 79: ...X X X X X X 1 Rear belt idler and sprockets Inspect X X X X X X 1 Throttle brake and clutch con trols sidestand active muffler cable and active intake cable adjustment if equipped Check adjust and lubricate X X X X X X 1 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 Spark plugs Replace X X 1 Electrical equipment and switches Check operatio...

Page 80: ...phragm spring Primary chaincase drain plug torque Apply Loctite 565 Thread Sealant and reinstall plug and tighten to 14 30 ft lbs 19 41 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 GENUINE HARLEY DAVIDSON FORMULA TRANSMISSION AND PRI...

Page 81: ...que 25 33 in lbs 2 8 3 7 Nm Spark 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 21 in 107 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 Maintena...

Page 82: ...To minimize swirl marks cleaning should be done when motorcycle is cool and parked in the shade HARLEY DAVIDSON BUG REMOVER Part No 94657 98 HARLEY DAVIDSON SUNWASH PART No 94659 98 NOVUS 1 CLEANER PROTECTANT Part No 99837 94T NOVUS 2 SCRATCH REMOVER Part No 99836 94T HARLEY GLAZE Part No 99701 84 to polish and seal after cleaning Figure 1 1 Firebolt Windshield b1220x1x ...

Page 83: ...ng could result in 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 ...

Page 84: ...ect the battery case 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 m...

Page 85: ...ten bolts on battery 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 ho...

Page 86: ...ust have the engine oil drained more fre quently ENGINE OIL LEVEL CHECK CAUTION Do NOT operate the engine when the oil level is below the add mark on the dipstick at operating temperature Engine damage will result 00187a CAUTION Do not overfill oil 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 lub...

Page 87: ...lter using pliers or belt type OIL FILTER WRENCH 3 Clean filter gasket contact surface on crankcase Sur face must be smooth and free of 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 filter until filter is approximately 1 2 full 6 Screw filter onto adapter until filter gasket touches crankcase surface...

Page 88: ...ed air can pierce the skin and flying debris from compressed air could cause serious eye injury Wear safety glasses when working with compressed air Never use your hand to check for air leaks or to deter mine air flow rates 00061a 7 Blow out any debris from fins with compressed air from the inside of the oil cooler outward Inspect cooler fins for debris or damage 8 Wipe up any spilled oil on muffl...

Page 89: ...lt in death or seri ous injury 1WARNING 1WARNING Use only fresh uncontaminated D O T 4 fluid Cans of fluid that have been opened may have been contami nated by moisture in the air or dirt Use of contaminated brake fluid may adversely affect braking ability and lead to brake failure which could result in death or serious injury 1WARNING 1WARNING Use only new copper crush banjo washers See Parts Cat...

Page 90: ...unting bolts Warped 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...

Page 91: ... voir Bring fluid level to within 1 8 in 3 2 mm of molded boss inside front master cylinder NOTE Do not reuse brake fluid 5 Slowly depress and release hand lever several times to build up hydraulic pressure then hold brake hand lever in the depressed position 6 While holding brake hand lever in the depressed posi tion open bleeder valve about 1 2 turn counterclockwise Brake fluid will flow from bl...

Page 92: ... reuse brake fluid 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 t...

Page 93: ... pedal 1WARNING 1WARNING Threaded rod should not be adjusted to the point of con tacting brake pedal Improper adjustment could result in death or serious injury 1 See Figure 1 13 Inspect for minimum and maximum brake rod engagement in brake clevis 4 Adjust as required 2 Adjust brake pedal a See Figure 1 13 Loosen locknut 3 while holding rod adjuster 2 Move locknut away from top surface of clevis 4...

Page 94: ...ubricant gets on tires wheels or brakes when 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 15 Check brake rotors for minimum thickness At every scheduled service interval 1 Inspect rotor Replace rotor if warped or badly scored 2 Measure rotor thickness Replace rotor if minimum thick ness is ...

Page 95: ...3 2 mm You may have to remove fluid to allow for this 1 Push pistons in with suitable tool such as a clean paint scraper until fully seated in bores Be careful not to dam age rotor 2 Install new inner pad from left side of motorcycle 3 Install new outer pad from right side of motorcycle 4 See Figure 1 16 Install pin hanger 2 making sure it engages hole on both pads and spring clip 5 Rotate caliper...

Page 96: ...ove fluid to allow for this 3 Push piston in with suitable tool such as a clean paint scraper until fully seated in bore 4 Install new inner and outer brake pads 5 See Figure 1 17 Install hanger pin 4 making sure pin engages hole on both pads 6 Install brake caliper and carrier assembly over rotor 7 Apply 271 Loctite to two mounting fasteners 1 and install through swingarm into carrier and tighten...

Page 97: ...re wear indicator bars appear New tires are needed if any of the following conditions exist 1 Tire wear indicator bars become visible on the tread sur faces 2 Tire cords or fabric become visible through cracked side walls snags or deep cuts 3 A bump bulge or split in the tire 4 Puncture cut or other damage to the tire that cannot be repaired WHEEL BEARINGS 1WARNING 1WARNING Never use compressed ai...

Page 98: ...rom clutch inspec 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 NOTE Make certain primary chaincase is filled with proper amount of lubricant with motorcyc...

Page 99: ...here is a large amount of free play at clutch hand lever 3 See Figure 1 20 Remove three fasteners and washers from clutch inspection cover Remove clutch inspection cover and gasket from primary cover 4 See Figure 1 24 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 lo...

Page 100: ...ule end of cable housing away from bracket Gap between ferrule and bracket should be 1 16 1 8 in 1 6 3 2 mm b See Figure 1 23 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 20 Install clutch inspection cover and new gasket using three fasteners and washers and tig...

Page 101: ...r 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 and indicates worn transmission sprocket ...

Page 102: ...oth wear Rough or damaged sprocket Inspect replace sprocket Worn sprocket Inspect replace sprocket Debris in sprocket Clean and protect drive Inspect for damaged or missing guards Abrasive environment Eliminate or control exposure Inspect for damaged or missing guards Apparent belt stretch NOTE The drive belt tension on a new belt will loosen after approxi mately 1000 mi 1600 km Worn sprocket Insp...

Page 103: ...et or belt Inspect 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 i...

Page 104: ...cessary adjust as described under 1 11 PRIMARY CHAIN in ADJUST MENT NOTE The initial primary chain vertical free play specification used at the assembly plant is 1 4 1 2 in 6 4 12 7 mm with a cold engine The 1 4 in 6 4 mm minimum is only allowed at the absolute tightest point in the drive as measured with special ized factory equipment If a chain has less than 1 4 in 6 4 mm vertical free play with...

Page 105: ...orn beyond adjustment limits Replace parts as necessary See 6 5 PRI MARY CHAIN 1 See Figure 1 29 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 29 Chain Tension Adjusting Fastener Typical 10309a 1 Locknut 2 Adjusting fastener 1 2 ...

Page 106: ... 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 Increasing the load carried requires adding more 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 ...

Page 107: ...ing It is recommended 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 2 Reduce front and rear compression damping and rebound damping by turning adjuster counterclockwise 1 4 1 2 turn Table 1 10 Recommended Suspension Se...

Page 108: ...er of lines 3 to be showing for your load condition Refer to Table 1 10 2 Adjust preload by turning the adjuster nut 2 with a wrench Setting Front Fork Rebound Damping 1 See Figure 1 30 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 Fo...

Page 109: ...eload b Rotate adjuster 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 33 Using a screwdriver turn the slotted d...

Page 110: ...the left rear corner of the rider seat 2 See Figure 1 35 Using a screwdriver turn the slotted dial clockwise until it stops This is the maximum com pression damping setting 3 Then turn the dial counterclockwise the recommended amount specified in Table 1 10 Figure 1 34 Accessing Rear Shock Compression Adjuster Figure 1 35 Rear Shock Compression Adjustment 8415 8976 ...

Page 111: ...rect steering head resistance turn front wheel all the way to the right 6 See Figure 1 36 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 adjustmen...

Page 112: ...des and ceramic insulator tip indicates an oil fouled plug The condition may be caused by one or more of the following worn pistons worn piston rings worn valves worn valve guides worn valve seals a weak battery or a faulty ignition system b A dry fluffy or sooty black deposit indicates an air fuel mixture that is too rich and or engine idling for excessive periods c A light brown glassy deposit i...

Page 113: ...heck electrode 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 ...

Page 114: ... more often if the motorcycle is run in a dusty environment 1 Remove seat See 2 38 SEAT 2 Remove four fasteners nylon washers and intake cover assembly See 2 34 INTAKE COVER ASSEMBLY 3 See Figure 1 40 Remove fuel vent tube 3 from vapor valve at front of air cleaner cover and groove on top of air cleaner cover 1 4 See Figure 1 41 Unlatch six latching tabs and remove air cleaner cover from base plat...

Page 115: ...2 2 See Figure 1 41 Position air cleaner cover 1 over base plate Make sure air filter remains correctly positioned 3 Install air cleaner cover by latching six latch tabs 2 to base plate 4 For 1200 models verify that the actuator cable and har ness are in the grooves on the air cleaner cover 5 See Figure 1 40 Position fuel vent tube in groove on top of air cleaner cover and connect to fuel vent val...

Page 116: ...le housings to minimum length 5 Point front wheel straight ahead Twist throttle control grip to fully open position hold in position 6 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 7 Turn handlebars fully to right Turn adjuster on idle con trol cable until end of cable housing jus...

Page 117: ...it comes out of the housing 7 Release the cable core and reattach the cable to the cable wheel and bracket 8 Tighten jam nut CAUTION Do not overtighten jam nut on interactive exhaust cable 9 See Figure 1 47 Adjust interactive exhaust cable as fol lows a See Figure 1 46 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 w...

Page 118: ...lug 2 before installing air intake cover CAUTION If cable is routed in front of the frame lug it will cause the muffler valve to stay open not allowing it to work prop erly 12 Install air intake cover See 2 34 INTAKE COVER ASSEMBLY Figure 1 48 Correct Cable Routing Behind Frame Lug 10514a 1 Interactive exhaust cable 2 Frame lug 2 1 ...

Page 119: ...tion using the rear wheel Position the flywheel TDC mark at the very left edge of the inspection hole 7 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 8 Gently bump flywheel forward in tiny increments 9 See Figure 1 50 If the static timing is correct the screen will switch to HIG...

Page 120: ... appears on left side of window rotate timing plate counterclockwise See Figure 1 52 3 Check timing See CHECKING STATIC TIMING 4 See Figure 1 54 If timing is retarded mark appears on right side of window rotate timing plate clockwise 5 Tighten sensor assembly fasteners to 15 30 in lbs 1 7 3 4 Nm 6 Recheck timing Figure 1 51 Timer Cover Figure 1 52 Cam Position Sensor Timing Plate 12136a 8391a Figu...

Page 121: ...ill compress vehicle suspension slightly 5 Stand motorcycle upright with front fairing aimed straight forward 6 Check LOW beam right lens for alignment a See Figure 1 56 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 horizon...

Page 122: ...juster 1 is on the left and the LOW Beam adjuster 2 is on the right beneath the front fairing If headlamp requires adjustment perform the following as required To lower beam Turn adjuster clockwise To raise beam Turn adjuster counterclockwise Figure 1 57 Headlamp Height Adjustment 8392 1 2 1 High beam adjuster left 2 Low beam adjuster right ...

Page 123: ...hrottle control grip 2 3 times NOTE This is to ensure that the throttle plate is completely closed before beginning recalibration 7 With ignition and run switch in the on position with engine off and throttle in the closed position press the TPS zero button at the bottom of the screen 8 Select TPS zero button and perform TPS zero NOTE When calibration is complete dialogue box will appear on Digita...

Page 124: ...otorcycle will be stored for an extended period of time securely support the motorcycle so that 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 7 Wash and polish molded in color painted and chr...

Page 125: ... output from CMP sensor See dealer 20 Inoperative fuel pump See dealer Starts Hard 1 Spark plugs in bad condition have improper gap or are partially fouled 2 Wires are crossed 3 Spark plug cables in bad condition and shorting 4 Battery nearly discharged 5 Loose wire connection at one of the battery terminals at coil or at plug between ignition sensor and module 6 Throttle controls not adjusted cor...

Page 126: ... of insufficient lubrication 5 Wheels not aligned and or tires worn 6 Internal engine problem 7 Wheels not balanced correctly 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 wo...

Page 127: ...at 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 than 0 080 in 2 03 m...

Page 128: ...uspension 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 1 ...

Page 129: ...1 56 2007 Buell Firebolt Maintenance HOME NOTES ...

Page 130: ... 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 131: ......

Page 132: ...83 3 3 83 Rake 21 Degrees 21 Degrees Table 2 2 Weight Specifications WEIGHT U S MODELS XB9R XB12R LBS KG LBS KG Wet weight 452 205 462 210 GVWR 850 386 850 386 GAWR front 325 147 325 147 GAWR rear 525 238 525 238 Load capacity 398 181 388 176 Table 2 3 Capacities CAPACITIES U S LITERS Fuel tank inc reserve 3 82 gal lons 14 5 Reserve Low fuel light at illuminates at 0 75 gal lons 2 80 Oil tank 2 5 ...

Page 133: ... 43 Brake pin plug rear 24 in lbs 3 Nm page 2 43 Brake reservoir fastener rear 48 72 in lbs 5 4 8 1 Nm page 2 91 Caliper banjo bolt front 16 20 ft lbs 22 27 Nm metric page 2 32 Caliper banjo bolt rear 16 20 ft lbs 22 27 Nm page 2 41 Caliper bleeder valves 36 60 in lbs 4 7 Nm metric page 2 27 Caliper carrier rear 24 26 ft lbs 32 35 Nm page 2 20 Caliper fasteners front 15 19 ft lbs 20 26 Nm page 2 3...

Page 134: ...ubber upper 12 36 in lbs 1 4 Nm page 2 62 Front isolator threaded frame insert 59 61 ft lbs 80 82 7 Nm LOCTITE 271 red page 2 62 Fuse block and relay fasteners 72 96 in lbs 8 11 Nm page 2 74 Hand lever pivot fastener 80 120 in lbs 9 13 5 Nm page 2 29 Handlebar clipon fastener left 24 26 ft lbs 33 35 Nm page 2 76 Handlebar clipon fastener right 24 26 ft lbs 33 35 Nm page 2 76 Headlight fasteners 20...

Page 135: ...mounting fasteners rear 25 27 ft lbs 34 37 Nm metric Replace with new page 2 19 Seat fasteners 12 36 in lbs 1 4 Nm page 2 94 Shift linkage fasteners 36 60 in lbs 4 6 8 Nm LOCTITE 271 red page 2 69 Shift pedal flange head bolt 22 24 ft lbs 30 32 5 Nm LOCTITE 271 red page 2 69 Shock mounting fastener lower 15 17 ft lbs 20 3 23 Nm page 2 65 Shock mounting fastener upper 48 52 ft lbs 65 70 5 Nm page 2...

Page 136: ...2007 Buell Firebolt Chassis 2 5 HOME Valve stem nut 40 44 in lbs 4 5 4 9 Nm page 2 23 Wear peg rider 36 48 in lbs 4 1 5 4 m LOCTITE 271 red page 2 81 ITEM TORQUE NOTES ...

Page 137: ...ior surface Example MT 3 5 x 17 0 DOT MT designates the rim contour 3 5 is the width of the bead seat measured in inches 17 0 is the normal diameter of the rim in inches mea sured at the bead seat diameter DOT means that the rim meets Department of Transpor tation Federal Motor Vehicle Safety Standards See Table 2 6 Figure 2 1 Rim Markings 8423 Table 2 6 Tire Fitment Tubeless Cast Wheels WHEEL SIZ...

Page 138: ...cation Number 4MZ KP 01 D 3 7 3 0 00456 1 2 3 4 5 6 7 9 8 Table 2 7 Buell 2007 XB Models V I N Description ITEM DESCRIPTION POSSIBLE VALUES 1 WMI Code 4MZ Buell vehicles originally manufactured for sale within the United States 5MZ Buell vehicles originally manufactured for sale outside the United States 2 Model KP Blast AX Firebolt KX Lightning CityX SX Lightning WX Lightning Scg JX Lightning Lon...

Page 139: ...s inflated to the 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...

Page 140: ...andling irregularities are noted perform the recommended ser vice checks See Table 2 8 If tires must be replaced same as original equipment tires must be used Other tires may not fit correctly and may be hazardous to use Table 2 8 Wheel Service CHECK FOR REMEDY Loose axles Tighten front axle See 2 5 FRONT WHEEL Tighten rear axle See 2 6 REAR WHEEL Excessive side play or radial up and down play in ...

Page 141: ...fender fasteners See 2 31 FEND ERS 3 See Figure 2 4 Loosen front axle pinch fasteners 2 metric on front fork 4 Remove axle 1 NOTES The front axle is left handed thread 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 remova...

Page 142: ...NSTALLER 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 wheel hub 9 H...

Page 143: ...ING Never use compressed air to spin dry bearings Very high bearing speeds can damage unlubricated bearings Spinning bearings with compressed air can also cause a bearing to fly apart which could result in death or seri ous injury 1 Inspect all parts for damage or excessive wear NOTE XB wheel bearings are designed as sealed bearings which are not intended to be disassembled serviced or cleaned wit...

Page 144: ...for the front wheel the procedure for the rear wheel is the same 1 See Figure 2 12 Install the Backing Plate Part No B 43993 11 onto the long forcing screw from the Wheel Bearing Installer Remover 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...

Page 145: ...ing bore 13 Install 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...

Page 146: ...19b 5 Install new rotor mounting fasteners in a criss cross pat tern around the wheel to insure proper fitting between rotor fastener and bushing Tighten to 25 27 ft lbs 34 37 Nm 11WARNING 1WARNING Rotor mounting fasteners must be seated into drive bushings and drive bushings must be fitted into rotor properly Failure to comply can affect braking ability and lead to brake failure which could resul...

Page 147: ...ront axle is left handed thread 3 Install front axle 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 4 See Figure 2 19 Tighten the front axl...

Page 148: ...ARNING Never use compressed air to spin dry bearings Very high bearing speeds can damage unlubricated bearings Spinning bearings with compressed air can also cause a bearing to fly apart which could result in death or seri ous injury 1 Inspect all parts for damage or excessive wear 2 Inspect brake rotor See1 7 BRAKE SYSTEM MAINTE NANCE and 2 15 REAR BRAKE CALIPER DISASSEMBLY 1 Remove sprocket a Re...

Page 149: ...t brake pads or discs Such contact can adversely affect braking ability which could cause loss of control resulting in death or serious injury 00290a 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 150: ...ning to 35 37 ft lbs 48 50 Nm CAUTION Do not re use brake disc screws Re using disc screws can result in torque loss and damage to rotor and or brake assembly 00319b 5 Install rear rotor 2 a Position rear brake rotor 2 on wheel 5 b Install brake rotor 2 with new rotor mounting fas teners 1 and tighten to 25 27 ft lbs 34 37 Nm INSTALLATION 1 Center rear wheel in the swingarm at the same time slid i...

Page 151: ...ill not allow the 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 152: ...nout exceeds specification shown in Table 2 9 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 9 Table 2 9 Wheel Rim Runout RUNOUT IN MM Maximum lateral 0 040 ...

Page 153: ...dequate 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 11WARNI...

Page 154: ...ires 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 with tire lubricant NOTE The red dot on the sidewall is a balance mark and should be aligned 180 degrees from the balance mark blue dot on inside of rim ...

Page 155: ...ll tire and check 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 10 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 chec...

Page 156: ...ed to within 1 4 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...

Page 157: ...pedal 6 INSTALLATION 1 See Figure 2 36 Install pedal bushings 3 2 Install shift brake pedal sleeve 4 3 Install brake pedal 6 using LOCTITE 271 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 peda...

Page 158: ...aliper bleeder valve Place free end in a suitable container b Open bleeder valve metric about 1 2 turn c Pump brake hand lever to drain brake fluid d Tighten bleeder valve to 36 60 in lbs 4 7 Nm NOTE Damaged banjo bolt seating surfaces will leak when reas sembled Prevent damage to seating surfaces by carefully removing brake line components 2 See Figure 2 37 Remove the banjo bolt 13 metric and two...

Page 159: ...ystem compo nents 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 f...

Page 160: ...ration which could 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 han...

Page 161: ...r 2 and cover gasket 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 injur...

Page 162: ...p NOTE Damaged banjo bolt seating surfaces will leak when reas sembled Prevent damage to seating surfaces by carefully removing brake line components 3 See Figure 2 37 Remove master cylinder banjo bolt 13 metric and two copper washers 15 to disconnect brake line from master cylinder 4 Discard copper washers 4 See Figure 2 42 Remove caliper banjo bolt 5 metric two copper washers and wire form 3 to ...

Page 163: ...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 bolt ...

Page 164: ...Disconnect 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 8 4 See Figure 2 46 Remove pistons using a ...

Page 165: ... new o rings 6 pistons 5 and caliper piston bores with 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 tighten to 15 19 ft lbs 20 26 Nm INSTALLATION 1 See Figure 2 47 Install brake pads 10 2 Install pin hanger set 1 and tighten...

Page 166: ...igure 2 47 Front 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 167: ...36 60 in lbs 4 7 Nm 2 Remove brake pedal See 2 9 BRAKE PEDAL 3 Remove heel guard See 2 29 FOOTPEG HEEL GUARD AND MOUNT NOTE Damaged banjo bolt seating surfaces will leak when reas sembled 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 Cal...

Page 168: ...m rider footpeg mount 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 be...

Page 169: ...tem components Stand master cylinder on wooden block or towel to protect seating surfaces a Examine walls of master cylinder reservoir for scratches and grooves Replace if damaged b Verify that vent holes on master cylinder are com pletely open and free of dirt or debris 2 Inspect boot on front of master cylinder for cuts tears or general deterioration Replace if necessary ASSEMBLY 1 Obtain PISTON...

Page 170: ...oir 1 to frame using clamp fastener 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 11WARNING 1WARNING...

Page 171: ... laws a Install a length of plastic tubing over caliper bleeder valve Place free end in a suitable container b Open bleeder valve metric about 1 2 turn c Pump brake foot pedal to drain brake fluid d Tighten bleeder valve to 36 60 in lbs 4 7 Nm 7 See Figure 2 55 Remove p clamp 2 securing brake line 1 to the left side of swingarm NOTE Damaged banjo bolt seating surfaces will leak when reas sembled P...

Page 172: ...ly captured by rear fender See 2 31 FENDERS 6 Install right heel guard See 2 29 FOOTPEG HEEL GUARD AND MOUNT 7 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...

Page 173: ...m 2 Remove 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 fro...

Page 174: ...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 the way in...

Page 175: ... 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 3 Depress rear brake pedal several times to set brake pads to proper position within caliper Bleed brake system See 1 7 BRAKE SYSTEM MAINTENANCE 4 See Figure 2 61 Verify proper fluid level in reservoir 11WARNING 1WARNING After repairing the brake system test brakes at low spee...

Page 176: ...SION DAMPING 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 See Figure 2 62 Loosen upper 1 and lower 3 fork clamp pinch fasteners 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 ...

Page 177: ...e front fork in the 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 Pr...

Page 178: ...SING TOOL be sure 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 NOTE 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 COMPRESSING TOOL Figure 2 67 Fork Spring Compressing Tool HD 45966 b1145x1x Figure 2 68 H...

Page 179: ...nap ring 9 Rebound adjuster assembly 10 Damper locknut 11 Damper rod assembly 12 Centering plate 13 Ceiling washer 14 Center bolt 15 Collar 16 Spring joint 17 Spring 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 b0991a2x 1 2 3 4 5 6 7 8 9 10 11 12 13 14 20 15 17 18 21 22 23 24 25...

Page 180: ...de bushing 22 seal spacer 23 oil seal 24 stopper ring 25 and dust seal 26 Damper Rod Disassembly 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 fol lowing disassembly and assembly procedures for setting the correct r...

Page 181: ...t seal 26 and stopper ring 25 onto the slider fork 27 3 Coat the sealing lips of the new oil seal 24 with fork oil or sealing grease and install onto the slider fork with its marked side facing the dust seal 26 4 Remove the tape from the slider fork end 5 Install the seal spacer 23 the guide bushing 22 and the slide bushing 21 onto the slider fork 27 6 Coat the slide bushing 21 and the guide bushi...

Page 182: ... spring 17 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 38 42 ft lbs 51 57 Nm NOTE See Figure 2 68 Careful not to damage preload pins 2 while holding damper rod assembly 3 22 Remove t...

Page 183: ...ure 2 74 Position 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 271 red on upper fork clamp fasteners and tighten to 23 25 ft lbs 31 34 Nm 8 Use LOCTITE 271 red on lower fork clamp fasteners and tigh...

Page 184: ...g 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 capnut 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 185: ...assembly 8 Tighten steering stem cap nut to 38 42 ft lbs 52 57 Nm 9 Install steering stem pinch bolt applying LOCTITE 271 and tightening to 20 22 ft lbs 27 30 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 10 See Figure 2 74 Position both forks wi...

Page 186: ...lace 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 ing head bearings are not reusable 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 backing plate for wheel bearing installation B ...

Page 187: ... bearing installation 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 4552...

Page 188: ...at 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 Apply LOCTITE 271 on steering stem pinch fastener and tighten to 20 22 ft lbs 27 30 Nm 13 Apply LOCTITE 271 to the upper clamp fasteners and tighten to 23 25 ft lbs 31 34 Nm 14 Install brake lever...

Page 189: ...ngarm brace without releasing tension will cause swingarm brace damage 1 See Figure 2 81 Loosen rear axle pinch fastener 2 2 Loosen rear axle 1 approximately 15 rotations to allow partial tension to be removed from rear drive system 3 Remove right side footpeg mount See 2 29 FOOTPEG HEEL GUARD AND MOUNT Figure 2 81 Rear Wheel Mounting Right Side 11810 2 1 Axle 2 Pinch bolt fastener 1 Figure 2 82 B...

Page 190: ... swingarm 6 Remove drive belt See 6 6 DRIVE BELT SYSTEM 7 Remove p clamps and washers that secure oil lines to swingarm 8 Remove rear inner fender See 2 31 FENDERS 9 Disconnect the three oil lines from swingarm fittings See 3 10 OIL LINE FITTINGS 10 See Figure 2 88 With vehicle supported remove lower shock absorber mounting fastener and spacer from shock absorber and swingarm 11 See Figure 2 83 Lo...

Page 191: ...sses when working with compressed air Never use your hand to 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 Sw...

Page 192: ...lt drive See 6 6 DRIVE BELT SYSTEM 2 See Figure 2 83 Install swingarm brace 12 with swing arm brace mounting fasteners 11 loosely Do not tighten 3 Tighten swingarm brace fasteners 11 to 25 27 ft lbs 34 37 Nm 4 Tighten rear axle See 6 6 DRIVE BELT SYSTEM DRIVE BELT INSTALLATION 5 Tighten rear axle pinch fastener 13 to 40 45 ft lbs 54 61 Nm 6 Install right side rider footpeg mount Tighten fasteners ...

Page 193: ...tall front isolator bracket fasteners 5 and tighten 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 NOTE Hold wire form while tightening to prevent it from twisting 5 See F...

Page 194: ...23 MAIN WIRE HAR NESS 8 Remove rear isolator fastener See 3 4 STRIPPING MOTORCYCLE FOR ENGINE SERVICE 9 Lift and remove frame from the motorcycle INSTALLATION 1 Place frame over the motorcycle 2 Install rear isolator fastener See 3 5 ENGINE INSTAL LATION 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...

Page 195: ... damping adjustments set the proper preload See 1 12 SUSPENSION DAMPING ADJUST MENTS Figure 2 88 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...

Page 196: ...ft lbs 20 3 23 Nm NOTE Verify that fan spins freely after shock is installed 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 90 Temporarily place upper body work onto tail section and adjust reservoir placement so the adjuster screw aligns with bodywork c Tighten clamp on reservoir to 120 144 in lbs ...

Page 197: ...r 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 ho...

Page 198: ...g clutch cable to voltage reg ulator wire 8 See Figure 2 94 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 95 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 of upper triple clamp 12 Remove t...

Page 199: ...See Figure 2 98 Unscrew the cable fitting from the pri mary cover Remove clutch cable and fitting 17 Remove and discard o ring on the clutch cable fitting Figure 2 96 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 8 Sleeve shift lever 9 Bearings shift lever 3 1 4 5 6 2...

Page 200: ...1 5 See Figure 2 96 Install 9 bearings and 8 sleeve into the shift lever 6 After applying LOCTITE 271 red install flange bolt 5 and shift pedal to primary cover and tighten to 22 24 ft lbs 30 32 5Nm 7 After applying LOCTITE 271 red tighten engine shift lever pinch screw to 48 60 in lbs 5 4 6 8 Nm 8 See Figure 2 99 If the shift linkage assembly 8 was removed for any reason apply Loctite 271 to fast...

Page 201: ...ie bar to V bracket and tighten fastener to 25 27 ft lbs 33 9 36 6 Nm 17 Adjust clutch cable See 1 9 CLUTCH 18 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 serious injury 00068a 19 Install ...

Page 202: ...ing See 2 37 FRONT FAIRING WIND SHIELD AND MIRRORS 4 See Figure 2 101 Disconnect flasher 1 and bank angle sensor 2 Remove electronic control module fasteners 3 5 See Figure 2 103 Rotate headlamp support bracket a Loosen headlamp pivot fasteners 1 b Rotate headlight bracket 2 down 6 See Figure 2 102 Disconnect headlight connection 7 Disconnect and remove electronic control module See 4 30 ELECTRONI...

Page 203: ...et 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 2 101 Install bank angle sensor connector case 2 Tighten to 12 36 in lbs 1 4 Nm 6 Install flasher 1 and tighten to 36 60 in lbs 4 6 7 Nm Figure 2 103 Headlight Support Bracket Assembly 1 Headlight ...

Page 204: ...cket with fairing support bracket b Tighten electronic control module fasteners 3 to 72 96 in lbs 8 11 Nm 8 See Figure 2 101 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 ba...

Page 205: ...ort bracket with fas teners p clamp 7 and washers 4 Tightening to 16 18 ft lbs 22 26 Nm 3 Connect instrument cluster connector and install instru ment cluster Tightening to 12 36 in lbs 1 3 4 Nm See 7 18 INSTRUMENT MODULE 4 Install horn and tighten fasteners to 72 96 in lbs 8 10 Nm See 7 20 HORN 5 Install fuse block relay and p clamp tightening fasteners to 72 96 in lbs 8 11 Nm See 7 22 MAIN FUSE ...

Page 206: ...igure 2 105 Fairing 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 207: ...the clip on 2 from the upper left fork clamp 3 Repeat this procedure until fastener 4 and clip on 2 has been removed from fork clamp 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 and tighten fas tener to 24 26 ft lbs 33 35 Nm 3 Install front brake master cylinder Tighten but do not torque 4 Install throttle an...

Page 208: ...2007 Buell Firebolt Chassis 2 77 HOME Figure 2 107 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 209: ...active exhaust cable from muffler 8 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 2 108 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 S...

Page 210: ...XB12R 4 Muffler XB9R 5 Front muffler strap 6 Front muffler strap fastener 7 Front muffler mount 8 Front muffler mount fastener 9 Front muffler mount bushings 10 Interactive exhaust cable 11 Rear muffler bracket 12 Rear muffler bracket fasteners 2 13 Jacking point on muffler Jacking point symbol shown on both sides of muffler 2 1 3 4 6 5 7 8 10 11 13 9 12 ...

Page 211: ...nds 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 2 Install interactive exhaust cable to muffler 3 See Figure 2 108 Loosely install new front and rear muffler straps 2 4 NOTES Never re use front muffler strap Always replace front muffler strap with a ...

Page 212: ...bs 14 9 16 2 Nm Install Heel Guard 1 See Figure 2 110 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 2 110 Position spring 6 in footpeg 8 2 Position footpeg 8 and spring in footpeg mou...

Page 213: ...ount 3 Using LOCTITE 271 tighten fasteners 10 to 25 28 ft lbs 34 38 Nm Install Heel Guard 1 See Figure 2 111 Position heel guard 2 onto footpeg mounts 3 2 Install heel guard 2 3 Tighten heel guard fasteners to 48 72 in lbs 5 8 Nm Install Footpeg 1 See Figure 2 111 Position footpeg 8 detent plate 6 ball 5 and spring 4 on to footpeg mount 3 2 Install footpeg pin 9 3 Install clip 7 4 Check that footp...

Page 214: ...cket 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 2 112 Chin Fairing Assembly Right Rear Fasteners Figure 2 113 Sprocket Cover b0942x2x b1187x2x 1 Long fastener and washer 2 Sprocket cov...

Page 215: ...nd install front fender 1 with fasteners and washers 2 and tighten to 36 48 in lbs 4 5 4 Nm REAR FENDER Removal 1 See Figure 2 114 Remove fasteners and washers 4 securing the rear fender 3 to swingarm 2 Remove rear fender 3 Installation 1 See Figure 2 114 Align rear brake line in rear fender 2 Install rear fender 3 with fasteners and washers 4 Tighten to 12 36 in lbs 1 4 Nm Figure 2 114 Front and ...

Page 216: ... guard 1 by removing fasteners from swingarm INSTALLATION 1 Install upper belt guard 1 tightening fasteners to 12 36 in lbs 1 4 Nm 2 Install stone guard and tighten fasteners to 12 36 in lbs 1 4 Nm 3 Install lower belt guard 3 and tighten fasteners 4 to 12 36 in lbs 1 4 Nm 4 Tighten rear axle See 6 6 DRIVE BELT SYSTEM 5 Tighten rear axle pinch fastener to 40 45 ft lbs 54 61 Nm 6 Install right side...

Page 217: ...Tool Kit MODEL NO MAR39200HD 1 Apply LOCTITE 271 red on all fasteners 2 See Figure 2 116 Position the assembled chin fairing 5 and loosely install right side fasteners and washers 6 3 Align center section 1 and loosely install center section fasteners and washers 2 NOTE Turn wheel full right or left for easier access to center fasten ers 4 Align left section 3 and loosely install left side fastene...

Page 218: ... Figure 2 117 Secure intake cover assembly 1 with fasteners and nylon washers 2 Tighten to 12 36 in lbs 1 3 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 SE...

Page 219: ...on 1 See Figure 2 118 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 2 118 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 2 118 Position oil cooler air scoop 2 2 Apply LOCT...

Page 220: ...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 Figure 2 119 Subframe Tail Assembly and Body Work Assembly 1 Upper tail body work 2 Upper tail body work fasteners 3 Pa...

Page 221: ...k 11 from sub frame tail assembly 7 a Remove lower body work 9 underneath subframe tail assembly by removing fasteners 10 b Remove trunk 11 13 See Figure 2 121 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 ...

Page 222: ...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 48 72 in lbs 5 4 8 Nm 6 See Figure 2 120 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 tighten See 2 22 R...

Page 223: ...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 2 119 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 224: ...1 See Figure 2 123 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 and tighten to 10 12 in lbs 1 1 4 Nm Figure 2 123 Front Fairing and Windscreen b0967x2x 1 Windshield 2 Mirrors 3 Side windshield fastener 4 Center wind...

Page 225: ...engage center 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 Insta...

Page 226: ...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 the washer...

Page 227: ...d bracket 5 to engine 3 Remove sidestand 1 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 fair ing See 2 33 CHIN FAIRING 2 See Figure 2 129 Remove sidestand leg a Retract sidestand leg 1 b Remove sidestand spring 2 and spring extension plate 4 using SNAP ON SPRING TOOL Part No HE 52B...

Page 228: ...ide stand bracket fasteners 6 Loosely install the sidestand assembly to the crankcase with the sidestand bracket fasteners 6 Extend the sidestand leg 1 and hold for ward in the fully extended position while tightening the sidestand bracket fasteners 6 in the following sequence a Tighten the front fastener to 25 27 ft lbs 34 37 Nm b Tighten the rear fastener to 25 27 ft lbs 34 37 Nm 2 Repeat the ti...

Page 229: ...2 98 2007 Buell Firebolt Chassis HOME NOTES ...

Page 230: ...3 7 Cylinder and Piston 3 61 3 8 Lubrication System 3 71 3 9 Oil Hose Routing and Oil Reservoir 3 72 3 10 Oil Line Fittings 3 73 3 11 Oil Cooler 3 75 3 12 Oil Pressure Indicator Switch 3 78 3 13 Crankcase Breathing System 3 80 3 14 Oiling System 3 82 3 15 Oil Pump 3 83 3 16 Oil Filter Mount 3 86 3 17 Hydraulic Lifters 3 87 3 18 Gearcase Cover And Cam Gears 3 89 3 19 Crankcase 3 94 Table Of Content...

Page 231: ......

Page 232: ... non waste spark 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...

Page 233: ...0 0094 in 0 2388 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...

Page 234: ...ations GEARCASE NEW COMPONENTS SERVICE WEAR LIMITS Cam gear shaft in bushing loose 0 0007 0 0022 in 0 0178 0 0559 mm 0 003 in 0 076 mm Cam gear shaft end play min 0 005 0 024 in 0 127 0 610 mm 0 025 in 0 635 mm Intake cam gear shaft end play min 0 006 0 024 in 0 152 0 610 mm 0 040 in 1 016 mm Table 3 13 Flywheel Specifications FLYWHEEL NEW COMPONENTS SERVICE WEAR LIMITS Runout Flywheels at rim 0 0...

Page 235: ... Special proce dure Special pattern to tighten page 3 58 Cylinder studs 10 20 ft lbs 14 27 Nm Special method to tighten page 3 107 Exhaust header nuts 72 96 in lbs 8 1 10 8 Nm page 3 14 Feed oil line at rear of oil pump 27 29 ft lbs 36 6 39 3 Nm page 3 35 Front isolator bolt 49 51 ft lbs 66 4 69 1 Nm page 3 14 Front isolator bracket mount ing fasteners 49 51 ft lbs 66 4 69 1 Nm page 3 14 3 32 Gear...

Page 236: ...OCTITE 271 red page 3 33 Reed block fasteners 25 35 in lbs 2 8 4 Nm LOCTITE 222 purple page 3 81 Reed valve stop fastener 5 7 in lbs 0 6 0 8 Nm LOCTITE 222 purple page 3 81 Return oil line at top front oil pump 22 24 ft lbs 29 8 32 5 Nm page 3 35 Rocker box cover screws 120 168 in lbs 13 6 18 9 Nm page 3 60 Rocker box to head bolts 135 155 in lbs 15 18 Nm Small fasteners 3 page 3 60 Rocker box to ...

Page 237: ...oblems Buell rec ommends that you operate your motorcycle on straight unleaded gasoline ADJUSTMENT TESTING General When an engine needs repair it is not always possible to determine definitely beforehand whether repair is possible with only cylinder head cylinder and piston disassembled or whether complete engine disassembly is required for crank case repair Most commonly only cylinder head and cy...

Page 238: ...und spark 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 ...

Page 239: ... 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 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 base plate See 4 44 AIR ...

Page 240: ...gnition coil 1 11 Disconnect 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 10647a 4 ...

Page 241: ...ve muffler See 2 28 EXHAUST SYSTEM Figure 3 3 Muffler and Mounting System XB9R 1 Clamp Torca 2 Muffler mount front 3 Screw front muffler mount 1 4 Bushings front muffler mount 2 5 Flat washer front muffler mount 1 6 Nut front muffler mount 1 7 Front muffler strap fastener 8 Muffler strap front 9 Muffler bracket rear 10 Screw rear muffler bracket 2 11 Flat washer rear muffler bracket 2 12 Rear muff...

Page 242: ...Disconnect clutch cable a Remove wire form 1 from front isolator b Slide clutch 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 Clutch Cable Wire Form Retainer and Adjuster Boot 1 Wire form retainer 2 Clutch cable adjuster boot 1 2 10502 ...

Page 243: ...embly 10 Center tie bar mount 11 Fasteners for center tie bar mount 2 12 Washers for center tie bar mount 2 13 Center tie bar assembly 14 Fasteners for center tie bar assembly 2 15 Washers for center tie bar assembly 2 16 Ground strap 17 Rear isolator assembly 18 Fasteners for rear isolator assembly 4 19 Washers for rear isolator assembly 4 20 Bolt 21 Rear tie bar assembly 22 Fasteners for rear ti...

Page 244: ...ve rear tie bar 2 from frame only 21 Loosen rear isolator bolt DO NOT REMOVE 22 See Figure 3 7 Remove front isolator bolt 1 23 Remove front isolator mount 2 from engine 24 Rotate engine down Figure 3 6 Rear Isolator Bolt and Rear Tie Bar Typical 1 Rear isolator bolt 2 Rear tie bar 2 1 8735 Figure 3 7 Front Isolator and Tie Bar Assemblies 1 Front isolator bolt 2 Front isolator mount 3 Front tie bar...

Page 245: ...rtant to keep load off of isolator bolt for installation purposes Alter nate between tightening isolator bolt and raising engine with scissors jack 2 See Figure 3 8 Insert front isolator 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 4 69 1 Nm 4 Tighten front isolator bolt to 49 51 ft...

Page 246: ... a Connect clutch cable to handlebars and adjust to specifications See 1 9 CLUTCH b Install wire form and tighten fastener to 84 92 in lbs 9 5 10 4 Nm Figure 3 9 Clutch Cable Wire Form Retainer 10502 Figure 3 10 Oil Cooler Feed and Return Oil Line 1 8 1 4 in 3 175 6 35 mm Clearance to Clutch Cable 10501a 1 ...

Page 247: ...igure 3 11 Install the ignition coil 1 and connect 2 83 and tighten fasteners to 120 144 in lbs 13 6 16 3 Nm Figure 3 11 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 10647a 4 ...

Page 248: ... See 2 33 CHIN FAIRING 24 Install air scoops right and left sides See 2 35 AIR SCOOPS 25 Connect fuel pump See 4 39 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 first If positive cable should contact ground with negative cable con nected the resulting sparks ...

Page 249: ...revent accidental vehicle 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 air cleaner assembly See 4 44 AIR CLEANER ASSEMBLY 5 Remove throttle body velocity stack NOTES A clamp ring secures the velocity stack to the throttle body Install shop towel in entrance to throttle bo...

Page 250: ...following sensors a Temperature sensor 90 3 b Oxygen sensor 137 4 11 Disconnect throttle cables from induction module throttle body 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 10647a 4 ...

Page 251: ...ACTIVE EXHAUST SYSTEM XB12 MODEL 16 See Figure 3 15 Remove muffler See 2 28 EXHAUST SYSTEM Figure 3 15 Muffler and Mounting System XB9R 1 Clamp Torca 2 Muffler mount front 3 Screw front muffler mount 1 4 Bushings front muffler mount 2 5 Flat washer front muffler mount 1 6 Nut front muffler mount 1 7 Front muffler strap fastener 8 Muffler strap front 9 Muffler bracket rear 10 Screw rear muffler bra...

Page 252: ... vehicle Figure 3 16 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 Cable interactive exhaust 12 P clamp 13 Oil line clamp 14 Oil pump 2 7 5 4 3 4 11964b 11963a 10 1 2 3 3 8...

Page 253: ... bar assembly 10 Center tie bar mount 11 Fasteners for center tie bar mount 2 12 Washers for center tie bar mount 2 13 Center tie bar assembly 14 Fasteners for center tie bar assembly 2 15 Washers for center tie bar assembly 2 16 Ground strap 17 Rear isolator assembly 18 Fasteners for rear isolator assembly 4 19 Washers for rear isolator assembly 4 20 Bolt 21 Rear tie bar assembly 22 Fasteners for...

Page 254: ...nnect oil cooler lines at oil cooler d Remove front tie bar 7 from V bracket e Remove front tie bar 7 from engine f Unbolt V bracket from main frame and remove V bracket 20 See Figure 3 16 Remove center tie bar 13 from engine 21 Remove rear tie bar 21 from frame 22 Remove cable strap securing wire bundle to return oil line 23 See Figure 3 18 Disconnect electrical components a Neutral switch 131 b ...

Page 255: ... vent oil line to return oil line c Disconnect vent oil line at swingarm oil reservoir 1 and remove SeeFigure 3 16 Oil Lines and Connec tions 26 See Figure 3 16 Remove feed oil line 3 a Loosen fitting at oil pump 14 b Remove two p clamps 12 from feed oil line one on crankcase and one on swingarm oil reservoir c Remove feed oil line 3 at oil pump 14 d Disconnect feed oil line at swingarm oil reserv...

Page 256: ...ever d Remove clutch cable ferrule from hand lever 30 See Figure 3 21 Remove two fasteners 5 and remove sidestand assembly 31 Support engine with wide scissors jack 32 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 1031...

Page 257: ...e 3 24 Remove a Rear isolator bolt b Swingarm pivot shaft 35 See Figure 3 25 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 beneath the rear brake reservoir and hose 36 See Figure 3 23 Support swingarm oil tank with wooden blocks jack etc 37 Lower engine...

Page 258: ...unt c See Figure 3 27 Swingarm pivot shaft pinch bolt threaded insert d See Figure 3 28 Aluminum bushings from front exhaust mount e Timer cover f See Figure 3 29 Wire guard located under the sprocket cover Figure 3 26 Center Tie Bar Mount Figure 3 27 Removing Threaded Insert 8725 8724 8729 Figure 3 28 Front Exhaust Mount Bushings 2 piece Figure 3 29 Wire Guard Left Side Right Side 8718 8727 12367...

Page 259: ...ank 43 Route 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 32 This allows the vehicle to remain together as a rolling chassis and to be removed from the lift and stored if necessary 44 Remove support from under swingarm oil tank 45 Remove overhead sup...

Page 260: ...as required a Shifter assembly See 6 2 PRIMARY COVER b See Figure 3 34 Center tie bar mount 30 33 ft lbs 40 6 44 7 Nm NOTE Hand thread pivot shaft into crankcase prior to installing the threaded insert Remove pivot shaft after installing the threaded insert c See Figure 3 35 Apply LOCTITE 242 blue to swin garm pivot shaft pinch bolt threaded insert and install d See Figure 3 36 Aluminum bushings f...

Page 261: ...eize to swingarm pivot shaft threads and tighten swingarm pivot shaft to 24 26 ft lbs 32 5 35 2 Nm 5 Apply LOCTITE 271 red and tighten swingarm pivot shaft pinch bolt to 17 19 ft lbs 23 25 8 Nm 6 See Figure 3 39 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 Ins...

Page 262: ... bar assembly 10 Center tie bar mount 11 Fasteners for center tie bar mount 2 12 Washers for center tie bar mount 2 13 Center tie bar assembly 14 Fasteners for center tie bar assembly 2 15 Washers for center tie bar assembly 2 16 Ground strap 17 Rear isolator assembly 18 Fasteners for rear isolator assembly 4 19 Washers for rear isolator assembly 4 20 Bolt 21 Rear tie bar assembly 22 Fasteners for...

Page 263: ...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 42 Tighten rear isolator bolt to 25 27 ft lbs 33 9 36 6 Nm 14 Install rear tie bar 21 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 NOTE When reinstalling the tie bar first mount to engine and then to V bracket in ...

Page 264: ...in the proper position those fittings must be removed and thoroughly cleaned After cleaning apply LOCTITE 565 Sealant to the fitting and re install to the correct ori entation When tightening oil lines always support the oil line fitting with a wrench to maintain proper orientation and prevent damage to the oil line fitting Figure 3 44 Muffler Mounting System XB12R and XB9R Rear muffler mount b098...

Page 265: ...uted through the right side of the rear muffler bracket 10 Figure 3 45 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 Cable interactive exhaust 12 P clamp 13 Oil line clamp ...

Page 266: ... 5 5 5 Nm 25 See Figure 3 46 The feed oil line 2 at the rear of the of the oil pump should be tightened to 27 29 ft lbs 36 6 39 3 Nm 26 Tighten the return oil line 4 at the top front oil pump fit ting to 22 24 ft lbs 29 8 32 5 Nm NOTE See Figure 3 46 Once the return oil line 4 has been installed it will be necessary to install the convolute covering 3 over the return oil line 27 Tighten the vent o...

Page 267: ... oil cooler feed and return lines to oil cooler verify that the lines do not twist while tightening If any oil line fittings are found to be loose or not oriented in the proper position those fittings must be removed and thoroughly cleaned After cleaning apply LOCTITE 565 Sealant to the fitting and re install to the correct ori entation When tightening oil lines always support the oil line fitting...

Page 268: ...proximately 6 o clock to allow for proper alignment and clearance of other components on the vehicle 30 Install the oil cooler return oil line at crankcase and tighten to 15 17 ft lbs 20 3 23 Nm Lightly coat the threads of the oil cooler fitting with clean H D 20W50 engine oil Wipe off any excess oil Tighten return oil line to 19 21 ft lbs 25 8 28 5 Nm at oil cooler 31 Install oil cooler line clam...

Page 269: ...sitive battery cable at starter g Starter solenoid 128 h Oil pressure switch 120 Figure 3 50 Sprocket Cover Wiring and Connections 1 Voltage regulator connector 77 2 Neutral switch connector 131 3 Neutral switch location 4 Vehicle speed sensor connector 65 5 Main harness 6 Gear cover vent line 7 Cam position sensor connector 14 8 Stator connector 46 9 Oil pressure switch wiring 10 Interactive exha...

Page 270: ...cable to handlebars and adjust to specifications See 1 9 CLUTCH b Install wire form retainer and tighten fastener to 84 92 in lbs 9 5 10 4 Nm 35 Install sidestand assembly See 2 40 SIDESTAND Figure 3 51 Correct Routing of Wiring Harnesses and Interactive Muffler Cable 11970c Figure 3 52 Clutch Cable Wire Form Retainer 10502 ...

Page 271: ...Figure 3 53 Muffler and Mounting System b0986x3c 1 Clamp Torca 2 Muffler 3 Muffler strap front 4 Front muffler strap fastener 5 Front muffler mount 6 Rear muffler bracket 7 Rear muffler strap fastener 8 Muffler strap rear 2 1 4 6 5 2 3 7 8 ...

Page 272: ... sensors a Temperature sensor 90 3 b Oxygen sensor 137 Install cable strap on harness 4 39 See Figure 3 54 Install the ignition coil 1 and spark plug wires and connect 83 2 Tighten ignition coil fas teners to 120 144 in lbs 13 6 16 3 Nm Figure 3 54 Electrical Connections and Throttle Cables Typical 1 Ignition coil 2 Coil connection 83 3 Cylinder head temperature sensor connection 90 4 Oxygen senso...

Page 273: ... of the fuel tank on the left side of the vehicle 48 Install rear belt and idler pulley See 6 6 DRIVE BELT SYSTEM 49 Install left and right side rider footrests and support plates See 2 29 FOOTPEG HEEL GUARD AND MOUNT 50 Install sprocket cover See 2 30 SPROCKET COVER 51 Install chin fairing See 2 33 CHIN FAIRING 52 Install air scoops right and left sides See 2 35 AIR SCOOPS 11WARNING 1WARNING Conn...

Page 274: ...s Do not re use fiber cover seals Engine damage may result Figure 3 56 Rocker Arm and Pushrod Cover Assemblies 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 Screw 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 1...

Page 275: ... order to relieve valve spring pressure on the lower rocker box 7 See Figure 3 56 Remove lower rocker cover NOTE Remove lower rocker box as an assembly and then disas semble as required NOTE Mark rocker arm shafts for reassembly in their original posi tions Valve train components must be reinstalled in their orig inal positions to prevent accelerated wear and increased valve train noise 8 See Figu...

Page 276: ...G COMPRES SOR TOOL Part No HD 34736B in vise 2 See Figure 3 60 Compress valve spring with VALVE SPRING COMPRESSOR 3 See Figure 3 61 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 Remo...

Page 277: ... 3 Valve collar 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 278: ...loosened carbon 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 oth...

Page 279: ...ure 3 66 Measure 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 63 Measuring Rocker ...

Page 280: ...face must be flush with or below the head surface See 3 1 SPECIFICATIONS for valve seat to cylinder head fit 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...

Page 281: ...ng From opposite 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 69 Replacing Rocker Arm Bushings...

Page 282: ...e guide At this 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 th...

Page 283: ...to be cut and be 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...

Page 284: ...mplete clean up 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...

Page 285: ... 3 Valve collar 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 286: ... air flow rates 00061a 3 Blow dry with compressed air 4 Apply a liberal amount of engine oil to the valve stem 5 See Figure 3 74 Insert valve into valve guide and bottom valve on valve seat 6 See Figure 3 75 Place a protective sleeve over the valve stem keeper groove NOTE Failure to use a protective sleeve on the valve stem keeper groove when installing the valve stem seal and collar assem bly wil...

Page 287: ...talled Repeated installations will damage seal 8 Install valve spring and upper collar 9 See Figure 3 78 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 groove...

Page 288: ... to the crankcase d Tighten fasteners to 30 40 in lbs 3 4 4 5 Nm 2 See Table 3 20 Identify push rod color coding length and respective push rod positions in engine Place intake and exhaust push rods onto seat at top of tappet NOTE After head s have been installed do not turn engine over until both push rods can be turned with fingers Otherwise dam age to push rods or rocker arms may result Figure ...

Page 289: ...E 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 cylinder distortion Always tighten in sequence shown 6 Start the cylinder head screws onto the cylinder studs two short screws on the left side of the engine two long bolts on the right 7 See Figure 3 81 For each cylinder head start with ...

Page 290: ... inner 10 Gasket lower 11 Rocker arm shafts 12 Screw 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 b1266x3x 18 ...

Page 291: ...zes and torque specifications are listed in Table 3 21 a Tighten bolts 1 to 18 22 ft lbs 24 30 Nm b Tighten bolts 2 to 135 155 in lbs 15 17 5 Nm c Tighten screws 3 to 135 155 in lbs 15 17 5 Nm NOTE Do not stretch gaskets while installing position gaskets in cover and use top rocker cover to press gaskets into position 11 See Figure 3 83 Install upper rocker covers a Place a new inner gaskets on lo...

Page 292: ...ll against cylinder studs Discard cyl inder base gasket NOTE With cylinder removed be careful not to bend the cylinder 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 removin...

Page 293: ... shop towel over the 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 87 The arrows on the pistons must a...

Page 294: ... piston pin to bushing 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 S...

Page 295: ...ol in a slow speed drill The speed at which the tool rotates determines the speed at which it must be stroked up and down the bore to produce the desired cross hatch pattern 4 Starting at the bottom of the cylinder move the deglazing tool up and down the entire length of the cylinder bore for 10 to 12 complete strokes NOTES Stop to examine the cylinder bore and or take measure ments A precise 60 c...

Page 296: ...g spec ifications See Table 3 23 NOTES The same piston may be used if cylinder bore was not changed unless it is scuffed or grooved If re using pis ton replace piston rings and hone the cylinder walls with a No 240 grit flexible hone to facilitate ring seating Piston ring sets must be properly fitted to piston and cyl inder Figure 3 91 Piston Rings 1 Top compression ring Install either side up 2 S...

Page 297: ...nstall rings so 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 95 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 93 Installing Piston Rings Transmission Sha...

Page 298: ...ction as it 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...

Page 299: ... it has been installed and then removed for any rea son A loosely installed ring will come out of the piston groove and damage cylinder and piston beyond repair 4 See Figure 3 102 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 seat...

Page 300: ...or crankcase 9 See Figure 3 105 Compress the piston rings using PIS TON RING COMPRESSOR Part No HD 96333 51E 10 Install cylinder over piston 11 Remove PISTON RING COMPRESSOR NOTE Push rod covers must be installed prior to installing cylinder heads 12 Assemble and install cylinder head See 3 6 CYLINDER HEAD 13 Rotate engine back up into frame See 3 3 ENGINE ROTATION FOR SERVICE Figure 3 103 Ring En...

Page 301: ...3 70 2007 Buell Firebolt Engine HOME NOTES ...

Page 302: ... operation at temperature above 80 F 26 7 C extensive idling speeds in excess of 65 mph 105 kph and or extensive two up riding or similar loads the oil should be changed at 2500 mile 4000 km intervals Refill with fresh oil Always change oil filter when changing engine oil NOTE See 1 6 ENGINE LUBRICATION SYSTEM for more informa tion on checking oil level and changing oil and filter WINTER LUBRICATI...

Page 303: ...e front of the engine to the oil cooler on the left front side of the crankcases The oil cooler return line 6 then exits the oil cooler and connects to the oil filter housing on the right front side of the crankcases For more information see 3 14 OILING SYSTEM Figure 3 106 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 ...

Page 304: ... the OIL LINE REMOVER B 41623 B squarely against the fitting to keep the spring clip expanded Use only enough pressure to hold the tool square Excess pressure will prevent simulta neously pulling the line and tool from the fitting 4 Pull the oil line and the tool from the fitting 5 Repeat to remove the remaining oil lines 6 Remove oil line fittings and plug the holes until they can be replaced PAR...

Page 305: ... the correct fitting in the swingarm until each one clicks in place under the spring clip 3 Lightly tug on oil line to verify that it is securely locked to fitting and the spring clip is seated in the oil line fitting groove 4 Check oil level and add oil if required 5 After running engine a Inspect oil fittings for oil leaks b Check oil level and add oil if required Figure 3 109 Flanged Oil Line 1...

Page 306: ...riented in the proper position those fittings must be removed and thor oughly cleaned After cleaning apply LOCTITE 565 Sealant to the fitting and re install to the correct orientation When tightening oil lines always support the oil line fitting with a wrench to maintain proper orientation and prevent damage to the oil line fitting Figure 3 110 Oil Cooler 1 Oil cooler feed line 2 Oil cooler return...

Page 307: ...ust be removed and thor oughly cleaned After cleaning apply LOCTITE 565 Sealant to the fitting and re install to the correct orientation When tightening oil lines always support the oil line fitting with a wrench to maintain proper orientation and prevent damage to the oil line fitting 1 See Figure 3 110 Lightly coat the threads of the oil cooler fittings with clean H D 20W50 engine oil Wipe off a...

Page 308: ...ooler Feed Oil Line Orientation Approximately 2 O Clock and Oil LIne Clearances 11971b 10501b 1 Clutch cable 2 1 8 1 4 in 3 175 6 35 mm clearance 3 Feed oil line 4 Return oil line 5 Feed oil line to oil cooler 6 Return oil line from oil cooler 1 2 3 4 3 5 6 ...

Page 309: ... 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 1 Remove cable strap securing oil pressure wiring to oil pressure switch 2 See Figure 3 112 Unplug connector 3 from oil pres sure indicator lamp switch 2 located un...

Page 310: ...se Cut cable straps that you installed in step 5 above and remove banjo bolt gauge assembly wash ers and adapter from vehicle 7 Coat threads of oil pressure switch with LOCTITE 565 HIGH PERFORMANCE PIPE SEALANT with TEFLON Reinstall oil pressure switch Using OIL PRESSURE SENDING UNIT WRENCH tighten switch snugly to 50 70 in lbs 5 6 7 9 Nm 8 Plug in connector 3 by pushing elbow connector straight u...

Page 311: ... vent PCV valves 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...

Page 312: ... the reed valve 3 and the reed valve stop 2 to prevent premature failure of the reed valve NOTE See Figure 3 116 It is not necessary to replace the reed block 4 along with the reed valve The block can only be replaced after separating the crankcase halves 3 With the lower part of the curve on the stop facing out Apply LOCTITE 222 purple install and tighten fastener to 5 7 in lbs 0 6 0 8 Nm 4 If it...

Page 313: ...in Oil is forced 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 ...

Page 314: ...sure be sure that all possible related malfunctions have been eliminated NOTE If any oil line fittings are found to be loose or not oriented in the proper position those fittings must be removed and thor oughly cleaned After cleaning apply LOCTITE 565 Sealant to the fitting and re install to the correct orientation When tightening oil lines always support the oil line fitting with a wrench to main...

Page 315: ...refully remove mounting screws 5 and washers only Pump will drop with screws removed Discard mounting gasket 7 Remove cover TORX screws 2 Lift cover off body 8 Remove and discard o ring 9 Slide both pieces of gerotor feed set separator plate and both pieces of gerotor scavenge set off gear shaft 10 Remove and discard retaining ring 11 Remove thrust washer and gear shaft Figure 3 119 Oil Pump Hardw...

Page 316: ...oper orientation and prevent damage to the oil line fitting Liberally coat all moving parts with clean engine oil to ensure easy assembly and smooth operation at start up 1 See Figure 3 118 Install gear shaft through body Posi tion thrust washer over end of shaft Install new retaining ring into groove in shaft 2 Insert inner gerotor of the gerotor scavenge set over gear shaft 3 Place outer gerotor...

Page 317: ...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 The filter adapter has identical ends either end may be installed into the filter mount 1 Apply several drops of LOCTITE 243 blue to last few threads on that end of the filter adapter which is installed into filter...

Page 318: ...move gaskets and o rings Discard parts 4 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 injury Wear safety glasses w...

Page 319: ...OTE Before installing o rings on the top of each pushrod cover be sure to apply a small amount of clean engine oil to each o ring 5 See Figure 3 125 Install push rod cover a Place new push rod 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...

Page 320: ...any others It is 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 pum...

Page 321: ...d readings 6 Remove cam position 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 ...

Page 322: ...y a letter E The numbers identify the cam location function and the letter E indicates model 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 pin...

Page 323: ...on shaft Tighten 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 XB uses V style timing marks on the front intake cam assembly Please note the V design Because of the larger d...

Page 324: ...cover using a flat 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 See 3 17 HYDRAULIC LIFTERS 8 Install cylinder heads See 3 6 CYLI...

Page 325: ...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 15 OIL PUMP 4 Remove gearcase components See 3 18 GEARCASE COVER AND CAM GEARS 5 Remove primary cover and primary drive clutch compo nents See 6 2 PRIMARY COVER 6 ...

Page 326: ...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 Removing Cylinder Base Studs If cylinder base studs require replacement proceed as fol lows 1 Thread a 3 8 16 nut onto cylinder base stud 2 Thread a second nut onto stud until it contacts the first nut 3 Tighten...

Page 327: ...ion shaft bearing 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 rac...

Page 328: ...l seal 3 from crankcase using Snap On Tool Part No CJ 114 Body Dent 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...

Page 329: ...heel assembly is 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 Bear...

Page 330: ...ass A or B inner 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...

Page 331: ...ue White Gray Green 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 3...

Page 332: ...t specifications 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 Th...

Page 333: ...any provides a flywheel 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 ...

Page 334: ...hing or bushing will develop 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 was...

Page 335: ...ft bearing into 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 new 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...

Page 336: ...t bearing with engine 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 ...

Page 337: ...aces b Slide outer race in right crankcase over pinion shaft and bearing assembly c Apply LOCTITE 271 to the last few threads and 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 338: ...uds have a shoulder at the lower end Place the end of the stud without the shoulder into the head screw d Install the stud in the crankcase with the shoulder end down Use an air gun to drive the stud until the shoulder reaches the crankcase e Remove air gun Use a torque wrench to tighten stud to 10 20 ft lbs 14 27 Nm 12 Install piston and cylinder See 3 7 CYLINDER AND PIS TON 13 Install cylinder h...

Page 339: ...3 108 2007 Buell Firebolt Engine HOME NOTES ...

Page 340: ...uble 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 30 Electroni...

Page 341: ...9 Fuel Pump 4 107 4 40 Fuel Tank Vent Valve 4 115 4 41 Fuel Cap Retaining Ring 4 116 4 42 Throttle Body 4 117 4 43 Intake Leak Test 4 123 4 44 Air Cleaner Assembly 4 125 4 45 Evaporative Emissions Control California Models 4 128 ...

Page 342: ...sensor 120 168 in lbs 13 6 19 Nm page 4 102 Fuel cap retaining ring fasten ers 62 71 in lbs 7 8 Nm page 4 116 Fuel pump assembly ground screw 18 22 in lbs 2 0 2 5 Nm page 4 111 Fuel pump drain plug 84 108 in lbs 9 5 12 2 Nm page 4 107 Fuel pump screws 48 51 in lbs 5 4 5 8 Nm page 4 114 Fuel rail fasteners 20 25 in lbs 2 3 2 8 Nm LOCTITE 271 red page 4 120 Fuel supply line banjo fitting 84 108 in l...

Page 343: ...ervoir clamp rear 120 144 in lbs 13 6 16 3 Nm page 4 129 Throttle position sensor 12 15 in lbs 1 4 1 7 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 ITEM TORQUE NOTES ...

Page 344: ...muffler The engine ECM monitors engine speed and throttle position while activating the valve See 7 6 INTERACTIVE EXHAUST SYSTEM XB12 MODEL GENERAL The Buell DDFII 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 starti...

Page 345: ...Y LT GN 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 only 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 ...

Page 346: ...ob lems RESOLVING 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 engi...

Page 347: ...rn 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 functional...

Page 348: ... to note that historic trouble codes may also be present whenever the system indicates the existence of a current fault See 4 4 CHECKING FOR TROUBLE CODES if multiple trouble codes are found Functional Trouble codes 52 through 56 are considered to be functional codes They indicate an internal problem with the ECM trou ble codes 52 through 55 or with the camshaft sensor timing trouble code 56 RETRI...

Page 349: ... trouble code The 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...

Page 350: ...sing a jumper wire on Pins 1 and 2 of the data link connector However if the jumper wire is removed with the engine running the check engine lamp will continue to flash trouble codes To stop check engine lamp from flashing codes turn engine stop switch OFF CLEARING CODES After correcting system problems clear trouble codes If the Digital Technician Part No HD 44750 is not available per form 50 sta...

Page 351: ...k connector from Breakout 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...

Page 352: ...M Part No HD 39978 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 F...

Page 353: ...r 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 See Table 4...

Page 354: ...Table 4 7 Trouble Codes and Fault Conditions CODE NO FAULT CONDITION RELEVANT TOPIC 11 Throttle position sensor 4 16 TROUBLE CODE 11 13 Oxygen sensor 4 17 TROUBLE CODE 13 14 Engine temperature sensor 4 18 TROUBLE CODE 14 15 Intake air temperature sensor 4 19 TROUBLE CODE 15 16 Battery voltage 4 20 TROUBLE CODE 16 21 Interactive muffler control 1203 s only 4 21 TROUBLE CODE 21 23 Front fuel injecto...

Page 355: ...le ECM Connector 10 Connector 11 LTGN R GY BK BK V R Data Link 91A b1080a4x To IGN relay Table 4 8 Wire Harness Connectors in Figure 4 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 356: ...0 CHECK ENGINE LAMP ON CONTINUOUSLY NO Does engine start YES See 4 11 ENGINE CRANKS BUT WILL NOT START NO YES NO Are any trouble codes displayed YES NO Refer to applicable trouble code flow chart Start with lowest trouble code All diagnostic codes are listed on page 4 13 in Table 4 7 YES Go to Diagnostic Check Part 2 of 2 Refer to diagnostic tips in related trouble code chart even if no code is se...

Page 357: ... and 4 Continu ity 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 ...

Page 358: ...TICS Diagnostic Tips Check for the following conditions Check for open in BK Y wire Check for blown fuse Check for failed bulb 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 conn...

Page 359: ... Diode Bk Hn Mflr Fan IGN Acces Key Sw Lights ECM Spare Empty Empty BK Ignition Switch 33 To battery Electronic Control Module ECM Connector 10 Connector 11 Instrument Module 39 R BK Y 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 O W Table 4 9 Wire Harness Connectors in Figure 4 15 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 p...

Page 360: ...y YES No ECM 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 Connect jumper wire from pin 7 at connector 39 to ground Check is engine lamp on YES Repair open or short to voltage on BK Y wire between connector 39 and connector 10B NO Di...

Page 361: ...o off for four seconds It may then come back on for an eight second period for a stored error or remain on continuously current error DIAGNOSTICS Diagnostic Notes 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 Engi...

Page 362: ... Diode Bk Hn Mflr Fan IGN Acces Key Sw Lights ECM Spare Empty Empty BK Ignition Switch 33 To Battery Electronic Control Module ECM Connector 10 Connector 11 Instrument Module 39 R BK Y 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 O W Table 4 10 Wire Harness Connectors in Figure 4 18 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 ...

Page 363: ... 39A Reconnect 39 Check engine lamp ON YES NO 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 Replace Instrum...

Page 364: ... Connect BREAKOUT BOX 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 7 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 te...

Page 365: ...il can sometimes cause 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...

Page 366: ...n 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 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 R W 83B 83B 14A 14B 134B 134A B 84A 84B 85A 85B Bank Angle Sensor ...

Page 367: ...ck engine lamp illuminate 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 S...

Page 368: ...ge between Terminal A and Terminal C of connector 14B Is 5 volts present YES Poor connection at connector 10B 83 or open in harness between coil and ECM Repair open NO With ignition OFF measure resistance between connector 14 Terminal A and Breakout Box GY Pin 1 Also between connector 14 Terminal C BK W wire and ECM Pin 7 on connector 11B Is resistance greater than 1 0 ohm NO Go to 4 11 PART 3 of ...

Page 369: ...osition 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 tance between Terminal B and Connector 14B and Breakout Box GY Pin 3 Is resistance greater than 1 0 ohms Remov...

Page 370: ...te If the ground is 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 371: ...vides power to fuel pump 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 ...

Page 372: ...nt Replace ignition 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 righ...

Page 373: ...l 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 ADAPT...

Page 374: ...emoved 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 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 adapte...

Page 375: ... 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 A B C D BK Tab...

Page 376: ...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 negativ...

Page 377: ...tive terminal Probe BN Y wire at 86A during the first two seconds after key ON Does test lamp light YES NO Connect Breakout Box HD 42682 to ECM Check continuity between 86A Ter minal C BN Y wire and ECM connector 10 black Termi nal 3 Is continuity present Inspect fuel pump wiring Is wiring OK YES NO Repair fuel pump wiring NO Replace fuel pump assembly See 4 39 FUEL PUMP YES Locate and repair open...

Page 378: ...er knob NOTE 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 moderate injury The idle speed should be adjusted when the engine is at nor mal operating temperature 320 F 160 C NOTE An idle speed too low can cause poor throttle response An idle speed too high can cause a slow return to idle...

Page 379: ...o jump tester gap 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 o...

Page 380: ...ock beneath right side of fairing 83 ignition coil 3 place Packard beneath airbox base 1 2 3 4 5 6 1 2 3 4 5 6 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 b1...

Page 381: ...Tester Also check 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...

Page 382: ... 7 of Breakout Box 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...

Page 383: ...4 42 2007 Buell Firebolt Fuel System HOME NOTES ...

Page 384: ...tion Inspect ECM harness connector for backed out terminals improper 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 displa...

Page 385: ...nic Control Module ECM Connector Connector LTGN GY R W 5 Volt Reference 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 bene...

Page 386: ...test Did check engine 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 ...

Page 387: ...ate and repair open 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 Replac...

Page 388: ...w 5000 RPM for the 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 motorcycl...

Page 389: ...29x4x Oxygen Sensor 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 390: ... to Pin 4 and Pin 7 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 ...

Page 391: ... Restriction present NO Check 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 42 THROTTLE BODY YES Repair Go to Code 13 Test Part 3 of 3 STOP YES Repair low pres sure problem See 4 13 FUEL PRES SURE TEST Replace fuel pump See 4 39 FUEL PUMP Clear codes and confirm proper operation with no check engine lamp...

Page 392: ...nstall original O2 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 p...

Page 393: ...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 calibration sensor which ...

Page 394: ...ne Temperature Sensor 90 PK Y Electronic Control Module ECM Connector 10 Connector 11 PK Y 1 b0801x4x 90A 90B Table 4 20 Wire Harness Connectors in Figure 4 38 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch in fairing 90 engine temperature sensor 1 place bullet beneath air cleaner baseplate ...

Page 395: ...ng a DVOM measure 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 b...

Page 396: ...ensor disconnected dis 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 ...

Page 397: ...minal to wire connection and damaged harness Perform 4 7 WIGGLE TEST to locate intermittents If connections and harness check out OK check intake air temperature reading while moving related connectors and wiring harness If the failure is induced the IAT sen sor display will change Shifted sensor The temperature to resistance values table may be used to test the IAT sensor at various tem perature ...

Page 398: ...0 Connector 11 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 39 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch in fairing 89 intake air temperature sensor 2 place Amp in air cleaner baseplate ...

Page 399: ...OR clear codes and 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 In...

Page 400: ...ce between ECM Pins 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 har...

Page 401: ...elate 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 40 Electrical Relays Figure 4 41 Fuse...

Page 402: ... Lights ECM Spare Empty 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 fue...

Page 403: ... 1 of 10 on Breakout 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 ...

Page 404: ...ge drop greater than 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 volta...

Page 405: ...anical fault in the actuator valve or cable Electrical fault in the actuator circuit Electrical fault in the actuator feedback circuit Electrical fault in the brake light or horn circuits Blown fuse 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 Usi...

Page 406: ...ronic Control Module ECM Connector 10 Connector 11 b1240a1x Brake Switch Brake Horn Muffler Foot Brakes Tail Light LH Controls Ground Horn Interactive Muffler Sub Harness Muffler Valve Actuator Motor Position Sensor Table 4 24 Wire Harness Connectors in Figure 4 45 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch in fairing 161 Interactive muffler actuator 4 place Amp beneath air cleaner...

Page 407: ...p in Run position 12V present at pin 1 161B NO Locate and repair open on O wire between fuse and 161B YES Check for continuity between 164B and 161B pin 3 Continuity present NO Locate and repair open on W wire Locate and repair open on TN V wire 161B Using pliers gently pull on cable to interactive muffler actuator Cable should cause interactive muffler valve to open and close freely without bind ...

Page 408: ...s ignition coils 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 ...

Page 409: ...85 Cam Position Sensor 14 GY W Y GN GY R W GN W BK W G Y W Y GY GN GY GY BK W BK W BK W Table 4 25 Wire Harness Connectors in Figure 4 48 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch in fairing 14 cam position sensor 3 place Deutsch beneath sprocket cover 84 front fuel injector 2 place Packard beneath air cleaner baseplate 85 rear fuel injector 2 place Packard beneath air cleaner bas...

Page 410: ...5 Black and Terminal 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 42 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 c...

Page 411: ...the ignition relay 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 Cod...

Page 412: ...circled num bers on 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 50 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 ign...

Page 413: ...Connector Cam Position Sensor A GN W Y BE GY BE O BK W B C A C B To Rear Cylinder To Front Cylinder R W GY Ignition Relay Y BE GY BE O Dyno Loop b1072a4x 10A 83A 83B 14A 14B 11A 11B 10B RELAY CENTER Table 4 26 Wire Harness Connectors in Figure 4 51 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch beneath fairing 83 ignition coil 3 place Packard beneath air cleaner baseplate ...

Page 414: ...ES Measure voltage 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 Br...

Page 415: ...even when the motor 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 Pa...

Page 416: ...mpty 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 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 Tabl...

Page 417: ...ad test Did check engine lamp come on and set only CODE 33 YES NO Install original fuel pump 4 39 FUEL PUMP and replace ECM 4 30 ELECTRONIC CONTROL MODULE System OK Fuel pump on continuously NO Check continuity of BN Y wire between 10 Pin 3 and Pin C of 86 Continuity present YES Repair open NO Check continuity of GY wire from ignition relay Terminal 87 to Pin D of 86 Continuity present YES Repair ...

Page 418: ...d DIAGNOSTICS Diagnostic 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 54 Installed Breakout Box Figure 4 55 Instrument Module Connector 39 8427 1 ECM 2 Breakout box 1 2 8426 ...

Page 419: ... Spare Diode Bk Hn Mflr 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 R Y R GY O W R R R Main Fuse Fuse Block R GY Accessory Fuse KeySwitch Fuse b1084c4x PK Top View R GY Table 4 28 Wire Harness Connectors in Figure 4 56 NO DESCRIPTION TYPE LOCATION 10 ECM black 12 place Deutsch ...

Page 420: ...12 and Pin 11 in connector 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 i...

Page 421: ...his code can also set if fan blade does not spin blocked fan blade when fan is commanded on and battery voltage is applied to fan Cooling Fan Low Voltage This code will set when the ignition key is ON and the ECM does not sense voltage at pin 6 of ECM terminal 11 gray connector DIAGNOSTICS Diagnostic Notes The reference numbers below correlate with the circled num bers on the Code 36 flow charts 1...

Page 422: ... Bk Hn Mflr Fan IGN 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 58 NO DESCRIPTION TYPE LOCATION 11 ECM gray 12 place Deutsch in fairing 97 cooling fan 2 place Multiloc...

Page 423: ...t Box to ECM gray connector 11 Turn IGN ON Measure volts at pin 9 of Breakout Box Is voltage greater than 1 3 volts YES 2 Does cooling fan run continuously NO YES NO See 4 18 TROUBLE CODE 14 engine temperature sen sor Turn IGN switch ON Does fan run continuously YES Defective ECM or ECM connection NO System ok At some point in the flow chart you may be instructed to jump directly to a the box with...

Page 424: ...epair short to ground in Y BN wire Is there an obstruction preventing fan from rotating YES Remove obstruction preventing fan rotation NO Disconnect fan harness at fan Use ohmmeter to mea sure resistance between Y BN terminal and BK terminal of fan connector 97A Resistance greater than 1 Check for continuity between pin 6 gray of Breakout Box and BK O wire of fan connector 97A Continuity present C...

Page 425: ...harness between sensor and elec tronic control module Failed sensor If this code occurs the engine will continue to run and can be 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 H...

Page 426: ...nector 10 Connector 11 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 61 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 beneath sprocket cover 88 throttle position sensor 3 place Pac...

Page 427: ...Repair short to voltage 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...

Page 428: ...inuity present NO Repair 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...

Page 429: ...8 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 Figure 4 62 Mounting Location of ECM 8428 ...

Page 430: ...e motorcycle may continue 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 63 ...

Page 431: ...TGN GY R W 5 Volt Reference 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 64 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 beneath sprocket cover 88 throttle position sens...

Page 432: ...tinuity between Pin 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...

Page 433: ... R W Perform 4 7 WIGGLE 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 ...

Page 434: ...RACKET 4 Install front fairing See 2 37 FRONT FAIRING WIND SHIELD AND MIRRORS 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 5 Thread positive cable red fastener into threaded hole first tightening to 72 96 in lbs 8 ...

Page 435: ...or 10 Black PIN FUNCTION 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 ...

Page 436: ...minal pins 7 See B 2 DEUTSCH ELECTRICAL CONNECTORS 7 See Figure 4 69 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 19 c Remove timer cover Remove inner cover screws 3 and inner cover 19 d Carefully remove any remaining pieces of rivets from gearcase cover timer bore...

Page 437: ...nsor connector 14 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 Cylinder brace 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 438: ...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 SENSOR CONTROL SIGNAL TN V W O 3 1 2 R...

Page 439: ...4 R W GN 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 6 See Figure 4 66 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 Install inner cover 20 using screws 3...

Page 440: ...installation install spark plug cables to ignition coil first 1 Connect spark plug cables to ignition coil 2 See Figure 4 72 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 air cleaner cover See 4 44 AIR CLEANER ASSEMBLY 6 Install intake cover assembly See 2 34 INTAKE COV...

Page 441: ...TEST RESULTS which follows if resistance is not within normal 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 oh...

Page 442: ... ABSORBER 5 Remove cooling fan See 4 38 COOLING FAN 6 See Figure 4 76 Remove cable straps 2 Unplug 1 place connector 137 1 7 Remove oxygen sensor from exhaust header using Snap on Part No YA8875 INSTALLATION 1 Apply LOCTITE ANTI SEIZE LUBRICANT to threads of sensor 2 See Figure 4 75 Thread sensor into exhaust header Tighten sensor to 40 45 ft lbs 54 61 Nm 3 Install cooling fan See 4 38 COOLING FAN...

Page 443: ... rear cylinder head using Snap on socket M3503B INSTALLATION NOTE Do not pull on engine temperature sensor wiring Excess strain to sensor wiring will cause sensor damage 1 See Figure 4 77 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 Snap on socket M3503B Tighten ET sensor to 120 168 in lbs 13 6 19 N...

Page 444: ...gure 4 79 Unplug bank angle sensor connector 134 5 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 locknuts Tighten fastener to 12 36 in lbs 1 4 4 1 Nm 3 See Figure 4 79 Install bank angle ...

Page 445: ...e battery cable before proceeding 00048a 1 Disconnect negative battery cable 2 See Figure 4 80 Remove air cleaner cover filter Remove fasteners securing base See 4 44 AIR CLEANER ASSEMBLY 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 conn...

Page 446: ...ower mounting hole of sensor prior to installation 3 Attach TP sensor with both fasteners and washers Tighten to 12 15 in lbs 1 4 1 7 Nm 4 See Figure 4 83 Attach throttle position sensor connec tor 88 Slots on female connector 88B must fully engage tabs on male connector housing 88A NOTE Throttle position sensor can only be calibrated using DIGITAL TECHNICIAN Part No HD 44750 5 Calibrate throttle ...

Page 447: ...g fan 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 2...

Page 448: ...n 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 near gasoline Gasoline is extremely flammable and highly explosive whi...

Page 449: ...asteners 5 6 See Figure 4 87 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 88 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 contac...

Page 450: ...ressure regulator 3 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 89 Fuel Pressure Regulator 10937a 1 Plastic retaining ring 2 Plastic retainers 3 F...

Page 451: ...lace 4 Install new sensor 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 90 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 sensor 8 Fastener 9 Fuel pressure regula...

Page 452: ...l 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 pump assem...

Page 453: ... con nect ground wires to bracket 9 and tighten to 18 22 in lbs 2 0 2 5 Nm 11 See Figure 4 91 Disconnect fuel pump connector 5 and low fuel level sensor connector 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 Specification...

Page 454: ...bricate new o rings with clean engine oil From inner side of fuel pump assembly push new wire harness into assembly 8 See Figure 4 91 Insert new fastener 12 through ground wire terminal and secure to bracket 9 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 locations of fuel pum...

Page 455: ...ightening fas teners may result in excessive compression of sealing components and fuel leakage which could result in death or serious injury NOTE Install fuel line onto fitting on fuel pump so that the fuel line is at approximately the one o clock position Ensure that the sheathing on the fuel line comes down to the bend as shown 6 Install fuel supply line banjo fitting 2 over fuel supply stud 3 ...

Page 456: ...e 4 97 Remove vent valve fasteners 5 8 Remove bracket 4 vent valve 3 and o ring 2 from fuel tank frame 1 INSTALLATION 1 See Figure 4 97 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 ...

Page 457: ...e fuel cap retaining ring and o ring 2 Discard o ring INSTALLATION 1 Coat new 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 62 71 in lbs 7 8 Nm 5 Install fuel f...

Page 458: ...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 Remove air cleaner assembly See 4 44 AIR CLEANER ASSEMBLY 3 Label and detach throttle cables See 2 23 THROTTLE CONTROL 4 See Figure 4 103 On California models pull EVAP hose from fitting 1 5 Remove left and right air scoops See 2 35 AIR SCOOPS...

Page 459: ...ail 7 Fuel injector rear 8 Screw 2 9 Washer flat 2 10 Throttle position sensor 11 Clamp wire spring 12 Velocity stack 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...

Page 460: ... from throttle body a See Figure 4 106 Remove both injector clips 4 b See Figure 4 104 Remove fuel rail fastener 1 that holds 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 from the manifold NOTE Front and ...

Page 461: ...r o rings NOTE Front and rear fuel injectors are not interchangeable 6 See Figure 4 106 Install fuel injectors a Install both injectors 2 5 into throttle body b Press the fuel rail assembly 3 onto the top of the injectors c Apply a drop of LOCTITE 271 red to threads of fuel rail fastener 1 d Secure the fuel rail to the throttle body with fastener Tighten to 20 25 in lbs 2 3 2 8 Nm 7 Snap the injec...

Page 462: ... CONTROL 6 Attach wiring a Injector cables are tagged F ront and R ear for ease of assembly Push connector halves together until latches click Grooves in female connector must align with the tabs in male housing b Connect throttle position sensor by pushing the con nector halves together Slots on female connector must fully engage tabs on male connector housing 7 Connect fuel line and EVAP hose to...

Page 463: ... OFF for two seconds c Repeat Steps A and B five consecutive times d Open throttle replace fuel injectors if there is any evidence of raw fuel in throttle body manifold 4 Install air cleaner cover See 4 44 AIR CLEANER ASSEMBLY 5 Install intake cover assembly See 2 34 INTAKE COVER ASSEMBLY Figure 4 109 Fuel Injectors 2 5 1 1 Fuel rail fastener 2 Rear fuel injector 3 Fuel rail assembly 4 Clip 2 5 Fr...

Page 464: ... connectors on which heat shrink work is being performed Always keep hands away from tool tip area and heat shrink attachment To prevent false readings keep air cleaner 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...

Page 465: ...ny fuel system compo nent Extreme heat can cause fuel ignition explosion resulting in death or serious injury Avoid directing heat toward any electrical system component other than the connectors on which heat shrink work is being performed Always keep hands away from tool tip area and heat shrink attachment 1 Start engine 2 Warm engine to operating temperature 3 See Figure 4 111 Turn knob 5 count...

Page 466: ...t on bottom of baseplate e Lift baseplate off of frame carefully disengaging baseplate from rubber sealing ring 8 on velocity stack 7 f Remove baseplate from motorcycle INSPECTION 1 Inspect air cleaner cover Check for dirt torn filter mate rial and general condition Replace if necessary 2 Inspect inside of backing plate and cover Remove any dirt or debris 3 Inspect condition of velocity stack and ...

Page 467: ...een upper and lower rubber sealing rings 6 Install baseplate to frame with four fasteners and wash ers 5 Tighten fasteners to 84 120 in lbs 9 5 13 6 Nm 7 Position air cleaner filter on baseplate 8 Install air cleaner to baseplate and latch six latches to secure 9 If interactive exhaust actuator XB12R was removed install at this time and tighten fasteners to 36 40 in lbs 4 4 5 Nm See 1 17 INTERACTI...

Page 468: ...XB12R 1 Actuator interactive exhaust 2 Harness interactive exhaust 3 Cable bracket 4 Interactive exhaust cable 5 Mounting fasteners actuator 6 Cover air cleaner 7 Filter element 8 Air cleaner seal 9 Shoulder screw 4 10 Base plate assembly 11 Breather hoses front and rear 1 8 10 5 2 3 4 6 7 9 11 b1246x1x ...

Page 469: ... part of normal combustion 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 kin...

Page 470: ...ent hole 2 3 See Figure 4 119 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 ...

Page 471: ...ND WIRE ROUTING 1WARNING 1WARNING Always make sure fuel hoses are seated against the com ponent they connect to and that hose clamps are prop erly tightened and positioned on straight section of fitting and not on the fitting barb Failure to comply may result in fuel leakage which could result in death or seri ous injury Figure 4 121 Emissions Hose Attachment California Models Only 10645 ...

Page 472: ...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 473: ......

Page 474: ...400 amp max 2 4 V Stall Torque 8 ft lbs 11 Nm min 2 4 V Table 5 2 Service Wear Specifications SERVICE WEAR LIMITS IN MM Brush length minimum 0 433 11 0 Commutator diameter minimum 1 141 28 981 ITEM TORQUE NOTES Battery terminal fasteners 72 96 in lbs 8 11 Nm page 5 19 Starter battery positive cable 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 475: ...arter relay is activated 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 thr...

Page 476: ...ng circuit see wiring 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 477: ...nal 3 Relay terminal d0361x5x 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 Clic...

Page 478: ...ter than 1 volt 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...

Page 479: ... BK R wire at connector 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 581...

Page 480: ...oltage drop tests 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 starte...

Page 481: ...0 1A 0 1A 0 1A 0 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 V...

Page 482: ...tial displayed on 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 syste...

Page 483: ...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 87 87 87 87A 87A 87A 30 30 30 85 85 85 86 86 86 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 2 4 3 1 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 CONN...

Page 484: ...erly proceed to 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 amme...

Page 485: ...VER 4 Remove sprocket cover 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 ...

Page 486: ...tion there may be a problem with engine or primary drive Starter Solenoid NOTES Do not disassemble solenoid Before testing disconnect field wire from motor terminal as shown in Figure 5 11 Each test should be performed for only 3 5 seconds to prevent damage to solenoid The solenoid Pull in Hold in and Return tests must be performed together in one continuous operation Con duct all three tests one ...

Page 487: ...y b If starter pinion 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 wor...

Page 488: ...eter is less than 1 141 in 28 981 mm c Check armature bearings Replace if necessary NOTES 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 See Figure 5 17 If an undercutting machine is not avail able undercutting can be done satisfactorily using a...

Page 489: ...Mica Separators 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 490: ... one probe to any 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 p...

Page 491: ...ntinuity 0 ohms If 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 eithe...

Page 492: ...tric Tighten nut to 60 85 in lbs 7 10 Nm d Reinstall existing 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 th...

Page 493: ...bearing 2 9 Drive 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 494: ...a hollow cylinder 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 Insta...

Page 495: ...5 22 2007 Buell Firebolt Starter HOME NOTES ...

Page 496: ... 6 25 6 8 Case Disassembly for Transmission Removal 6 26 6 9 Transmission Disassembly 6 29 6 10 Transmission Assembly 6 35 6 11 Main Drive Gear and Bearing 6 37 6 12 Transmission Right Case Bearings 6 45 6 13 Transmission Left Case Bearings 6 46 6 14 Transmission Installation 6 47 6 15 Shifter Shaft 6 51 6 16 Transmission Sprocket 6 53 Table Of Contents DRIVE TRANSMISSION 6 ...

Page 497: ......

Page 498: ... of teeth 27 Inspect at 5 000 mi 8 000 km Rear wheel sprocket number of teeth 65 Inspect at 5 000 mi 8 000 km Secondary drive belt number of teeth 128 Inspect at 5 000 mi 8 000 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 10 688 9 563 Second gear 7...

Page 499: ... 3 25 Nm Apply several drops of LOCTITE 271 red to last few threads page 6 49 Engine sprocket nut 240 260 ft lbs 325 4 352 5 Nm Apply LOCTITE 271 red onto threads of sprocket shaft page 6 19 Idler pulley nut and washer 33 35 ft lbs 45 47Nm page 6 24 Idler pulley wheel fastener 20 23 ft lbs 27 1 31 2 Nm page 6 24 Magnetic drain plug 14 30 ft lbs 19 40 7 Nm page 6 5 Negative battery cable at bat ter...

Page 500: ...ry chain 9 Remove three 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 shift...

Page 501: ...ifter bushing 3 Primary cover 4 Gasket 5 Clutch inspection cover 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 25 Rubber washer 20 23 25 ...

Page 502: ...ry cover 3 Install primary cover and gasket onto left crankcase half using mounting bolts 4 See Figure 6 5 Tighten fasteners to 100 120 in lbs 11 3 13 5 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 pla...

Page 503: ... chin 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 17 Connect negative battery cable to battery terminal Tighten fastener to 72 96 in lbs 8 11 Nm 11WARNING 1WARNING After installing s...

Page 504: ... screw is turned ramp assembly moves forward Unscrew nut 6 from end of adjusting screw 7 Remove hook of ramp from cable end coupling 10 Remove cable end from slot in coupling 8 Remove and discard retaining ring from ramp assembly to separate inner and outer halves Remove three balls from ramp sockets CLEANING AND INSPECTION 1 Thoroughly clean all parts in cleaning solvent 2 See Figure 6 9 Inspect ...

Page 505: ... hex into recess of outer ramp e Install clutch adjusting lockplate and spring 4 Install clutch inspection cover and new gasket with three TORX screws with washers Tighten in a crosswise pat tern to 84 108 in lbs 9 5 12 2 Nm 5 Adjust clutch cable See 1 9 CLUTCH 11WARNING 1WARNING Connect positive battery cable first If positive cable should contact ground with negative cable con nected the resulti...

Page 506: ...n a forward gear power 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 a...

Page 507: ...ing ring 9 Retaining ring 10 Spring seat 11 Diaphragm spring 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 ...

Page 508: ... TOOL Part No HD 38515 A against diaphragm spring c Install bearing and washer d Thread the tool handle onto end of forcing screw NOTE 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 dam age clutch pressure plate 5 See Figure 6 14 Remove pressure plate assembly a Place a wrench on the ...

Page 509: ...ponents as required and reassemble adjusting screw assembly in reverse order 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 Diaphra...

Page 510: ...ore than 0 006 in 0 15 mm 4 Inspect the damper spring for cracks or distortion Install a new spring if either condition exists 5 See Figure 6 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 thicknes...

Page 511: ... handle only the amount required to install spring seat and snap ring Exces sive compression of diaphragm spring could damage 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 u...

Page 512: ...ury 00068a 10 Connect negative battery cable to battery terminal Tighten fastener to 72 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 Figur...

Page 513: ...FLUID under 1 9 CLUTCH 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 46283 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 asse...

Page 514: ... 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 NOTE As you proceed around the back of the clutch shell the com pensating springs go from being loaded to unloaded so it is possible for the clutch ...

Page 515: ... 4 Place new needle bearing onto installer end of tool and insert the bearing guide to prevent the bearing from fall ing off during installation and to align bearing with clutch shell 5 See Figure 6 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...

Page 516: ...nd 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 for XB9R models and Part No HD 46283 for XB12R models b Apply two or three drops of LOCTITE 271 red onto threads of sprocket shaft c Install engine sprocket nut Tighten to 240 260 ft lbs 325 4 352 5 Nm NOTE See Figure 6 35 Washer must be installed wit...

Page 517: ...Clutch See 1 9 CLUTCH 12 Add GENUINE HARLEY DAVIDSON FORMULA TRANSMISSION AND PRIMARY CHAINCASE LUBRI CANT Part No 99851 05 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 C...

Page 518: ...he belt INSPECTION CLEANING See 1 10 DRIVE BELT Figure 6 38 Proper Drive Belt Handling NOTE Mishandling drive belt will result in premature failure For maximum strength integrity and longevity avoid over bending A and B twisting C crimping pinching or kink ing 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...

Page 519: ... 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 9 Remove lower belt guard See 2 32 BELT GUARDS NOTE When removing or installing belt do not bend or twist belt partially slide belt onto sprocket and roll wheel or belt dam age will occur 10 Slide belt f...

Page 520: ...eze together until belt teeth are fully seated in rear sprocket 4 While keeping tension on lower belt install idler pulley assembly tightening washers and nuts to 33 35 ft lbs 45 47 Nm 5 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 6 Tighten rear axle pinch fastener 2 to 40 45 ft lbs 54 61 Nm 7 See Figure 6...

Page 521: ... PULLEY INSTALLATION 1 See Figure 6 44 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 4...

Page 522: ...hich transmits the force through a gear shifter shaft The shifter shaft actuates a pawl and a shifter fork drum The shifter fork drum moves shifter forks which slide a series of shifter dogs on the mainshaft and countershaft into and out of mesh with the other gears Figure 6 45 Transmission Power Flow 2 3 4 1 5 Neutral 1st Gear 2nd Gear 3rd Gear 4th Gear 5th Gear Mainshaft Countershaft SLIDING MEM...

Page 523: ...le top end See 3 6 CYLINDER HEAD 5 Disassemble gearcase See 3 18 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 5 PRIMARY CHAIN 8 See Figure 6 46 Place transmission in 1st gear Remove hex fastener 9 See Figure 6 47 Place transmission in neutral Remove neutral switch to ensure shifter drum detent is visible ...

Page 524: ...embly from left crankcase half 13 Remove starter See 5 7 STARTER 14 See Figure 6 51 Remove rear isolator assembly by removing the forward two fasteners first and then the two rear fasteners re install with new fasteners Figure 6 49 Removing Shifter Shaft Assembly 11403 Figure 6 50 Shifter Shaft Assembly Figure 6 51 Rear Isolator Assembly 1 Shifter shaft 2 Return spring 3 Ratchet arms 1 11462 3 2 8...

Page 525: ... slides out of the left main bearing by hand No tools are required for this operation 17 See Figure 6 54 Remove the flywheel assembly from left crankcase half Figure 6 52 Crankcase Fasteners D b1016x3x Indicates Bolt Pattern Location 14 fasteners One Behind Shifter Mechanism Figure 6 53 Separating Crankcase Halves 8621 Figure 6 54 Removing Flywheels from Left Case Half 8636 ...

Page 526: ...nch in the slots and tapping on the end of each shaft until it falls free NOTE Carefully tap on alternate sides of the shaft using the pro vided slots 2 See Figure 6 57 Remove shifter drum 1 and shifter forks 2 Mark each shifter fork as it is removed so it can be reinstalled in the same location PART NO SPECIALTY TOOL B 43985 1 Transmission remover J 5586 A Retaining ring pliers Figure 6 55 Shifte...

Page 527: ...ork assembly shifter 4th 5th 9 Pin shifter stop 10 Spring shifter return 11 Spring extension 12 Shifter lever assembly 13 Oil seal 14 Rubber washer 15 Lever engine 16 Bolt engine lever 17 Bearing shift lever assembly 2 18 Shift lever 19 Bolt linkage assembly 20 Sleeve shift brake lever 21 Bolt shift lever 22 Pad rubber shift lever 23 Linkage assembly shifter 24 Bolt linkage assembly 17 3 2 1 4 4 7...

Page 528: ...ns mission assembly 4 from engine stand a Place crankcase half 3 and transmission assembly 4 on arbor press 1 and support transmission assembly on parallel supports 5 b Press transmission assembly using TRANSMIS SION REMOVER 2 Part No B 43895 1 to remove transmission assembly from crankcase half c Remove crankcase from press Figure 6 59 Removing Transmission Assembly from Left Case Half 1 Arbor pr...

Page 529: ...16 Mainshaft bearing 17 Retaining ring 18 Closed end bearing 19 Countershaft 5th gear 20 Countershaft 21 Countershaft 1st gear 22 Dog ring 23 Countershaft 4th gear 24 Countershaft 3rd gear 25 Dog ring 26 Thrust washer 27 Countershaft 2nd gear 28 Spacer 29 Countershaft bearing 30 Retaining ring 31 Countershaft retaining screw x0572a6x 14 13 3 2 1 20 21 22 23 19 18 17 16 12 9 12 8 6 5 4 7 11 10 12 1...

Page 530: ...d correct tips Verify that tips are not excessively worn or damaged 1 See Figure 6 62 Remove 1st gear 1 2 Use RETAINING RING PLIERS Part No J 5586 A to expand and remove retaining ring 2 Discard retaining ring 3 Slide thrust washer 3 off end of mainshaft 4 Remove 4th gear 4 and split bearing 5 Discard bear ing Cleaning And Inspection 11WARNING 1WARNING Compressed air can pierce the skin and flying...

Page 531: ...g 6 Remove thrust washer 10 7 Expand remove and discard retaining ring 9 8 Remove 4th gear 8 and dog ring 7 9 Expand remove and discard retaining ring 6 10 Remove thrust washer 5 1st gear 4 and split bearing 3 Discard bearing Cleaning And Inspection 11WARNING 1WARNING Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury Wear safety glasses when wo...

Page 532: ... Harley David son FORMULA TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT prior to assembly Leaving these parts dry could accelerate wear at start up 1 See Figure 6 64 Install new split bearing 5 in 4th gear position on mainshaft 2 Install 4th gear 4 and thrust washer 3 3 Using RETAINING RING PLIERS Part No J 5586 expand and install new retaining ring 2 4 Install 1st gear 1 PART NO SPECIALTY TOOL J 5...

Page 533: ...nto countershaft 5 Expand and install new retaining ring 9 6 Install thrust washer 10 7 Install new split bearing 11 in 3rd gear position on mainshaft 8 Install 3rd gear 12 and thrust washer 13 9 Expand and install new retaining ring 14 10 Install dog ring 15 Make sure to install with dog ring facing same direction as when it was removed 11 Install spacer 16 12 Install new split bearing 17 in 2nd ...

Page 534: ... be replaced PART NO SPECIALTY TOOL HD 35316 C Main drive gear remover and installer B 45847 Cross plate HD 47855 Inner outer main drive gear needle bearing installation tool HD 95637 46A Bearing race puller HD 47856 Seal driver Figure 6 66 Transmission Assembly Right Crankcase Half 1 Retaining ring 2 Bearing Inner 3 Fifth gear mainshaft 4 Bearing Outer 5 O ring 6 Oil seal 7 Right crankcase half 8...

Page 535: ...hen 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 6 At outside of case place WASHER Part No HD 35316 7 4 NICE BEARING 5 FLAT WASHER 6 and NUT 7 over end of bolt Tighten nut until main...

Page 536: ...r bearing DISASSEMBLY 1 See Figure 6 67 Remove and discard retaining ring 5 2 Drive out needle bearings 2 from inside bore of main drive gear 1 using appropriate bearing and bushing puller Discard bearings Do not reuse bearings after removal 3 Remove o ring 4 from outside of main drive gear and discard Do not reuse o ring after removal NOTE When the main drive gear is removed a portion of the bear...

Page 537: ... of the shifter dogs on the main drive gear 5 Install new retaining ring 6 See Figure 6 73 Place main drive gear 4 on press bed with gear end facing down 7 Place needle bearing 3 squarely into end of drive gear Insert installation tool 2 with end stamped OUTER facing needle bearing 8 Press in the outer bearing until the installation tool bot toms on the main drive gear The surface of the needle be...

Page 538: ...nto crankcase bearing bore 5 Remove main drive gear bearing installer tool 11WARNING 1WARNING Wear safety glasses or goggles when removing or install ing retaining rings Retaining rings can slip from the pli ers and could be propelled with enough force to cause serious eye injury 00312a NOTE Use correct retaining ring pliers and correct tips Verify that tips are not excessively worn or damaged 6 S...

Page 539: ...WASHER Part No HD 35316 7 2 and main drive gear 3 From inside of case insert bolt with washer and main drive gear through inner race of main drive gear bearing 4 At outside of case place INSTALLER CUP Part No HD 35316 12 4 NICE BEARING 5 FLAT WASHER 6 and NUT 7 over end of bolt Tighten nut until main drive gear bottoms against main drive gear bearing 5 Remove MAIN DRIVE GEAR REMOVER AND INSTALLER ...

Page 540: ...l over pilot and position seal squarely in end of crankcase bore 4 See Figure 6 80 Thread ADAPTER Part No HD 47856 4 onto end of main drive gear several turns Do NOT tighten Doing so could make it difficult to remove adapter after seal has been installed 5 See Figure 6 81 Slide INSTALLER Part No HD 47856 1 over adapter until cupped end of installer is flat against seal Figure 6 78 Install Pilot Pa...

Page 541: ...lats of hex head cast into end of adapter 8 Holding smaller wrench tighten nut with larger wrench until outer face of seal is flush with outer edge of crank case 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 9 Remove nut installer adapter and pilot Figure 6 82 Install Nut Part No HD 47856 5 Typical 12044 Figure 6 83 Pr...

Page 542: ...the closed end needle bearing 11 open end first next to the bearing bore Hold the driver squarely against the closed end of the bearing and tap the bearing into place The bearing is properly positioned when it is driven flush or 0 030 in 0 762 mm below the outside surface of the case 3 Lubricate bearing with GENUINE HARLEY DAVIDSON FORMULA TRANSMISSION AND PRIMARY CHAIN CASE LUBRICANT Shifter Drum...

Page 543: ...inshaft 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 side facing away from bearing ...

Page 544: ... onto TRANSMISSION REMOVER INSTALLER FIXTURE Part No B 43985 2 on arbor press 2 Install COUNTERSHAFT GUIDE ADAPTER Part No B 43985 4 3 See Figure 6 88 Place left case half over transmission assembly and install TRANSMISSION INSTALLER Part No B 43985 3 into crankcase 4 Press crankcase onto transmission assembly into until it bottoms out 5 Remove COUNTERSHAFT GUIDE ADAPTER Part No B 43985 4 6 Remove...

Page 545: ... 12o clock position This will place shifter drum in neutral position NOTE See Figure 6 90 Install shifter fork shafts in the left case half by lightly tapping on the end of the shaft with a brass or hard plastic hammer until shaft is seated in bore 3 Place 1st gear shifter fork onto dog ring between coun tershaft 1st and 4th gear gears Install shifter fork shaft through two installed shifter forks...

Page 546: ... the mating surface of the mainshaft and countershaft with HARLEY DAVIDSON SPECIAL PURPOSE GREASE Part No 99857 97 5 See Figure 6 93 Assemble crankcase halves together a Apply a thin coat of GRAY HIGH PERFORMANCE SEALANT Part No 99650 02 to crankcase joint faces b See Figure 6 94 Apply several drops of LOCTITE 271 red to last few threads and tighten 5 16 in fas teners to 15 19 ft lbs 20 3 25 Nm c ...

Page 547: ...6 50 2007 Buell Firebolt Drive Transmission HOME Figure 6 94 Crankcase Fasteners D b1016x3x Indicates Bolt Pattern Location One Behind Shifter Mechanism ...

Page 548: ...f NOTE See Figure 6 96 The shifter shaft return spring can be installed incorrectly and then assembled in the left crankcase half Failure to install the spring properly will result in improper shifting Figure 6 95 Shifter Shaft Return Spring Correctly Installed Figure 6 96 Shifter Shaft Return Spring Incorrectly Installed b0950x6x b0951x6x Figure 6 97 Shifter Shaft Assembly 1 Shifter shaft 2 Retur...

Page 549: ...hread screw into end of shaft 4 Place transmission in gear and tighten screw to 33 37 ft lbs 44 8 50 Nm 5 Install transmission sprocket See 6 16 TRANSMISSION SPROCKET 6 Continue assembling engine See appropriate sections of 3 19 CRANKCASE ASSEMBLY and 3 6 CYLINDER HEAD 3 7 CYLINDER AND PISTON ASSEMBLY INSTALLATION 7 Install primary chain and engine sprocket clutch assem bly and primary cover See 6...

Page 550: ...hreads Turn nut clockwise to loosen and remove from main drive gear shaft Use the P3 Blast SPROCKET HOLDING TOOL Part No B 43982 with the spacer and fastener from the Firebolt SPROCKET LOCKING TOOL Part No B 45659 to hold the sprocket 9 See Figure 6 102 Place transmission in neutral Install the P3 Blast SPROCKET HOLDING TOOL Part No B 43982 to hold the sprocket 10 Remove transmission sprocket nut ...

Page 551: ... four screw holes and can be turned to either side so you should be able to find a position without having to additionally tighten the nut If you cannot align lock plate and sprocket screw holes nut may be additionally tight ened to 45 as specified above Tightening too much or too little may cause the nut to come loose during vehicle opera tion If you cannot align lockplate and sprocket screw hole...

Page 552: ...ed 12 See Figure 6 105 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 13 Tighten pinch fastener 2 on right side of swingarm to 40 45 ft lbs 54 61 Nm Figure 6 105 Rear Wheel Mounting Right Side 11810 2 1 Axle 2 Pinch bolt fastener 1 ...

Page 553: ...6 56 2007 Buell Firebolt Drive Transmission HOME NOTES ...

Page 554: ... 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 52 7 19 Speedometer Performance Check 7 54 7 20 Horn 7 59 7 21 Neutral Indicator Switch 7 61 7 22 Main Fuse and Fuses 7 62 7 23 Main Wire Harness 7 63 7 24 Interactive Exhaust Harness X...

Page 555: ......

Page 556: ...ondary 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 European models o...

Page 557: ...Instrument module fastener 12 36 in lbs 1 4 4 0Nm page 7 53 Main battery ground to frame 48 72 in lbs 5 4 8 1 Nm page 7 33 Neutral indicator switch 60 84 in lbs 6 7 9 5 Nm LOCTITE 243 blue page 7 61 Relay block mounting fasten ers 72 96 in lbs 8 1 10 8 Nm Always install with new fasteners page 7 65 Rotor mounting fasteners 120 140 in lbs 13 5 15 8 Nm LOCTITE THREADLOCKER 243 blue page 7 31 Spark p...

Page 558: ...ree of spark advance 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...

Page 559: ...nsor connector 14 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 560: ...positions The P position is located counter clockwise from the LOCK position and allows the rider to remove the key while leaving the lights on When the key is placed in the P position several indicator markers are or can be activated 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 ...

Page 561: ...p 6 Remove air cleaner 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 capnut 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 te...

Page 562: ...tch 4 NOTE In next 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 As...

Page 563: ... igni tion switch fuse block and right handlebar switch wires 6 Install intake cover assembly See 2 34 INTAKE COVER ASSEMBLY 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...

Page 564: ...tal elec tric shock from the ignition system which could result in death or serious injury NOTE 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 possible to the spark plug terminal Do not pull on the cable portion itself Pulling on the cable will damage the cable s carbon core 1 Remove air cl...

Page 565: ...e of spark 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 ...

Page 566: ...ral switch By disengaging 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 Inap...

Page 567: ...e Polarity TN LTGN Terminal 8 Terminal 2 Figure 7 12 Ohmmeter Diode Test Continuity Infinite ohms b0643x4x Figure 7 13 Diode Wiring 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 Em...

Page 568: ...t cover Check for 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 p...

Page 569: ...on TN LT GN wire of clutch switch connector 95 Ground present YES Repair open on TN LT 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 570: ... 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 and tighten switch fasteners to 7 10 in lbs 0 8 1 12 Nm See 2 24 CLUTCH CONTROL Figure 7 14 Clutch Switc...

Page 571: ... Check for continuity 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 R...

Page 572: ...e block 2 Test diode 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 573: ...ve 1 is opened 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 p...

Page 574: ...rebolt Electrical 7 19 HOME Figure 7 20 Interactive Control System XB12R 1 Interactive exhaust cable 2 Harness with connector 161B 3 Interactive exhaust cable bracket 4 Actuator 5 Air cleaner cover 4 b0064b 1 2 3 5 ...

Page 575: ...st cable from muffler partially remove and support muffler until interactive exhaust cable is removed 11 Remove cable strap above starter securing actuator cable vent line main harness and positive battery cable 12 Remove cable strap securing actuator cable and main harness to oil return line 13 Remove muffler See 2 28 EXHAUST SYSTEM 14 Loosen jam nut and remove interactive exhaust cable from brac...

Page 576: ...tuator and adjust See 1 17 INTERACTIVE EXHAUST CABLE 7 Install cable strap above starter securing actuator cable vent line main harness and positive battery cable 8 Install cable strap securing actuator cable and main har ness to oil return line 9 Install front sprocket cover See 2 30 SPROCKET COVER 10 Install chin fairing See 2 33 CHIN FAIRING 11 Install intake cover See 2 34 INTAKE COVER ASSEM B...

Page 577: ...7 22 2007 Buell Firebolt Electrical HOME NOTES ...

Page 578: ...procket shaft The 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 Chec...

Page 579: ... 2 STOP PASS FAIL PASS 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 FAIL Correct as required 5306 ...

Page 580: ...w because vehicle 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 ...

Page 581: ...uit 128A A B 46B 46A 77A 77B 30A 5A GRD2 BK 2 1 1 4 4 3 3 2 2 2 1 1 R BK 2 1 R R Y BK bd0018xx BK R R Y BK BK BK BK BK BK Battery Cable Starter Solenoid Starter Motor Battery To J Fuse Assembly To Voltage Regulator Voltage Regulator Male Female Stator H D 3 Phase Maxifuse BK ...

Page 582: ...n 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 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 regulato...

Page 583: ...is higher regulator is not functioning prop erly Stator Check 1 Turn ignition key switch to OFF 2 See Figure 7 29 Connect an ohmmeter a Locate voltage regulator connector 46 under sprocket cover See 7 25 SPROCKET COVER WIR ING Disconnect from alternator stator wiring b Insert one ohmmeter lead into a stator socket c Attach the other lead to a suitable ground 3 Test for continuity with ohmmeter set...

Page 584: ...uld be 32 40 volts 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 O...

Page 585: ... See Figure 7 34 Disconnect stator wiring 4 from volt age regulator wiring at connector 5 46 under sprocket cover See 7 25 SPROCKET COVER WIRING 2 Remove cable straps holding stator wire to wire harness NOTE Stator TORX screws contain a thread locking compound Do not reuse existing screws Always use new screws with the proper thread locking compound Loss of torque on TORX fasteners could result in...

Page 586: ... 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 Install retainer plate with new fasteners and tighten to 56 in lbs 6 3Nm 5 See Figure 7 34 Route stator wiring 4 behind rear cyl inder and in front of transmission breather hose a Route stator wire 4 between The vent oil line and the return oil line b Install connecto...

Page 587: ... SPROCKET COVER WIRING 4 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 fasteners 5 to 60 72in lbs 6 7 8 Nm 2 Connect stator connector 46 1 and voltage regulator connector 77 2 located under sprocket cover See 7 25 SPROCKET COVER WIRING 3 Connect negative battery cable to battery terminal 1WARNING 1WARNIN...

Page 588: ...in 152 4 mm below the positive battery terminal 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 CAUTI...

Page 589: ... Red Yellow wire from positive bat tery cable to main fuse wire c Connect positive cable to positive battery termi nal using fastener d Connect negative cable to negative battery termi nal using fastener e Tighten terminal fasteners to 72 96 in lbs 8 11 Nm Figure 7 40 Positive Battery Cable Protective Boot Not Shown 12097a 1 Fastener with washer 2 Positive battery cable 1 2 ...

Page 590: ...by milk of magnesia 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 Thisbatte ry willbe replace dwithoutch arge iffoun dto be de fectivein materialsor workm an sh ip 12 mon thsfrom da te o...

Page 591: ...ER Perform a battery test as follows 1 Connect the MCR 101 HD analyzer leads to the vehicle s battery 2 Follow the instructions in the analyzer s instruction man ual to perform a battery test The test results will include a decision on the battery s condi tion the measured state of charge and the measured CCA See Figure 7 43 The analyzer s printer will provide you with a printout including one of ...

Page 592: ...ION AND CONNECTION DISCONNECTION AND REMOVAL 1 Remove seat See 2 38 SEAT 1WARNING 1WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 1WARNING 1WARNING Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery...

Page 593: ...battery gets hot ter 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 proceed to step 2 CAUTION Remove battery from motorcycle before charging Elec trolyte leakage will da...

Page 594: ... 30 minutes 2 hours 14 minutes 1 hour 20 minutes 40 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 premat...

Page 595: ...rque 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 battery negative terminal Tighten fastener to 72 96 in lbs 8 11 Nm NOTE See Fi...

Page 596: ...ition and occurs continuously 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 47 Charge the battery every month if stored at temperatures below 60 F 16 C Charge the battery more frequently if stored in...

Page 597: ...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 bulb with pape...

Page 598: ...housing 4 Connect the headlight bulb connector 5 Connect negative battery cable and tighten fastener to 72 96 in lbs 8 11 Nm 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 6 Check headlight for proper operation If operation fails reread procedure and verify that all steps were ...

Page 599: ... light lens 4 and tail light 5 with two fas teners 3 and tighten to 6 7 in lbs 0 7 0 8 Nm 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 3 Check tail lamp for proper operation If operation fails reread procedure and verify that all steps were per formed a Turn ignition key swit...

Page 600: ...acket 4 and fairing 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 54 Disconnect bullet connectors on turn signal wires 4 See Figure 7 53 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...

Page 601: ...007 Buell Firebolt Electrical HOME Figure 7 53 Rear Turn Signals 1 Turn signal 2 Turn signal bulb 3 Reflector bracket 4 License plate bracket 5 Lockwasher 2 6 Fastener 2 7 Tail section 1 2 4 7 5 6 b1008a7x 3 ...

Page 602: ... bracket and tab on reflector bracket fits into hole in license plate bracket 3 Attach turn signal using lockwasher and fastener 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 54 1WARNING 1WARNING Be sure that all lights and switches operate properly before operating motorcycle Low visibility of rider can result in death or serious ...

Page 603: ...2 37 FRONT FAIRING WIND 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 56 Activate left tu...

Page 604: ...ch connector 22 from 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 57 Right Handlebar Switch Connection 1 2 1 3 2 4 b1101x7x Right Handlebar Switch 22 Brake Switch 121 To starter ...

Page 605: ...alignment pin on front 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 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 00316...

Page 606: ...meter Sensor 1 8723a 2 3 1 Fastener 2 Vehicle speed sensor 3 Rear isolator assembly 4 Strain relief 4 Figure 7 60 Vehicle Speed Sensor Wiring 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...

Page 607: ... Pull instrument module 2 from headlight support 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 NOTE Do not turn display over Speedometer and Tachometer will fall out possibly causing damage to instruments 3 See Figure...

Page 608: ...DLIGHT ASSEMBLY AND 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 6 Install seat See 2 38 SEAT Figure 7 64 Instrument Module Connector 39 8426 Figure 7 65 Instrument Module b1009x...

Page 609: ... It can also assist in determining if speedometer replacement is necessary Speedometer Operation Test NOTE For information on the correct routing of vehicle speed sensor wiring see 7 25 SPROCKET COVER WIRING 1 See Figure 7 67 Locate the 3 place vehicle speed sen sor connector 65 under the sprocket cover See 7 25 SPROCKET COVER WIRING 2 Place speedometer tester power switch in the ON posi tion Plac...

Page 610: ...ess 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 68 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 D...

Page 611: ...e between trip and 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 612: ...ness connections Output erratic YES Repair as necessary NO Replace instrument module NO Bad connection found Repair con nector or harness DIAGNOSTIC NOTES Low battery voltage on speedometer tester may cause inaccurate test results Make sure speedometer tester battery is fully charged If necessary remove vehicle speed sensor and check for accumulation of debris If debris is not present replace sens...

Page 613: ...meter should 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 instrument module NO 4 6 VDC...

Page 614: ...g fastener 3 Tighten to 72 96 in lbs 8 1 10 8 Nm 3 Install negative battery cable 4 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 1WARNING 1WARNING After installing seat pull upward on front of seat to be sure it is in locked position While riding ...

Page 615: ...sing voltmeter a See Figure 7 70 Remove Y BK power 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 71 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...

Page 616: ...ose connections burned out indicator lamps 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 25 SPROCKET COVER WIRING for correct wire rou...

Page 617: ...ry fuses are rated at 10 0 Amps Always investigate the cause of blown fuses before replacing them Main Fuse See Figure 7 76 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 74 Fuse Block Figure 7 75 Fuse Block Figure 7 76 30 A Main Fuse Location 10960 19 20 21 22 23 24 13 14 15 16 17 18 1 2 3 4...

Page 618: ...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 and solenoid connec tor 128 from starter 6 Remove tail frame upper body work 2 36 SUBFRAME TAIL ASSEMBLY AND BODY WORK 7 See Figure 7 77 Disconnect tail h...

Page 619: ...r connector 30 b Bank angle sensor connector 134 c Electronic control module ECM See 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 Headlight con...

Page 620: ...r 137 d Air temperature sensor 90 e Fuel injectors 84 85 f Ignition coil See 4 32 IGNITION COIL 8 Install sprocket cover wiring See 7 25 SPROCKET COVER WIRING 9 Install oil pressure switch connector to oil pressure switch NOTE Snap fuse and relay blocks into mounting brackets before installing blocks to fairing mounting bracket 10 Place clamp around fuse block wiring Mount fuse block and clamp to ...

Page 621: ...tor 3 Attach cable strap 2 25 Connect interactive exhaust connector 165 to main har ness XB12 models only 26 Install starter side of positive battery cable and connect starter solenoid 128 to starter 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 ...

Page 622: ...g b1023b8x 11 10 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 623: ...rate exhaust actuator harness connector 165 2 at main harness 7 Note location of cable strap and cut as required 8 Pull actuator harness through frame 9 Disconnect connector 161B from actuator NOTE For actuator and actuator cable replacement see 7 6 INTER ACTIVE EXHAUST SYSTEM XB12 MODEL Figure 7 84 Left Side Subframe Hose and Wire Routing Figure 2 85 Battery and Harness Ground battery removed for...

Page 624: ...G 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 Connect negative battery cable to battery terminal Tighten fastener to 72 96 in lbs 8 11 Nm 8 Install subframe tail body work See 2 36 SUBFRAME TAIL ASSEMBLY AND BODY WORK 9 Install i...

Page 625: ...131 are located under the sprocket cover Figure 7 87 Sprocket Cover Wiring and Connections 1 Voltage regulator connector 77 2 Neutral switch connector 3 Sprocket cover boss 4 Vehicle speed sensor connector 65 5 Main harness 6 Gear cover vent line 7 Cam position sensor connector 14 8 Stator connector 46 9 Oil pressure switch wiring 10 Interactive exhaust cable 4 11999ba 5 7 10 1 2 6 10 9 8 3 ...

Page 626: ...wn 6 Connect the 2 pin voltage regulator 1 7 See Figure 7 87 Position the voltage regulator connec tor 1 as it is shown with the connector latch to the back and above the bottom sprocket cover boss NOTE Make sure that the voltage regulator connector is all the way back against the plastic wire guard 8 See Figure 7 90 At the oil pressure switch use a cable strap to encircle the voltage regulator wi...

Page 627: ...e sure main harness 2 is routed around sprocket cover boss 1 15 Install sprocket cover See 2 30 SPROCKET COVER Figure 7 89 Sprocket Cover Wiring and Connections 1 Stator connector 46 2 Oil pressure switch wiring 3 Vehicle speed sensor connector 65 4 Gear cover vent line with cover to protect wiring 5 Extended wire guard to protect wiring 6 Main harness 7 Interactive exhaust cable 8 Cable wrap secu...

Page 628: ...re Bundle to Return Oil Line Figure 7 91 Vehicle Speed Sensor 12007 12369 Figure 7 92 Correct Location for Sprocket Cover Wiring 1 Sprocket cover boss 2 Main harness 3 Cable strap securing main harness wiring to Return Oil Line Upper Part of Sprocket Cover 3 12367 2 1 ...

Page 629: ...7 74 2007 Buell Firebolt Electrical HOME NOTES ...

Page 630: ... 2 Deutsch Electrical Connectors B 5 B 3 Packard Electrical Connectors B 10 B 4 Electrical Connectors B 14 B 5 Index to Wiring Diagrams B 16 C 1 Metric Conversions C 1 D 1 Hose and Wire Routing D 1 E 1 Active Intake System Japanese models only E 1 Table Of Contents APPENDICES ...

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