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A.5

METRI-PACK TERMINALS

METRI-PACK TERMINAL CRIMPS

TOOL NAME

PART NUMBER

PACKARD TERMINAL CRIMP TOOL

HD-38125-6

PACKARD TERMINAL CRIMPER

HD-38125-7

PACKARD CRIMPING TOOL

HD-38125-8

Matching Terminal To Crimper

Metri-Pack connectors embossed with the initials P.E.D. require
Packard crimp tools to crimp terminals to wire leads.

Terminals are crimped twice to a wire lead, once over the wire
core and a second time over the insulation/seal.

See 

Figure A-17

. A completed crimp may require two different

crimping dies found on PACKARD TERMINAL CRIMP
TOOL (Part No. HD-38125-6) and/or PACKARD TERMINAL
CRIMPER (Part No. HD-38125-7). The terminal (pin or socket)
and the wire lead gauge will determine the core crimp die and
the insulator/seal die.

NOTE

The PACKARD CRIMPING TOOL (Part No. HD-38125-8) will
also crimp sealed splice connectors in wire gauge sizes 18-20,
14-16 and 10-12.

Preparing Wire Lead

Use a wire striper to strip off the insulation and expose  5/32
in. (4.0 mm) of wire core.

Crimping Wire Core

NOTE

Metri-Pack terminal crimps require two steps. Always perform
Crimping Wire Core before Crimping Insulation/Seal.

1.

Squeeze and release handles until ratchet automatically
opens.

2.

Identify the corresponding sized nest for the core crimp.

3.

Position the core crimp in the die. Be Sure the core crimp
tails are facing the forming jaws.

4.

Gently squeeze the handles until crimpers just secure the
core crimp tails.

5.

Insert stripped wire between crimp tails. Verify that wire
is positioned so that short pair of crimp tails squeeze core
wire strands, while long pair is positioned over the insula-
tion or seal material.

6.

Squeeze handles tightly closed. Release grip and the tool
will automatically open.

1

2

3

sm00035

1.

HD-38125-6 sealed terminals

2.

HD-38125-7 non-sealed terminals

3.

HD-38125-8 non-sealed terminals

Figure A-17. Metri-Pack Terminal Crimp Tools

Crimping Insulation/Seal

NOTE

Always perform Crimping Wire Core before Crimping Insu-
lation/Seal.

1.

See 

Figure A-18

. Identify the correct die for the insula-

tion/seal crimp (2).

A-12  2008 Buell XB Diagnostics:  Appendix A Connector Repair

Summary of Contents for 2008 XB SERIES

Page 1: ...2008 Buell XB Models Electrical Diagnostics Manual 99493 08Y 2007 Buell Motorcycle Company ...

Page 2: ...ure To maintain the safety dependability and emission and noise control performance it is essential that the procedures specifications and service instructions in this manual are followed Any substitution alteration or adjustment of emission system and noise control components outside of factory specifications may be prohibited by law IMPORTANT NOTICE Buell Motorcycle Company ...

Page 3: ...2008 Buell XB Models Electrical Diagnostics Manual 2007 Buell Motorcycle Company ALL RIGHTS RESERVED 99493 08Y Printed in the U S A VISIT THE BUELL WEB SITE http www buell com ...

Page 4: ...Blank Text Here ...

Page 5: ... manual Occupation Name Dealership Street Department City State Zip Please clip out and mail to Service Communications Department Buell Motorcycle Company P O Box 653 Milwaukee WI USA 53201 The Buell Motorcycle Company maintains a continuous effort to improve the quality and usefulness of its publications To do this effectively we need user feedback your critical evaluation of this manual 2008 Bue...

Page 6: ...NOTES ...

Page 7: ...cover sources of trouble Tools instruments and any parts needed for the job should be gathered before work is started Interrupting a job to locate tools or parts is a distraction and causes needless delay NOTES To avoid unnecessary disassembly carefully read all rel ative service information before repair work is started In figure legends the number which follows the name of a part indicates the q...

Page 8: ...ent an equivalent product tool or instrument may be substituted Kent Moore Products All tools mentioned in this manual with an HD J or B preface must be ordered through SPX Kent Moore For ordering information or product returns warranty or otherwise visit www spx com Loctite Sealing andThreadlocking Products Some procedures in this manual call for the use of Loctite products If you have any questi...

Page 9: ... 31 AC Output Check 1 32 1 10 BATTERY TESTING General 1 33 Voltmeter Test 1 33 Installation 1 33 Load Test 1 33 ENGINE MANAGEMENT 2 1 SPECIFICATIONS Specifications 2 1 2 2 DYNAMIC DIGITAL FUEL INJECTION DDFI Introduction 2 2 General 2 2 For More Information 2 2 Troubleshooting 2 2 2 3 DIAGNOSTIC INTRODUCTION System Problems 2 5 No Start 2 5 Poor Performance 2 5 Check Engine Lamp 2 5 Resolving Prob...

Page 10: ...Diagnostics 2 66 Diagnostic Tips 2 66 Diagnostic Notes 2 67 2 21 DTC P0261 23 P0262 23 P0264 32 P0265 32 General 2 70 Front and Rear Fuel Injectors 2 70 Diagnostics 2 70 Diagnostic Notes 2 70 2 22 DTC P0339 56 General 2 74 Crankshaft Position CKP Sensor 2 74 Diagnostics 2 74 Diagnostic Tips 2 74 Diagnostic Notes 2 74 2 23 DTC P0502 43 P0503 43 P0608 37 General 2 77 Vehicle Speed Sensor 2 77 Diagno...

Page 11: ...gs A 1 Removing Terminals from Housing A 1 Inserting Terminals into Housing A 2 Preparing Wire Leads for Crimping A 2 Crimping Terminals to Leads A 3 Inspecting Crimped Terminals A 4 A 2 DELPHI CONNECTORS Delphi Connector Repair A 5 General A 5 Separating Pin and Socket Housings A 5 Mating Pin and Socket Housings A 5 Removing Socket Terminals A 5 Installing Socket Terminals A 5 A 3 DEUTSCH ELECTRI...

Page 12: ...TORS Sealed Splice Connector Repair A 20 General A 20 Preparing Wire Leads A 20 Splicing Wire Leads A 20 Inspecting Seals A 20 APPENDIX B WIRING DIAGRAMS B 1 CONNECTORS Connector Locations B 1 B 2 WIRING DIAGRAMS Wiring Diagram Information B 3 Wire Color Codes B 3 Wiring Diagram Symbols B 3 2008 Buell Wiring Diagrams B 4 Wire Routing B 27 APPENDIX C CONVERSIONS C 1 METRIC CONVERSION Conversion Tab...

Page 13: ...TARTING SYSTEM DIAGNOSIS 1 4 1 4 STARTER ACTIVATION CIRCUITS 1 14 1 5 DIAGNOSTICS TROUBLESHOOTING 1 15 1 6 STARTER TROUBLESHOOTING 1 16 1 7 TESTING STARTER ON MOTORCYCLE 1 18 1 8 TESTING STARTER ON BENCH 1 22 1 9 CHARGING SYSTEM 1 25 1 10 BATTERY TESTING 1 33 STARTING CHARGING ...

Page 14: ...NOTES ...

Page 15: ...ent 400 Amp max 2 4 V Stall current 8 1 ft lbs 11 Nm min 2 4 V Stall torque Table 1 2 Service Wear Specifications MM IN SERVICE WEAR LIMITS 11 0 0 433 Brush length minimum 28 981 1 141 Commutator diameter min imum Table 1 3 Torque Values TORQUE ITEM 8 11 Nm 72 96 in lbs Battery terminal fasteners 7 10 Nm 60 85 in lbs Starter battery positive cable nut 18 27 Nm 13 20 ft lbs Starter mounting bolts 2...

Page 16: ...urrent flows into the pull in winding 10 and the hold in winding 11 to ground The magnetic forces of the pull in and hold in windings in the solenoid push the plunger 7 causing it to shift to the left This action engages the pinion gear 1 with the clutch ring gear 13 At the same time the main solenoid contacts 8 are closed so battery current flows directly through the field wind ings 3 to the arma...

Page 17: ...itch is closed 14 8 Overrunning clutch Ball bearing 2 9 Starter during cranking 15 Solenoid plunger Clutch ring gear 16 10 3 Starting circuit see wiring diagram Main solenoid contacts Pinion gear 4 11 Idler gear Battery 12 5 Pull in winding Field winding 6 Armature Figure 1 1 Starter Operation 2008 Buell XB Diagnostics Starting Charging 1 3 ...

Page 18: ...BENCH 3 Connect BREAKOUT BOX Part No B 48115 to Elec tronic Control Module ECM 4 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 B gray terminal socket probe and patch cord 5 See Starter Current Draw Test under 1 7 TESTING STARTER ON MOTORCYCLE 6 See Free Running Current Draw Test under 1 8 TESTING STARTER ON BENCH Job Time Code Values Dealership technicians filing warranty claims should use the j...

Page 19: ...R Y TN Y TN Y R R R R BK R BK GY O R BK BE R Y R TN LGN TN LGN BK BK GY BE GN BK W BK GY O GN O GN O TN Y R BK R BK BK R R J1 11A GY ECM 11B 11A 10B 62B 10A J2 10A BK GND 2 R GY Ignition Switch 1 3 4 1 2 3 4 R R R BK 33B 33A LOCK IGN em00076 Figure 1 3 Starting Circuit Ulysses Lightning Table 1 4 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under seat 34 place Amp Tyco ECM BK 10 Under seat...

Page 20: ...10A 62B 7 8 2 7 8 2 Start relay 8 8 Switched ignition Neutral switch Clutch switch J1 11A GY ECM J2 10A BK Clutch Switch 95B 1 2 TN LGN BK R GY Ignition Switch 1 3 4 1 2 3 4 R R R BK R R R BK 33B 33A LOCK IGN em00152 Figure 1 4 Starting Circuit Firebolt Table 1 5 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under seat Spade terminals J Fuse 5 In fairing 34 place Amp Tyco ECM BK 10 In fairi...

Page 21: ... Start Switch not pressed See Starter Test Starter Spins But Does Not Engage See Starter Test Starter Stalls or Spins Too Slowly Solenoid clicks See Starter Test Solenoid Clicks YES NO Is 12V present on Start Relay terminal 86 with Start Switch not pressed NOTE Depending on relay used relay socket terminal could be shown as 1 or U Replace Starter Solenoid YES NO Replace Start Switch Replace Start ...

Page 22: ...than 1 0 volt YES Perform voltage drop tests from Battery positive to Starter Battery terminal Crank engine Is voltage drop greater than 1 0 volt YES Repair connection between Battery and Starter NO Perform voltage drop tests between Battery negative and Starter studs or bolts Is voltage drop greater than 1 0 volt NO Repair or replace solenoid contacts YES Clean ground connections STOP NO 5824 584...

Page 23: ... on relay used relay socket terminal could be shown as 3 or E YES NO Test for voltage from Start Relay Is 12V present on Start Relay socket terminal 87 when Start Switch is pressed NOTE Depending on relay used relay socket terminal could be shown as 5 or K Repair open or poor connections on BE wire feeding Start Relay socket terminal 3 YES Repair open or poor connections on GN wire between Start R...

Page 24: ...e ignition switch terminal 1 Is voltage present Yes No Repair open in circuits between Ignition Switch and Fuse Block Replace Ignition Switch Place Engine Stop Switch in the RUN position Does the check engine lamp turn ON Yes No Disconnect right hand controls connector 22 Check for continuity between terminal 3 and terminal 4 of connector 22B with the Engine Stop Switch in the Run position Does co...

Page 25: ...es the Engine start Yes No Test the Start Relay Refer to 1 5 DIAGNOSTICS TROUBLESHOOTING Did the Start Relay test out good Yes No System functioning normally Disconnect Clutch switch connector 95 Check for continuity between terminal 1 and terminal 2 of connector 95A with the clutch disengaged pulled in Is there continuity Yes No Test for continuity from connector 95B terminal 2 to chassis Ground ...

Page 26: ...Disassemble Drive Housing assembly Inspect for damage to Armature Gear or Idler Gear Is damage present YES Replace damaged Idler Gear and Armature NO Starter Clutch failure Replace Starter Clutch 5825 5837 fc01589_en 1 12 2008 Buell XB Diagnostics Starting Charging ...

Page 27: ...r studs or bolts Is voltage drop greater than 1 0 volt 1 1 YES Repair connection between Battery and Starter NO Repair or replace Starter Solenoid contacts 5824 5845 NO YES Clean Ground connections Perform Starter Current Draw Test on vehicle Perform Free Running Current Draw Test on bench Are test results within range 5 6 YES NO Remove spark plugs while in 5th gear Rotate rear wheel Check for eng...

Page 28: ...A 0 1A 0 1A 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 150A 20A 20A 0 1A 150A 15A 0 1A 0 1A 0 1A 0 1A 0 1A 0 1A 0 1A ed01445 9 5 1 Start switch Engine stop switch Battery 2 10 6 30 Amp battery fuse Ulysses Lightning 30 Amp J Fuse Firebolt Start relay Ignition relay used for junction purposes only 11 Solenoid 7 12 Ignition fuse Starter 3 8 Key switch fuse Key ...

Page 29: ...s on the ground side will read zero 5 Typically a good circuit will drop less than 1 0 volt If the voltage drop is greater back track through the connections until the source of the potential difference is found The benefits of doing it this way are speed and accuracy a Readings aren t as sensitive to real battery voltage b Readings show the actual voltage dropped not just the presence of voltage ...

Page 30: ...ace solenoid assembly Pull in winding open or short circuited Repair or replace solenoid assembly Hold in winding open or short circuited Check brush spring tension Replace field frame and holder Brushes worn below specification Starting motor Re face or replace Commutator burnt Correct by undercutting Commutator high mica Replace starter Field winding grounded Replace armature Armature winding gr...

Page 31: ...ondition of spline teeth Replace overrunning clutch and idler gear Reduction gears damaged Replace clutch shell Excessively worn teeth Gear teeth on clutch shell Table 1 8 Starter Does Not Stop Running SOLUTION PROBABLE CAUSE SOURCE OF PROBLEM Replace start switch or start relay Unopened contacts Start switch or start relay Replace start switch or start relay Poor return caused by sticky switch or...

Page 32: ...1 8 Lightning and Figure 1 9 Firebolt Unplug start relay from relay fuse block b See Figure 1 8 and Figure 1 6 To energize the relay connect relay terminal 85 to the negative battery terminal and relay terminal 86 to the positive battery terminal c Check for continuity between relay terminals 3 and 5 A good relay shows continuity continuity tester lamp on or a zero ohm reading on the ohmmeter A ma...

Page 33: ...re Fan 36 42 43 37 31 25 Key SW Spare 44 38 32 26 24 30 ECM Fuel pump IGN Ignition 1 3 4 5 6 7 9 2 8 10 11 13 14 15 16 17 19 12 18 20 Start Key SW AUX 10 10 30 10 15 15 15 10 10 10 10 15 ed01239 Figure 1 8 Fuses and Relays Lightning 2008 Buell XB Diagnostics Starting Charging 1 19 ...

Page 34: ...y Proceed as follows 1 Verify that transmission is in neutral Disconnect spark plug wires from spark plug terminals 2 Clamp induction ammeter over positive battery cable next to starter 3 With ignition switch ON turn engine over by pressing starter switch while reading the ammeter Disregard initial high current reading which is normal when engine is first turned over a Typical starter current draw...

Page 35: ...1 2 3 ed01525 1 Starter 2 Induction ammeter 3 Battery Figure 1 11 Starter Current Draw Test 2008 Buell XB Diagnostics Starting Charging 1 21 ...

Page 36: ...ice Manual c If starter current draw on vehicle was over 200 amps and this test was within specification there may be a problem with engine or primary drive 1 3 5 4 2 ed01526 1 Mounting flange 2 Battery 3 Induction ammeter 4 Battery terminal 5 Relay terminal Figure 1 12 Free Running Current Draw Test STARTER SOLENOID Do not disassemble solenoid Before testing disconnect field wire from motor termi...

Page 37: ...If starter shaft remains extended solenoid is working properly b If starter shaft retracts replace the solenoid 3 1 2 ed01528 1 Motor terminal 2 Battery 3 Relay terminal Figure 1 14 Test 2 Hold in Test SOLENOID RETURN TEST 1 See Figure 1 15 With test leads still connected in the manner specified at the end of the previous 1 8 TESTING STARTER ON BENCH Solenoid Hold In Test disconnect solenoid relay...

Page 38: ...est 3 Return Test POST TEST 1 Carefully remove battery cables and jumpers 2 Reattach starter cable to starter solenoid 3 Reinstall starter assembly to motorcycle engine in accordance with the procedures in the Service Manual 1 24 2008 Buell XB Diagnostics Starting Charging ...

Page 39: ...Voltage Regulator Connector 77 TROUBLESHOOTING TOOL NAME PART NUMBER ADVANCED BATTERY CONDUCT ANCE AND ELECTRICAL SYSTEM ANALYZER HD 48053 When the charging system fails to charge or does not charge at a satisfactory rate make the following recommended checks Battery Check for a weak or dead battery See 1 10 BATTERY TESTING for battery testing procedures Battery must be fully charged in order to p...

Page 40: ...relay block BK BK BK BK BK BK BK R Y R R 46A BK em00118 Figure 1 18 Charging System Circuit Ulysses Lightning Table 1 9 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under ram air scoop 2 place Packard Stator 46 Under ram air scoop 2 place Packard Voltage regulator 77 1 26 2008 Buell XB Diagnostics Starting Charging ...

Page 41: ... BK BK BK R Y R 46A BK 41 35 em00170 Figure 1 19 Charging System Circuit Firebolt Table 1 10 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under seat Spade terminals J Fuse 5 Under ram air scoop 2 place Packard Stator 46 Under ram air scoop 2 place Packard Voltage regulator 77 2008 Buell XB Diagnostics Starting Charging 1 27 ...

Page 42: ...measurement FAIL Disconnect Regulator Does milliampere draw drop 5308 PASS FAIL Isolate damaged wiring or excessive accessories 5310 Go to Charging System Test Part 2 of 2 NOTE Whenever a charging system component fails a test and is replaced re test the system to be sure the problem has been corrected STOP fc01591_en Isolate damaged component or wiring Replace grounded stator YES NO 5312 1 28 200...

Page 43: ...idden very slowly for long periods Battery self discharge and or accessory draw because vehicle was not operated for a long period PASS FAIL Perform AC Output Check Replace Stator 5312 PASS Replace Voltage Regulator Perform Current and Voltage Output Test Inspect Rotor FAIL FAIL PASS Damaged or slipping Rotor System OK 5315 NOTE Whenever a charging system component fails a test and is replaced re ...

Page 44: ...nts and accessories may exceed output of the charging system NOTE If a load tester is unavailable an ammeter with current probe may be used Turn battery load tester OFF before connecting tester cables to battery terminals Connecting tester cables with load tester ON can cause a spark and battery explosion which could result in death or serious injury 00252a 1 See Figure 1 21 To check for this cond...

Page 45: ...a constant 13 0 VDC 3 The current output should be 28 34 amps Make note of measurement for use in 1 9 CHARGING SYSTEM Testing NOTE Rider s habits may require output test at lower RPM 4 After removing the load read the load tester voltage meter a If voltage to the battery is not more than 15 VDC voltage output is within specifications Investigate other possible problems See Charging System Test flo...

Page 46: ...tput should be 40 56 volts AC approximately 20 28 volts per 1000 RPM 2 Compare test results to specifications a If the output is below specifications charging problem could be a faulty rotor or stator b If output is good charging problem might be faulty voltage regulator Replace as required 3 Check the output again as previously described under 1 9 CHARGING SYSTEM Testing ed01456 Figure 1 25 Check...

Page 47: ...lts GOOD BATTERY Return the battery to service GOOD RECHARGE Fully charge the battery and return to service CHARGE RETEST Fully charge the battery and retest REPLACE BATTERY Replace the battery and retest BAD CELL REPLACE Replace the battery and retest NOTE A REPLACE BATTERY test result may also mean a poor connection between the battery cables and the vehicle After disconnecting the battery cable...

Page 48: ...the resulting sparks can cause a battery explosion which could result in death or serious injury 00068a Do not over tighten bolts on battery terminals Use recommended torque values Over tightening battery ter minal bolts could result in damage to battery terminals 00216a 6 Install the battery on the motorcycle 1 2 3 ed01461 1 Load Tester 2 Induction Pick Up 3 Battery Figure 1 27 Load Test Battery ...

Page 49: ... 14 2 58 2 19 DTC P0122 11 P0123 11 2 62 2 20 DTC P0151 13 P0152 11 P0154 13 2 66 2 21 DTC P0261 23 P0262 23 P0264 32 P0265 32 2 70 2 22 DTC P0339 56 2 74 2 23 DTC P0502 43 P0503 43 P0608 37 2 77 2 24 DTC P0506 34 P0507 34 P0511 34 2 84 2 25 DTC P0562 16 P0563 16 2 88 2 26 DTC P0603 54 P0604 52 P0605 53 P0607 55 2 93 2 27 DTC P0617 46 2 94 2 28 DTC P0628 33 P0629 33 2 99 2 29 DTC P0691 36 P0692 36...

Page 50: ...NOTES ...

Page 51: ... 16 24 Nm 12 18 ft lbs Torque 1 350 3 465 ohms Cable resistance front and rear Table 2 5 Alternator Specifications ALTERNATOR 20 28 VAC per 1000 engine RPM AC voltage output 0 1 0 3 ohms Stator coil resist ance Table 2 6 Regulator Specifications REGULATOR 14 3 14 7 VDC 75 F 24 C Voltage output 3600 RPM 32 Amps Amperes 3600 RPM Table 2 7 Electrical System Specifications AMPERES ELECTRICAL SYSTEM 30...

Page 52: ... internally so it will be available for the next ride The 1200 models utilize an interactive exhaust system which has an electronically controlled actuator that activates a but terfly valve that controls exhaust flow in the dual chamber muffler The Electronic Control Module ECM monitors engine speed and throttle position while activating the valve See 2 33 DTC P1470 21 P1471 21 P1477 21 P1478 21 G...

Page 53: ...11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 Sensor ground 2 28 4 9 11 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 32 28 11B 11A From cooling fan fuse From fuel pump fuse Fuel Pump Cooling Fan From brake horn muffler fuse Interactive Muffler Control Throttle Position Sensor 97B 97A 86B 86A 161B 161A 165A 165B 83B 83A 39B 39A 39B 39A 39B 39A 84B 84A 85B 85A 134B 134A 65B 65A 88B 88A 89B 89A ...

Page 54: ...LOCATION TYPE MODEL DESCRIPTION NO In fairing 34 place Amp Tyco Firebolt ECM BK 10 Under seat Ulysses Lightning In fairing 34 place Amp Tyco Firebolt ECM GY 11 Under seat Ulysses Lightning 2 4 2008 Buell XB Diagnostics Engine Management ...

Page 55: ...amp Figure 2 2 Check Engine Lamp Typical RESOLVING PROBLEMS TOOL NAME PART NUMBER DIGITAL TECHNICIAN HD 44750 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 diagnostic trouble codes DTCs by obser...

Page 56: ...y four seconds and then turn off 2 See Figure 2 5 After check engine lamp turns off after being illuminated for the first four second period one of three situations may occur a The check engine lamp remains off This indicates there are no current fault conditions or stored func tional trouble codes currently detected by the Elec tronic Control Module ECM b The check engine lamp stays off for only ...

Page 57: ...e flow charts for solutions Historic If a particular problem happens to resolve itself the active status problem is dropped and it becomes a historic fault rather than a current fault Historic trouble codes are stored for a length of time to assist in the diagnosis of intermittent faults The check engine lamp will not turn on during normal operation if only historic codes are present It is importa...

Page 58: ... a safe operating temperature The check engine lamp will flash until the engine has cooled to a safe operating temper ature This will not set a trouble code 2 8 2008 Buell XB Diagnostics Engine Management ...

Page 59: ...nd digit of the trouble code Count the number of times the check engine lamp flashes to retrieve the second digit 5 If more than one trouble code is sent a Following transmission of the second digit of the first code there is a third 2 second pause in which the check engine lamp is off b After the pause comes the intermission which is fol lowed by transmission of the next recorded trouble code c A...

Page 60: ...ission Pause before 1st digit Pause before 2nd digit 2 Sec 2 Sec 1 Sec 1 Sec ed01466 Figure 2 8 Check Engine Lamp Diagnostics CLEARING CODES TOOL NAME PART NUMBER DIGITAL TECHNICIAN HD 44750 After correcting system problems clear trouble codes If the DIGITAL TECHNICIAN Part No HD 44750 is not available perform 50 start and run cycles To execute one run cycle 1 Start the vehicle 2 Let it run for at...

Page 61: ...ector from the wiring harness to black connector on Breakout Box 3 Attach Breakout Box to gray connector 11 a Attach gray connector from Breakout Box to corres ponding gray ECM connector b Attach gray connector from the wiring harness to gray connector on Breakout Box 1 3 4 2 ed01330 1 ECM 2 Breakout box 3 ECM gray connector 4 ECM black connector Figure 2 9 ECM and Breakout Box with Connections Ul...

Page 62: ...2 Detach Breakout Box connectors from ECM connectors 3 Detach Breakout Box connectors from wiring harness 4 Reconnect harness to ECM 2 12 2008 Buell XB Diagnostics Engine Management ...

Page 63: ...t No HD 39978 to wiring harness between the suspect connections When diagnosing Electronic Control Module ECM connections a BREAKOUT BOX Part No B 48115 may be used to simplify the procedure See 2 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 intermit tents are present radical voltage changes will re...

Page 64: ...TICS TOOL NAME PART NUMBER BREAKOUT BOX B 48115 HARNESS CONNECTOR TEST KIT HD 41404 B General Information The diagnostic check is an organized approach to identifying a problem caused by an electronic control system malfunction NOTE The engine may be started and run when the trouble codes are received using a jumper wire on terminals 1 and 2 of the data link connector However if the jumper wire is...

Page 65: ...112 15 P0113 15 Clogged air filter Test fuel injectors 2 23 DTC P0502 43 P0503 43 P0608 37 Leaky injectors 2 15 FUEL PRESSURE TEST Improper fuel pressure Table 2 13 Trouble Codes and Fault Conditions SOLUTION FAULT CONDITION CHECK ENGINE LAMP CODE DTC RANKING 2 26 DTC P0603 54 P0604 52 P0605 53 P0607 55 ECM RAM Failure 52 P0604 1 2 26 DTC P0603 54 P0604 52 P0605 53 P0607 55 ECM ROM Failure 53 P060...

Page 66: ...261 23 P0262 23 P0264 32 P0265 32 Front Fuel Injector Circuit High 23 P0262 25 2 21 DTC P0261 23 P0262 23 P0264 32 P0265 32 Front Fuel Injector Circuit Low 23 P0261 26 2 21 DTC P0261 23 P0262 23 P0264 32 P0265 32 Rear Fuel Injector Circuit High 32 P0265 27 2 21 DTC P0261 23 P0262 23 P0264 32 P0265 32 Rear Fuel Injector Circuit High 32 P0264 28 2 25 DTC P0562 16 P0563 16 Battery Voltage High 16 P05...

Page 67: ...APANESE MODELS ONLY Active Intake Control Circuit Short High 22 P1111 47 2 30 DTC P1110 22 P1111 22 P1112 22 JAPANESE MODELS ONLY Active Intake Control Circuit Short Low Open 22 P1110 48 2 35 DTC P1601 47 Auxiliary Relay Driver Circuit 47 P1601 49 2 36 DTC P1653 35 P1654 35 Vehicle Speed Sensor Control Module Fail 37 P0608 50 2 36 DTC P1653 35 P1654 35 Tachometer Output High 35 P1654 51 2 36 DTC P...

Page 68: ...yco Firebolt ECM BK 10 Under seat Ulysses Lightning In fairing 34 place Amp Tyco Firebolt ECM GY 11 Under seat Ulysses Lightning Under fairing 4 place Deutsch Firebolt Data link con nector 91A Behind left airflow guide Ulysses Under seat Lightning 2 18 2008 Buell XB Diagnostics Engine Management ...

Page 69: ...T WILL NOT START Does check engine lamp display ignition module data See 2 4 CHECKING FOR TROUBLE CODES Does check engine lamp turn OFF after four seconds Does engine start Are any trouble codes displayed Refer to applicable trouble code flow chart Start with highest priority trouble code All DTCs are listed in Table 2 13 Refer to diagnostic tips in related trouble code chart even if no DTC codes ...

Page 70: ...or damage or repair opens as necessary Pin 1 2 3 4 YES Test the four data link connector terminals against their ECM connector terminals for continuity Continuity present in all four circumstances DATA LINK TERMINAL DATA LINK TERMINAL Pin 15 19 16 9 Connector 11B 11B 11B 10B Wire Color LGN R BK W V R GY NOTE After replacing ECM or TPS the TPS zero set procedure must be performed Refer to THROTTLE ...

Page 71: ...5 4 6 1 3 2 ed02010 1 Nozzle 2 Copper tubing 3 Hose 4 Valve 5 Knob 6 Propane bottle Figure 2 15 Leak Tester INTAKE LEAK TESTING Do not allow open flame or sparks near propane Propane is extremely flammable which could cause death or ser ious injury 00521b 1 Start engine 2 Warm engine to operating temperature 3 See Figure 2 15 Turn knob 5 counterclockwise to open propane bottle NOTE Do not direct p...

Page 72: ...ed01568 Figure 2 16 Checking for Leaks 2 22 2008 Buell XB Diagnostics Engine Management ...

Page 73: ...R HARNESS CONNECTOR TEST KIT HD 41404 B Diagnostic Tips Check for the following conditions Check for open BK Y wire Check for open fuse Check for failed bulb Diagnostic Notes Each reference number below correlates to a circled number on the flow chart s 1 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 B black pin probe and patch cord 2 See Figure 2 18 Figure 2 19 Figure 2 20 Inspect con nector 10...

Page 74: ... BK Y R BK Check engine lamp 23 23 J1 11A GY ECM 10B 10A 11B 11A J2 10A BK Ignition Switch 1 2 3 4 1 3 4 R R R BK R R R BK R GY 33B 33A LOCK IGN em01168 Figure 2 21 Check Engine Lamp Circuit Ulysses Lightning Table 2 15 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under seat 34 place Amp Tyco ECM BK 10 Behind windscreen 20 place Multilock Instrument module 39 2 24 2008 Buell XB Diagnostics...

Page 75: ... 11A GY ECM 11B 11A 10B 10A J2 10A BK Ignition Switch 1 2 3 4 1 3 4 R R R BK R R R BK R GY 33B 33A LOCK IGN em00140 Figure 2 22 Check Engine Lamp Circuit Firebolt Table 2 16 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under seat Spade terminals J Fuse 5 In fairing 34 place Amp Tyco ECM BK 10 In fairing 20 place Multilock Instrument module 39 2008 Buell XB Diagnostics Engine Management 2 2...

Page 76: ...nd Is check engine lamp ON Replace ECM No ECM power Refer to NO ECM POWER See 2 12 ENGINE CRANKS BUT WILL NOT START for no start condition and then return to 2 10 CHECK ENGINE LAMP NOT ILLUMINATED AT KEY ON to resolve no engine check lamp Disassemble Instrument Module Inspect check engine lamp bulb Bulb failed Repair open or short to voltage on BK Y wire between connector 39 and connector 10B Blac...

Page 77: ...t second period for a stored error or remain on continuously current error ed01488 Figure 2 23 Check Engine Lamp DIAGNOSTICS Diagnostic Notes Each reference number below correlates to a circled number on the flow chart s 1 See Figure 2 25 If the check engine lamp turns off when the black Electronic Control Module ECM connector 10 is unplugged the BK Y wire is not shorted to ground ed01508 Figure 2...

Page 78: ... BK Y R BK Check engine lamp 23 23 J1 11A GY ECM 10B 10A 11B 11A J2 10A BK Ignition Switch 1 2 3 4 1 3 4 R R R BK R R R BK R GY 33B 33A LOCK IGN em01168 Figure 2 27 Check Engine Lamp Circuit Ulysses Lightning Table 2 17 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under seat 34 place Amp Tyco ECM BK 10 Behind windscreen 20 place Multilock Instrument module 39 2 28 2008 Buell XB Diagnostics...

Page 79: ... 11A GY ECM 11B 11A 10B 10A J2 10A BK Ignition Switch 1 2 3 4 1 3 4 R R R BK R R R BK R GY 33B 33A LOCK IGN em00140 Figure 2 28 Check Engine Lamp Circuit Firebolt Table 2 18 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under seat Spade terminals J Fuse 5 In fairing 34 place Amp Tyco ECM BK 10 In fairing 20 place Multilock Instrument module 39 2008 Buell XB Diagnostics Engine Management 2 2...

Page 80: ...re a check engine lamp OFF period Disconnect Instrument Module connector 39 Remove BK Y wire from connector 39A Reconnect 39 Check engine lamp ON Check engine lamp function OK Check for trouble codes See CHECKING FOR TROUBLE CODES Replace ECM Replace Instrument Module Repair short to ground on BK Y wire between connector 39 and connector 10 Black NOTE After replacing ECM or TPS the TPS zero set pr...

Page 81: ...hile cranking starter look for spark Repeat pro cedure on other spark plug cable 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 4 Purge fuel line of high pressure gasoline See appropriate Buell Service Manual 5 Access fuel injectors a Remove righ...

Page 82: ...Y LGN GY GN GY GN GY BK BE BK BE GN W GN W BK W BK W BE O BE O BE O Y BE Y BE Y BE J1 11A GY ECM J2 10A BK em01169 Figure 2 31 Ignition Circuit Table 2 19 Wire Harness Connectors LOCATION TYPE MODEL DESCRIPTION NO In fairing 34 place Amp Tyco Firebolt ECM BK 10 Under seat Ulysses Lightning In fairing 34 place Amp Tyco Firebolt ECM GY 11 Under seat Ulysses Lightning Below left ram air scoop 2 place...

Page 83: ...n Switch ON and set Engine Stop Switch to RUN Did fuel pump run 2 3 seconds and did the check engine lamp illuminate No Fuel Pump response or check engine lamp See 2 13 NO ECM POWER Short Fuel Pump response check engine lamp OK See 2 31 DTC P1151 44 P1152 44 No Fuel Pump response but check engine lamp is OK See 2 15 FUEL PRESSURE TEST Fuel Pump OK but no check engine lamp See 2 10 CHECK ENGINE LAM...

Page 84: ...k ignition coil connections Are connections OK Check continuity between ignition coil connector 83 terminal 1 and ECM connector 10 Black terminals 31 and 32 Check continuity between ignition coil connector 83 terminal 3 and ECM connector 10 Black terminals 25 and 34 Is resistance less than 1 0 ohm Test Spark Plug Cable resistance See 2 16 MISFIRE Test Resistance OK Poor connection at connector 10B...

Page 85: ...r continuity between Breakout Box terminal 26 Gray to crankshaft position sensor connector 79B terminal 2 Is resistance greater than 1 0 ohm Replace Crankshaft Position Sensor Locate and repair open circuit Above 1500 Ohms Disconnect Crankshaft Position Sensor Check for continuity between connector 79B terminal 1 and ground Check for continuity between connector 79B terminal 2 and ground Is resist...

Page 86: ... Ignition Relay Ignition Fuse Battery Fuse Key Switch Fuse 91A 86 85 30 87A 87 1 21 27 35 38 41 44 5 9 4 R R R R R BK R Y GY O GY O W BK W BK W BK BK GY GY GY LGN R V R BK W 22B 22A LGN R V R BK W Serial data receive Serial data transmit Sensor ground 3 Switched ignition BK GY BK BK BK 15 16 19 8 15 16 19 8 9 9 16 16 24 24 33 33 System ground 4 System ground 3 System ground 2 System ground 1 J1 11...

Page 87: ...15 16 19 8 15 16 19 8 9 9 16 16 24 24 33 33 System ground 4 System ground 3 System ground 2 System ground 1 J1 11A GY ECM 11B 11A 10B 10A J2 10A BK R GY Ignition Switch 1 2 3 4 1 2 3 4 R R R BK R R R BK 33B 33A LOCK IGN em00141 Figure 2 33 ECM Power Circuit Firebolt Table 2 21 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under seat Spade terminals J Fuse 5 In fairing 34 place Amp Tyco ECM ...

Page 88: ... Relay Locate and repair open on BK wire to ground from ignition relay Check for battery voltage on ignition relay terminal 30 GY O Is voltage present Check for battery voltage on ignition relay terminal 86 W BK Is voltage present Replace Ignition Relay Check for battery voltage on right handlebar switch connector 22A terminal 3 W BK wire Is voltage present Repair open on GY O wire between Ignitio...

Page 89: ...IGN relay CKP Sensor Bank Angle Sensor Rear Injector Front Injector 1 2 1 2 134B 134A 2 1 3 2 1 3 Side Stand Sensor 133B 133A 85B 85A 84B 84A 83B 83A 1 2 1 2 Ignition Coil Rear Front 25 31 32 34 Front coil primary Rear coil Rear coil Front coil secondary 25 31 32 34 BK BK BK BK GY GY GY GY Neutral Switch 1 1 131B 131A GY R W R W W Y W Y LGN GY LGN GY GN GY GN GY BK BE BK BE GN W GN W BK W BK W TN ...

Page 90: ...i All Ignition coil 83 Beneath airbox base 2 place Packard All Front injector 84 Beneath airbox base 2 place Packard All Rear injector 85 Under sprocket cover 1 place All Neutral switch 131 Below left ram air scoop 3 place Amp All Side stand sensor 133 In fairing 6 place Sumitomo Firebolt Bank angle sensor 134 Under seat Ulysses Lightning 2 40 2008 Buell XB Diagnostics Engine Management ...

Page 91: ...ne start and stay running YES NO Repair or replace Clutch or Neutral switches or circuitry Replace Electronic Control Module ECM YES NO See 2 24 DTC P0506 34 P0507 34 P0511 34 Will engine start with throttle opened partially and stall when throttle is closed NOTES Clear DTCs and confirm proper operation with no check engine lamp Codes can be cleared using DIGITAL TECHNICIAN Part No HD 44750 After ...

Page 92: ...gauge are closed 6 Attach FUEL PRESSURE GAUGE Part No HD 41182 4 to fuel pressure gauge adapter 1 7 See Figure 2 35 Attach fuel pump connector 86 to main wiring harness 8 See Figure 2 40 Pressurize the fuel system a Start and idle engine to pressurize the fuel system b Open fuel valve 2 on fuel pressure gauge to allow fuel to flow down the gauge hose c Position the air bleed tube 3 into proper con...

Page 93: ...uel Pump Connector 86 Firebolt swingarm removed for illustration 1 2 3 ed01490 1 Throttle body inlet 2 Button 3 Fuel line Figure 2 38 Fuel Line 1 2 3 ed01470 1 Throttle body inlet 2 Fuel pressure gauge adapter 3 Fuel line Figure 2 39 Fuel Pressure Gauge Adapter 2008 Buell XB Diagnostics Engine Management 2 43 ...

Page 94: ... Pump connector 86A terminal 4 but not both the open must be repaired but this repair will not correct the concern 27 27 24 24 16 16 9 9 8 8 3 3 2 1 4 15 15 3 2 1 4 4 3 4 Fuel pump output 27 27 Fuel pump output 33 33 System ground 1 System ground 4 Low fuel lamp System ground 2 System ground 3 Switched ignition From battery Right Handlebar Switch 22B 22A 86B 86A 39A 39B Ignition Relay Fuel Pump Fu...

Page 95: ...ctors LOCATION TYPE DESCRIPTION NO Under seat 34 place Amp Tyco ECM BK 10 Behind windscreen 20 place Multilock Instrument module 39 Left side of frame 4 place Multilock Fuel pump 86 2008 Buell XB Diagnostics Engine Management 2 45 ...

Page 96: ...p Instrument Module Ignition Fuse BN Y BN Y BN Y O GY O GY From battery R Y 5A 5B 1 2 J Fuse 1 2 R Switched ignition 9 Fuel pump output Fuel pump output 27 28 System ground 4 8 System ground 3 16 System ground 2 24 System ground 1 33 9 27 28 8 16 24 33 J1 11A GY ECM 11B 11A 10B 10A J2 10A BK Ignition Switch 1 2 3 4 1 3 4 R R R BK R R R BK R GY 33B 33A LOCK IGN em00144 Figure 2 42 Fuel Pump Circuit...

Page 97: ... TYPE DESCRIPTION NO Under seat Spade terminals J Fuse 5 In fairing 34 place Amp Tyco ECM BK 10 In fairing 20 place Multilock Instrument module 39 Left side of frame 4 place Multilock Fuel pump 86 2008 Buell XB Diagnostics Engine Management 2 47 ...

Page 98: ...e negative probe to Ignition Relay terminal 87 or 5 GY Measure voltage on during first two seconds after Ignition Switch is ON Is voltage greater than 1 0V NO Low Pressure YES NO Locate and repair poor connection between Ignition Relay and Fuel Pump Locate and repair poor connection between Battery and Ignition Relay Check for restricted Fuel Pump Inlet Screen Is screen restricted YES NO Check for...

Page 99: ...x B 48115 to Electronic Control Module ECM Check continuity between fuel pump connector 86B terminal 4 and ECM connector 10 Black terminals 27 and 28 Is continuity present Inspect fuel pump wiring Is wiring OK Locate and repair open in O GY wire Repair fuel pump wiring Replace Fuel Pump assembly See FUEL PUMP in appropriate Buell Service Manual Replace ECM Locate and repair open on BN Y wire NOTE ...

Page 100: ... spark to jump tester gap on leads 2 Perform spark plug cable resistance test a Remove spark plug cable from spark plug and ignition coil b Using an ohmmeter touch probes to terminals on each end of plug wire c Compare resistance values to Table 2 25 Replace cables not meeting specifications Reinstall and repeat procedure on other spark plug cable 3 If carbon tracking is evident replace ignition c...

Page 101: ...Y LGN GY GN GY GN GY BK BE BK BE GN W GN W BK W BK W BE O BE O BE O Y BE Y BE Y BE J1 11A GY ECM J2 10A BK em01169 Figure 2 44 Ignition Circuit Table 2 26 Wire Harness Connectors LOCATION TYPE MODEL DESCRIPTION NO In fairing 34 place Amp Tyco Firebolt ECM BK 10 Under seat Ulysses Lightning In fairing 34 place Amp Tyco Firebolt ECM GY 11 Under seat Ulysses Lightning Below left ram air scoop 2 place...

Page 102: ...bon tracking Are wires OK Check for Faulty worn or cracked Spark Plug s Spark Plug fouling due to engine mechanical fault Faulty or poor connection at Spark Plug Drain and flush fuel tank Refill with fresh fuel Ignition Coils should be free of carbon tracking Are they Replace faulty Spark Plug Wires Replace Ignition Coil Switch Ignition Coil with unit known to be good Perform spark test Did spark ...

Page 103: ...reakout Box terminal 26 Gray to crankshaft position sensor connector 79B terminal 2 Is resistance greater than 1 0 ohm Replace Crankshaft Position Sensor Locate and repair open circuit Above 1500 Ohms Disconnect Crankshaft Position Sensor Check for continuity between connector 79B terminal 1 and Ground Check for continuity between connector 79B terminal 2 and Ground Is resistance greater than 1 0 ...

Page 104: ... 90 2920 1 13 176 80 3889 1 40 140 60 8149 2 25 104 40 16 178 3 09 86 30 23 670 3 52 68 20 31 170 3 94 50 10 55 359 4 24 32 0 96 383 4 53 14 10 146 250 4 68 4 20 284 118 4 83 NOTE All voltage and resistance values are approximate 20 DIAGNOSTICS TOOL NAME PART NUMBER BREAKOUT BOX B 48115 HARNESS CONNECTOR TEST KIT HD 41404 B Diagnostic Tips An intermittent may be caused by a poor connection rubbed ...

Page 105: ...N Y BK W LGN Y BK W LGN Y BK W J1 11A GY ECM 11B 11A 10B 10A J2 10A BK Air temp input Sensor ground 1 em01215 Figure 2 46 Intake Air Temperature Sensor Circuit Table 2 29 Wire Harness Connectors LOCATION TYPE MODEL DESCRIPTION NO In fairing 34 place Amp Tyco Firebolt ECM GY 11 Under seat Ulysses Lightning In air cleaner baseplate 2 place Amp All Intake Air Temperature IAT sensor 89 2008 Buell XB D...

Page 106: ...ed disconnect Breakout Box connector 11 Gray Measure resistance between Breakout Box terminal 14 Gray and ground Is resistance less than 1 megohm Replace IAT Sensor See INTAKE AIR TEMPERATURE SENSOR in appropriate Buell Service Manual clear codes and road test Did check engine lamp turn ON and set only DTC P0112 15 or P0113 15 Install original IAT Sensor replace ECM then road test Repair short to ...

Page 107: ... and Breakout Box connector 11 Gray terminal 14 Is it less than 1 0 ohm Using a DVOM measure the resistance between IAT Sensor connector 89 terminal 2 and ECM connector 11 Gray terminal 27 on Breakout Box Is it less than 1 0 ohm Using a DVOM measure the resistance between ECM connector 11 Gray terminals 14 and 27 on Breakout Box Is it greater than 1 0 megohm Using a DVOM measure the resistance bet...

Page 108: ...ure Sensor Specifications TEMP F TEMP C RESISTANCE VOLTS 572 300 0 0 00 491 255 145 0 21 410 210 303 0 42 374 190 463 0 62 338 170 638 0 81 302 150 1042 1 20 266 130 1539 1 59 185 85 4991 3 01 104 40 25 647 4 43 77 25 41 295 4 63 50 10 93 759 4 83 32 0 134 200 4 88 14 10 232 414 4 93 NOTE All voltage and resistance values are approximate 20 DIAGNOSTICS TOOL NAME PART NUMBER BREAKOUT BOX B 48115 HA...

Page 109: ...9 Figure 2 48 Engine Temperature Sensor Circuit Table 2 32 Wire Harness Connectors LOCATION TYPE MODEL DESCRIPTION NO In fairing 34 place Amp Tyco Firebolt ECM GY 11 Under seat Ulysses Lightning Beneath air cleaner base plate 1 place bullet All Engine Temperature ET sensor 90 2008 Buell XB Diagnostics Engine Management 2 59 ...

Page 110: ...Sensor Is resistance between 33761 74328 ohms when engine temperature ranges 68 86o F 20 30o C Attach Breakout Box B 48115 to the Electronic Control Module ECM Using a DVOM Part No HD 39978 measure the resistance between ET Sensor connector and ECM connector 11 terminal 11 Is it less than 1 0 ohm Using a DVOM measure the resistance between Breakout Box terminal 11 of 11 and Ground Is it greater th...

Page 111: ...ted disconnect ECM connector 11 Measure resistance between ECM connector 11 Gray terminal 11 and ground Is resistance less than 1 ohm Replace ET Sensor See ENGINE TEMPERATURE SENSOR in Buell Service Manual clear codes and road test Did check engine lamp turn on and set P0117 14 P0118 14 System OK Repair short to ground on PK Y wire Replace ECM Examine ET sensor signal wire PK Y for short to 12 vol...

Page 112: ...ST KIT HD 41404 B Diagnostic Tips An intermittent may be caused by a poor connection rubbed through wire insulation or a wire broken inside the insulation Check for the following conditions Poor Connection 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 2 6 BREAKO...

Page 113: ...A 88B 88A V Y R W R W LGN GY BK W BK W J1 11A GY ECM 11B 11A 10B 10A J2 10A BK em01194 Figure 2 51 Throttle Position Sensor Circuit Table 2 34 Wire Harness Connectors LOCATION TYPE MODEL DESCRIPTION NO In fairing 34 place Amp Tyco Firebolt ECM GY 11 Under seat Ulysses Lightning Below left ram air scoop 2 place Deutsch All Crankshaft Position CKP sensor 79 Beneath air cleaner base plate 3 place Amp...

Page 114: ... DVOM Replace TPS See THROTTLE POSITION SENSOR in Buell Service Manual Clear codes and road test Did check engine lamp come on and set DTC P0122 11 P0123 11 Reconnect TPS connector 88 Measure TPS voltage at wide open throttle Is voltage greater than 5 0 volts Locate and repair short between V Y wire and battery voltage Install original TPS and replace ECM Road test again to verify System now OK Lo...

Page 115: ... Is resistance greater than 1 0 megohm Check continuity from connector 11 terminal 4 to connector 88 terminal 2 Is continuity present Check continuity between connector 88 terminal 2 V Y wire and connector 11 Gray terminal 4 Is continuity present Locate and repair open in R W wire Locate and repair open in V Y wire Check continuity between connector 88 terminal 1 BK W wire and connector 11 Gray te...

Page 116: ...g temperature of the engine engine speed and throttle position An open short to voltage or short to ground in the V GY wire will cause the engine to run rich short to ground or lean short to voltage until fault is detected vehicle will run in open loop The engine must be running below 5000 RPM for the ECM to detect an oxygen failure Check for the following conditions Poor Connection Inspect ECM ha...

Page 117: ...sensor 32 32 137B 137A 1 1 V GY V GY V GY J1 11A GY ECM 11B 11A 10B 10A J2 10A BK em01198 Figure 2 54 Oxygen Sensor Circuit Table 2 36 Wire Harness Connectors LOCATION TYPE MODEL DESCRIPTION NO In fairing 34 place Amp Tyco Firebolt ECM GY 11 Under seat Ulysses Lightning Above rear cylinder head 1 place Packard All Oxygen O2 sensor 137 2008 Buell XB Diagnostics Engine Management 2 67 ...

Page 118: ...ss side connector 11 Gray disconnected from the Breakout Box Measure voltage to ground on terminal 32 of connector 11 Gray on breakout box Is voltage present Locate and repair short to ground on V GY wire Replace ECM Inspect V GY wire for shorts to voltage and repair Replace ECM NO 0 volts NO Greater than 1 volt Go to Oxygen Sensor Test DTC P0151 13 P0152 13 P0154 13 Part 2 of 2 NOTES Clear DTCs a...

Page 119: ... 21 DTC P0261 23 P0262 23 P0264 32 P0265 32 Retest Replace O2 sensor See OXYGEN SENSOR in appropriate Buell Service Manual Repair open on V GY wire Replace fuel line or filter Check for air leaks at induction module Air leak present Fuel injectors may be dirty See Fuel Injectors under THROTTLE BODY in appropriate Buell Service Manual Repair fc000393_en NO NO YES YES Check for intermittents See 2 7...

Page 120: ...NE LAMP CODE DTC Front fuel injector circuit low 23 P0261 Front fuel injector circuit high 23 P0262 Rear fuel injector circuit low 32 P0264 Rear fuel injector circuit high 32 P0265 ed01300 Figure 2 55 Fuel Injectors DIAGNOSTICS TOOL NAME PART NUMBER BREAKOUT BOX B 48115 FUEL INJECTOR TEST LAMP HD 34730 2C HARNESS CONNECTOR TEST KIT HD 41404 B Diagnostic Notes Each reference number below correlates...

Page 121: ... GY GN W BK BE GN W Ignition Relay 86 85 30 87A 87 1 5 9 4 em01225 Figure 2 56 Fuel Injector Circuit Table 2 38 Wire Harness Connectors LOCATION TYPE MODEL DESCRIPTION NO In fairing 34 place Amp Tyco Firebolt ECM BK 10 Under seat Ulysses Lightning In fairing 34 place Amp Tyco Firebolt ECM GY 11 Under seat Ulysses Lightning Below left ram air scoop 2 place Mini Deutsch All Crankshaft Position CKP s...

Page 122: ... BK terminal 29 W Y wire and terminal 2 of the front fuel injector connector 84 If DTC P0264 32 P0265 32 measure resistance between ECM connector 10 BK terminal 30 GN GY wire and terminal 2 of the rear fuel injector connector 85 Is resistance less than 0 5 ohm Using Breakout Box check with test lamp between ECM 10 terminal 29 DTC P0261 23 P0262 23 or ECM 10 terminal 30 DTC P0264 32 P0265 32 and EC...

Page 123: ...rt 1 of 2 Check for battery voltage at terminal 87 or 5 of the Ignition Relay Is voltage present Ignition Relay is OK Measure resistance between terminal 87 or 5 of the ignition relay and terminal 1 GY at the fuel injector connector Is resistance less than 0 5 ohm With DVOM still attached perform wiggle test See 2 7 WIGGLE TEST to locate intermittents Repair as necessary Check for multiple codes S...

Page 124: ...AGNOSTICS TOOL NAME PART NUMBER BREAKOUT BOX B 48115 HARNESS CONNECTOR TEST KIT HD 41404 B Diagnostic Tips Engine must be cranked for more than five seconds without CKP signal to set code Diagnostic Notes Each reference number below correlates to a circled number on the flow chart s 1 Connect BREAKOUT BOX Part No B 48115 to ECM See 2 6 BREAKOUT BOX 2 One megohm is very high resistance Some meters ...

Page 125: ...2 10A BK em00073 Figure 2 58 CKP Sensor Circuit Table 2 40 Wire Harness Connectors LOCATION TYPE MODEL DESCRIPTION NO In fairing 34 place Amp Tyco Firebolt ECM GY 11 Under seat Ulysses Lightning Below left ram air scoop 2 place Mini Deutsch All Crankshaft Position CKP sensor 79 2008 Buell XB Diagnostics Engine Management 2 75 ...

Page 126: ...rmittents present YES Repair as necessary YES Install known good CKP sensor Clear codes and retest DTC P0339 set NO YES Check for continuity between terminal 1 of connector 79B and terminal 18 on Breakout Box 11 Gray Is continuity present NO YES NO Reinstall original CKP sensor Replace ECM YES NO Repair open on BK BE wire between terminal 2 of connector 79B and terminal 26 of connector 11B Gray Re...

Page 127: ...nsor ed01306 Figure 2 60 Vehicle Speed Sensor Location DIAGNOSTICS TOOL NAME PART NUMBER BREAKOUT BOX B 48115 SPEEDOMETER TESTER HD 41354 INPUT OUTPUT CABLE HD 41354 1 Diagnostic Notes If a short low open or a short high condition the P0608 code is set reflecting a problem in the Vehicle Speed Sensor VSS Electronic Control Module ECM Instrument Module IM or wiring harness Each reference number bel...

Page 128: ...ed01338 Figure 2 61 Speedometer Tester Part No HD 41354 2 78 2008 Buell XB Diagnostics Engine Management ...

Page 129: ...M 15A 41 35 30A R R W R R 36 42 10A R Y Y W W R Y R Y J1 11A GY ECM 11A 11B 10A 10B J2 10A BK Ignition Switch 1 2 3 4 1 3 4 R R R BK R R R BK R GY 33B 33A LOCK IGN em00173 Figure 2 62 Vehicle Speed Sensor Circuit Ulysses Lightning Table 2 42 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under seat 34 place Amp Tyco ECM BK 10 Under seat 34 place Amp Tyco ECM GY 11 Behind windscreen 4 place A...

Page 130: ...21 8 16 17 21 System ground 4 System ground 3 Battery Vehicle speed 33 33 System ground 1 10B 10A R GY Ignition Switch 1 2 3 4 1 2 3 4 R R R BK R R R BK 33B 33A LOCK IGN em00174 Figure 2 63 Vehicle Speed Sensor Circuit Firebolt Table 2 43 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under seat Spade terminals J Fuse 5 In fairing 34 place Amp Tyco ECM BK 10 In fairing 34 place Amp Tyco ECM ...

Page 131: ...to Vehicle Speed Sensor Test DTC P0502 43 P0503 43 P0608 37 Part 2 of 3 STOP NO Go to Vehicle Speed Sensor Test DTC P0502 43 P0503 43 P0608 37 Part 2 of 3 NO STOP YES Go to Vehicle Speed Sensor Test DTC P0502 43 P0503 43 P0608 37 Part 2 of 3 While observing trip 1 or trip 2 odometer readings press reset button for 5 seconds minimum Does reading reset to zero Replace instrument module Check for bat...

Page 132: ...diagnostic trouble codes Connect all circuits and ride motorcycle for approximately 1 0 mile 1 6 km Check for speedometer function Speedometer functioning properly System OK Go to Vehicle Speed Sensor Test DTC P0502 43 P0503 43 P0608 37 Part 3 of 3 fc01630_en Mate connector 65 Ride motorcycle for approximately 1 0 mile 1 6 km Check for speedometer function Speedometer functioning properly YES Syst...

Page 133: ...rn Speedometer Tester power on and allow the tester to self test On the tester perform the following 1 Press the CLEAR button 2 Press 1 then 3 Press ENTER Enter 4000Hz by pressing 4000 and then ENTER Does the speedometer on the instrument module read 70MPH Replace Vehicle Speed Sensor NO NOTE After replacing ECM the TPS zero set procedure must be performed Refer to THROTTLE POSITION SENSOR in the ...

Page 134: ...around throttle plate This correlates with an increase in the amount of air flowing through the throttle body Five steps represents a fully extend pintle A five reading indicates an abnormal condition in which the pintle has been fully extended and has consequently closed the passage around the throttle plate Each time the ignition switch is turned ON the ECM resets the IAC motor by sending enough...

Page 135: ...ed number on the flow chart s 1 When the ignition is keyed ON the IAC motor pintle extends and then retracts to a fixed position for increased airflow and idle speed during the engine start sequence This ON reset procedure takes 2 seconds to perform 2 Test lamp behavior may follow two patterns The color of the lights is not relevant to IAC motor operation a Normal behavior At ignition switch ON te...

Page 136: ...akout Box to connector 11B leaving the Electronic Control Module ECM disconnected Check terminal 17 for battery voltage Battery voltage present YES NO YES NO YES NO Turn Ignition Switch ON With ECM still disconnected check voltage on all four terminals at connector 87B Is voltage present Repair poor connection at connectors 87B or 11B or repair open wire in harness Repair short to voltage Go to Id...

Page 137: ...egohm for all terminals Inspect ECM connections Connections OK Repair short to ground Replace ECM Repair ECM connections 5 4 NOTES Clear DTCs and confirm proper operation with no check engine lamp Codes can be cleared using DIGITAL TECHNICIAN Part No HD 44750 After replacing Electronic Control Module ECM or TPS TPS zero set procedure must be performed Refer to THROTTLE POSITION SENSOR in the appro...

Page 138: ... voltage high 16 P0563 DIAGNOSTICS TOOL NAME PART NUMBER BREAKOUT BOX B 48115 Diagnostic Notes Each reference number below correlates to a circled number on the flow chart s 1 The ECM is monitoring voltage at ECM connector 10 black terminal 9 Connect BREAKOUT BOX Part No B 48115 to ECM See 2 6 BREAKOUT BOX 2 This checks for voltage drops in the ECM power circuit If a significant voltage drop is no...

Page 139: ...System ground 4 System ground 3 System ground 2 System ground 1 J1 11A GY ECM 11B 11A 10B 10A J2 10A BK R GY Ignition Switch 1 2 3 4 1 2 3 4 R R R BK R R R BK 33B 33A LOCK IGN em01192 Figure 2 71 Battery Voltage Circuit Ulysses Lightning Table 2 47 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under seat 34 place Amp Tyco ECM BK 10 Under seat 34 place Amp Tyco ECM GY 11 Behind windscreen 4 ...

Page 140: ...nd 4 System ground 3 System ground 2 System ground 1 J1 11A GY ECM 11B 11A 10B 10A J2 10A BK R GY Ignition Switch 1 2 3 4 1 2 3 4 R R R BK R R R BK 33B 33A LOCK IGN em00141 Figure 2 72 Battery Voltage Circuit Firebolt Table 2 48 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under seat Spade terminals J Fuse 5 In fairing 34 place Amp Tyco ECM BK 10 In fairing 34 place Amp Tyco ECM GY 11 To t...

Page 141: ... 2 volts Measure voltage drop between battery positive terminal and Breakout Box connector 10 Black terminal 9 with key ON Is voltage drop greater than 0 5 volt Measure voltage drop between battery positive terminal and ignition relay terminal 87 or 5 with Ignition Switch ON Is voltage drop greater than 0 5 volt Measure voltage drop between battery positive terminal and ignition relay terminal 30 ...

Page 142: ... drop between battery positive terminal and R wire terminal on ignition fuse with Ignition Switch ON Is voltage drop greater than 0 5 volt Measure voltage drop between battery positive terminal and R wire terminal of battery fuse with Ignition Switch ON Is voltage drop greater than 0 5 volt Measure voltage drop between battery positive terminal and R Y wire terminal of battery fuse with ignition s...

Page 143: ...er to ELECTRONIC CONTROL MODULE in the appropriate Buell Service Manual Code 52 RAM failure Code 53 ROM failure Code 54 EE PROM failure Code 55 Microprocessor failure ed01508 Figure 2 73 Electronic Control Module Ulysses ed01348 Figure 2 74 Electronic Control Module Lightning ed01347 Figure 2 75 Electronic Control Module Firebolt 2008 Buell XB Diagnostics Engine Management 2 93 ...

Page 144: ...ay is not repairable Replace the unit if it fails Table 2 49 Code Description DESCRIPTION CHECK ENGINE LAMP CODE DTC Start relay circuit high 46 P0617 2 1 3 4 ed01350 1 Start 2 Auxiliary 3 Key switch 4 Ignition Figure 2 76 Start Relay Ulysses 4 3 1 2 ed01337 1 Start 2 Auxiliary 3 Key switch 4 Ignition Figure 2 77 Start Relay Lightning 1 2 4 3 ed01336 1 Start 2 Auxiliary 3 Key switch 4 Ignition Fig...

Page 145: ... TN Y TN Y R R R R BK R BK GY O R BK BE R Y R TN LGN TN LGN BK BK GY BE GN BK W BK GY O GN O GN O TN Y R BK R BK BK R R J1 11A GY ECM 11B 11A 10B 62B 10A J2 10A BK GND 2 R GY Ignition Switch 1 3 4 1 2 3 4 R R R BK 33B 33A LOCK IGN em00076 Figure 2 79 Electric Starting System Circuit Ulysses Lightning Table 2 50 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under seat 34 place Amp Tyco ECM B...

Page 146: ... 8 2 7 8 2 Start relay 8 8 Switched ignition Neutral switch Clutch switch J1 11A GY ECM J2 10A BK Clutch Switch 95B 1 2 TN LGN BK R GY Ignition Switch 1 3 4 1 2 3 4 R R R BK R R R BK 33B 33A LOCK IGN em00152 Figure 2 80 Electric Starting System Circuit Firebolt Table 2 51 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under seat Spade terminals J Fuse 5 In fairing 34 place Amp Tyco ECM BK 10...

Page 147: ...ES NO NO Replace headlamp Remove Key Switch Relay and measure voltage at connector 62B terminal 11 Is battery voltage present Go to Start System Relay Test DTC P0616 46 P0617 46 Part 2 of 2 STOP Check continuity between connector 62B terminal 19 and GND Is continuity present Replace Key Switch Relay Replace Key Switch Locate and repair open wire BK Check continuity between connector 33B terminal 3...

Page 148: ...ound Is continuity present Check neutral connector 131 for proper mating to neutral switch Is connector 131 mated properly YES YES NO Mate connectors and retest Locate and repair open wire TN Y and retest NO fc01636_en Check for continuity between ECM connector 10B Black terminal 7 GN O and start relay connector 62B terminal 2 GN O Is continuity present YES NO Locate and repair open wire GN O and ...

Page 149: ... 1 4 3 2 ed01476 1 Fuel screen 2 Wiring harness 3 Pressure regulator 4 Low fuel level sensor Figure 2 81 Fuel Pump Assembly DIAGNOSTICS TOOL NAME PART NUMBER BREAKOUT BOX B 48115 HARNESS CONNECTOR TEST KIT HD 41404 B Diagnostic Notes Each reference number below correlates to a circled number on the flow chart s 1 Connect BREAKOUT BOX Part No B 48115 to ECM See 2 6 BREAKOUT BOX 2 Use HARNESS CONNEC...

Page 150: ...GY GY BK BK BK GY O Fuel Pump Instrument Module Ignition Fuse BN Y BN Y BN Y O GY O GY J1 11A GY ECM 11B 11A 10B 10A J2 10A BK R GY Ignition Switch 1 2 3 4 1 2 3 4 R R R BK R R R BK 33B 33A LOCK IGN em01193 Figure 2 82 Fuel Pump Circuit Ulysses Lightning Table 2 53 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under seat 34 place Amp Tyco ECM BK 10 Behind windscreen 4 place Multilock Right ...

Page 151: ...p Instrument Module Ignition Fuse BN Y BN Y BN Y O GY O GY From battery R Y 5A 5B 1 2 J Fuse 1 2 R Switched ignition 9 Fuel pump output Fuel pump output 27 28 System ground 4 8 System ground 3 16 System ground 2 24 System ground 1 33 9 27 28 8 16 24 33 J1 11A GY ECM 11B 11A 10B 10A J2 10A BK Ignition Switch 1 2 3 4 1 3 4 R R R BK R R R BK R GY 33B 33A LOCK IGN em00144 Figure 2 83 Fuel Pump Circuit...

Page 152: ... 5 In fairing 34 place Amp Tyco ECM BK 10 Beneath fairing 4 place Multilock Right hand controls 22 Beneath fairing 4 place Augat Ignition switch 33 In fairing 20 place Multilock Instrument module 39 Left side of frame 4 place Multilock Fuel pump 86 2 102 2008 Buell XB Diagnostics Engine Management ...

Page 153: ...d replace ECM Disconnect ECM Does Fuel Pump run continuously Locate and repair short to ground on BN Y wire Replace ECM Check continuity of BN Y wire between connector 10 Black terminals 27 and 28 and connector 86A terminal 4 Is continuity present Repair open Fuel Pump on continuously System OK NOTES Clear DTCs and confirm proper operation with no check engine lamp Codes can be cleared using DIGIT...

Page 154: ... ECM 10 BK connector Table 2 56 Code Description DESCRIPTION CHECK ENGINE LAMP CODE DTC Fan control circuit low 36 P0691 Fan control circuit high 36 P0692 ed01477 Figure 2 84 Cooling Fan DIAGNOSTICS TOOL NAME PART NUMBER BREAKOUT BOX B 48115 Diagnostic Notes Each reference number below correlates to a circled number on the flow chart s 1 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 B purple pin...

Page 155: ...m ground 3 16 System ground 2 24 System ground 1 33 2 3 8 16 24 33 J1 11A GY ECM 11B 11A 10B 10A J2 10A BK BK O BK O em01244 Figure 2 85 Cooling Fan Circuit Ulysses Lightning Table 2 57 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under seat 34 place Amp Tyco ECM BK 10 Behind rear cylinder 2 place Multilock Cooling fan 97 2008 Buell XB Diagnostics Engine Management 2 105 ...

Page 156: ... System ground 2 24 System ground 1 33 2 3 8 16 24 33 J1 11A GY ECM 11B 11A 10B 10A J2 10A BK BK O BK O em00153 Figure 2 86 Cooling Fan Circuit Firebolt Table 2 58 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under seat Spade terminals J Fuse 5 In fairing 34 place Amp Tyco ECM BK 10 Behind rear cylinder 2 place Multilock Cooling fan 97 2 106 2008 Buell XB Diagnostics Engine Management ...

Page 157: ...r 11 Gray terminal 11 Is voltage greater than 1 3 volts Repair short to ground in BK O wire between ECM and Cooling Fan Allow engine to cool Go to BOLD ASTERISK on this page Turn Ignition Switch ON Does the Cooling Fan run continuously See Engine Temperature Sensor Test Defective ECM or ECM connection System OK fc00407_en Go to Cooling Fan Test DTC P0691 36 P0692 36 Part 2 of 2 At some point in th...

Page 158: ...oling Fan from rotating Remove obstruction Repair open in circuit between cooling fan connector 97B Y BN wire and fuse block Disconnect cooling fan harness at fan Use ohmmeter to measure resistance between Y BN terminal and BK terminal of connector 97A Is resistance greater than 1 ohm Replace ECM Check for continuity between Y BN wire and BK wire of cooling fan connector 97A Is continuity present ...

Page 159: ...ottle position sensor TPS zero set procedure See Throttle Position Sensor TPS in the appropriate Buell Service Manual 2 Leave Digital Technician attached to vehicle 3 In Digital Technician go to Active Intake test screen 4 Rotate throttle grip to wide open throttle WOT 5 Check that when the throttle plate reaches WOT TPS reads above 82 degrees If not proceed to the cable adjustment procedure in th...

Page 160: ...ut the cable will not work properly and will not be able to be adjusted When installing baseplate be sure to feed the electrical connector 1 through hole in baseplate first and then insert active cable and then grommet Follow next step only if solenoid was removed 2 Install solenoid 8 into bracket 9 and tighten pinch fastener to 48 60 in lbs 5 4 6 7 Nm and bracket to solenoid fasteners to 20 24 in...

Page 161: ...ystem ground 3 System ground 2 System ground 1 J1 11A GY ECM 11B 11A 10B 10A J2 10A BK R GY Ignition Switch 1 3 4 1 2 3 4 R R R BK 33B 33A LOCK IGN em00031 Figure 2 88 Active Intake System Ulysses Lightning Table 2 60 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under seat 34 place Amp Tyco ECM BK 10 Behind windscreen 4 place Multilock Right hand controls 22 Behind windscreen 4 place Augat...

Page 162: ...System ground 2 System ground 1 J1 11A GY ECM 11B 11A 10B 10A J2 10A BK R GY Ignition Switch 1 2 3 4 1 2 3 4 R R R BK R R R BK 33B 33A LOCK IGN em00154 Figure 2 89 Active Intake System Firebolt Table 2 61 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under seat Spade terminals J Fuse 5 In fairing 34 place Amp Tyco ECM BK 10 In fairing 4 place Multilock Right hand controls 22 In fairing 4 pl...

Page 163: ...c then wiggle harness while performing measurements in chart to indicate intermittents fc01607_en Repair as needed NO YES NO Disconnect connector 179B Measure resistance at terminal 2 to chassis ground Is resistance less than 10 000 ohms Measure voltage at 178A terminal 1 Is battery voltage present YES NO Locate and repair short to voltage on GY O wire Measure resistance between connector 178A ter...

Page 164: ...degrees YES NO Replace Electronic Control Module ECM See CABLE ADJUSTMENT in the appropriate BUELL SERVICE MANUAL Replace Active Intake Solenoid Connect battery voltage to 178B terminal 2 of Active Intake Solenoid use HD 41404 Brown Pin and patch cable Hold throttle wide open Observe throttle plate and connect active intake solenoid terminal 1 to ground Does the Active Air Intake Solenoid attempt ...

Page 165: ...the BAS is below 0 24V or above 4 79V the ECM sets a code Refer to Table 2 62 DTC P1151 is set when the BAS output is shorted low to ground and P1152 is set when the BAS output is shorted high to voltage An open circuit output will act like a shorted high and set DTC P1152 If a code occurs the engine will continue to run A tipped vehicle will not set a DTC Table 2 62 Code Description DESCRIPTION C...

Page 166: ... BREAKOUT BOX Bank angle sensor Sensor ground 3 5V sensor power 17 19 25 17 19 25 LGN GY BK W R W 5 4 6 5 4 6 134B Bank Angle Sensor 134A R W LGN GY BK W J1 11A GY ECM 11B 11A 10B 10A J2 10A BK em01245 Figure 2 92 Bank Angle Sensor Circuit Table 2 64 Wire Harness Connectors LOCATION TYPE MODEL DESCRIPTION NO In fairing 34 place Amp Tyco Firebolt ECM GY 11 Under seat Ulysses Lightning In fairing 6 ...

Page 167: ...GY wire Is Bank Angle Sensor properly installed Repair open in R W wire between connector 134B terminal 4 and connector 11B terminal 25 Are ferrous metals located within 0 25 in 6 4 mm of sides face or top of Bank Angle Sensor Install properly See BANK ANGLE SENSOR in the appropriate Buell Service Manual Replace Bank Angle Sensor See BANK ANGLE SENSOR in the appropriate Buell Service Manual Return...

Page 168: ...r 11B Gray terminal 19 GY Is continuity present Check LGN GY circuit continuity to ground for connector 134B terminal 5 and connector 11B Gray terminal 17 Is continuity present Repair short to ground on LGN GY wire Replace ECM Repair open on BK W wire Repair open in LGN GY wire NOTES Clear DTCs and confirm proper operation with no check engine lamp Codes can be cleared using DIGITAL TECHNICIAN Par...

Page 169: ... TN LGN BE BN Y W BK V O Y BK BE W 24B 24A Left Handlebar Switch 1 2 3 4 5 6 7 8 To headlight Light power High beam Horn From flasher Left turn Right turn Horn power 1 2 3 4 5 6 7 8 95A 95B Clutch Switch 1 2 To interlock circuit To ground 1 2 O W em01242 Figure 2 94 Left Handlebar Switch Connection No pin 1 connection on Firebolt DIAGNOSTICS TOOL NAME PART NUMBER BREAKOUT BOX B 48115 Diagnostic No...

Page 170: ...h 1 2 3 4 1 3 4 R R R BK R R R BK R GY 33B 33A LOCK IGN em00060 Figure 2 95 Clutch and Neutral Interlock Circuits Ulysses Lightning Table 2 66 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under seat 34 place Amp Tyco ECM GY 11 Behind windscreen 4 place Augat Ignition switch 33 In front modules behind windscreen 20 place Multilock Instrument module 39 Underside of clutch lever assembly 2 pl...

Page 171: ...ch 1 2 3 4 1 3 4 R R R BK R R R BK R GY 33B 33A LOCK IGN em00161 Figure 2 96 Clutch and Neutral Interlock Circuits Firebolt Table 2 67 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under seat Spade terminals J Fuse 5 In fairing 34 place Amp Tyco ECM GY 11 Beneath fairing 4 place Augat Ignition switch 33 In fairing 20 place Multilock Instrument module 39 Underside of clutch lever assembly 2 ...

Page 172: ...reakout Box terminal 2 Gray and ground Is continuity present Replace ECM 1 YES NO Locate and repair short to ground on TN LGN wire in main wiring harness between 11B and 95B Locate and repair short to ground in left handlebar switch wiring NOTES After replacing Electronic Control Module ECM or TPS TPS zero set procedure must be performed Refer to THROTTLE POSITION SENSOR in the appropriate BUELL S...

Page 173: ...n 10 ohms YES NO Disconnect Neutral Switch 131 Measure resistance between Breakout Box terminal 8 Gray and ground Is resistance less than 10 ohms Replace ECM 1 2 3 3 YES NO Locate and repair short to ground on TN Y wire in main wiring harness Replace Neutral Switch NOTES After replacing Electronic Control Module ECM or TPS TPS zero set procedure must be performed Refer to THROTTLE POSITION SENSOR ...

Page 174: ...cable Electrical fault in the actuator circuit Electrical fault in the actuator feedback circuit Electrical fault in the brake light or horn circuits Table 2 68 Code Description DESCRIPTION CHECK ENGINE LAMP CODE DTC Interactive muffler control actuator stuck open 21 P1470 Interactive muffler control actuator stuck closed 21 P1471 Interactive muffler control actuator low open 21 P1477 Interactive ...

Page 175: ...y switch relay 23 3 2 1 3 2 1 4 1 1 2 2 1 2 1 2 1 2 1 8 4 3 2 1 4 3 2 1 Motor Muffler Valve Actuator Position Sensor Brake Horn Muffler Horn Front Brake Switch Tail Light Rear Brake Switch 165B 165A 161A 161B 122B 93B 170B 24A 122A 121B 121A Left Handlebar Switch BK BK W O O O O O TN V W W O TN V TN V Y BK Y BK W O TN V R Y R Y R Y R Y R BK 29 DC 9 1 9 1 Active muffler feedback J1 11A GY ECM 11A 1...

Page 176: ...ce Multilock Left hand controls 24 Under seat 3 place Amp Tail light 93 Underside of front master cylinder assembly 2 place Multilock Front brake switch 121 Behind windscreen Spade lugs Horn switch 122 Beneath intake cover assembly 4 place Deutsch Muffler valve actuator 161 Under seat 3 place Packard Sub harness 165 2 126 2008 Buell XB Diagnostics Engine Management ...

Page 177: ...e Switch Tail Light Rear Brake Switch 165B 165A 161A 161B 122B 45B 170B 24A 122A 121B 121A Left Handlebar Switch BK BK W O O O O O O O TN V Y BK W O TN V W TN V O W TN V R Y R Y R Y R Y R BK 9 DC 11A 11B 10B 10A ECM 9 1 9 1 Active muffler feedback Exhaust valve actuator em00162 Figure 2 101 Interactive Exhaust Circuit Firebolt 2008 Buell XB Diagnostics Engine Management 2 127 ...

Page 178: ...eneath fairing 4 place Multilock Left hand controls 24 Under seat 3 place Amp Tail light 45 Underside of front master cylinder assembly 2 place Multilock Front brake switch 121 In fairing Spade lugs Horn switch 122 Beneath intake cover assembly 4 place Deutsch Muffler valve actuator 161 Under seat 3 place Packard Sub harness 165 2 128 2008 Buell XB Diagnostics Engine Management ...

Page 179: ...s Check continuity between Breakout Box terminal 9 Gray and 161B terminal 4 Is continuity present Check for continuity to ground on terminal 9 Gray Is continuity present Locate and repair open on TN V wire Check for continuity between connector 10B Gray terminal 1 at Breakout Box and connector 161B terminal 3 Is continuity present Using pliers gently pull on cable to Interactive Muffler Control Ac...

Page 180: ...CHECK ENGINE LAMP CODE DTC Side stand sensor low 45 P1501 Side stand sensor high 45 P1502 Side stand down at vehicle speed 9 MPH 15 km h or greater 45 P1503 ed01309 Figure 2 102 Side Stand Sensor ed01310 Figure 2 103 Side Stand Sensor Connector DIAGNOSTICS TOOL NAME PART NUMBER DVOM HD 39978 HARNESS CONNECTOR TEST KIT HD 41404 B Diagnostic Notes Each reference number below correlates to a circled ...

Page 181: ...33B Side Stand Sensor 11B 11A em00075 Figure 2 104 Side Stand Sensor Circuit HDI only Table 2 72 Wire Harness Connectors LOCATION TYPE MODEL DESCRIPTION NO In fairing 34 place Amp Tyco Firebolt ECM GY 11 Under seat Ulysses Lightning Behind left ram air scoop 3 place Amp All Side stand sensor 133 2008 Buell XB Diagnostics Engine Management 2 131 ...

Page 182: ... P1501 clear or go to history and P1502 set as a current DTC NOTES Clear DTCs and confirm proper operation with no check engine lamp Codes can be cleared using DIGITAL TECHNICIAN Part No HD 44750 After replacing Electronic Control Module ECM or TPS TPS zero set procedure must be performed Refer to THROTTLE POSITION SENSOR in the appropriate BUELL SERVICE MANUAL Connect Breakout Box Part No B 48115...

Page 183: ...nect ECM connector 11 Test for voltage on terminal 1 of connector 133B Is voltage present NO YES Repair short to voltage Turn off Ignition Switch Connect Breakout Box Part No B 48115 to wiring harness connector 11B Gray leaving ECM connector 11A Gray disconnected Test for continuity from connector 11B Gray terminal 34 to connector 133B terminal 2 Is continuity present NO YES YES NO Repair open Con...

Page 184: ...ppropriate Buell Service Manual and retest Check spring for proper tension Does spring have correct tension YES NO Operation normal Install Side Stand in accordance with the appropriate Buell Service Manual Replace spring Inspect the Side Stand tab for correct clearance to Side Stand sensor 0 18 inches 4 5mm maximum Is the sensor mounted correctly NO YES Turn on ignition switch and check voltage o...

Page 185: ... Figure 2 106 Rear 12 Volt Auxiliary Power Outlet Ulysses Only DIAGNOSTICS Diagnostic Tips The 12 volt auxiliary power outlets will function with the ignition switch key in the ON or PARK positions The 12 volt auxiliary power outlet circuit contains a 10 amp fuse to protect overloading of the circuit Verify that the combined accessory load of the both power outlets does not exceed the amperage rat...

Page 186: ...BK GN BK GN J1 11A GY ECM 11B 11A 10B 10A J2 10A BK R GY Ignition Switch 1 2 3 4 1 2 3 4 R R R BK R R R BK 33B 33A LOCK IGN em00085 Figure 2 107 12 Volt Auxiliary Power Outlet Circuit Ulysses Lightning Table 2 74 Wire Harness Connectors LOCATION TYPE MODEL DESCRIPTION NO Under seat 34 place Amp Tyco All ECM BK 10 Behind windscreen 4 place Multilock All Right handlebar switch 22 Behind windscreen 4...

Page 187: ...uxiliary relay ground 19 J1 11A GY ECM 11B 11A 10B 10A J2 10A BK R GY Ignition Switch 1 2 3 4 1 2 3 4 R R R BK R R R BK 33B 33A LOCK IGN em00163 Figure 2 108 12 Volt Auxiliary Power Outlet Circuit Firebolt Table 2 75 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Under seat Spade terminals J Fuse 5 In fairing 34 place Amp Tyco ECM BK 10 Beneath fairing 4 place Multilock Right handlebar switc...

Page 188: ... ignition switch ON Check voltage at relay assembly connector 62B terminal 1 W BK and ground Is battery voltage present Locate and repair open wire between ignition switch connector 33B terminal 3 R BK and relay assembly terminal 1 W BK Check voltage at relay assembly connector 62B terminal 20 GY and ground Is battery voltage present YES NO If wire is OK replace Ignition Relay If wiring is OK repl...

Page 189: ...NAME PART NUMBER BREAKOUT BOX B 48115 Diagnostic Notes Each reference number below correlates to a circled number on the flow chart s 1 Connect BREAKOUT BOX Part No B 48115 to ECM See 2 6 BREAKOUT BOX 2 Replace instrument module See Instrument Module in the appropriate Buell Service Manual ed01482 Figure 2 109 Instrument Module Connector 39 Typical ed01483 Figure 2 110 Instrument Module Connector ...

Page 190: ...nnectors LOCATION TYPE DESCRIPTION NO Under seat 34 place Amp Tyco ECM BK 10 Behind windscreen 4 place Augat Ignition switch 33 Behind windscreen 20 place Multilock Instrument module 39 From battery R Y 5A 5B 2 1 J Fuse 2 1 R R TACH Ground Ignition Battery Instrument Module 13 12 14 2 13 12 14 2 39A 39B Key Switch Fuse 38 44 BK PK PK R R R BK 22 22 J1 11A GY ECM 11A 11B 10B 10A Tachometer output J...

Page 191: ... TYPE DESCRIPTION NO Under seat Spade terminals J Fuse 5 In fairing 34 place Amp Tyco ECM BK 10 Beneath fairing 4 place Augat Ignition switch 33 In fairing 20 place Multilock Instrument module 39 2008 Buell XB Diagnostics Engine Management 2 141 ...

Page 192: ...e to ground Reconnect connector 10 BK Connect DVOM to Breakout Box connector 10 Black terminals 22 and 24 Start engine and let idle Does voltage measure approximately 4 0 6 0 volts Replace ECM Reconnect connector 39 Locate intermittents using wiggle test See 2 7 WIGGLE TEST Intermittents found Repair Replace Instrument Module See INSTRUMENT MODULE in the appropriate Buell Service Manual NOTES Clea...

Page 193: ...8115 FUEL INJECTOR TEST LAMP HD 34730 2C HARNESS CONNECTOR TEST KIT HD 41404 B IGNITION COIL CIRCUIT TEST ADAPTER HD 44687 Diagnostic Notes Each reference number below correlates to a circled number on the flow chart s 1 Use HARNESS CONNECTOR TEST KIT Part No HD 41404 B purple pin probes and patch cord 2 Connect BREAKOUT BOX Part No B 48115 to ECM See 2 6 BREAKOUT BOX 3 Plug IGNITION COIL CIRCUIT ...

Page 194: ...round 1 33 9 34 25 31 32 8 16 24 33 J1 11A GY ECM 11B 11A 10B 10A J2 10A BK GY Y BE Y BE Y BE BE O BE O GY BE O em01226 Figure 2 115 Ignition Coil Circuit Table 2 80 Wire Harness Connectors LOCATION TYPE MODEL DESCRIPTION NO In fairing 34 place Amp Tyco Firebolt ECM BK 10 Under seat Ulysses Lightning In fairing 34 place Amp Tyco Firebolt ECM GY 11 Under seat Ulysses Lightning Below left ram air sc...

Page 195: ...te Buell Service Manual Perform wiggle test See 2 7 WIGGLE TEST Intermittents found Repair open wire or connection Replace ECM Repair as necessary Rear Ignition Coil Insert test lamp between Electronic Control Module ECM terminal 9 Black and ECM terminal 31 of Breakout Box Insert test adapter between ECM terminal 9 Black wire and ECM terminal 32 Black of Breakout Box Does test lamp flash when engi...

Page 196: ...iliary circuit contains a 10 Amp fuse to protect overloading the circuit Any auxiliary loads in addition to the heated handlebar grips should be reduced when the heated handlebar grips are used so as to not exceed the ampere rating of the fuse Diagnostic Notes Each reference number below correlates to a circled number on the flow chart s 1 Remove windscreen to access the connectors for the Heated ...

Page 197: ...89R 2 Right hand controls 22 3 Heated handlebar grip subharness 206 4 Auxiliary power 160 5 Left heated handlebar grip 189L 6 Left hand controls 24 Figure 2 117 Heated Handlebar Grips Connector Locations 2008 Buell XB Diagnostics Engine Management 2 147 ...

Page 198: ...m00229 Figure 2 118 Heated Handlebar Grips Circuit Table 2 82 Wire Harness Connectors LOCATION TYPE DESCRIPTION NO Inside windscreen 4 place Multilock Right handlebar grip controls 22A Inside windscreen 8 place Multilock Left handlebar grip controls 24B Inside windscreen 2 place Sumitomo Auxiliary power 160A Inside windscreen 3 place Deutsch Left heated handlebar grip 189L Inside windscreen 3 plac...

Page 199: ...y fuse is good and all auxiliary devices removed fc01655_en YES NO Locate and repair open wire between connector 206B terminal 1 O R and Heated Handlebar Grip switch Replace Heated Handlebar Grip switch Place ignition switch and Heated Handlebar Grip switch OFF Disconnect 206B from vehicle wiring harness connector 160A Place ignition switch to ON Measure the voltage from vehicle harness connector ...

Page 200: ...ck for continuity from connector 206B terminal 1 O R and ground Is continuity present NO YES NO Place ignition switch OFF Disconnect 189L or 189R as appropriate Measure the resistance between 189LA or 189RA terminal 1 BK and 2 BN 13 Ohms then between 1 BK and 3 BE 21 Ohms Are resistance values correct NO YES Replace appropriate Heated Handlebar Grip Does heat remain LOW in both grips YES System Op...

Page 201: ...CTRICAL CONNECTORS A 7 A 4 DEUTSCH STANDARD TERMINALS A 11 A 5 METRI PACK TERMINALS A 12 A 6 150 METRI PACK CONNECTORS A 14 A 7 280 METRI PACK CONNECTORS A 16 A 8 480 METRI PACK CONNECTORS A 18 A 9 630 METRI PACK CONNECTORS A 19 A 10 SEALED SPLICE CONNECTORS A 20 APPENDIX A CONNECTOR REPAIR ...

Page 202: ...NOTES ...

Page 203: ... Hold the housings to match wire color to wire color 2 Insert the socket housing into the pin housing until it snaps in place 3 If OE location is a T stud fit large opening end of attach ment clip over T stud and slide connector to engage T stud to small end of opening 2 3 1 4 sm00002 1 Attachment clip 2 Release button 3 Socket housing 4 Pin housing Figure A 1 AMP Multilock Connector Removing Term...

Page 204: ... the connector On the pin side of the connector tangs are positioned at the bottom of each cavity so the slot in the pin terminal on the side opposite the crimp tails must face downward On the socket side tangs are at the top of each cavity so the socket terminal slot on the same side as the crimp tails must face upward 2 Gently tug on wire end to verify that the terminal is locked in place 3 Rota...

Page 205: ... 1 2 Raise locking bar by pushing up on bottom flange 2 NOTE See Figure A 2 and Figure A 5 Hold the terminal with the insulation crimp tail 1 facing up The tool will hold the terminal by the locking bar groove 3 and crimp the wire crimp tail 2 around the bare wire of the stripped lead and the insulation crimp tail around the insulation 3 See Figure A 6 With the insulation crimp tail facing upward ...

Page 206: ...ped terminal Figure A 6 AMP Multilock Connector Terminal Crimping Procedure Inspecting Crimped Terminals See Figure A 7 Inspect the wire core crimp 2 and insulation crimp 1 Distortion should be minimal 1 2 sm00008 1 Insulation crimp 2 Wire core crimp Figure A 7 AMP Multilock Connector Terminal Crimp A 4 2008 Buell XB Diagnostics Appendix A Connector Repair ...

Page 207: ...lored terminal lock 2 loose and then remove from mating end of socket housing 3 Using a thin flat blade like the unsharpened edge of a hobby knife gently pry tang 3 outward away from ter minal and then tug on wire to back terminal out wire end of chamber Do not pull on wire until tang is released or terminal will be difficult to remove Installing Socket Terminals NOTE For wire location purposes al...

Page 208: ...2 3 1 sm00015 1 Remove wire lock 2 Remove terminal lock 3 Pry tang outward Figure A 9 Delphi Connector Removing SocketTerminals A 6 2008 Buell XB Diagnostics Appendix A Connector Repair ...

Page 209: ...h cover on the pin side b For Two External Latches 8 place and 12 place Align the tabs on the socket housing with the grooves on the pin housing 2 Insert socket housing into pin housing until it snaps or clicks into place For Two External Latches 8 place and 12 place If latches do not click latch press on one side of the con nector until that latch engages then press on the opposite side to engage...

Page 210: ... of the 3 place connector must be installed with the arrow 1 pointing toward the external latch If the secondary locking wedge does not slide into the installed position easily verify that 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 sm00009 Figure A 11 Deutsch Connector Remove Seco...

Page 211: ...ay be mated with the gray since the alignment tabs are absent and the orientation of the external latch is the same sm00019 Figure A 14 Deutsch Connector Depress Terminal Latch and Back Out Pin Installing Pin Terminals 1 See Figure A 15 Fit wire seal 1 into back of pin housing 2 2 Grasp wire lead approximately 1 0 in 25 4 mm behind the pin terminal 3 Gently push pin through holes in wire seal into...

Page 212: ...minals Identify which of the types of Deutsch terminals are used with the connector and follow the corresponding crimping instruc tions Refer to Table A 2 Table A 2 Deutsch Connector Terminal Crimping Instructions CRIMPING INSTRUCTIONS TYPE A 4 DEUTSCH STANDARD TERMINALS Standard with crimp tails A 10 2008 Buell XB Diagnostics Appendix A Connector Repair ...

Page 213: ...e tails face straight upward When positioned the locking bar fits snugly in the space between the contact band and the core crimp tails 4 Insert stripped wire core 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 the insulation 5 Squeeze handle of crimp tool until tight...

Page 214: ...expose 5 32 in 4 0 mm of wire core Crimping Wire Core NOTE Metri Pack terminal crimps require two steps Always perform Crimping Wire Core before Crimping Insulation Seal 1 Squeeze and release handles until ratchet automatically opens 2 Identify the corresponding sized nest for the core crimp 3 Position the core crimp in the die Be Sure the core crimp tails are facing the forming jaws 4 Gently sque...

Page 215: ... A 18 Inspect the wire core crimp 1 The tails should be folded in on the wire core without any distortion or excess wire strands 2 Inspect the insulation 2 or seal 3 crimp The tails of the terminal should be wrapped around the insulation without distortion 3 2 1 sm00036 1 Wire core crimp 2 Insulation crimp 3 Seal crimp Figure A 18 Metri Pack Connector Inspect Core and Insulation Seal Crimps 2008 B...

Page 216: ...lick is the sound of the tang returning to the locked posi tion as it slips from the point of the pin 5 Pick at the tang until the clicking stops and the pin seems to slide in deeper than it had previously This is an indica tion that the tang has been depressed NOTE On those terminals that have been extracted on multiple occasions the click may not be heard but pivot the pin as if the click was he...

Page 217: ... 4 Raise tang to install Figure A 19 150 Metri Pack Connector Pull to Seat 3 4 2 1 sm00028 1 Remove wire lock 2 Pivot pin to depress tang 3 Pull to remove 4 Raise tang to install Figure A 20 150 Metri Pack Connector Push to Seat 2008 Buell XB Diagnostics Appendix A Connector Repair A 15 ...

Page 218: ...ang is depressed Remove safety pin NOTE Repeat as necessary until the terminal can be pushed out of the connector 4 Push on wire end of the lead to extract the terminal from the mating end of the connector 5 If necessary crimp new terminals on wires See A 5 METRI PACK TERMINALS Metri Pack Terminal Crimps Installing Socket Terminals NOTE Terminal cavities are lettered on the socket housing To match...

Page 219: ...afety pin to depress tang 3 Push on lead to remove terminal 4 Raise tang with X Acto knife 5 Pull on lead to draw terminal into chamber Figure A 22 280 Metri Pack Connector Remove Install Socket Terminal 2008 Buell XB Diagnostics Appendix A Connector Repair A 17 ...

Page 220: ...he terminal Gently insert the point of a stick pin or large safety pin into the opening 3 between the tang and the chamber wall until it stops 3 Pivot the end of the pin toward the terminal body to depress the tang 4 Remove the pin and then pull terminal out of the wire end of connector housing 5 If necessary crimp new terminals on wires See A 5 METRI PACK TERMINALS Installing Socket Terminals 1 C...

Page 221: ...l in place 3 Moving to the mating end of the connector take note of the small opening on the chamber wall side of each ter minal 4 Insert SNAP ON PICK Part No TT600 3 into opening until it stops Pivot the end of the pick toward the terminal to depress the locking tang 5 Remove the pick and gently tug on the wire to pull the terminal from the wire end of the connector Repeat steps if the terminal i...

Page 222: ...e handles until the connector is held in the jaws 4 See Figure A 25 Feed the stripped end of a wire into the connector until the wire stops inside the metal insert 1 5 Squeeze the handles tightly closed to crimp the lead in the insert 2 The tool automatically opens when the crimping is complete 6 Slide the connector to the other half of the metal insert Insert the stripped wire lead 1 until it sto...

Page 223: ...1 1 4 2 2 4 3 sm00051 1 Wire lead in metal insert 2 Crimp metal insert 3 Center of crimp 4 Melted sealant Figure A 25 Sealed Splice Connector 2008 Buell XB Diagnostics Appendix A Connector Repair A 21 ...

Page 224: ...A 22 2008 Buell XB Diagnostics Appendix A Connector Repair NOTES ...

Page 225: ...SUBJECT PAGE NO B 1 CONNECTORS B 1 B 2 WIRING DIAGRAMS B 3 APPENDIX B WIRING DIAGRAMS ...

Page 226: ...NOTES ...

Page 227: ...rn signal 31R Beneath fairing Firebolt Behind windscreen Ulysses Lightning 2 1 place bullet Left front turn signal 31L Beneath fairing Firebolt Behind windscreen Ulysses Lightning 4 place Augat Ignition switch 33 Beneath fairing Firebolt Behind windscreen Ulysses Lightning 4 place Amp Headlight connector 38 Beneath fairing Firebolt Behind windscreen Ulysses Lightning 20 place Multilock Instrument ...

Page 228: ...indscreen Ulysses Lightning Spade terminals Horn 122 In fairing Firebolt Top of starter Spade terminal Starter solenoid 128 Under sprocket cover 1 place bullet Neutral switch 131 Behind left ram air scoop 3 place Deutsch Side stand sensor 133 Under seat Ulysses Lightning 6 place Sumitomo Bank angle sensor 134 In fairing Firebolt Above rear cylinder head 1 place Packard Oxygen sensor 137 Behind win...

Page 229: ...ntifies a pin housing B Socket The letter B after a connector number and the socket symbol 5 identifies a socket housing Other symbols found on the wiring diagrams include the symbol for a diode 7 a symbol for a wire to wire connection 8 a symbol that verifies that no connection 9 between two wire traces exists and a symbol identifying two wires that are twisted together 10 9 10 1 2 1 2 8 7 6 5 3 ...

Page 230: ... Lighting Circuit Ulysses and Lightning Figure B 6 Lighting Circuit Firebolt Figure B 7 Component Circuits All Models Figure B 8 Horn and Instruments Circuit All Models Figure B 9 Starting Circuit Ulysses and Lightning Figure B 10 Starting Circuit Firebolt Figure B 11 Charging Circuits All Models Figure B 12 Heated Handlebar Grips Ulysses only B 4 2008 Buell XB Diagnostics Appendix B Wiring Diagra...

Page 231: ...O W 1 2 TN V 3 GN Y 1 PK Y V GY 1 V BN 1 2 BK 4 BK 1 1 BK 1 1 1 2 1 2 1 1 2 3 1 2 3 1 2 1 2 1 1 BK 165A 120A 77B 65A 65B 131B 131A 128A 128B 97A 97B 86A 86B 178 18B 93B 45B 19B 134B 62B 85B 84B 88B 88A 89B 83B 83A 90B 90A 137B 137A 30B 87B 95B 24A 31B 39A 39B 31B 22A 121A 121B 15A 15A 10A 15A 10A 10A 15A 10A 10A 30A BK TN LGN 11 9 13 14 22 21 17 16 10 9 8 3 2 1 23 24 15 16 17 34 33 32 31 30 29 28 ...

Page 232: ...Figure B 2 Figure B 2 Main Harness Ulysses and Lightning Main Harness Ulysses and Lightning ...

Page 233: ...V Y R W R W LGN GY 4 5 BK W 6 BK W LGN Y 1 2 Y BE GY BE O O W 1 2 TN V 3 1 2 4 1 2 3 1 2 3 165A 134B 88B 88A 89B 83B 83A 30B GY V R BK W LGN R 91A 121B 121A 160A TN W BK W R W 133B GY GY O GN GY BK O 1 2 3 4 V BN O W BK Key Switch Accessary Igniton Brake Horn EVA Cooling Fan ECM Lights 6 5 4 3 23 16 18 12 11 10 9 17 22 24 Auxiliary 21 15 Fuel Pump R BK Y BN O W O R GY O R GY Y BE R R R BK R R R R ...

Page 234: ...Figure B 3 Figure B 3 Main Harness Firebolt Main Harness Firebolt ...

Page 235: ...IAGRAM Japan only CONNECTING WIRE SECT MM WIRE COLOR ON OFF LOCK V Y 4 TN Y 8 TN V 9 PK Y 11 W 13 LGN Y 14 LGN R 15 V R 16 LGN GY 17 GN W 18 BK W 19 R W 24 R W 25 BK BE 26 BK W 27 BK W 28 V GY 32 TN W 34 W 1 BK O 2 BK O 3 BK 8 GY 9 GY O 10 BK 16 Y 17 W 21 BK Y 23 BK 24 BE O 25 BN Y 27 BN Y 28 W Y 29 GN GY 30 Y BE Y BE 31 BE O 32 BK 33 34 2 4 8 9 11 13 14 15 16 17 18 19 24 25 26 27 28 32 34 1 2 3 8...

Page 236: ...Figure B 4 Figure B 4 Engine Management Circuit All Models Engine Management Circuit All Models ...

Page 237: ... 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 Speedometer 39A Ground Ignition Oil pressure Check engine High beam Right turn Left turn Neutral Battery 2 4 5 6 13 12 2 4 5 6 13 12 39B 10 Amp 30 Amp 15 Amp 15 Amp 10 Amp GRD 5 GRD 4 1 2 4 BK BE BK BK BK BN BK BK BN BK GRD 1 BK R Y R Y R Y R Y O W O W R ...

Page 238: ...Figure B 5 Figure B 5 Lighting Circuit Ulysses and Lightning Lighting Circuit Ulysses and Lightning ...

Page 239: ...N SWITCH WIRING DIAGRAM CONNECTING WIRE SECT MM WIRE COLOR ON OFF LOCK Speedometer 39A Ground Ignition Oil pressure Check engine High beam Right turn Left turn Neutral Battery 2 4 5 6 13 12 2 4 5 6 13 12 39B GRD 4 GRD 4 1 2 4 BE BK BK BK BK BK BN BN BK BN BK BK R Y R Y O W R Y R Y O V O R Y O R R R R R R R GY R BK R BK R GY R BK BK BK BN BE BE BN BE BE BE BK BK O W O W BK BN R Y R Y V V O W O W O ...

Page 240: ...Figure B 6 Figure B 6 Lighting Circuit Firebolt Lighting Circuit Firebolt ...

Page 241: ...Lightning Tail Lamp Rear Turning Lights Firebolt To main harness RH Turn Signal Tail Light 93A 19A 45A 18A LH Turn Signal LIC Plate Lamp To main harness 165B 161B 161A Fuel Pump Vehicle Speed Sensor 65A RH Controls LH Controls Horn 22B 31B RH Turn Signals LH Turn Signals 122A 31A 31B 31A 29B 29A 24A 24B 122A 1 2 Brake SW 121A Clutch SW 95A 2 1 Main Harness 1 1 1 1 4 2 1 4 2 1 6 5 4 6 5 4 1 1 2 2 1...

Page 242: ...Figure B 7 Figure B 7 Component Circuits All Models Component Circuits All Models ...

Page 243: ...R BK R GY BATTERY BATTERY 1 R 0 0 0 0 0 PARK KEY POSITION IGNITION SWITCH WIRING DIAGRAM CONNECTING WIRE SECT MM WIRE COLOR ON OFF LOCK Tachometer output System ground 2 7 7 Start relay System ground 1 Vehicle speed sensor Sensor ground Sidestand switch 5V sensor power Speedometer 39A VSS in Low fuel Tach in Ground Ignition Oil pressure Neutral Battery 8 3 2 12 16 15 14 13 8 3 2 12 16 15 14 13 39B...

Page 244: ...Figure B 8 Figure B 8 Horn and Instruments Circuit All Models Horn and Instruments Circuit All Models ...

Page 245: ...GY GY R R 10 5 87 87A 30 85 86 Ignition Key Sw Start 4 7 15 6 9 14 2 19 11 1 2 3 1 2 3 4 1 1 2 Ignition Key Switch 131A 1 Male Female 0 0 0 2 4 3 1 1 R 1 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 15 Amp 37 43 BE R BK Lights 15 Amp 29 23 O R BK Brake Horn EVA 10 Amp 15 Amp R R Y R Y 87 87A 30 85 86 87 87A 30...

Page 246: ...Figure B 9 Figure B 9 Starting Circuit Ulysses and Lightning Starting Circuit Ulysses and Lightning ...

Page 247: ... V W GN O GY GY R R 10 5 87 87A 30 85 86 Ignition Key Sw Start 4 7 6 9 2 1 2 3 1 2 3 4 1 1 2 Ignition Key Switch 131A 1 Male Female 0 0 0 2 4 3 1 1 R 1 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 15 Amp 17 23 BE R BK Lights 15 Amp 9 3 O R BK Brake Horn EVA 10 Amp 15 Amp R R Y R Y 87 87A 30 85 86 87 87A 3...

Page 248: ...Figure B 10 Figure B 10 Starting Circuit Firebolt Starting Circuit Firebolt ...

Page 249: ...77B To Voltage Regulator Starter Motor Battery 2 1 1 2 2 2 1 1 41 35 Fuse Relay Assembly Battery 30 Amp Ulysses Lightning Firebolt OR 61B BK BK BK BK BK BK BK BK R Y R 1 2 Fuse Relay Assembly Battery 30 Amp J FUSE 5 R Y R GRD2 et00005 Figure B 11 Charging Circuits All Models ...

Page 250: ...Figure B 11 Figure B 11 Charging Circuits All Models Charging Circuits All Models ...

Page 251: ...ls Left Hand Controls 24B 189LA 189LB 189RA 189RB R Heat Grip L Heat Grip 1 2 3 1 2 3 1 2 3 2 3 4 5 6 7 8 1 1 2 3 1 2 3 To Heated Grips Switch Right Side Left Side 4 BK R W BK W BK O R BK BN BE BK BN BE BK O R BK BK BN BN BE BE O O BN PK P BN Y BK BE Y W et00087 Figure B 12 Heated Handlebar Grips Ulysses only ...

Page 252: ...Figure B 12 Figure B 12 Heated Handlebar Grips Ulysses only Heated Handlebar Grips Ulysses only ...

Page 253: ... Harness Top View Lightning Figure B 18 Wiring Harness Top View Firebolt Figure B 19 Wiring Harness Right Side View Ulysses Figure B 20 Wiring Harness Right Side View Lightning Figure B 21 Wiring Harness Right Side View Firebolt Figure B 22 Exhaust Valve Actuator Right Side View Ulysses Figure B 23 Exhaust Valve Actuator Right Side View Lightning Figure B 24 Exhaust Valve Actuator Right Side View ...

Page 254: ... ed01556 1 Active intake solenoid Japan only 2 Ignition coil 3 Fuel pump 4 Crank Position CKP sensor Figure B 13 Wiring Harness Left Side View Ulysses B 28 2008 Buell XB Diagnostics Appendix B Wiring Diagrams ...

Page 255: ...ed01557 1 Active Intake Solenoid Japan only 2 Ignition coil 3 Fuel pump 4 Crank Position CKP sensor Figure B 14 Wiring Harness Left Side View Lightning 2008 Buell XB Diagnostics Appendix B Wiring Diagrams B 29 ...

Page 256: ...58 1 Active intake solenoid Japan only 2 Ignition coil 3 Fuel pump 4 Crankshaft Position CKP sensor 5 To ECM Figure B 15 Wiring Harness Left Side View Firebolt B 30 2008 Buell XB Diagnostics Appendix B Wiring Diagrams ...

Page 257: ...el injector 2 2 Idle Air Control IAC 3 Throttle Position Sensor TPS 4 Intake Air Temperature IAT sensor 5 Oxygen O2 sensor Figure B 16 Wiring Harness Top View Ulysses 2008 Buell XB Diagnostics Appendix B Wiring Diagrams B 31 ...

Page 258: ...l injector 2 2 Idle Air Control IAC 3 Throttle Position Sensor TPS 4 Intake Air Temperature IAT sensor 5 Oxygen O2 sensor Figure B 17 Wiring Harness Top View Lightning B 32 2008 Buell XB Diagnostics Appendix B Wiring Diagrams ...

Page 259: ... Idle Air Control IAC 3 Throttle Position Sensor TPS 4 Intake Air Temperature IAT sensor 5 Oxygen O2 sensor 6 Engine Temperature ET sensor Figure B 18 Wiring Harness Top View Firebolt 2008 Buell XB Diagnostics Appendix B Wiring Diagrams B 33 ...

Page 260: ...le Speed Sensor VSS 2 Cable starter to battery positive 3 Solenoid 4 Oil pressure switch 5 Neutral switch 6 Relay terminal Figure B 19 Wiring Harness Right Side View Ulysses B 34 2008 Buell XB Diagnostics Appendix B Wiring Diagrams ...

Page 261: ...nsor VSS 2 Cable starter to battery positive 3 Solenoid 4 Voltage regulator 5 Oil pressure switch 6 Neutral switch 7 Relay terminal Figure B 20 Wiring Harness Right Side View Lightning 2008 Buell XB Diagnostics Appendix B Wiring Diagrams B 35 ...

Page 262: ...nsor VSS 2 Cable starter to battery positive 3 Solenoid 4 Voltage regulator 5 Oil pressure switch 6 Neutral switch 7 Relay terminal Figure B 21 Wiring Harness Right Side View Firebolt B 36 2008 Buell XB Diagnostics Appendix B Wiring Diagrams ...

Page 263: ...2 1 ed01567 1 Exhaust valve actuator 2 Muffler valve Figure B 22 Exhaust Valve Actuator Right Side View Ulysses 2008 Buell XB Diagnostics Appendix B Wiring Diagrams B 37 ...

Page 264: ...2 1 ed01566 1 Exhaust valve actuator 2 Muffler valve Figure B 23 Exhaust Valve Actuator Right Side View Lightning B 38 2008 Buell XB Diagnostics Appendix B Wiring Diagrams ...

Page 265: ...2 1 ed01565 1 Exhaust valve actuator 2 Muffler valve Figure B 24 Exhaust Valve Actuator Right Side View Firebolt 2008 Buell XB Diagnostics Appendix B Wiring Diagrams B 39 ...

Page 266: ...B 40 2008 Buell XB Diagnostics Appendix B Wiring Diagrams NOTES ...

Page 267: ...SUBJECT PAGE NO C 1 METRIC CONVERSION C 1 C 2 FLUID CONVERSIONS C 2 C 3 TORQUE CONVERSIONS C 3 APPENDIX C CONVERSIONS ...

Page 268: ...NOTES ...

Page 269: ...35 39 2362 6 100 01 3 15 16 66 04 2 6 30 48 1 2 1 270 050 4 173 106 2 874 73 1 575 40 2756 7 101 6 4 66 67 2 5 8 31 75 1 1 4 1 524 060 4 212 107 2 913 74 1 614 41 3149 8 102 19 4 1 16 68 26 2 11 16 33 02 1 3 1 588 1 16 4 252 108 2 953 75 1 653 42 3543 9 104 14 4 1 68 58 2 7 33 34 1 5 16 1 778 070 4 291 109 2 992 76 1 693 43 3937 10 104 77 4 1 8 69 85 2 3 4 34 92 1 3 8 2 032 080 4 331 110 3 031 77 ...

Page 270: ...surements in this Service Manual do not include the British Imperial Imp system equivalents The fol lowing conversions exist in the British Imperial system 1 pint Imp 20 fluid ounces Imp 1 quart Imp 2 pints Imp 1 gallon Imp 4 quarts Imp Although the same unit of measure terminology as the U S system is used in the British Imperial Imp system the actual volume of each British Imperial unit of measu...

Page 271: ...X 0 08333 foot pounds ft lbs METRIC SYSTEM All metric torque specifications are written in Newton meters Nm To convert metric to United States units and United States to metric use the following equations Newton meters Nm X 0 737563 foot pounds ft lbs Newton meters Nm X 8 85085 inch pounds in lbs foot pounds ft lbs X 1 35582 Newton meters Nm inch pounds in lbs X 0 112985 Newton meters Nm 2008 Buel...

Page 272: ...C 4 2008 Buell XB Diagnostics Appendix C Conversions NOTES ...

Page 273: ...SUBJECT PAGE NO D 1 GLOSSARY D 1 APPENDIX D GLOSSARY ...

Page 274: ...NOTES ...

Page 275: ...ct Current DC Data Link Connector DLC Domestic DOM Diagnostic Trouble Code DTC Digital Volt Ohm Meter DVOM Electronic Control Module ECM Engine Coolant Temperature ECT Electrically Erasable Programmable Read Only Memory EEPROM Electronic Fuel Injection EFI Engine Temperature ET Evaporative Emissions Control System EVAP Fahrenheit F Foot Pounds ft lbs Fluid Ounce fl oz Gram g Gallon GAL Gross Axle ...

Page 276: ...les Per Hour MPH millisecond ms Newton Meter Nm Not Applicable N A Number no Oxygen O2 Outside Diameter OD Original Equipment Manufacturer OEM Ounce oz Parts and Accessories P A Part Number PN Pounds per Square Inch PSI Reserve RES Revolutions Per Minute RPM Cubic Feet per Hour at Standard Conditions SCFH Throttle Control Actuator TCA Top Dead Center TDC Twist Grip Sensor TGS Throttle Position TP ...

Page 277: ...Table D 1 Acronyms and Abbreviations DESCRIPTION ACRONYM OR ABBREVIATION Vehicle Identification Number VIN Vehicle Speed Sensor VSS 2008 Buell XB Diagnostics Appendix D Glossary D 3 ...

Page 278: ...D 4 2008 Buell XB Diagnostics Appendix D Glossary NOTES ...

Page 279: ...B 48115 2 29 DTC P0691 36 P0692 36 Diagnostics BREAKOUT BOX B 48115 2 31 DTC P1151 44 P1152 44 Diagnostics BREAKOUT BOX B 48115 2 36 DTC P1653 35 P1654 35 Diagnostics BREAKOUT BOX B 48115 2 37 DTC P2300 24 P2301 24 P2303 25 P2304 25 Diagnostics BREAKOUT BOX B 48115 A 10 SEALED SPLICE CONNECTORS Sealed Splice Connector Repair ROBINAIR HEAT GUN HD 25070 2 12 ENGINE CRANKS BUT WILL NOT START Dia gnos...

Page 280: ... DTC P0122 11 P0123 11 Diagnostics HARNESS CONNECTOR TEST KIT HD 41404 B 2 21 DTC P0261 23 P0262 23 P0264 32 P0265 32 Diagnostics HARNESS CONNECTOR TEST KIT HD 41404 B 2 22 DTC P0339 56 Diagnostics HARNESS CONNECTOR TEST KIT HD 41404 B 2 24 DTC P0506 34 P0507 34 P0511 34 Dia gnostics HARNESS CONNECTOR TEST KIT HD 41404 B 2 28 DTC P0628 33 P0629 33 Diagnostics HARNESS CONNECTOR TEST KIT HD 41404 B ...

Page 281: ...D 44750 2 7 WIGGLE TEST General DIGITAL TECHNICIAN HD 44750 2 24 DTC P0506 34 P0507 34 P0511 34 General DIGITAL TECHNICIAN HD 44750 1 9 CHARGING SYSTEM Troubleshooting ADVANCED BATTERY CONDUCTANCE AND ELECTRICAL SYSTEM ANALYZER HD 48053 A 9 630 METRI PACK CONNECTORS 630 Metri Pack Connector Repair SNAP ON PICK TT600 3 TOOLS III ...

Page 282: ...IV TOOLS NOTES ...

Page 283: ...2 22 JAPANESE MODELS ONLY Installation 5 4 6 7 Nm 48 60 in lbs Jam nuts 2 30 DTC P1110 22 P1111 22 P1112 22 JAPANESE MODELS ONLY Installation 5 4 6 7 Nm 48 60 in lbs Pinch fastener 2 30 DTC P1110 22 P1111 22 P1112 22 JAPANESE MODELS ONLY Installation 2 3 2 7 Nm 20 24 in lbs Solenoid fastener 2 30 DTC P1110 22 P1111 22 P1112 22 JAPANESE MODELS ONLY Installation 5 4 6 7 Nm 48 60 in lbs Solenoid fast...

Page 284: ...VI TORQUE VALUES NOTES ...

Page 285: ...uble Codes 2 7 Retrieving Trouble Codes 2 7 Clutch Switch and Neutral Switch Diagnostic Notes 2 119 Diagnostics 2 119 Conversions Fluid C 2 Length C 1 Torque C 3 Cooling Fan Specifications table 2 104 Specifications table 2 104 Cooling Fan High Voltage Diagnostic Notes 2 104 Diagnostics 2 104 Diagnostic Tips 2 104 Cooling Fan Low Voltage Diagnostic Notes 2 104 Diagnostics 2 104 Diagnostic Tips 2 1...

Page 286: ...tics 2 66 Diagnostic Tips 2 66 S Sealed Splice A 20 Service Bulletins I I Service Preparation I I Side Stand Sensor Diagnostic Notes 2 130 Diagnostics 2 130 Specifications Alternator Specifications 2 1 Battery Specifications 2 1 Electrical System Specifications 2 1 Fuel System Specifications 2 1 Idle Speed Specifications 2 1 Ignition Coil Specifications 2 1 Regulator Specifications 2 1 Spark Plug ...

Page 287: ...INSIDE BACK COVER GOES HERE ...

Page 288: ...OUTSIDE BACK COVER GOES HERE ...

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