Buell 2009 XB Series Service Manual Download Page 1

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2009 Buell XB Models Service Manual

99490-09Y

Summary of Contents for 2009 XB Series

Page 1: ...2009 Buell XB Models Service Manual 99490 09Y 2008 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 4: ...Blank Text Here ...

Page 5: ...ve this 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 2...

Page 6: ...NOTES ...

Page 7: ... be cleaned before work starts Cleaning will occasionally uncover 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...

Page 8: ...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 questions regarding Loct...

Page 9: ... and Inspection 1 12 Charging Battery 1 12 Safety Precautions 1 12 Using a Battery Charger 1 12 Battery Installation and Connection 1 13 Storage 1 14 1 6 ENGINE OIL AND FILTER General 1 15 Engine Oil Level Check 1 15 Change Engine Oil and Filter 1 15 Drain Oil 1 15 Change Filter 1 16 Fill Engine With Oil 1 16 Clear Oil Cooler 1 16 Return to Service 1 17 1 7 BRAKE SYSTEM MAINTENANCE General 1 18 Bl...

Page 10: ...rd 1 51 Jumps Out Of Gear 1 51 Clutch Slips 1 51 Clutch Drags Or Does Not Release 1 51 Clutch Chatters 1 51 Clutch 1 51 Slips 1 51 Drags or Does Not Release 1 51 Chatters 1 51 Chassis 1 51 Irregular Inadequate Brake Action 1 51 Handling Irregularities 1 51 Suspension 1 52 CHASSIS 2 1 FASTENER TORQUE VALUES Fastener Torque Values in this Chapter 2 1 2 2 SPECIFICATIONS Firebolt 2 11 Lightning 2 12 U...

Page 11: ...5 Removal Ulysses 2 65 Installation Ulysses 2 66 2 14 REAR BRAKE CALIPER Removal 2 68 Disassembly 2 68 Cleaning and Inspection 2 69 Assembly 2 69 Installation 2 69 2 15 FENDERS Front Fender XB12R 2 71 Removal 2 71 Installation 2 71 Rear Fender XB12R 2 71 Removal 2 71 Installation 2 71 Front Fender XB9SX XB12Scg XB12XT 2 71 Removal 2 71 Installation 2 71 Rear Fender XB9SX XB12Scg 2 71 Removal 2 71 ...

Page 12: ...2XT XB12XP Removal and Disassembly 2 114 Assembly and Installation 2 114 2 29 GRILLE XB9SX XB12X XB12XP General 2 115 Removal and Installation 2 115 2 30 FRONT MODULES LIGHTNING ULYSSES Removal 2 116 Installation 2 117 2 31 HANDLEBARS FIREBOLT General 2 118 Removal 2 118 Right Clip On 2 118 Left Clip On 2 118 Installation 2 118 Right Clip On 2 118 Left Clip On 2 118 2 32 HANDLEBARS LIGHTNING ULYSS...

Page 13: ...p 2 156 Removal 2 156 Installation 2 156 Engine Shroud Air Scoop 2 156 Removal 2 156 Installation 2 156 Oil Cooler Air Scoop 2 156 Removal 2 156 Installation 2 156 2 50 CHIN FAIRING Removal 2 158 Installation 2 158 2 51 SEAT Firebolt 2 159 Rider Seat 2 159 Pillion 2 159 Lightning 2 159 Removal 2 159 Installation 2 160 Ulysses 2 161 Removal 2 161 Installation 2 161 2 52 SEAT LOCKS LIGHTNING 2 163 R...

Page 14: ...Rings 3 54 Connecting Rod Bushing 3 56 Assembly Installation 3 57 3 9 OILING SYSTEM General 3 60 3 10 OIL PUMP General 3 61 Removal Disassembly 3 62 Cleaning and Inspection 3 64 Assembly Installation 3 65 3 11 OIL RESERVOIR AND OIL HOSE ROUTING General 3 67 3 12 OIL LINE FITTINGS Removal 3 69 Installation 3 69 3 13 OIL COOLER General 3 71 Removal 3 71 Installation 3 71 3 14 OIL PRESSURE INDICATOR ...

Page 15: ... Installation 4 19 4 12 FUEL TANK VENT VALVE General 4 20 Removal 4 20 Installation 4 20 4 13 FUEL CAP RETAINING RING Removal 4 21 Installation 4 21 4 14 FUEL PUMP Draining Fuel Tank 4 22 Removal 4 22 Repair 4 23 Fuel Pressure Regulator Replacement 4 23 Low Fuel Level Sensor Replacement 4 24 Fuel Filter Replacement 4 25 Fuel Pump Wire Harness Replacement 4 27 Installation 4 27 4 15 THROTTLE BODY G...

Page 16: ...al 5 28 Right Crankcase Removal 5 28 5 10 TRANSMISSION DISASSEMBLY Transmission Removal From Left Crankcase 5 31 Mainshaft Countershaft 5 35 Mainshaft Disassembly 5 35 Cleaning and Inspection 5 36 Countershaft Disassembly 5 36 Cleaning and Inspection 5 36 5 11 TRANSMISSION ASSEMBLY Mainshaft Assembly 5 38 Countershaft Assembly 5 38 5 12 MAIN DRIVE GEAR AND BEARING General 5 40 Removal 5 40 Main Dr...

Page 17: ...ssembly 6 28 Solenoid Plunger 6 28 Disassembly 6 28 Assembly 6 28 Solenoid Contacts 6 28 Disassembly 6 28 Assembly 6 29 6 10 VOLTAGE REGULATOR General 6 31 Removal 6 31 Installation 6 31 6 11 ALTERNATOR Removal and Disassembly 6 33 Rotor 6 33 Stator 6 33 Cleaning and Inspection 6 34 Assembly and Installation 6 34 6 12 HEATED HAND GRIPS ULYSSES MODELS Heated Hand Grips 6 35 Removal 6 35 Installatio...

Page 18: ...IRE HARNESS General 6 74 Removal 6 74 Installation 6 81 6 28 AUXILIARY HARNESS XB12XP XB12XP Ulysses Police Model Auxiliary Harness 6 90 Removal 6 90 Installation 6 92 6 29 INTERACTIVE EXHAUST HARNESS XB12 MODELS Firebolt 6 94 Removal 6 94 Installation 6 94 Lightning 6 95 Removal 6 95 Installation 6 95 Ulysses 6 96 Removal 6 96 Installation 6 96 6 30 SPROCKET COVER WIRING General 6 98 Removal 6 98...

Page 19: ...0 A 10 PACKARD 280 METRI PACK RELAY AND FUSE BLOCK CONNECTORS Fuse Block Repair A 22 Removing Socket Terminals A 22 Installing Socket Terminals A 22 Crimping Terminals A 22 A 11 PACKARD 480 METRI PACK CONNECTORS 480 Metri Pack Connector Repair A 23 General A 23 Separating Pin and Socket Housings A 23 Mating Pin and Socket Housings A 23 Removing Socket Terminals A 23 Installing Socket Terminals A 2...

Page 20: ... United States System C 3 Metric System C 3 APPENDIX D HOSE AND WIRE ROUTING D 1 APPENDIX D HOSE AND WIRE ROUTING Firebolt D 1 Lightning D 14 Ulysses D 26 APPENDIX E ACTIVE INTAKE JAPANESE MODELS E 1 ACTIVE INTAKE SYSTEM JAPANESE MODELS ONLY General E 1 Active Intake System E 1 Diagnostic Notes E 1 Verify Settings E 1 WOT Check E 1 Cable E 1 Adjustment E 1 Throttle Stop Screw E 3 Removal E 4 Insta...

Page 21: ... MAINTENANCE 1 18 1 8 TIRES AND WHEELS 1 25 1 9 CLUTCH TRANSMISSION PRIMARY FLUID 1 27 1 10 DRIVE BELT MAINTENANCE 1 30 1 11 PRIMARY CHAIN 1 33 1 12 STEERING HEAD BEARINGS 1 35 1 13 SPARK PLUGS 1 36 1 14 AIR CLEANER AND EXHAUST SYSTEM 1 38 1 15 THROTTLE CABLE 1 41 1 16 INTERACTIVE EXHAUST CABLE 1 42 1 17 HEADLAMP 1 44 1 18 WINDSHIELD MAINTENANCE 1 47 1 19 STORAGE 1 48 1 20 TROUBLESHOOTING 1 49 MAI...

Page 22: ...NOTES ...

Page 23: ...e Pad Replacement 15 19 Nm 11 14 ft lbs Front caliper pin hanger 1 7 BRAKE SYSTEM MAINTENANCE Bleeding Brakes 1 0 1 5 Nm 9 13 in lbs Front master cylinder reservoir cover fasteners 1 7 BRAKE SYSTEM MAINTENANCE Brake Pad Replacement 1 0 1 5 Nm 9 13 in lbs Front master cylinder reservoir cover fasteners 1 4 MAINTENANCE SCHEDULE General 6 8 9 5 Nm 60 84 in lbs Handlebar clamp screw 1 4 MAINTENANCE SC...

Page 24: ... 7 Nm 36 60 in lbs Rear caliper bleeder valve 1 7 BRAKE SYSTEM MAINTENANCE Brake Pad Replacement 14 9 18 9 Nm 11 14 ft lbs Rear caliper pin hanger 1 7 BRAKE SYSTEM MAINTENANCE Brake Pad Replacement 3 Nm 24 in lbs Rear caliper pin plug 1 4 MAINTENANCE SCHEDULE General 9 5 12 Nm 84 108 in lbs Screw primary chain inspection cover 1 4 MAINTENANCE SCHEDULE General 16 24 Nm 12 18 ft lbs Spark plug 1 13 ...

Page 25: ... Parts Always consider the weight of a part when lifting Use a hoist whenever necessary Do not lift heavy parts by hand A hoist and adjustable lifting beam or sling are needed to remove some parts The lengths of chains or cables from the hoist to the part should be equal and parallel and should be positioned directly over the center of the part Be sure that no obstructions will interfere with the ...

Page 26: ...existing fasteners Always use the recommended threadlocking agent for your specific procedure Wiring Hoses and Lines Hoses clamps electrical wiring electrical switches or fuel lines if they do not meet specifications Instruments and Gauges Replace broken or defective instruments and gauges Replace dials and glass that are so scratched or discolored that reading is difficult Bearings Anti friction ...

Page 27: ...bber part if it cannot be properly protected Cleaning Process Any cleaning method may be used as long as it does not result in parts damage Thorough cleaning is necessary for proper parts inspection Strip rusted paint areas to bare metal before priming and repainting Rust or Corrosion Removal Remove rust and corrosion with a wire brush abrasive cloth sand blasting vapor blasting or rust remover Us...

Page 28: ...ver with rounded edges because it will slip Redress with a file Ratchets and Handles Periodically clean and lubricate ratchet mechanisms with a light grade oil Do not replace parts individually ratchets should be rebuilt with the entire contents of service kit Never hammer or put a pipe extension on a ratchet or handle for added leverage Always support the ratchet head when using socket extensions...

Page 29: ...ed to describe gasoline blends that are specifically designed to burn cleaner than other types of gasoline leaving fewer tailpipe emissions They are also formulated to evaporate less when you are filling your tank Reformulated gasolines use additives to oxygenate the gas Your motorcycle will run normally using this type of gas and Harley Davidson recommends you use it when possible as an aid to cl...

Page 30: ...change interval should be Water vapor is a normal by product of combustion in any engine During cold weather operation some of the water vapor condenses to liquid form on the cool metal surfaces inside the engine In freezing weather this water will become slush or ice and if allowed to accumulate too long may block the oil lines and cause damage to the engine If the engine is run frequently and al...

Page 31: ... X X X X X Clean Oil cooler fins 1 X X X X X X Inspect Brake system oil lines front forks rear shock exhaust system exhaust system mounting evaporative emis sion system if applicable 1 X X Check tightness Critical fasteners 1 X X Inspect Engine mounts stabilizer and links X X X X X X Verify component and system func tions Road test 1 Should be performed by an authorized Buell dealer unless you hav...

Page 32: ...per fluid level Rear master cylinder between upper and lower lines 9 13 in lbs 1 0 1 5 Nm Front master cylinder reservoir cover torque 0 040 in 1 0 mm or less Minimum brake pad thickness Brake pad linings and discs 0 18 in 4 5 mm or less Minimum brake disc thickness 12 36 in lbs 1 4 4 Nm Intake cover screw torque Intake cover assembly LUBIT 8 TUFOIL CHAIN AND CABLE LUBE Part No HD 94968 85TV Lubri...

Page 33: ...efects or other reproductive harm Wash hands after handling 00019e All AGM batteries are permanently sealed maintenance free valve regulated lead calcium and sulfuric acid batteries The batteries are shipped pre charged and ready to be put into service Do not attempt to open these batteries for any reason NOTE For charging information see 1 5 BATTERY MAINTENANCE Charging Battery For testing inform...

Page 34: ... addition to the manufacturer s instructions follow these general safety precautions Always wear eye face and hand protection Always charge batteries in a well ventilated area Turn the charger off before connecting the leads to the battery to avoid dangerous sparks Never try to charge a visibly damaged or frozen battery Connect the charger leads to the battery red positive lead to the positive ter...

Page 35: ...the motorcycle could be damaged 00214a 2 Connect red battery charger lead to the positive ter minal of the battery 3 Connect black battery charger lead to the negative terminal of the battery NOTE If the battery is still in the vehicle connect the negative lead to the chassis ground Be sure that the ignition and all electrical accessories are turned off 4 Step away from the battery and turn on the...

Page 36: ...d battery will freeze The more dis charged a battery is the more easily it can freeze and crack the battery case 00218a If the motorcycle will not be operated for several months such as during the winter season remove the battery from the motorcycle and fully charge See Figure 1 3 Self discharge is a normal condition and occurs continuously at a rate that depends on the ambient temperature and the...

Page 37: ...lt in oil carryover to the air cleaner leading to equipment damage and or equipment malfunction 00190a Do not switch lubricant brands indiscriminately because some lubricants interact chemically when mixed Use of inferior lubricants can damage the engine 00184a 1 The motorcycle must be on level ground on the sidestand with the engine off 2 See Figure 1 4 Unscrew and remove dipstick from oil tank s...

Page 38: ...il 1 Inspect drain plug O ring for tears or damage Replace if required Wipe any foreign material from drain plug 2 Apply LOCTITE 565 THREAD SEALANT reinstall plug and tighten to 26 29 ft lbs 35 39 Nm 3 Fill oil tank through filler dipstick hole with fresh oil NOTES Use the grade of oil for the lowest temperature expected before the next oil change Oil tank capacity with filter change is approximat...

Page 39: ...ipe up any spilled oil on muffler 2 Start engine Verify that oil pressure signal light on instru ment cluster turns off after a few seconds when engine speed is 1000 RPM or above 3 Check for oil leaks at oil filter drain plug hoses and oil cooler 4 Install chin fairing See 2 50 CHIN FAIRING 5 Check hot oil level See 1 6 ENGINE OIL AND FILTER Engine Oil Level Check HOME 2009 XB Service Maintenance ...

Page 40: ...ke pads Inspect master cylinder Cup in master cylinder not uncovering relief port Brake pads drag on rotor will not retract Adjust brake pedal linkage Rear brake pedal linkage out of adjust ment BLEEDING BRAKES Direct contact of D O T 4 brake fluid with eyes can cause irritation Avoid eye contact In case of eye contact flush with large amounts of water and get medical attention Swallowing large am...

Page 41: ... O T 4 BRAKE FLUID to master cylinder reservoir Bring fluid level to within 1 8 in 3 2 mm of molded boss level indicator inside front master cylinder NOTE Do not reuse brake fluid b Slowly squeeze and release brake lever several times to build up hydraulic pressure then squeeze or apply pressure to brake lever c Open bleeder valve about 1 2 turn counterclockwise Brake fluid will flow from bleeder ...

Page 42: ...en hold brake pedal in the pressed position c While holding brake pedal in the pressed position open bleeder valve about 1 2 turn counterclockwise Brake fluid will flow from bleeder valve and through tubing into clean container d When brake pedal has moved 1 2 to 3 4 of its full range of travel close bleeder valve clockwise Allow brake pedal to return slowly to its released position 5 Tighten rear...

Page 43: ...op surface of clevis and tighten to 130 173 5 in lbs 14 7 19 6 Nm NOTE Brake pedal has no free play adjustment 1 3 4 2 pd00211 1 Extruded nut 2 Flat sides on the end of the threaded brake rod 3 Clevis 4 Minimum engagement Figure 1 13 Critical Measurements with Brake Pedal 1 5 4 2 3 sm00490 1 Bottom of master cylinder 2 Rod adjuster 3 Locknut 4 Clevis 5 Clevis pin Figure 1 14 Brake Pedal Pushrod Ad...

Page 44: ...liper fasteners 1 See Figure 1 18 Loosen pin hanger 2 but do not remove 2 Rotate wheel so that caliper is centered between rotor mounting fasteners 1 3 Remove lower caliper mounting fastener 4 that secures caliper to fork lower 4 Loosen but do not remove upper caliper mounting fastener 3 that secures caliper to fork lower 5 Remove pin hanger 2 6 Rotate caliper counterclockwise to allow access to o...

Page 45: ...ove pin hanger 4 7 See Figure 1 20 Remove inner and outer pads being careful not to dislodge pad spring Rear Pad Installation 1 Remove rear master cylinder reservoir cover NOTE As the pistons are pushed back into the caliper fluid level may rise more than 1 8 in 3 2 mm and overflow the reservoir Watch the fluid level as the pistons are retracted and remove fluid from the reservoir if necessary 2 S...

Page 46: ... Rear caliper mounting fasteners 2 Brake pad retainer 3 Rear caliper pin plug 4 Rear caliper pin hanger Figure 1 19 Rear Brake Caliper sm00496 Figure 1 20 Rear Brake Pad Spring Installed HOME 1 24 2009 XB Service Maintenance ...

Page 47: ... Diablo T and Scorpion Sync Tires PRESSURE AT GVWR PRESSURE FOR SOLO RIDING TIRE kPa PSI Same as solo 234 34 Front Same as solo 248 36 Rear TIRE WEAR See Figure 1 21 and Figure 1 22 Tread wear indicator bars will appear on tire tread surfaces when 1 32 in 0 8 mm or less of tire tread remains The letters TWI on tire sidewalls pinpoint location of wear indicators bars Always remove tires from servic...

Page 48: ... XB12Scg riding values 248 36 Pirelli Diablo T 180 55 ZR 17 Rear Same as solo 234 34 Pirelli Diablo Strada 120 70 ZR 17 Front XB12XT riding values 248 36 Pirelli Diablo Strada 180 55 ZR 17 Rear WHEEL BEARINGS Using compressed air to spin dry bearings can cause bearing to fly apart which could result in death or serious injury 00505b Check front and rear wheel bearings for wear Every time a wheel i...

Page 49: ... 4 sm01388 1 Adjusting screw 2 Cable end 3 Coupling 4 Correct fluid level Figure 1 24 Primary Fluid Level TRANSMISSION FLUID Transmission fluid capacity is approximately 1 0 quart 0 95 liter For best results drain fluid while hot 1 When the engine reaches normal operating temperature turn the engine off and position motorcycle on sidestand This will allow the chaincase lubricant to drain out of th...

Page 50: ... When necessary lubricate cable with LUBIT 8 TUFOIL CHAIN AND CABLE LUBE Part No HD 94968 85TV 1 Position the vehicle upright and level This will prevent lubricant from draining out when clutch inspection cover is removed 2 See Figure 1 27 Slide rubber boot 1 upward to expose adjuster mechanism Loosen jam nut 3 from adjuster 4 Turn adjuster to shorten cable housing until there is a large amount of...

Page 51: ...ee play by turning adjuster 4 d Tighten jam nut 3 against adjuster 4 e Slide boot 1 over cable adjuster mechanism 7 Change or add transmission fluid if necessary NOTE Each time the clutch inspection cover is removed the gasket must be replaced 8 See Figure 1 25 Install clutch inspection cover and new gasket using three fasteners and washers and tighten to 84 108 in lbs 9 5 12 Nm 1 2 3 4 sm00090 1 ...

Page 52: ...Outside surface for signs of stone puncture If cracks damage exists near edge of belt replace belt immediately Damage to center of belt will require belt replacement eventually but when cracks extend to edge of belt belt failure is imminent Inside toothed portion of belt for exposed tensile cords normally covered by facing fabric This condition will result in belt failure and indicates worn transm...

Page 53: ...te or control exposure Abrasive environment Inspect for damaged or missing guards Inspect replace sprocket Worn sprocket Apparent belt stretch NOTE Clean and protect drive Debris in sprocket Tension on a new belt will loosen after approximately 1000 mi 1600 km Inspect for damaged or missing guards Replace idler assembly Idler bearing failure Riding practice operator choice Aggressive riding hard u...

Page 54: ...ket Worn damaged sprocket Excessive drive noise Missing damaged belt guards Repair flange replace sprocket Damaged flange Check structure bad bearing bent members etc Damaged idler Replace idler assembly Follow proper handling installation procedure Damaged belt Inspect replace belt Inspect replace sprocket Debris stuck in belt Clean and protect drive Inspect replace belt Missing damaged belt guar...

Page 55: ...s only allowed at the absolute tightest point in the drive as measured with special ized factory equipment If a chain has less than 1 4 in 6 4 mm vertical tension with a cold engine adjust tension to the field specification of 3 8 1 2 in 9 5 12 7 mm The looser specification will avoid overtightening which might otherwise occur during adjustment using non factory equipment and methods 4 See Figure ...

Page 56: ...3 Tighten locknut 1 to 20 25 ft lbs 27 34 Nm 1 2 sm00096 1 Locknut 2 Adjusting fastener Figure 1 33 Chain Tension Adjusting Fastener Typical HOME 1 34 2009 XB Service Maintenance ...

Page 57: ... pull front wheel to center position a The desired resistance to pull front wheel to center is between 1 7 lbs 0 5 3 2 kg b If steering head resistance measurement is not within specification see 1 12 STEERING HEAD BEARINGS Determining Proper Resistance 7 When adjustment is complete attach clutch cable and adjust See 1 9 CLUTCH TRANSMISSION PRIMARY FLUID sm00098 Figure 1 34 Measuring Steering Head...

Page 58: ...ctrodes and is caused by an air fuel mixture that is too lean a hot running engine valves not seating or improper ignition timing The glassy deposit on the spark plug is a conductor when hot and may cause high speed misfiring A plug with eroded electrodes heavy deposits or a cracked insulator must be replaced d A plug with a white yellow tan or rusty brown powdery deposit 4 indicates balanced comb...

Page 59: ...oil and spark plugs See 6 5 SPARK PLUG CABLES 14 Install left side air scoop See 2 49 AIR SCOOPS 15 Install air cleaner assembly and intake cover See 2 38 INTAKE COVER and 4 3 AIR CLEANER ASSEMBLY After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 16 Install s...

Page 60: ...emove seat 2 Remove intake cover assembly See 2 38 INTAKE COVER 3 See Figure 1 38 or Figure 1 39 Remove fuel tank vent tube 3 from fuel tank vent valve 2 at front of air cleaner cover and groove on top of air cleaner cover 1 4 See Figure 1 40 Unlatch six latching tabs and remove air cleaner cover from baseplate 5 See Figure 1 41 Remove the filter element 1 from baseplate 2 Inspect and replace if n...

Page 61: ...ement 1 on baseplate 2 2 Position air cleaner cover over baseplate Make sure air filter remains correctly positioned 3 Install air cleaner cover by latching latch tabs to baseplate 4 For XB12 models verify that the actuator cable and har ness are located in the grooves in the air cleaner cover NOTE The vent tube is now a larger outer diameter than previous and requires extra effort to install into...

Page 62: ...ntire exhaust system for loose or missing fasteners broken pipe clamps or brackets and obvious signs of leakage carbon tracks at pipe joints etc 2 Check for loose or broken heat shields Repair or replace as necessary 3 Start engine cover muffler ends with clean dry shop towels and listen for audible signs of exhaust leakage 4 Correct any leaks detected See 4 18 EXHAUST SYSTEM for exhaust system re...

Page 63: ...er on throttle control cable 2 until throttle cam stop touches stop plate Tighten cable adjuster lock 5 on throttle control cable adjuster release throttle control grip 5 Turn handlebars fully to right Turn adjuster on idle control cable 3 until end of cable housing just touches the cable guide 6 Twist and release throttle control grip a few times Throttle plate must return to idle position each t...

Page 64: ...ket 8 Tighten jam nut NOTE Do not overtighten jam nut on interactive exhaust cable 9 See Figure 1 46 Adjust interactive exhaust cable as fol lows a Move cable with your fingers from side to side There should be no more than 1 8 in 3 2 mm side play in cable in either direction with 1 4 in 6 4 mm max imum overall side play b See Figure 1 45 Adjust cable as needed using cable adjuster 1 NOTES In this...

Page 65: ...g For 1 8 in 3 2 mm Maximum Free Play In Either Direction For Proper Adjustment 2 1 sm00506 1 Interactive exhaust cable 2 Frame lug Figure 1 47 Correct Cable Routing Behind Frame Lug Typical HOME 2009 XB Service Maintenance 1 43 ...

Page 66: ...d upright point the front wheel straight forward at wall and measure the distance 4 from the floor to the center of the HIGH BEAM bulb 6 Draw a horizontal line 5 through the vertical line on the wall that is 2 1 in 53 3 mm lower than the measured bulb centerline 2 3 5 4 1 om00029 1 Perpendicular line 2 Vertical line 3 25 feet 7 6 meters 4 High beam bulb centerline 5 Horizontal line 2 1 in 53 3 mm ...

Page 67: ...o adjust headlamp Once headlamps are aligned tighten fasteners to 48 72 in lbs 5 8 Nm pd00197 Figure 1 50 Horizontal Headlamp Adjustment Fastener Locations Lightning pd00198 Figure 1 51 Horizontal Headlamp Adjustment Fastener Lightning pd00199 Figure 1 52 Vertical Headlamp Adjustment Fastener Lightning Models HEADLAMP ADJUSTMENT ULYSSES Horizontal Alignment See Figure 1 53 and Figure 1 54 Loosen f...

Page 68: ... alignment fastener enough to adjust headlamp Once headlamps are aligned tighten fastener to 36 48 in lbs 4 5 Nm pd00200 Figure 1 53 Horizontal Headlamp Adjustment Fastener Locations Ulysses pd00201 Figure 1 54 Horizontal Headlamp Adjustment Fastener Ulysses pd00202 Figure 1 55 Vertical Headlamp Adjustment Fastener Ulysses XB12X XB12XP sm05318 Figure 1 56 Vertical Headlamp Adjustment Fastener XB12...

Page 69: ...creen To minimize swirl marks cleaning should be done when motorcycle is cool and parked in the shade HARLEY DAVIDSON BUG REMOVER Part No 94657 98 HARLEY DAVIDSON SUNWASH PART No 94659 98 NOVUS 1 CLEANER PROTECTANT Part No 99837 94T NOVUS 2 SCRATCH REMOVER Part No 99836 94T HARLEY GLAZE Part No 99701 84 to polish and seal after cleaning NOTE Faint swirl marks are normal and may be more visible on ...

Page 70: ...ly support the motorcycle so that all weight is off the tires Be sure that brake fluid or other lubricants do not contact brake pads or discs Such contact can adversely affect braking ability which could cause loss of control resulting in death or serious injury 00290a 8 Wash and polish molded in color painted and chrome plated surfaces 9 If motorcycle is to be covered use a material that will bre...

Page 71: ...timing incorrect due to faulty coil ECM or faulty sensors 8 Bank Angle Sensor tripped and ignition switch not cycled OFF then ON 9 Fuel filter clogged 10 Sticking or damaged valve or wrong length push rod 11 Cam primary gear key sheared or missing the spacer 12 Fuel pump inoperative 13 Plugged fuel injectors 14 Fuse blown Starts Hard 1 Spark plugs in bad condition or have improper gap or are parti...

Page 72: ...puts poorly tuned engine 6 Internal engine problem 7 Broken frame 8 Stabilizer links worn or loose or stabilizer link brackets loose or broken Check Engine Light Illuminates During Operation 1 Fault detected See the Electrical Diagnostic Manual for this motorcycle LUBRICATION SYSTEM TOOL NAME PART NUMBER BLACK LIGHT LEAK DETECTOR HD 35457 Oil Does Not Return To Oil Tank 1 Oil tank empty 2 Oil pump...

Page 73: ...r forks bent 4 Damaged gears Clutch Slips 1 Clutch controls improperly adjusted 2 Insufficient clutch spring tension 3 Worn friction discs Clutch Drags Or Does Not Release 1 Lubricant level too high in primary chaincase 2 Clutch controls improperly adjusted 3 Primary chain badly misaligned 4 Insufficient clutch spring tension 5 Clutch discs excessively warped 6 Clutch spacer missing or installed b...

Page 74: ...torcycle continue to bounce as it travels over multiple bumps Reduce rebound damping Wheel responds to bump but doesn t return to ground quickly after bumps This is more pronounced over a series of bumps and is often referred to as packing down Increase compression damping The motorcycle bottoms out or dips while cornering Motorcycle has excessive brake dive Reduce compression damping Harsh ride p...

Page 75: ...ood suspension is a balance between damping and track condition Finding this balance requires exploring all possible compression settings Not absorbing bumps Increase compression damping Lack of tire feedback Decrease compression damping Tire slides HOME 2009 XB Service Maintenance 1 53 ...

Page 76: ...1 54 2009 XB Service Maintenance NOTES ...

Page 77: ...TORS XB9SX XB12X XB12XT XB12XP 2 114 2 29 GRILLE XB9SX XB12X XB12XP 2 115 2 30 FRONT MODULES LIGHTNING ULYSSES 2 116 2 31 HANDLEBARS FIREBOLT 2 118 2 32 HANDLEBARS LIGHTNING ULYSSES 2 119 2 33 MIRRORS 2 121 2 34 FOOTPEG HEEL GUARD AND MOUNT FIREBOLT LIGHTNING 2 122 2 35 HEEL GUARD AND FOOTPEG MOUNTS ULYSSES MODELS 2 124 2 36 SPROCKET COVER 2 126 2 37 BELT GUARDS 2 127 2 38 INTAKE COVER 2 128 2 39 ...

Page 78: ...NOTES ...

Page 79: ... in lbs Battery terminal fasteners 2 26 HEADLAMP ASSEMBLY AND SUPPORT BRACKET Installation Firebolt 8 11 Nm 72 96 in lbs Battery terminal fasteners 2 26 HEADLAMP ASSEMBLY AND SUPPORT BRACKET Installation Lightning Ulysses 8 11 Nm 72 96 in lbs Battery terminal fasteners 2 27 FAIRING SUPPORT BRACKET FIRE BOLT Installation 8 11 Nm 72 96 in lbs Battery terminal fasteners 2 30 FRONT MODULES LIGHT NING ...

Page 80: ... 1 Nm 7 10 in lbs Brake light switch fastener front 2 9 FRONT BRAKE EIGHT PISTON CAL IPER Front Brake Fluid Line 4 7 Nm 36 60 in lbs Brake line P clamp front 2 10 FRONT BRAKE SIX PISTON CAL IPER Brake Line Installation 4 7 Nm 36 60 in lbs Brake line p clamp fastener front 2 13 REAR BRAKE LINE Installation Firebolt 4 7 Nm 36 60 in lbs Brake line p clamp fastener rear 2 13 REAR BRAKE LINE Installati...

Page 81: ...AKE LINE Removal Firebolt 4 7 Nm 36 60 in lbs Caliper bleeder valves 2 13 REAR BRAKE LINE Removal Lightning 4 7 Nm 36 60 in lbs Caliper bleeder valves 2 13 REAR BRAKE LINE Removal Ulysses 4 7 Nm 36 60 in lbs Caliper bleeder valves 2 14 REAR BRAKE CALIPER Removal 4 7 Nm 36 60 in lbs Caliper bleeder valves 2 14 REAR BRAKE CALIPER Assembly 4 7 Nm 36 60 in lbs Caliper bleeder valves 2 9 FRONT BRAKE EI...

Page 82: ...RS Rear Fender XB12Ss XB12XT XB12X 1 4 4 Nm 12 36 in lbs Fender fasteners 2 26 HEADLAMP ASSEMBLY AND SUPPORT BRACKET Assembly Firebolt 4 7 Nm 36 60 in lbs Flasher fastener 2 35 HEEL GUARD AND FOOTPEG MOUNTS ULYSSES MODELS Mount Installation 15 16 Nm 132 144 in lbs Footpeg mount 2 34 FOOTPEG HEEL GUARD AND MOUNT FIREBOLT LIGHTNING Passenger LOCTITE 271 red 34 38 Nm 25 28 ft lbs Footpeg mount Firebo...

Page 83: ... in lbs Fuse block and relay fasteners 2 54 LUGGAGE XB12XT Installation Top Case 26 27 Nm 19 20 ft lbs Grab rail fasteners 2 32 HANDLEBARS LIGHT NING ULYSSES Installation LOCTITE 271 red Tighten front screws first 14 16 Nm 10 12 ft lbs Handlebar clamp screws Lightning and Ulysses 2 32 HANDLEBARS LIGHT NING ULYSSES Installation LOCTITE 271 red Tighten front screws first 14 16 Nm 10 12 ft lbs Handle...

Page 84: ...ake Line Installation 22 27 Nm 16 20 ft lbs Master cylinder banjo bolt front 2 10 FRONT BRAKE SIX PISTON CAL IPER Master Cylinder Installation 1 0 1 5 Nm 9 13 in lbs Master cylinder cover fasteners front 2 12 REAR BRAKE MASTER CYLINDER Installa tion Firebolt Lightning 8 11 Nm 72 96 in lbs Master cylinder mounting fasteners rear 2 12 REAR BRAKE MASTER CYLINDER Installa tion Ulysses 8 11 Nm 72 96 in...

Page 85: ...L ASSEMBLY AND BODY WORK FIREBOLT Assembly 13 6 16 3 Nm 120 144 in lbs Rear shock reservoir clamp Firebolt 2 23 REAR SHOCK ABSORBER Installation Ulysses 9 0 9 9 Nm 80 88 in lbs Rear shock reservoir fastener 2 43 LEFT TAIL SECTION AND BATTERY PAN ULYSSES MODELS Assembly 9 0 9 9 Nm 80 88 in lbs Rear shock reservoir fastener Ulysses 2 45 RIGHT TAIL SECTION ULYSSES MODELS Assembly 9 0 9 9 Nm 80 88 in ...

Page 86: ... fastener upper 2 23 REAR SHOCK ABSORBER Installation Lightning 4 7 Nm 36 60 in lbs Shock reservoir clamp rear Lightning except XB12Ss 2 23 REAR SHOCK ABSORBER Installation Lightning 9 10 Nm 80 88 in lbs Shock reservoir clamp rear XB12Ss 2 54 LUGGAGE XB12XT Installation Side Case 12 13 Nm 108 120 in lbs Side case brackets 2 55 LUGGAGE XB12XP SIDE CASE 12 13 Nm 108 120 in lbs Side case brackets 2 4...

Page 87: ...on to main frame fuel tank assembly Lightning 2 42 RIGHT TAIL SECTION LIGHT NING Assembly LOCTITE 271 red 28 5 31 2 Nm 21 23 ft lbs Tail section to main frame fuel tank assembly Lightning 2 54 LUGGAGE XB12XT Installation Top Case 11 13 Nm 96 120 in lbs Top case fasteners 2 53 TRIPLE TAIL ULYSSES Installation 4 0 5 4 Nm 36 48 in lbs Triple tail plastic collar screw 2 40 LEFT TAIL SECTION AND BATTER...

Page 88: ...ASTENER 2 52 SEAT LOCKS Installation Ulysses Models 4 5 4 Nm 36 48 in lbs Wire cover screws Ulysses 2 53 TRIPLE TAIL ULYSSES Installation 4 0 5 4 Nm 36 48 in lbs Wire cover screws Ulysses HOME 2 10 2009 XB Service Chassis ...

Page 89: ...5 143 315 147 325 143 315 GAWR front 243 535 243 535 238 525 243 535 GAWR rear 169 373 177 391 172 379 180 396 Load capacity All measurements include a full tank of gasoline Table 2 2 Dimensions 2009 Firebolt MM IN ITEM 1320 52 0 Wheel base without rider 775 30 5 Seat height with rider 110 4 35 Ground clearance without rider 83 3 3 Trail 21 degree Rake Table 2 3 Capacities 2009 Firebolt LITERS U S...

Page 90: ... Capacities 2009 XB9SX and XB12Scg Models LITERS U S ITEM 14 46 3 82 gallons Fuel tank total including reserve 2 84 0 75 gallons Reserve low fuel lamp illuminates at 2 37 2 50 quarts Oil tank 0 95 1 00 quart Transmission NOTE Gross Vehicle Weight GVWR maximum allowable loaded vehicle weight and corresponding Gross Axle Weight Ratings GAWR are given on an information decal located on the steering h...

Page 91: ... degrees 23 5 degrees Rake steering angle 22 0 degrees 22 3 degrees 22 3 degrees 22 0 degrees Rake fork angle Specifications for vehicle with luggage Specifications for vehicle without luggage and brackets Table 2 9 Weights 2009 Ulysses Models XB12XP XB12XT XB12XT XB12X ITEM KG LB KG LB KG LB KG LB 242 533 226 498 243 536 225 495 Weight 431 950 431 950 431 950 431 950 GVWR 156 345 156 345 156 345 ...

Page 92: ...e 3 1 0 83 gallons Reserve low fuel lamp illuminates at 2 4 2 5 quarts Engine oil with filter 0 9 1 0 quart Transmission Do not inflate tire beyond maximum pressure as specified on sidewall Over inflated tires can blow out which could result in death or serious injury 00027a HOME 2 14 2009 XB Service Chassis ...

Page 93: ...D TURNS OUT FROM MAX IMUM COMPRES SION TURNS OUT FROM MAXIMUM PRELOAD TURNS IN FROM MIN IMUM KG LB 1 3 4 2 1 2 1 1 5 8 2 3 Less than 63 Less than 140 1 1 2 1 3 4 2 1 5 8 1 3 4 5 63 73 140 160 1 1 4 1 1 2 3 1 1 2 1 1 2 6 73 82 160 180 1 1 4 1 1 4 4 1 1 2 1 1 2 7 82 91 180 200 1 1 1 4 5 1 1 4 1 1 4 8 91 100 200 220 3 4 1 6 1 1 4 1 1 4 9 100 109 220 240 3 4 1 7 1 1 10 109 to GVWR 240 to GVWR Front pr...

Page 94: ... 4 1 3 4 5 Less than 68 Less than 150 1 1 4 2 1 2 2 1 1 2 1 3 4 6 68 77 150 170 1 1 4 2 1 4 3 1 1 2 1 1 2 7 77 86 170 190 1 2 4 1 1 4 1 1 2 8 86 95 190 210 1 1 3 4 5 1 1 4 1 1 4 9 95 104 210 230 3 4 1 1 2 6 1 1 1 4 10 104 113 230 250 3 4 1 1 4 7 1 1 11 113 GVWR 250 GVWR Front preload is set by loosening adjuster counterclockwise until it stops at minimum and then counting the number of turns in to...

Page 95: ...1 1 1 8 16 1 1 7 8 3 1 2 118 132 260 290 3 4 7 8 18 1 1 7 8 4 132 145 290 320 5 8 1 2 max 7 8 1 3 4 4 145 GVWR 320 GVWR Both front and rear spring preload is set by loosening adjuster counterclockwise until it stops at minimum and then counting the number of turns in to get to the desired setting The rear preload knob clicks every 1 2 turn All damping adjuster settings are done by tightening adjus...

Page 96: ...ttached refer to settings in ONE LOWER weight category Both Front and Rear Spring Preload is set by loosening adjuster counterclockwise until it stops at minimum and then counting the number of turns in to get to the desired setting The rear preload knob clicks every 1 2 turn All damping adjuster settings are done by tightening adjuster clockwise until it stops at maximum setting and then counting...

Page 97: ...N POSITION 4MZ Buell vehicles originally manufactured for sale within the United States Market designation WMI code 1 5MZ Buell vehicles originally manufactured for sale outside the United States 95Z Buell vehicles originally manufactured for sale in Brazil at Manaus CKD plant KP Blast Motorcycle type code 2 AX Firebolt JX Lightning Long KX Lightning CityX WX Lightning Scg DB Ulysses Police XB12XP...

Page 98: ...SIBLE VALUES DESCRIPTION POSITION 0 Blast Model 8 2 XB9SX 3 XB12R 5 XB12Scg 6 XB12Ss 7 XB12X 9 XB12XP A XB12XT B 1125R C 1125CR D 1125R 105 HP France E 1125CR 105 HP France Varies Sequential number last five digits 9 HOME 2 20 2009 XB Service Chassis ...

Page 99: ...sive side play or radial up and down play in wheel hubs Repair swingarm See 2 19 SWINGARM AND BRACE Alignment of rear wheel in frame or with front wheel Replace rims See 2 7 TIRES and 2 8 CHECKING CAST RIM RUNOUT Rims and tires out of true sideways should not be more than 0 080 in 2 03 mm Replace rims See 2 7 TIRES and 2 8 CHECKING CAST RIM RUNOUT Rims and tires out of round or eccentric with hub ...

Page 100: ...ury 00118a Use only Buell approved tires See a Buell dealer Using non approved tires can adversely affect stability which could result in death or serious injury 00133a Tires are a critical safety component Contact a Buell dealer for tire repair or replacement Improper tire service can adversely affect stability and handling which could result in death or serious injury 00134a Buell tires are equi...

Page 101: ...removal 5 See Figure 2 4 Raise the wheel up until the rotor clears the caliper and rotate the fork leg counterclockwise allowing wheel clearance for removal 6 Remove wheel 1 2 sm00510 1 Front axle pinch fasteners 2 2 Axle left handed thread Figure 2 3 Front Wheel Mounting sm00511 Figure 2 4 Front Wheel Removal Installation DISASSEMBLY TOOL NAME PART NUMBER WHEEL BEARING REMOVER INSTALLER KIT B 439...

Page 102: ...into the collet 2 f Hold the collet 2 and turn the forcing screw 3 to expand the collet g See Figure 2 8 Place the bridge 1 against the wheel hub h Hold the forcing screw 3 and turn the nut 2 clock wise until the bearing is free of the hub i See Figure 2 9 Loosen the nut 1 and back off the bridge 2 Hold the forcing screw 3 while holding the collet 4 to remove the forcing screw from the collet j Re...

Page 103: ...CALIPER Cleaning and Inspection 3 Remove drive bushings 8 and discard 4 Remove washers 9 and discard 5 Remove front brake springs 4 and discard CLEANING AND INSPECTION Using compressed air to spin dry bearings can cause bearing to fly apart which could result in death or serious injury 00505b 1 Inspect all parts for damage or excessive wear NOTE The wheel bearings are designed as sealed bearings w...

Page 104: ...3 11 front wheel Be sure that brake fluid or other lubricants do not contact brake pads or discs Such contact can adversely affect braking ability which could cause loss of control resulting in death or serious injury 00290a Bearing Installation NOTE Always install the brake side bearing first with the lettering facing out from the hub The following procedure describes the bearing installation for...

Page 105: ...holding the forcing screw 1 tighten the nut 6 until the bearing is seated firmly against the shoulder inside the bearing bore in the wheel hub 7 Remove the nut bearing washer front bearing installer and forcing screw 2 1 sm00520 1 Forcing screw 2 Backing plate Figure 2 13 Insert Forcing Screw and Backing Plate 8 See Figure 2 13 Remove the backing plate 2 from the long forcing screw 1 Reinstall the...

Page 106: ...quarely into the hub with the lettered side facing out away from the wheel 12 Slide the FRONT BEARING INSTALLER Part No B 43993 9 2 onto the forcing screw 3 with the smaller diameter toward the bearing bore 13 Install a washer 4 Nice bearing 5 and nut 6 onto the forcing screw 3 14 See Figure 2 15 While holding the forcing screw 3 tighten the nut 6 until the bearing contacts the spacer 15 Remove th...

Page 107: ... Re using disc screws can result in torque loss and damage to rotor and or brake assembly 00319b 5 Install new rotor mounting fasteners 7 in a crisscross pattern around the wheel to verify proper fitting between rotor fastener and bushing Tighten to 25 27 ft lbs 34 37 Nm Rotor mounting fasteners must be seated into drive bushings and drive bushings must be fitted into rotor properly Failure to com...

Page 108: ...ft side fork wheel hub and thread into right fork c Compress the front suspension to make sure it is free and not binding d Tighten axle 2 metric to 39 41 ft lbs 53 56 Nm 4 See Figure 2 18 Tighten the front axle pinch fasteners 1 to 20 22 ft lbs 27 30 Nm 5 Install right side fender fasteners See 2 15 FENDERS NOTE For Ulysses locate and secure the front brake line grommet between the right side and...

Page 109: ...andling of drive belt sm00524 Figure 2 19 Rear Brake Caliper Carrier Fasteners CLEANING AND INSPECTION Using compressed air to spin dry bearings can cause bearing to fly apart which could result in death or serious injury 00505b 1 Inspect all parts for damage or excessive wear 2 Inspect brake rotor See 1 7 BRAKE SYSTEM MAINTEN ANCE and 2 14 REAR BRAKE CALIPER DISASSEMBLY TOOL NAME PART NUMBER BUSH...

Page 110: ...3 1 3 6 7 8 2 sm00525 7 4 1 Sprocket fastener Wheel spacer Rotor mounting fastener 6 2 8 5 Brake rotor Axle Wheel 6 3 Sprocket Wheel bearing Figure 2 20 Rear Wheel Assembly HOME 2 32 2009 XB Service Chassis ...

Page 111: ...9 FRONT WHEEL BEARING INSTALLER Part No B 43993 10 and BACKING PLATES Part No B 43993 11 front wheel and B 43993 12 rear wheel The procedure for the rear wheel bearing installation is the same as front wheel bearing installation See 2 5 FRONT WHEEL Assembly 1 See Figure 2 20 Install wheel bearing 3 on rotor side of motorcycle 2 Install rear wheel spacer 4 3 Install wheel bearing 3 on sprocket side...

Page 112: ...1 Nm 9 Install lower belt guard See 2 37 BELT GUARDS sm00524 Figure 2 24 Rear Brake Caliper Carrier Fasteners 10 See Figure 2 24 Install caliper carrier and tighten fastener to 24 26 ft lbs 32 35 Nm See 2 14 REAR BRAKE CAL IPER 11 On XB12Ss XB12XT and XB12X models install the rear fender See 2 15 FENDERS NOTE The brake pads may become misaligned and will not allow the rotor to slide into the calip...

Page 113: ...tact a Buell dealer for tire repair or replacement Improper tire service can adversely affect stability and handling which could result in death or serious injury 00134a Buell tires are equipped with wear bars that run horizont ally across the tread When wear bars become visible and only 1 32 in 0 8 mm tread depth remains replace tire immediately Using a worn tire can adversely affect stability an...

Page 114: ...or corroded clean with a stiff wire brush 3 Inspect tire for wear and damage Replace worn or dam aged tires See 1 8 TIRES AND WHEELS INSTALLATION Only install original equipment tire valves and valve caps A valve or valve and cap combination that is too long or too heavy can strike adjacent components and damage the valve causing rapid tire deflation Rapid tire deflation can cause loss of vehicle ...

Page 115: ...l runout specification If tire lateral runout is greater than specification perform the following a Remove tire from rim b Check rim bead side runout See 2 8 CHECKING CAST RIM RUNOUT Replace rims not meeting specifications c Install tire and check again for tire tread lateral runout Table 2 20 Tire Runout MM IN TIRE RUNOUT 1 52 0 060 Radial 2 03 0 080 Lateral 1 2 sm04915 1 Gauge 2 Lateral runout F...

Page 116: ...WHEEL WEIGHTS to the flat surface of the wheel rim Refer to Table 2 21 for maximum weight permissible to accomplish balance 1 Make sure that area of application is completely clean dry and free of oil and grease 2 Remove paper backing from weight For additional adhesive strength apply three drops of LOCTITE SUPERBONDER 420 to adhesive side of weight 3 On the front wheel locate a flat surface on th...

Page 117: ...ecification Refer to Table 2 22 Rim Radial Runout 1 See Figure 2 33 Install truing arbor in wheel hub and place wheel in the WHEEL TRUING AND BALANCING STAND Part No HD 99500 80 2 Tighten arbor nuts so hub will turn on its bearings 3 Check radial runout as shown Replace wheel if runout exceeds specification Refer to Table 2 22 Table 2 22 Wheel Rim Runout MM IN MAXIMUM RUNOUT 0 76 0 030 Lateral 0 7...

Page 118: ...mfort If swallowed obtain medical atten tion Use in well ventilated area KEEP OUT OF REACH OF CHILDREN 00240a D O T 4 brake fluid will damage painted and body panel surfaces it comes in contact with Always use caution and protect surfaces from spills whenever brake work is per formed Failure to comply can result in cosmetic damage 00239b 1 Drain brake fluid into a suitable container Discard used f...

Page 119: ...er parts even after assembly Deterioration of these components can cause brake failure which could result in death or serious injury 00291a Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury Wear safety glasses when working with compressed air Never use your hand to check for air leaks or to determine air flow rates 00061a 1 Clean all parts with...

Page 120: ...Lubricate master cylinder bore piston and piston seals with D O T 4 brake fluid 2 Push the rubber seal onto the piston of a master cylinder piston set 3 Fit the rubber cap to the small end of the spring Be sure circlip snaps in place An unsecured circlip can cause brake failure which could result in death or serious injury 00513b 4 See Figure 2 41 Insert the spring 1 with cap 2 into master cylinde...

Page 121: ...ill damage painted and body panel surfaces it comes in contact with Always use caution and protect surfaces from spills whenever brake work is per formed Failure to comply can result in cosmetic damage 00239b 5 Protect the body work from the brake fluid 6 With the master cylinder in a level position add D O T 4 brake fluid until the level is above the LOWER line on the sight gauge A plugged or cov...

Page 122: ...brake fluid d Tighten the bleeder valve to 36 60 in lbs 4 7 Nm NOTE Damaged banjo bolt seating surfaces will leak when reas sembled Carefully remove banjo bolts to prevent damage to seating surfaces 2 Remove caliper banjo bolt 2 and two copper washers to disconnect brake line from caliper Discard copper washers 3 Remove master cylinder banjo bolt and two copper washers to disconnect brake line fro...

Page 123: ...f control which could result in death or serious injury 00289a 8 Fill the master cylinder reservoir and bleed the brakes See 1 7 BRAKE SYSTEM MAINTENANCE 9 Install and tighten the P clamp 3 on the front fork clamp Tighten to 36 60 in lbs 4 7 Nm Be sure that all lights and switches operate properly before operating motorcycle Low visibility of rider can result in death or serious injury 00316a 10 T...

Page 124: ...ring the brake system test brakes at low speed If brakes are not operating properly testing at high speeds can cause loss of control which could result in death or serious injury 00289a Be sure that all lights and switches operate properly before operating motorcycle Low visibility of rider can result in death or serious injury 00316a 8 Test the brake light CALIPER REPAIR TOOL NAME PART NUMBER BRA...

Page 125: ...ear safety glasses when working with compressed air Never use your hand to check for air leaks or to determine air flow rates 00061a 2 Blow out drilled passages and bore with a clean air supply 3 Wipe dry with a clean lint free cloth 4 Carefully inspect all components Replace any parts that appear damaged or worn Do not hone caliper piston bore Always replace brake pads in complete sets for correc...

Page 126: ...metric about 1 2 turn c Pump brake hand lever to drain brake fluid d Tighten bleeder valve to 36 60 in lbs 4 7 Nm NOTE Damaged banjo bolt seating surfaces will leak when reas sembled Prevent damage to seating surfaces by carefully removing brake line components 3 See Figure 2 50 Remove the banjo bolt 14 metric and two copper washers 16 to disconnect brake line 15 from master cylinder 4 Discard cop...

Page 127: ...use brake failure which could result in death or serious injury 00291a 1 Clean all parts with denatured alcohol or D O T 4 BRAKE FLUID Do not contaminate with mineral oil or other solvents Wipe dry with a clean lint free cloth Blow out drilled passages and bore with a clean air supply Do not use a wire or similar instrument to clean drilled passages in bottom of reservoir 2 Inspect piston bore in ...

Page 128: ...id will damage painted and body panel surfaces it comes in contact with Always use caution and protect surfaces from spills whenever brake work is per formed Failure to comply can result in cosmetic damage 00239b 6 Protect body work from brake fluid 7 With the master cylinder in a level position add D O T 4 BRAKE FLUID Bring fluid level to within 1 8 in 3 2 mm of molded boss inside front master cy...

Page 129: ...TNING ULYSSES 3 Remove p clamp 2 attaching brake line 3 to right side of lower fork clamp 4 On Ulysses models remove fasteners 4 on right lower fender NOTE Damaged banjo bolt seating surfaces will leak when reas sembled Prevent damage to seating surfaces by carefully removing brake line components 5 See Figure 2 50 Remove master cylinder banjo bolt metric 14 and two copper washers 16 to disconnect...

Page 130: ...ee Figure 2 55 Install new copper washer 3 brake line and new copper washer 3 onto banjo bolt 2 b See Figure 2 56 Finger tighten banjo bolt onto front caliper and position brake line as shown in the figure 6 See Figure 2 56 Install and tighten p clamp 1 with fastener on lower triple clamp to 36 60 in lbs 4 7 Nm 7 See Figure 2 50 Tighten master cylinder banjo bolt 14 metric to 16 20 ft lbs 22 27 Nm...

Page 131: ...using a BRAKE CAL IPER PISTON REMOVER Part No B 42887 5 See Figure 2 60 Remove and discard piston o rings 6 1 4 3 2 sm00535 1 Pin hanger set 2 Caliper pad spring 3 Caliper fasteners 4 4 Bleeder valve Figure 2 58 Pad Spring Typical sm00536 Figure 2 59 Removing Pistons B 42887 CLEANING AND INSPECTION Use denatured alcohol to clean brake system components Do not use mineral based solvents such as gas...

Page 132: ...o 15 19 ft lbs 20 26 Nm INSTALLATION 1 See Figure 2 60 Install pad spring 7 and brake pads 10 2 Install pin hanger set 1 and tighten to 11 14 ft lbs 15 19 Nm 3 Slide the caliper over the rotor up to the mount and install caliper on caliper mount Using LOCTITE 271 red Tighten caliper mounting fasteners 9 to 35 37 ft lbs 47 50 Nm Avoid leakage Be sure gaskets banjo bolt s brake line and master cylin...

Page 133: ...aliper mounting fasteners 2 Piston Pin hanger set 2 6 Brake bleeder Piston o rings 10 7 3 Brake pads Pad spring Bleeder cap 4 11 8 Caliper Caliper fasteners 4 Small o ring Figure 2 60 Front Caliper Assembly HOME 2009 XB Service Chassis 2 55 ...

Page 134: ...2 61 Install pedal bushings 6 2 Install shift brake pedal sleeve 5 3 Install brake pedal 7 using LOCTITE 271 Red and tighten fastener 4 to 22 24 ft lbs 30 33 Nm 4 Install clevis pin 2 5 Install new cotter pin 3 1 3 2 5 4 7 6 sm00119 1 Rear master cylinder body 2 Clevis pin 3 Cotter pin 4 Brake pedal fastener 5 Shift brake pedal sleeve 6 Pedal bushings 2 7 Brake pedal Figure 2 61 Brake Pedal Assemb...

Page 135: ... 4 See Figure 2 63 Remove brake reservoir hose 6 at master cylinder 5 Remove seat sm00488 Figure 2 62 Rear Caliper Bleeder Valve 3 1 6 5 2 4 sm00539 1 Banjo bolt metric and rear brake light switch 2 Brake line 3 Fasteners 2 metric 4 Master cylinder body 5 Clamp 6 Remote reservoir hose Figure 2 63 Rear Master Cylinder Firebolt 6 See Figure 2 64 or Figure 2 65 Disconnect brake light connector locate...

Page 136: ...e Reservoir Lightning REMOVAL ULYSSES 1 See Figure 2 68 Drain brake fluid into a suitable container Discard used fluid according to local laws a Install a length of plastic tubing over caliper bleeder valve Place free end in a suitable container b Open bleeder valve metric about 1 2 turn c Pump brake foot pedal to drain brake fluid d Tighten bleeder valve to 36 60 in lbs 4 7 Nm 2 Remove right side...

Page 137: ...ush washers 3 to detach brake line 2 from master cylinder 4 Discard copper crush washers 8 Remove fasteners 11 to detach master cylinder 4 from rider footpeg mount 9 See Figure 2 71 Detach remote reservoir a On Ulysses models remove air flow guide b Remove top clamp 2 on hose connected to master cylinder c Remove fastener and washer 3 to detach reservoir 1 from frame if necessary sm00546 Figure 2 ...

Page 138: ...rate rubber parts even after assembly Deterioration of these components can cause brake failure which could result in death or serious injury 00291a 1 Thoroughly clean master cylinder and all brake system components Stand master cylinder on wooden block or towel to protect seating surfaces a Examine walls of master cylinder reservoir for scratches and grooves Replace if damaged b Verify that vent ...

Page 139: ...cle Low visibility of rider can result in death or serious injury 00316a After servicing brakes and before moving motorcycle pump brakes to build brake system pressure Insufficient pressure can adversely affect brake performance which could result in death or serious injury 00279a After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift caus...

Page 140: ...cle pump brakes to build brake system pressure Insufficient pressure can adversely affect brake performance which could result in death or serious injury 00279a After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 8 Install seat HOME 2 62 2009 XB Service Chassis...

Page 141: ...alve metric about 1 2 turn c Pump brake foot pedal to drain brake fluid d Tighten bleeder valve to 36 60 in lbs 4 7 Nm 7 See Figure 2 75 Remove p clamp 2 securing brake line 1 to the left side of swingarm Remove brake line components carefully Damage to seating surfaces can cause leakage 00320a 8 Remove banjo bolt 3 from rear caliper Discard copper washers 9 See Figure 2 76 Remove brake light swit...

Page 142: ... result in death or serious injury 00279a After repairing the brake system test brakes at low speed If brakes are not operating properly testing at high speeds can cause loss of control which could result in death or serious injury 00289a 11 Test ride motorcycle and check for proper brake operation REMOVAL LIGHTNING 1 Remove seat To prevent accidental vehicle start up which could cause death or se...

Page 143: ...ore moving motorcycle pump brakes to build brake system pressure Insufficient pressure can adversely affect brake performance which could result in death or serious injury 00279a After repairing the brake system test brakes at low speed If brakes are not operating properly testing at high speeds can cause loss of control which could result in death or serious injury 00289a 11 Test ride motorcycle ...

Page 144: ...SES MODELS 5 See Figure 2 78 Connect brake line switch connector beneath seat 6 Install brake light switch banjo bolt and new copper washers to rear caliper Tighten to 16 20 ft lbs 22 27 Nm 7 Bleed brakes See 1 7 BRAKE SYSTEM MAINTENANCE Bleeding Brakes 8 Install negative battery cable and tighten to 72 96 in lbs 8 11 Nm See 1 5 BATTERY MAINTENANCE After installing seat pull upward on seat to be s...

Page 145: ...rmance which could result in death or serious injury 00279a After repairing the brake system test brakes at low speed If brakes are not operating properly testing at high speeds can cause loss of control which could result in death or serious injury 00289a 11 Test ride motorcycle and check for proper brake operation HOME 2009 XB Service Chassis 2 67 ...

Page 146: ...anjo bolt 2 connecting brake line to rear caliper 3 Remove caliper mounting fasteners 6 and 7 1 6 5 8 2 4 3 7 sm00554 1 Brake line 2 Banjo bolt metric 3 Copper washers 2 4 Bleeder valve metric 5 Pin plug 6 Small caliper fastener 7 Large caliper fastener 8 Caliper mounting fasteners 2 Figure 2 81 Rear Brake Caliper DISASSEMBLY TOOL NAME PART NUMBER BRAKE CALIPER PISTON REMOVER B 42887 1 See Figure ...

Page 147: ...d result in death or serious injury 00111a 4 Inspect brake pads for damage or excessive wear Replace both pads as a set if the friction material of either pad is worn to 0 04 in 1 0 mm or less Table 2 24 Rear Rotor Runout MM IN RUNOUT 0 45 0 0177 Rotor radial 0 39 0 0154 Rotor lateral ASSEMBLY 1 See Figure 2 82 Place clip 1 inside caliper body as shown NOTE To verify proper brake pad to brake roto...

Page 148: ...uid level in reservoir After servicing brakes and before moving motorcycle pump brakes to build brake system pressure Insufficient pressure can adversely affect brake performance which could result in death or serious injury 00279a After repairing the brake system test brakes at low speed If brakes are not operating properly testing at high speeds can cause loss of control which could result in de...

Page 149: ... front fender 1 with fasteners and washers 2 and tighten to 36 48 in lbs 4 5 4 Nm REAR FENDER XB9SX XB12SCG Removal 1 See Figure 2 86 a Remove fasteners 4 securing the rear fender 3 to swingarm b Remove fender fasteners 6 2 Remove rear fender 3 Installation 1 See Figure 2 86 Align rear fender to the swingarm 2 Install rear fender with fasteners 6 and tighten to 12 36 in lbs 1 4 4 Nm NOTE It is nec...

Page 150: ...Installing Upper Front Fender NOTE When installing the upper front fender it is important that the front brake line p clamp be aligned with the slot in the back right side of the upper front fender before installing and tight ening fastener 1 See Figure 2 87 Align upper front fender 2 to fender mounts on lower triple clamp and install upper front fender fasteners and washers 1 and tighten to 12 36...

Page 151: ...mp and slide the stopper ring up and over the top of the fork 6 See Figure 2 89 Remove fork from lower fork clamp 4 7 Repeat 4 through 6 on opposite side sm00560 Figure 2 88 Stopper Ring 2 3 1 4 5 5 sm00559 1 Screw pinch fastener 2 Steering stem pinch fastener 3 Triple clamp upper 4 Triple clamp assembly lower 5 Screw pinch fastener Figure 2 89 Upper and Lower Fork Clamp Assembly Typical DISASSEMB...

Page 152: ...s no resistance felt in order to remove the fork fluid FRONT FORK COMPRESSOR Part No HD 45966 comes with a cup and screw that are for FLT models only and not to be used with Buell When using the FRONT FORK COMPRESSOR Part No HD 45966 be sure not to bind the outer fork tube on the tool 5 See Figure 2 92 Install the fork assembly in the FRONT FORK COMPRESSOR Part No HD 45966 sm03817 Figure 2 91 Fork...

Page 153: ... slider fork 22 from the outer tube 14 14 Remove the slide bushing 16 from slider fork by prying the slide bushing at the split NOTE Be careful not to over expand slide bushing 15 Remove guide bushing 17 seal spacer 18 oil seal 19 oil seal stopper ring 20 and dust seal 21 16 See Figure 2 96 Push the damper rod 6 all the way down in order to seat it and prevent it from spinning in order to remove t...

Page 154: ...lar 11 3 19 Spring joint Slider piston Oil seal 20 12 4 Oil seal stopper ring Spring Push rod 5 21 13 Damper jamnut Dust seal Stopper ring 14 6 22 Outer tube Damper rod assembly Slider fork 23 15 7 Axle clamp bolt Reflector assembly Centering plate 8 16 Washer Slide bushing Figure 2 96 Front Fork Assembly XB All Models HOME 2 76 2009 XB Service Chassis ...

Page 155: ...the fork seal and dust boot depending on the size of your slider fork You will either use FORK SEAL DRIVER AND DUST BOOT INSTALLER Part No B 43721 41mm or FORK SEAL DRIVER AND DUST BOOT INSTALLER Part No B 42571 43mm or FORK SEAL DRIVER AND DUST BOOT INSTALLER Part No B 48867 47mm 2 Place the seal driver over the end of the slider fork 22 and the slide bushing channel to avoid damaging the oil sea...

Page 156: ...s installed down 17 See Figure 2 96 Install the fork spring 12 fork spring joint 11 and fork spring collar 10 over the damper rod retrieval tool NOTE Be sure to never over compress the fork assembly 18 Remove the fork slider from the vise and install the fork assembly in the front fork compressor 19 See Figure 2 93 Compress the fork spring until you have access to the damper rod assembly with jamn...

Page 157: ...4 Repeat previous steps on second front fork 5 Temporarily install front axle to the fork assemblies to verify correct alignment 6 Use LOCTITE 271 red on upper fork clamp fasteners Tighten to 23 25 ft lbs 31 2 33 8 Nm 7 Use LOCTITE 271 red on lower fork clamp fasteners Tighten to 20 22 ft lbs 27 30 Nm 8 Repeat torque sequence in previous two steps 9 Install front brake caliper onto caliper mount S...

Page 158: ...See Figure 2 102 Hold or brace the lower fork clamp and remove steering stem capnut 1 8 Remove the upper fork clamp 4 9 Remove the stem 6 and lower fork clamp 8 as an assembly 10 Remove ignition switch 11 If steering head bearings need replacing see 2 18 STEERING HEAD BEARINGS 1 3 2 3 4 5 6 7 8 7 sm00573 1 Stem capnut 2 Stem pinch fastener 3 Upper fork clamp pinch fastener 4 Upper fork clamp 5 Hea...

Page 159: ...stall handlebars See 2 31 HANDLEBARS FIREBOLT 15 Install cable straps a Install cable strap to the right of ignition switch securing right hand switch and brake line wires to upper fork clamp b Install cable strap to the left of ignition switch securing left hand switch and clutch cable wires to upper fork clamp c Connect ignition switch and install cable strap REMOVAL LIGHTNING ULYSSES 1 Place a ...

Page 160: ... should be adjusted equally Forks that are not properly adjusted can lead to loss of control which could result in death or serious injury 00124b NOTE For additional information see 2 16 FRONT FORKS ALL MODELS 9 See Figure 2 101 Position both forks with same number alignment lines 4 visible and reflectors facing to the sides Do not tighten 10 Use LOCTITE 271 red on upper fork clamp fasteners and t...

Page 161: ...ches Upper Bearing Removed For Clarity INSTALLATION TOOL NAME PART NUMBER BACKING PLATE B 43993 12 STEERING HEAD BEARING INSTALLATION TOOL B 45521 STEERING HEAD BEARING RACE INSTALLER HD 39302 NOTES Steering head bearings should be installed one at a time in order to verify proper alignment of bearing in bore Use the backing plate for wheel bearing installation B 43993 12 on the opposite side of t...

Page 162: ...LLATION TOOL Part No B 45521 3 Place the WHEEL BEARING BACKING PLATE with the large diameter facing the frame over the forcing screw 4 Install the bearing 4 washer 5 and nut 6 from the steering head bearing race installer onto the forcing screw 1 5 Tighten the nut 6 by hand until the bearing is started into the bore in the steering head 6 See Figure 2 108 Hold the forcing screw while tightening th...

Page 163: ... 8 Nm 14 On Lightning and Ulysses models install front modules See 2 30 FRONT MODULES LIGHTNING ULYSSES 15 On Firebolt models install headlight assembly and support bracket See 2 26 HEADLAMP ASSEMBLY AND SUP PORT BRACKET 16 Install front brake lever housing See 2 10 FRONT BRAKE SIX PISTON CALIPER 2 1 sm00579 1 Forcing screw 2 Nut Figure 2 108 Install Bearings HOME 2009 XB Service Chassis 2 85 ...

Page 164: ...Tighten rear axle pinch bolt 12 to 40 45 ft lbs 54 61 Nm 5 For Firebolt Lightning Install right side rider footpeg mount See 2 34 FOOTPEG HEEL GUARD AND MOUNT FIREBOLT LIGHTNING For Ulysses Install right side rider passenger footpeg heel guard and mount with the rider and passenger foot pegs See 2 35 HEEL GUARD AND FOOTPEG MOUNTS ULYSSES MODELS 2 1 sm00302 1 Axle 2 Pinch bolt Figure 2 109 Rear Axl...

Page 165: ... line fittings from swingarm See 3 12 OIL LINE FITTINGS NOTE See Figure 2 110 Remove swingarm bearings 5 only if replacement is required The complete bearing assembly must be replaced as a unit when replacement is necessary Do not intermix bearing components 2 See Figure 2 110 Remove swingarm bearings 5 using SLIDE HAMMER Part No SNAP ON CJ1275 or equi valent and 3 4 in bearing remover and spacer ...

Page 166: ...hten to 108 156 in lbs 12 17 6 Nm See 3 12 OIL LINE FITTINGS 4 See Figure 2 110 Install drain plug 8 Tighten to 26 29 ft lbs 35 39 Nm sm00585 Figure 2 111 Jiffy Tite Quick Disconnect Oil Line Fittings INSTALLATION SWINGARM 1 See Figure 2 110 Align swingarm 1 in pivot of engine crankcase 6 2 Install pivot shaft 9 with a special 7 8 in hex tool located in tool kit Apply ANTI SEIZE and tighten to 44 ...

Page 167: ... first If positive cable should contact ground with negative cable connected the resulting sparks can cause a battery explosion which could result in death or serious injury 00068a 14 Connect battery cables to battery positive cable red first Tighten to 72 96 in lbs 8 11 Nm See 1 5 BATTERY MAINTENANCE After installing seat pull upward on seat to be sure it is locked in position While riding a loos...

Page 168: ...ll upper snubber 1 tightening snubber fastener 2 to 12 36 in lbs 1 4 4 Nm 2 Loosely install front isolator bracket 4 with front isolator bolt 6 3 Install front isolator bracket fasteners 5 and tighten to 49 51 ft lbs 66 69 Nm NOTE Avoid cross threading front isolator bolt or insert Keep weight of motorcycle off front isolator by alternately tightening front isolator bolt and raising scissor jack t...

Page 169: ...orate NOTE Do not sand or scuff the surface where the puck will be installed 2 See Figure 2 114 Identify the left and right side pucks by forward facing directional point 3 With the adhesive backing in place locate the puck on the frame making contact all around its perimeter and fit ting the horizontal crease and V shaped edge 4 See Figure 2 115 With a pencil outline the upper rear and lower rear...

Page 170: ... fastener See 3 4 ENGINE ROTA TION FOR SERVICE 10 See Figure 2 117 Lift and remove frame from the motor cycle INSTALLATION 1 Place frame over the motorcycle 2 Install rear isolator fastener See 3 6 ENGINE INSTALLA TION 3 Install main wire harness See 6 27 MAIN WIRE HAR NESS 4 Install upper and lower fork clamps See 2 17 FORK CLAMPS UPPER AND LOWER 5 Install rear shock See 2 23 REAR SHOCK ABSORBER ...

Page 171: ...m00588 7 1 Lower shock mount Shock remote reservoir clamp fastener 2 8 Shock remote reservoir clamp Lower shock mount sleeve 9 3 Lower shock mount fastener Shock remote reservoir 4 10 Shock reservoir body Shock spring retainer kit 11 5 Rear shock spring Upper shock mount fastener 6 12 Lower shock mount nut and washer Washers Figure 2 118 Rear Shock Absorber Assembly Firebolt HOME 2009 XB Service C...

Page 172: ...ir clamp fastener 2 8 Remote reservoir clamp Shock reservoir body 9 3 Upper shock mount fastener Remote reservoir 4 10 Lower shock mount nut Lower shock mount 11 5 Shock spring retainer kit Washers 2 6 12 Lower shock mount sleeve Rear shock spring Figure 2 119 Rear Shock Absorber Assembly Lightning HOME 2 94 2009 XB Service Chassis ...

Page 173: ...tener Rear shock body 6 14 Remote reservoir clamp fastener Upper shock mount fastener 15 7 Rear shock spring Remote reservoir clamp 8 16 Remote reservoir Shock spring retainer kit Figure 2 120 Rear Shock Absorber Assembly Ulysses Models REMOVAL FIREBOLT 1 Remove seat Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks ...

Page 174: ...he cable tie 2 securing vent hose to shock housing 5 Remove the nut 4 and washer 5 from the lower shock bolt and raise scissor jack until the lower bolt can be removed by hand 6 After removing both shock fasteners 7 9 and reservoir clamp fastener 1 remove rear shock assembly and reservoir For XB9SX XB12S and XB12Scg The remote reservoir can be slid out of the clamp and the clamp left attached to t...

Page 175: ...t routing a Loosely install reservoir in clamp b See Figure 2 123 Temporarily place upper body work onto tail section and adjust reservoir placement so the adjuster screw aligns with bodywork c Tighten clamp on reservoir to 120 144 in lbs 13 5 16 2 Nm 4 Install cable strap NOTE See Figure 2 118 Verify compression adjuster screw is facing up 5 Install upper body work See 2 39 SUBFRAME TAIL ASSEMBLY...

Page 176: ...NOTES See Figure 2 125 Verify preload adjuster knob is facing out Verify that fan spins freely after shock is installed 4 Install the two fasteners holding the preload adjuster in place and tighten to 48 72 in lbs 5 4 8 Nm 5 Install rear shock reservoir clamp 7 and fastener 6 and tighten clamp fastener to 80 88 in lbs 9 0 9 9 Nm 6 Install ECM See 4 4 ELECTRONIC CONTROL MODULE ECM 7 Install cable s...

Page 177: ...ont housing 5 Screw long bottom 6 Ferrules 7 Cable wheel 8 Rear housing 9 Locating pin Figure 2 127 Cable Connections CLEANING AND INSPECTION Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury Wear safety glasses when working with compressed air Never use your hand to check for air leaks or to determine air flow rates 00061a Clean all parts exce...

Page 178: ...ol cable barrel in the throttle cam wheel of the throttle body and then slip the elbow into the slotted hole in the throttle cable mounting bracket Position the throttle control cable in the same manner so both elbows are inserted into the bracket 5 Tighten the cable adjustment nuts that were removed for installation purposes onto the threaded end of the elbows and thread them on until there is ex...

Page 179: ...sm03924 Figure 2 128 Throttle Cable Retention Clip sm03923 Figure 2 129 Throttle Cable Retention Clip Inside View sm04534 Figure 2 130 Throttle cable elbow alignment HOME 2009 XB Service Chassis 2 101 ...

Page 180: ... release tension from hand lever and clutch release mechanism 8 See Figure 2 133 Remove clutch cable ferrule 7 from hand lever 4 NOTE See D 1 APPENDIX D HOSE AND WIRE ROUTING 9 Pull clutch cable down and out of upper triple clamp 10 Remove three TORX screws with washers securing clutch inspection cover 3 2 1 4 is01014 1 Rubber boot 2 Cable adjuster 3 Jam nut 4 Cable end Figure 2 131 Clutch Cable A...

Page 181: ...Remove clutch cable and fitting 15 Remove and discard o ring on the clutch cable fitting 1 7 3 7 11 2 9 4 5 8 6 10 sm00602 1 Primary cover 2 Clutch inspection cover 3 Engine shift lever 4 Shift pedal assembly 5 Shift linkage assembly 6 Flange head bolt 7 Bearings shift lever 8 Sleeve shift lever 9 Shifter bracket Ulysses only 10 Oil seal rubber washer 11 Drain plug Figure 2 134 Shifter Linkage HOM...

Page 182: ...r pinch screw to 48 60 in lbs 5 4 7 Nm 8 See Figure 2 137 If the shift linkage assembly 8 was removed for any reason apply LOCTITE 271 to fasteners and tighten to 36 60 in lbs 4 7 Nm Adjust to rider com fort NOTE See D 1 APPENDIX D HOSE AND WIRE ROUTING 9 Route clutch cable through upper triple clamp 8 1 2 5 3 7 4 6 sm00949 1 Lever engine 2 Primary cover 3 Clutch inspection cover 4 Drain plug 5 Fl...

Page 183: ...9 36 6 Nm 17 Adjust clutch cable See 1 9 CLUTCH TRANSMIS SION PRIMARY FLUID 18 Install chin fairing See 2 50 CHIN FAIRING 19 Connect negative battery cable to battery terminal Tighten fastener to 72 96 in lbs 8 11 Nm After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury...

Page 184: ...rt bracket 1 3 2 sm00604 1 Flasher 2 Bank angle sensor 3 Electronic control module Figure 2 138 Headlamp Support Bracket Firebolt sm00605 Figure 2 139 Headlamp Connector Firebolt DISASSEMBLY FIREBOLT 1 See Figure 2 138 Remove bank angle sensor 2 2 Remove flasher 1 3 See Figure 2 140 Remove black rubber cover 4 from rear of headlights 4 Disconnect black connector from headlights 5 Disconnect headli...

Page 185: ...t bracket up 2 and tighten pivot fasteners 1 to 72 96 in lbs 8 11 Nm 7 See Figure 2 138 Install electronic control module 3 8 See Figure 2 140 Align electronic control module and headlight support bracket with fairing support bracket 9 Tighten electronic control module fasteners to 72 96 in lbs 8 11 Nm 10 Connect flasher 1 and bank angle sensor 2 11 Install front fairing See 2 47 FRONT FAIRING WIN...

Page 186: ... 2 142 b For Ulysses See Figure 2 143 NOTE Horn 1 can remain attached to support bracket The horn can be removed and replaced as needed 5 Separate headlight connector 38 5 6 Remove female connector 38B from headlight support bracket 9 by sliding connector up and off of bracket clip 7 Remove both upper headlight fasteners 6 NOTES Access the headlight fasteners with a socket extension through the op...

Page 187: ...n connectors 122 Headlight assembly 8 3 Fasteners 2 headlight support bracket Horn bracket 4 9 Horn fastener Headlight support bracket 10 5 Left and right front modules Headlight connector 38 Figure 2 142 Electrical Connectors Behind Windscreen Lightning HOME 2009 XB Service Chassis 2 109 ...

Page 188: ...5 from headlight bulbs 3 and remove along with position bulb socket 6 3 Remove bulb holders 2 4 Remove headlight bulbs 3 from back of headlight housing 4 ASSEMBLY LIGHTNING ULYSSES 1 See Figure 2 144 Align and install headlight bulbs 3 into back of headlight housing 4 NOTE The tab on the base of the headlight bulb should rest between the two tabs located at the top of the hole on the back of the h...

Page 189: ...n 4 Attach headlight connector to headlight support bracket 5 Connect headlight connector 38 5 6 Install horn 1 and tighten fastener 4 to 36 60 in lbs 4 7 Nm 7 Connect horn connectors 122 2 8 Adjust headlights See 1 17 HEADLAMP 9 Install windshield and windscreen See 2 48 WINDSHIELD AND WINDSCREEN LIGHTNING AND ULYSSES Connect positive battery cable first If positive cable should contact ground wi...

Page 190: ...eners and washers 4 8 and p clamp 7 Tighten to 16 18 ft lbs 22 26 Nm 3 Connect instrument cluster connector and install instru ment cluster Tightening to 12 36 in lbs 1 4 4 Nm See 6 26 INSTRUMENT MODULE 4 Install horn and tighten fasteners to 72 96 in lbs 8 10 Nm See 6 13 HORN 5 Install fuse block relay and p clamp tightening fasteners to 72 96 in lbs 8 11 Nm See 6 21 MAIN FUSE AND FUSES 6 Install...

Page 191: ...t bracket Jam nut 2 6 Washer Instrument cluster 7 3 P clamp Rubber grommet 4 8 Fairing support bracket fasteners and washers P clamp fastener and washers Figure 2 145 Fairing Support Bracket Assembly Firebolt HOME 2009 XB Service Chassis 2 113 ...

Page 192: ... with pivot shafts 3 6 See 2 25 CLUTCH CONTROL and 2 10 FRONT BRAKE SIX PISTON CALIPER 2 Install jam nuts 5 and tighten to 39 48 in lbs 4 4 5 4 Nm 3 Install pivot shaft risers 4 and tighten to 43 49 in lbs 4 8 5 5 Nm 4 Spread deflectors 1 and place over the pivot shaft and riser ends 5 Snap deflectors onto handlebar end caps 7 6 Install new deflector fasteners 2 and tighten to 24 36 in lbs 2 7 4 N...

Page 193: ... provide additional protection for the headlight assemblies REMOVAL AND INSTALLATION 1 See Figure 2 147 Grab headlamp grille on either side and spread to remove from headlamp assemblies 2 Spread headlamp grille with hands and snap back in place over headlamp assemblies sm00572 Figure 2 147 Headlamp Grille Typical HOME 2009 XB Service Chassis 2 115 ...

Page 194: ...KEY SWITCH NOTE See Figure 2 149 Once the ignition switch has been removed there will be two remaining fasteners 9 Disconnect front turn signals See 6 15 FRONT TURN SIGNALS 10 See Figure 2 149 Remove fastener attaching p clamp to rear side of right front module NOTE See Figure 2 148 Lightning or Figure 2 150 Ulysses Once the clamp load has been released on the final fastener securing the right fro...

Page 195: ... Tighten fasteners to 36 60 in lbs 4 7 Nm 8 Connect speedometer 9 On Ulysses model connect auxiliary outlet 10 Install headlamp assembly and support bracket See 2 26 HEADLAMP ASSEMBLY AND SUPPORT BRACKET 11 Install windshield and windscreen See 2 48 WINDSHIELD AND WINDSCREEN LIGHTNING AND ULYSSES Connect positive battery cable first If positive cable should contact ground with negative cable conne...

Page 196: ...oved from fork clamp 4 Remove clip on end cap 1 INSTALLATION Right Clip On 1 Install right switch gear housing 2 Install right clip on into right fork clamp and tighten fastener to 24 26 ft lbs 33 35 Nm 3 Install front brake master cylinder Tighten but do not torque 4 Install throttle and grip onto right clip on See 2 24 THROTTLE CONTROL 5 Install end cap onto right clip on 6 Position brake hand l...

Page 197: ... screws in place after applying LOC TITE 271 red c Tighten both front screws to 10 12 ft lbs 14 16 Nm d Then tighten both rear screws 10 12 ft lbs 14 16 Nm 3 Install clutch hand control Tighten but do not torque See 2 25 CLUTCH CONTROL 4 Install left switch housing 5 Check control wire routings See D 1 APPENDIX D HOSE AND WIRE ROUTING a Route right hand control wires between the lower clamp and fo...

Page 198: ... Handlebar clamp 5 Left hand grip XB12X models are OEM equipped with heated handgrips 6 Handlebar Ulysses models 7 Handlebar XB9SX 8 Handlebar XB12Scg XB12Ss 9 Clutch cable hook Ulysses models Figure 2 153 Handlebar Assembly Lightning Ulysses HOME 2 120 2009 XB Service Chassis ...

Page 199: ... they actually are Adjust mirrors to see a small portion of the riders shoulders in each mirror This helps the rider establish the relative distance of vehicles to the rear of the motorcycle Before tightening adjuster nut position mirrors for rider 2 Install mirror 1 and while holding in position for rider vision tighten adjuster nut to 115 130 in lbs 13 14 7 Nm 2 3 1 1 2 3 4 4 sm00634 1 Mirror 2 ...

Page 200: ... non California vent clamp 2 Install heel guard 3 with fasteners 4 Tighten to 72 96 in lbs 8 11 Nm 3 Position spring 6 in footpeg 8 4 Position footpeg 8 and spring in footpeg mount 1 5 Install footpeg pin 9 6 Install clip 5 7 Apply LOCTITE 271 red and tighten to 36 48 in lbs 4 5 Nm 3 2 7 5 8 9 1 6 4 sm03637 1 Footpeg mount 2 Footpeg mount fasteners 3 Heel guard 4 Heel guard fasteners 5 Clip footpe...

Page 201: ... in lbs 8 11 Nm 6 Position footpeg 8 detent plate 6 ball 5 and spring 4 on to footpeg mount 3 7 Install footpeg pin 9 8 Install clip 7 9 Check that footpeg clicks in the up and down position 2 4 3 9 10 8 1 6 7 5 11 sm03837 1 Heel guard fasteners 2 Heel guard 3 Footpeg mount 4 Spring 5 Ball 6 Detent plate 7 Clip 8 Footpeg 9 Pin 10 Footpeg mount fastener 11 Jamnut Lightning only Figure 2 156 Passeng...

Page 202: ...licks in the up and down position 1 8 10 8 9 2 3 6 4 7 5 3 sm03636 1 Footpeg mount 2 Footpeg mount fasteners 3 3 Clip footpeg 4 Passenger footpeg 5 Detent plate 6 Ball 7 Spring 8 Pin 9 Spring 10 Rider footpeg Figure 2 157 Rider Footpeg Mount and Heel Guard Assembly Ulysses MOUNT REMOVAL 1 On the right side Remove the rear brake pedal fastener See 2 11 BRAKE PEDAL 2 See Figure 2 155 Remove footpeg ...

Page 203: ...rake Master Cylinder Location Ulysses HEEL GUARD REPLACEMENT 1 See Figure 2 160 If necessary cut the rubber heel guard tabs on the inside of the footpeg mount to remove the heel guard 2 Pull rubber cones of replacement heel guard through the holes in footpeg mount 3 Cut excess rubber from ends of cones capturing the heel guard to the footpeg mount sm00650 Figure 2 160 Heel Guard Ulysses HOME 2009 ...

Page 204: ...er 1 only 1 See Figure 2 162 Install sprocket cover 2 using sprocket cover fasteners 1 3 and tighten all fasteners and washers 1 to 12 36 in lbs 1 4 4 Nm 2 Install chin fairing See 2 50 CHIN FAIRING sm00122 Figure 2 161 Chin Fairing Assembly Right Rear Fasteners 2 3 1 sm00123 1 Long fastener and washer 2 Sprocket cover 3 Short fastener and washer 2 Figure 2 162 Sprocket Cover HOME 2 126 2009 XB Se...

Page 205: ...2 163 Install upper belt guard 1 to swingarm brace tightening fasteners 2 to 12 36 in lbs 1 4 4 Nm 2 Install stone guard 6 and tighten fasteners to 12 36 in lbs 1 4 4 Nm 3 Install lower belt guard 3 and tighten fasteners 4 to 12 36 in lbs 1 4 4 Nm 4 Tighten rear axle See 5 7 DRIVE BELT AND IDLER PULLEY 5 Tighten rear axle pinch fastener to 40 45 ft lbs 54 61 Nm 6 Install right side rider footrest ...

Page 206: ...n washers 4 4 Remove intake cover assembly 2 INSTALLATION 1 See Figure 2 164 Position intake cover assembly 2 over top of air cleaner cover NOTE Front fasteners are installed at a slight angle 2 Loosely install front fasteners 4 5 a On models with a translucent intake cover start the two front fasteners with top hat bushings and isolator washers 5 b On other models with molded in color start the t...

Page 207: ...asteners with nylon washers 2 4 Front intake cover fasteners with nylon washers 2 models without translucent covers 5 Front intake cover fasteners with top hat bushings 2 and isolating washers 4 translucent covers only Figure 2 164 Intake Cover Assembly HOME 2009 XB Service Chassis 2 129 ...

Page 208: ...9a 2 Disconnect battery by unthreading fastener removing negative cable black from battery first See 1 5 BATTERY MAINTENANCE 3 See Figure 2 165 Remove upper body work 1 from subframe tail assembly 7 a Remove body work fasteners 2 b Disconnect passenger seat lock cable 6 by removing cable from seat lock plate 4 and ferrule from keylock 3 c Lift upper tail body work 1 off subframe tail assembly 7 4 ...

Page 209: ...k 10 3 Lower tail body work fasteners Passenger seat lock 4 11 Passenger seat lock plate Trunk 12 5 Fastener Passenger seat lock retainer 6 13 Passenger seat lock cable License plate bracket 14 7 Passenger seat latch and fastener Subframe tail assembly Figure 2 165 Subframe Tail Assembly and Body Work Assembly Firebolt HOME 2009 XB Service Chassis 2 131 ...

Page 210: ...ubframe tail assembly 7 a Remove lower body work 9 underneath subframe tail assembly by removing fasteners 10 b Remove trunk 11 13 See Figure 2 167 Disconnect main battery ground 1 and ground to wire harness 2 14 Remove main fuse case 3 from subframe tail assembly NOTE When removing the main fuse case from subframe tail assembly be very careful not to bend the subframe 15 Cut cable strap 4 holding...

Page 211: ...embly 11 See Figure 2 168 Feed rear brake reservoir hose under neath subframe tail assembly and install rear brake reservoir tightening fastener to 48 72 in lbs 5 4 8 Nm 12 See Figure 2 167 Install cable strap holding rear brake lamp wire and connector 6 and rear brake reservoir hose 5 13 See Figure 2 165 Install lower body work 9 and trunk 11 onto subframe tail assembly 7 a Install trunk 11 b Ins...

Page 212: ...ious injury 00068a 22 Connect battery cables to battery positive cable red first Tighten to 72 96 in lbs 8 11 Nm See 1 5 BATTERY MAINTENANCE After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 23 Install seat and pillion HOME 2 134 2009 XB Service Chassis ...

Page 213: ...9 Remove fuse block and relay center from support bracket 8 Move rear main harness and shock absorber reservoir to right side of vehicle 9 Remove left side passenger footrest support assembly See 2 34 FOOTPEG HEEL GUARD AND MOUNT FIREBOLT LIGHTNING 10 See Figure 2 169 Remove the following fasteners a Left front trunk pan to left side tail section 14 b Left rear tail section to center tail section ...

Page 214: ...tive cable 4 12 Battery positive cable License plate lamp connector 45 13 5 Tail light connectors 93 Rear brake light switch connector 121 6 14 Ground terminals GRD1 and GRD3 Left and right trunk pan fasteners 15 7 Center tail section fastener to rear tail section ECM connectors 10 and 11 8 16 Fuse block and relay center Right tail section Figure 2 169 Main Harness and Electrical Connectors Under ...

Page 215: ...teners securing battery tray to side castings and tighten to 48 72 in lbs 5 4 8 Nm 6 Tighten fasteners 12 securing trunk pan to center tail section to 48 72 in lbs 5 4 8 Nm 7 Install left side passenger footrest support assembly See 2 34 FOOTPEG HEEL GUARD AND MOUNT FIRE BOLT LIGHTNING 8 Move rear main harness and shock absorber reservoir back to left side of vehicle Be sure that all lights and sw...

Page 216: ...nd terminal fastener 2 7 Passenger footrest support fastener with jam nut 2 8 Front trunk pan fastener to side tail section 2 9 Passenger footrest support fastener no jam nut 2 10 Seat latch assembly 11 Trunk pan assembly 12 Rear trunk pan fastener to center tail section 2 13 Rear shock reservoir bracket 14 Plastic lugs for manufacturing purposes only Figure 2 170 Tail Frame and Trunk Pan Assembly...

Page 217: ...nd right tail sections to center tail section but do not tighten 3 Install two fasteners 12 securing trunk pan to center tail section but do not tighten 4 Apply LOCTITE 271 red to threads of left and right rear tail sections fasteners 4 and tighten to 102 114 in lbs 11 5 12 8 Nm 5 Tighten fasteners 12 securing trunk pan to center tail section to 48 72 in lbs 5 4 8 Nm Be sure that all lights and sw...

Page 218: ... 36 in lbs 1 4 4 Nm b On XB12Ss models apply LOCTITE 271 red and install battery tray fasteners and tighten to 48 72 in lbs 5 4 8 Nm c Apply LOCTITE 271 red and install center tail sec tion fastener to rear tail section 15 Tighten to 102 114 in lbs 11 5 12 8 Nm d Apply LOCTITE 271 red and install fasteners attaching left and right tail sections to main frame fuel tank assembly and tighten to 21 23...

Page 219: ...t location The rear fastener attaches directly to the battery pan b Disconnect rear brake light switch connector 121 c Disconnect and remove Bank Angle Sensor 2 134 d Remove fuse block and relay center 5 e Remove main harness and plastic grommet 7 from battery pan f Remove fasteners securing battery tray to left and right tail sections g Lift battery pan straight up and out 7 Remove fastener secur...

Page 220: ... fuel tank assembly and tighten to 21 23 ft lbs 28 5 31 2 Nm b Install fastener attaching left front trunk pan to left side tail section and tighten to 12 36 in lbs 1 4 4 Nm 5 Install two fasteners securing the preload adjuster to the trunk pan and tighten to 36 60 in lbs 4 7 Nm 6 Install battery pan a Install fasteners securing battery tray to left and right tail sections and tighten to 72 96 in ...

Page 221: ...t pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 10 Install seat HOME 2009 XB Service Chassis 2 143 ...

Page 222: ...ont trunk pan fastener to side tail section 2 6 Ground terminal fastener 2 7 Trunk pan assembly 8 Rear trunk pan fastener to center tail loop 2 9 Seat latch assembly 10 Bank angle sensor bracket 11 Center tail loop 12 Center tail loop fastener to rear tail section 4 Figure 2 172 Tail Frame and Trunk Pan Assembly Ulysses HOME 2 144 2009 XB Service Chassis ...

Page 223: ...BANK ANGLE SENSOR BAS ASSEMBLY 1 Install center tail loop around left and right tail sections 2 Install fasteners securing left and right tail sections to center tail loop but do not tighten 3 Install two fasteners securing trunk pan to center tail loop but do not tighten 4 Route wire harness and auxiliary power outlet under seat latch bracket 5 Tighten nuts of left and right tail sections to 20 2...

Page 224: ...1 2 3 sm00664 1 Tail loop 2 License plate bracket 3 Wire cover Figure 2 173 Wire Cover Tail Loop and License Plate Bracket Ulysses HOME 2 146 2009 XB Service Chassis ...

Page 225: ...ptured in the plastic shield below the ECM You need to place your finger under the nut when removing the fastener to prevent the nut from falling out Slide the ECM to one side and loosely install the fastener to retain the nut in the correct location The rear fastener attaches directly to the battery pan 4 Remove ECM 5 Remove rear shock reservoir fastener and retainer 6 Disconnect the rear brake l...

Page 226: ...See 2 12 REAR BRAKE MASTER CYLINDER 3 Install shock reservoir retainer and fastener Tighten to 80 88 in lbs 9 0 9 9 Nm 4 Connect rear brake light switch connector 121 Be sure that all lights and switches operate properly before operating motorcycle Low visibility of rider can result in death or serious injury 00316a 5 Install ECM and tighten fasteners to 36 60 in lbs 4 7 Nm Connect positive batter...

Page 227: ... Sidestand assembly does not have to be removed from motorcycle in order to remove sidestand leg 1 Remove two fasteners from the left side of chin fairing See 2 50 CHIN FAIRING 2 See Figure 2 178 or Figure 2 179 Remove sidestand leg 3 Retract sidestand leg 9 4 Remove sidestand spring 1 and spring extension plate 3 using SNAP ON SPRING TOOL Part No HE 52B 5 Remove sidestand pivot pin circlip 7 and ...

Page 228: ...Extension plate should curve away from primary chain adjustment screw to allow for clearance around adjustment screw INSTALLATION 1 See Figure 2 179 Apply LOCTITE 271 red to the sidestand bracket fasteners 6 Loosely install the sidestand assembly to the crankcase with the sidestand bracket fasteners 6 Extend the sidestand leg 9 and hold forward in the fully extended position while tightening the s...

Page 229: ... 5 onto fairing support bracket and install turn signals 6 7 See 6 15 FRONT TURN SIGNALS 2 Install mirrors 2 with fasteners and tighten to 72 96 in lbs 8 11 Nm 3 Install two center 4 and four side windscreen fasteners 3 and tighten to 10 12 in lbs 1 1 4 Nm 1 7 6 5 4 2 3 sm00682 5 1 Front fairing Windshield 2 6 Mirrors Turn signal 7 3 Turn signal fastener Side windshield fastener 4 8 Center windshi...

Page 230: ...four windscreen fasteners and washers 3 2 Remove windscreen 4 Installation 1 See Figure 2 182 Position windscreen 4 onto left and right front modules 2 5 2 Install four fasteners 3 and tighten to 10 12 in lbs 1 1 1 4 Nm 4 1 3 2 5 3 sm00683 4 1 Windscreen Headlight mounting bracket 2 5 Left front module Right front module 3 Windscreen fastener and washer 4 Figure 2 182 Front Windscreen Lightning HO...

Page 231: ...1 See Figure 2 183 Position windscreen 6 onto left and right front modules 2 8 and the center fairing support 7 2 Install six fasteners and tighten to 10 12 in lbs 1 1 1 4 Nm 3 Install windshield 4 by pushing into place Pull on wind shield when installed to verify attachment 4 1 3 2 7 8 5 6 sm00684 5 1 Windscreen fasteners 6 Headlight mounting bracket 2 6 Left front module Windscreen 7 3 Fairing s...

Page 232: ...ins Remove windshield mounting hardware 3 securing the windshield to the windscreen and pull windshield from wind screen 7 8 10 9 11 1 2 3 5 4 6 13 12 sm05264 8 1 Left front module Windshield 2 9 Windshield mounting pin upper 2 Right front module 10 3 Fairing support center Windshield mounting hardware lower 2 4 11 Screw 2 Windscreen 12 5 Mounting grommet 2 Washer 2 6 13 Well nut 2 Windscreen scre...

Page 233: ...ng grommets 12 on the windscreen and pushing in place to install Pull on windshield to verify attachment 2 Insert well nuts 6 into the windshield and windscreen holes 3 See Figure 2 185 Install mounting screws and tighten 8 10 revolutions into the well nuts pd00272 Figure 2 185 Turn Down 8 10 Turns HOME 2009 XB Service Chassis 2 155 ...

Page 234: ...bs 1 4 4 Nm 3 Secure the voltage regulator and alternator wiring har nesses to the bottom of the left air scoop with three cable straps ENGINE SHROUD AIR SCOOP Removal 1 See Figure 2 186 On right side of motorcycle locate engine shroud air scoop 6 2 Remove three engine shroud air scoop fasteners 5 3 Remove engine shroud air scoop 6 Installation 1 See Figure 2 186 Position engine shroud air scoop 6...

Page 235: ...r air scoop fastener and washer 2 2 5 Oil cooler air scoop Engine shroud scoop fastener and washer 3 6 3 Engine shroud scoop Ram air scoop fastener and washer Figure 2 186 Ram Air Scoop Engine Shroud and Oil Cooler HOME 2009 XB Service Chassis 2 157 ...

Page 236: ... SETTER TOOL KIT Part No MAR39200HD 1 Apply LOCTITE 271 red on all fasteners 2 See Figure 2 187 Position the assembled chin fairing and loosely install right side fasteners and washers 6 3 Align center section 1 and loosely install center section fasteners and washers 2 NOTE Turn wheel full right or left for easier access to center fasteners 4 Align left section 3 and loosely install left side fas...

Page 237: ...189 Center Tab and Frame Slot Firebolt Pillion NOTE The trunk is located under the pillion 1 See Figure 2 190 Insert ignition key into the pillion lock located on the left side of motorcycle Turn key clockwise to disengage rear pillion latch NOTE Do not place keys in the trunk If pillion is installed keys will not be accessible 2 Lift and remove pillion 3 Install pillion by sliding metal locating ...

Page 238: ...sts in tail section After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 3 See Figure 2 196 Press down rapidly and firmly on rear of seat to engage seat latch Pull up on rear of seat to make sure latch is engaged 3 1 1 2 pd00242 1 Seat hooks 2 2 Seat latch 3 Tab...

Page 239: ...e to remove om00576 Figure 2 197 Seat Lock Ulysses Models om00574 Figure 2 198 Seat Removal Ulysses Models Installation 1 See Figure 2 199 Position and slide seat forward on motorcycle to engage front tab 3 with slot in frame and engage all four seat hooks 1 with posts on tail section After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift ...

Page 240: ...2 1 3 om00573 1 Seat hook 2 Seat lock latch 3 Front tab Figure 2 199 Seat Tab Hooks Ulysses Models HOME 2 162 2009 XB Service Chassis ...

Page 241: ... the hole in the trunk pan and plate now is the time to connect the cable end to the seat lock Seat lock plate must be aligned to tab on seat lock for proper installation 3 Install seat lock retainer 3 by aligning retainer to retainer grooves on back side of seat lock 1 4 Connect seat lock cable to latch a Install cable end 8 and cable 5 onto latch b Slide retainer 7 over pin on latch to lock cabl...

Page 242: ...ble 5 a Remove latch 8 from latch bracket 9 by removing two fasteners 7 b Remove cable end 6 and cable 5 from latch 8 4 Remove seat lock a Remove wire cover from bottom side of license plate bracket to access seat lock b Remove seat lock retainer 3 from seat lock 1 c Remove seat lock 1 from plate 2 and license plate bracket NOTE When removing seat lock 1 cable end 4 should release from seat lock 5...

Page 243: ...6 48 in lbs 4 5 4 Nm 7 Install license plate light fasteners and tighten to 12 36 in lbs 1 4 4 Nm After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 8 Install cable strap around seat lock cable in original loca tion 9 Install seat 8 9 3 6 5 4 7 10 1 2 11 sm038...

Page 244: ...ing the lever to the square groove that is cast into the seat lock 7 8 Fasten the lock lever 4 to the seat lock 7 with the washer 3 and fastener 2 9 Install the ferrule 8 of the seat lock cable 9 into the seat lock lever 4 10 Open and close the seat lock with ignition key to verify that cable is working properly 11 Install the seat lock cable 9 into the seat lock plate 6 12 Install upper body work...

Page 245: ...ove the two screws and the two nuts to remove the plastic cover 3 Remove the right hand rear fastener 3 4 Loosen but do not remove the right hand front fastener 1 5 Hold the triple tail rack 5 in place and remove the right hand grab handle 2 6 Slowly slide the tail towards the right NOTE The spring 6 in the left hand grab handle is held under ten sion 7 Loosen but do not remove the left hand front...

Page 246: ...ten 7 Tighten front and rear fasteners to the following specifica tions a Tighten rear fasteners 3 11 to 23 25 ft lbs 31 34 Nm b Tighten front fasteners 1 12 to 108 120 in lbs 12 13 5 Nm 8 Verify that the rack operates properly 9 Install the plastic wire cover under the license plate lamp Tighten the screws to 36 48 in lbs 4 0 5 4 Nm and tighten the nuts to 12 36 in lbs 1 4 4 Nm 4 5 4 6 8 9 2 1 14...

Page 247: ...ection castings This operation should be performed for one side case bracket at a time It does not matter which side case bracket is removed first 9 1 2 4 3 12 11 6 8 7 5 10 sm05172 1 X brace bracket 2 Rear mount side case bracket 3 Side case 4 Forward mount side case bracket 5 Fastener with locknut X brace mount 2 6 X brace mount 7 Fastener with Belleville washer rear mount side case bracket 2 8 ...

Page 248: ...a final step 1 See Figure 2 205 Install rear fastener 7 securing side case support bracket 2 to trunk pan attaching bracket to vehicle snug only 2 Install forward fastener 8 attaching side case bracket 4 to trunk pan snug only 3 Install fastener with locknut 5 attaching the X brace bracket 1 to the side case bracket 6 snug only 4 Install bolt 10 attaching side case bracket 11 to the back of the pa...

Page 249: ...cket 2 by attaching trunk pan mounts 5 to the grab handles by installing two fasteners with Belleville washers 6 into the lower grab handle Thread the fasteners in but do not tighten at this time 2 Install fasteners with nuts 7 securing the top case bracket lower mounts 4 to the cross bar mount 3 Do not tighten at this time 3 Tighten the two fasteners 6 attaching the top case mounting bracket 2 to...

Page 250: ...h Mechanism and Lock 4 See Figure 2 210 Loosen large hex nut and remove lock from latch mechanism Installation 1 See Figure 2 210 Install lock into new latch mechanism and secure with large hex nut 2 Slide latch mechanism into luggage case 3 See Figure 2 208 or Figure 2 209 Install two new Phillips head screws into latch mechanism and tighten NOTE See Figure 2 209 On the top case it will be necess...

Page 251: ...se locking latch 2 with key 2 Remove side case by pulling away from vehicle 3 Remove fastener 9 securing the side case bracket 10 to the back of the passenger footrest support bracket 4 Remove fastener and locknut 11 securing the X brace bracket 5 to the side case bracket 6 5 Remove forward fastener 8 securing side case bracket 3 to trunk pan 6 Remove rear fastener 7 securing side case bracket 4 t...

Page 252: ...emaining side LUGGAGE CASE LATCH MECHANISM Removal NOTE The lock assembly is non replaceable If it is determined that a new lock is needed the entire side case latch mechanism must now be replaced sm06004 Figure 2 212 Side Case Latch Mechanism NOTE See Figure 2 212 In order to access the two rivets securing the latch to the side case it will be necessary to unlock the latch to expose the rivet hea...

Page 253: ...NE INSTALLATION 3 24 3 7 CYLINDER HEAD 3 35 3 8 CYLINDER AND PISTON 3 51 3 9 OILING SYSTEM 3 60 3 10 OIL PUMP 3 61 3 11 OIL RESERVOIR AND OIL HOSE ROUTING 3 67 3 12 OIL LINE FITTINGS 3 69 3 13 OIL COOLER 3 71 3 14 OIL PRESSURE INDICATOR SWITCH 3 72 3 15 CRANKCASE BREATHING SYSTEM 3 74 3 16 HYDRAULIC LIFTERS 3 76 3 17 GEARCASE AND CAM GEARS 3 78 3 18 CRANKCASE 3 82 ENGINE ...

Page 254: ...NOTES ...

Page 255: ... INSTALLATION Assembly 8 1 10 8 Nm 72 96 in lbs Exhaust header nuts 3 4 ENGINE ROTATION FOR SERVICE Assembly 66 4 69 1 Nm 49 51 ft lbs Front isolator bolt 3 6 ENGINE INSTALLATION Assembly 66 69 Nm 49 51 ft lbs Front isolator bolt 3 4 ENGINE ROTATION FOR SERVICE Assembly 66 4 69 1 Nm 49 51 ft lbs Front isolator bracket mounting fasteners 3 6 ENGINE INSTALLATION Assembly 66 69 Nm 49 51 ft lbs Front ...

Page 256: ... muffler bracket 3 15 CRANKCASE BREATHING SYSTEM Reed Valve Replacement LOCTITE 222 purple 2 8 4 0 Nm 25 35 in lbs Reed valve block fasteners 3 15 CRANKCASE BREATHING SYSTEM Reed Valve Replacement LOCTITE 222 purple 0 6 0 8 Nm 5 7 in lbs Reed valve stop fastener 3 13 OIL COOLER Installation 7 5 8 8 Nm 66 78 in lbs Stabilizer bracket fastener 3 6 ENGINE INSTALLATION Assembly ANTI SEIZE 60 62 Nm 44 ...

Page 257: ...ICATION ITEM Sequential non waste spark Type 1050 1150 RPM Regular idle 12 mm Spark plug size Harley Davidson No 10R12X Spark plug type 0 8890 mm 0 035 in Spark plug gap 16 24 Nm 12 18 ft lbs Spark plug torque Table 3 3 Valve and Valve Seat Specifications SERVICE WEAR LIMITS NEW COMPONENTS VALVE 0 965 mm 0 0038 in 0 0254 0 0762 mm 0 001 0 003 in Fit in guide exhaust 0 965 mm 0 0038 in 0 0254 0 076...

Page 258: ... gap 0 1651 mm 0 0065 in 0 0508 0 1143 mm 0 0020 0 0045 in Compression ring side clearance top 0 1651 mm 0 0065 in 0 0406 0 1041 mm 0 0016 0 0041 in Compression ring side clearance 2nd 0 2388 mm 0 0094 in 0 0406 0 1930 mm 0 0016 0 0076 in Oil control ring side clearance 0 02540 mm 0 00100 in 0 00127 0 01143 mm 0 00005 0 00045 in Pin fit loose at room temperature Table 3 7 Cylinder Head Specificati...

Page 259: ...076 mm 0 003 in Feed scavenge inner outer gerotor clearance Table 3 12 Gearcase Specifications SERVICE WEAR LIMITS NEW COMPONENTS GEARCASE 0 076 mm 0 003 in 0 018 0 056 mm 0 0007 0 0022 in Cam gear shaft in bore loose 0 635 mm 0 025 in 0 127 0 356 mm 0 005 0 014 in Cam gear shaft end play min 0 838 mm 0 033 in 0 127 0 559 mm 0 005 0 022 in Front intake cam gear shaft end play min Table 3 13 Flywhe...

Page 260: ...0012 0 00086 in Bearing running clearance 0 127 mm 0 0050 in 0 058 0 109 mm 0 0023 0 0043 in Fit in oil pump body bore Table 3 15 Sprocket Shaft Bearing Specifications SPECIFICATION INTERFERENCE FIT ITEM 0 152 mm 0 006 in Outer race fit in crankcase tight 0 152 mm 0 006 in Inner race fit on shaft tight HOME 3 6 2009 XB Service Engine ...

Page 261: ...ession test s make sure that the throttle plate is in the closed position before starting engine Engine will start at an extremely high RPM if throttle plate is left open 1 Disconnect spark plug wire Clean around plug base and remove spark plug 2 Connect compression tester to cylinder 3 With throttle body throttle plate in wide open position crank engine continuously through 5 7 full compression s...

Page 262: ...rottle plate is left open Table 3 17 Air Leakage Test POSSIBLE CAUSES AIR LEAK LOCATION Intake valve leaking Throttle body intake Exhaust valve leaking Exhaust pipe Leaking gasket Head gasket DIAGNOSING SMOKING ENGINE OR HIGH OIL CONSUMPTION Perform the Compression Test See 3 3 ENGINE Compression Test If further testing is needed remove the suspect cylinder heads and inspect the following Oil leve...

Page 263: ...n the left side of the vehicle To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 2 Remove seat and disconnect battery cables from battery negative cable black first 3 Remove intake cover See 2 38 INTAKE COVER 4 Remove air filter base plate See 4 3 AIR CLEANER ASSEMBLY NOTE When removing the left air scoop the...

Page 264: ...inder head 13 Disconnect the following sensors a Temperature sensor 10 90 b Oxygen sensor 11 137 14 Remove idler pulley See 5 7 DRIVE BELT AND IDLER PULLEY NOTE See 6 17 INTERACTIVE EXHAUST SYSTEM for specific details on removal of interactive components 15 Remove muffler See 4 18 EXHAUST SYSTEM NOTE Secure right side rider footrest mount to the side to prevent cosmetic damage 16 Remove left and r...

Page 265: ...nd strap Fasteners 2 6 17 Bolt Rear isolator assembly 18 7 Fasteners for rear isolator assembly 4 Front tie bar assembly 8 19 Fasteners for front tie bar assembly 2 Washers for rear isolator assembly 4 20 9 Rear isolator bolt Nut for one fastener for front tie bar assembly 10 21 Center tie bar mount Rear tie bar assembly 22 11 Fasteners for rear tie bar assembly 2 Fasteners for center tie bar moun...

Page 266: ...r bolt 6 through front isolator 4 and loosely thread into frame Do not tighten at this point 3 Install isolator mounting fasteners 5 and tighten to 49 51 ft lbs 66 4 69 1 Nm 4 Tighten front isolator bolt to 49 51 ft lbs 66 4 69 1 Nm 5 See Figure 3 2 Tighten rear isolator bolt 20 to 25 27 ft lbs 33 9 36 6 Nm 6 Install rear tie bar 21 to frame and tighten to 25 27 ft lbs 33 9 36 6 Nm 7 See Figure 3 ...

Page 267: ...ND IDLER PULLEY 21 Install left and right side rider footpeg mount See 2 34 FOOTPEG HEEL GUARD AND MOUNT FIRE BOLT LIGHTNING or 2 35 HEEL GUARD AND FOOTPEG MOUNTS ULYSSES MODELS 22 Install sprocket cover See 2 36 SPROCKET COVER NOTE When installing the left side air scoop it is necessary to verify that the voltage regulator and alternator wiring harnesses are not trapped between the air scoop and ...

Page 268: ...le before proceeding 00048a 3 Remove seat and disconnect battery negative cable black first 4 Remove intake cover and air cleaner assembly See 2 49 AIR SCOOPS NOTE When removing the left air scoop the alternator and voltage regulator harnesses and connections are secured to the bottom of the air scoop with three cable straps 5 Remove left and right side air scoops See 2 50 CHIN FAIRING 6 Remove ch...

Page 269: ... to the main frame above the rear cylinder head 13 Disconnect the following sensors a Temperature sensor 90 10 b Oxygen sensor 137 11 14 Disconnect throttle cables from induction module throttle body NOTE In order to remove the rear drive belt it will be necessary to remove all existing belt guards 15 Remove rear belt and idler pulley See 5 7 DRIVE BELT AND IDLER PULLEY 16 Remove transmission spro...

Page 270: ...l cooler e Remove front tie bar 7 from V bracket f Remove front tie bar 7 from engine g Unbolt V bracket from main frame and remove V bracket 22 Remove center tie bar 13 from engine 23 Remove rear tie bar 21 from frame 24 Remove the cable strap securing the oil pressure wire neutral safety wire and muffler actuator cable in a bundle on the right side of the motorcycle just behind the oil pump body...

Page 271: ...ne 6 a Remove two p clamps 8 from feed oil line one on crankcase and one on swingarm oil reservoir b Remove feed oil line 6 at oil pump 1 c Disconnect feed oil line at swingarm oil reservoir and remove See 3 12 OIL LINE FITTINGS 30 Remove return oil line 7 a Remove p clamp 8 at swingarm oil reservoir 10 b Disconnect oil return line 7 at swingarm oil reservoir 10 See 3 12 OIL LINE FITTINGS c Discon...

Page 272: ...o crankcase Rear muffler bracket 10 3 Swingarm Oil reservoir Oil cooler feed line from oil pump 4 11 Oil filter Vent oil line 12 5 Oil line clamp Front muffler mount 6 13 Feed oil line Cable interactive exhaust 14 7 Drain plug Return oil line Figure 3 8 Oil Lines and Connections HOME 3 18 2009 XB Service Engine ...

Page 273: ... assembly 2 16 5 Ground strap Fasteners 2 6 17 Bolt Rear isolator assembly 18 7 Fasteners for rear isolator assembly 4 Front tie bar assembly 8 19 Fasteners for front tie bar assembly 2 Washers for rear isolator assembly 4 20 9 Rear isolator bolt Nut for one fastener for front tie bar assembly 10 21 Center tie bar mount Rear tie bar assembly 22 11 Fasteners for rear tie bar assembly 2 Fasteners fo...

Page 274: ...idestand assembly NOTE On Ulysses models it will be necessary to remove three fasteners in order to remove the sidestand assembly 33 Support engine with wide scissors jack 1 2 sm03933 1 Sidestand assembly 2 Bracket fasteners 2 Figure 3 11 Sidestand Assembly Extended NOTE See Figure 3 12 At this point it is necessary to support main frame with overhead hoist in order to remove rear isolator bolt Fa...

Page 275: ...d to engine NOTES On Firebolt models the transmission vent line runs up the left side of the frame and exits beneath the rear brake reservoir and hose On Lightning and Ulysses models the transmission vent line runs up the left side of the frame and exits underneath the left rear side of the intake cover assembly sm00730 Figure 3 14 Transmission Vent Line Firebolt sm00737 Figure 3 15 Transmission V...

Page 276: ... See Figure 3 18 Swingarm pivot shaft pinch bolt threaded insert d See Figure 3 19 Aluminum bushings from front exhaust mount e See Figure 3 20 Wire guard located under the sprocket cover sm00740 Figure 3 18 Threaded Insert 1 2 sm03745 1 Left side 2 Right side Figure 3 19 Front Exhaust Mount Bushings 2 piece sm02996 Figure 3 20 Wire Guard sm02979 Figure 3 21 Rear Isolator Assembly HOME 3 22 2009 X...

Page 277: ...rame and swingarm oil tank 43 Route a ratcheting tie down through the swingarm bear ings up over the main frame through the top stabilizer area back down to the ratchet mechanism and secure swingarm to main frame NOTE See Figure 3 23 This allows the vehicle to remain together as a rolling chassis to be removed from the lift and stored if necessary 44 Remove overhead support sm03740 Figure 3 22 Sec...

Page 278: ...ing items on the engine assembly as required a Shifter assembly See 5 3 PRIMARY COVER b See Figure 3 25 Install center tie bar mount with fasteners and tighten to 30 33 ft lbs 40 6 44 7 Nm NOTE Hand thread pivot shaft into crankcase prior to installing the threaded insert Remove pivot shaft after installing the threaded insert c See Figure 3 26 Apply LOCTITE 242 blue to swingarm pivot shaft pinch ...

Page 279: ... swingarm pivot shaft to 44 46 ft lbs 60 62 Nm 4 Apply LOCTITE 271 red and tighten swingarm pivot shaft pinch bolt to 17 19 ft lbs 23 25 8 Nm 5 Install transmission vent line a See Figure 3 30 On Firebolt models route transmis sion vent line up through left side of frame exiting under the rear master cylinder under the rider s seat Install two tie wraps to secure transmission vent line in place In...

Page 280: ...on Vent Line Ulysses 6 See Figure 3 33 Using the overhead hoist to align the frame to the rear isolator install rear isolator bolt and leave loose at this time sm02952b Figure 3 33 Rear Isolator Bolt HOME 3 26 2009 XB Service Engine ...

Page 281: ...Rear isolator assembly 18 7 Fasteners for rear isolator assembly 4 Front tie bar assembly 8 19 Fasteners for front tie bar assembly 2 Washers for rear isolator assembly 4 20 9 Rear isolator bolt Nut for one fastener for front tie bar assembly 10 21 Center tie bar mount Rear tie bar assembly 22 11 Fasteners for rear tie bar assembly 2 Fasteners for center tie bar mount 2 Figure 3 34 Engine Mounting...

Page 282: ...front isolator 1 and loosely thread into frame Do not tighten at this point 10 Install isolator mounting fasteners 2 and tighten to 49 51 ft lbs 66 69 Nm 11 Tighten front isolator bolt to 49 51 ft lbs 66 69 Nm NOTE When installing the tie bar first mount to engine and then to V bracket in order to prevent damage to threaded area of crankcase 12 Install front tie bar and clutch cable lower retainin...

Page 283: ...ting System 18 See Figure 3 36 Apply LOCTITE 271 red to rear muffler bracket fasteners install and tighten to 32 36 ft lbs 43 4 48 8 Nm 19 Install front muffler mount and leave loose at this time NOTES DO NOT install muffler at this time It is necessary to install muffler mounts first in order to properly install feed oil line See Figure 3 37 The feed oil line is routed through the right side of t...

Page 284: ...fler mount 6 13 Feed oil line Cable interactive exhaust 14 7 Drain plug Return oil line Figure 3 37 Oil Lines and Connections 20 Install the feed oil line 6 starting at the engine working towards the rear of the vehicle See 5 3 PRIMARY COVER 21 Install p clamps 8 on feed oil line 6 at crankcase and swingarm oil reservoir and tighten fastener to 40 50 in lbs 4 5 5 6 Nm 22 Install the return oil lin...

Page 285: ...ap as shown 1 2 3 4 6 5 sm03858 4 1 Neutral switch 131 connection Speedometer sensor 65 2 5 Positive battery cable at starter Interactive exhaust cable 6 3 Oil pressure switch 120 Starter solenoid 128 Figure 3 38 Electrical Connections on Right Side of Motorcycle NOTE The connections for the alternator and voltage regulator are routed on the left side of the vehicle under the air scoop The harness...

Page 286: ...Install rear belt and idler pulley See 5 7 DRIVE BELT AND IDLER PULLEY 33 Install left and right side rider footrests and support plates See 2 34 FOOTPEG HEEL GUARD AND MOUNT FIREBOLT LIGHTNING or 2 35 HEEL GUARD AND FOOTPEG MOUNTS ULYSSES MODELS 34 Install sprocket cover See 2 36 SPROCKET COVER 35 See Figure 3 41 Connect throttle cables 4 to induction module throttle body See 1 15 THROTTLE CABLE ...

Page 287: ...rly before installing air box cover See 1 16 INTERACTIVE EXHAUST CABLE 42 Install air cleaner cover assembly See 4 3 AIR CLEANER ASSEMBLY 43 Install intake cover assembly Tighten fasteners to 12 36 in lbs 1 4 4 Nm See 2 38 INTAKE COVER 44 Install oil filter and fill oil tank See 1 6 ENGINE OIL AND FILTER NOTE The connection for fuel pump is just above the pump located at the rear of the fuel tank ...

Page 288: ...INTEN ANCE After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 49 Install seat HOME 3 34 2009 XB Service Engine ...

Page 289: ...a Remove two screws and washers 3 b Remove three bolts and washers 2 c Loosen the four rocker arm fasteners 1 in 1 4 1 2 turn increments using a cross pattern in order to relieve valve spring pressure on the lower rocker box 7 See Figure 3 44 Remove lower rocker cover 14 NOTES Remove lower rocker box as an assembly and then disas semble as required Mark rocker arm shafts for reassembly in their or...

Page 290: ...ts 12 3 21 Screw 2 Screw 4 Push rod cover 22 13 4 Screw 4 Washer 2 Washer 4 5 23 14 Fiber seal 4 O ring push rod cover 2 Rocker cover lower 15 6 24 Rocker arm 2 Rocker cover top Push rod 25 16 7 Washer 4 Bushing rocker arm 4 Bolt 3 8 26 17 Washer 3 Bolt 4 Gasket lower rocker cover 18 9 Hydraulic lifter Gasket inner Figure 3 44 Rocker Arm and Pushrod Cover Assemblies HOME 3 36 2009 XB Service Engin...

Page 291: ...B in vise 2 Compress valve spring with VALVE SPRING COM PRESSOR 3 See Figure 3 47 Remove valve retainers 3 upper collar 4 and valve spring 5 Mark valve retainers for reas sembly in their original locations 4 Use a fine tooth file to remove any burrs on the valve stem at the keeper groove 5 Mark valve to verify that it will be reassembled in the same head Remove valve 15 valve stem seal and lower c...

Page 292: ...sm00134 Figure 3 46 Valve Spring Compressor HOME 3 38 2009 XB Service Engine ...

Page 293: ...Cylinder head 3 Exhaust valve Valve collar retainer 4 16 9 Upper valve spring collar Exhaust valve seat Exhaust port stud 10 5 Cylinder head gasket Valve spring 6 11 Valve seal and lower valve spring collar assembly Cylinder insert 12 Cylinder with piston and rings Figure 3 47 Cylinder Head Cylinder and Piston Assembly HOME 2009 XB Service Engine 3 39 ...

Page 294: ...e a file or other hardened tool which could scratch or nick valve Polish valve stem with very fine emery cloth or steel wool 4 See Figure 3 48 Check head gasket surface on head for flatness Machine or replace any head which exceeds SERVICE WEAR LIMIT of 0 006 in 0 152 mm sm00137 Figure 3 48 Checking Gasket Surface Rocker Arm Assemblies 1 Check each rocker arm at pad end and push rod end for uneven...

Page 295: ...hed 1 Inspect seats for cracking chipping or burning Replace seats if any evidence of these conditions are found 2 See Figure 3 53 Check seats for recession by measuring valve stem protrusion 3 Wipe valve seats and valve faces clean 4 Measure valve stem protrusion 5 If valve stem protrudes more than 2 08 in 52 88 mm replace valve seat or cylinder head NOTE Replacing a valve seat is a complex opera...

Page 296: ... 12 mm spark plug repair kit Push Rods Examine push rods particularly the ball ends Replace any rods that are bent worn discolored or broken REPLACING ROCKER ARM BUSHINGS TOOL NAME PART NUMBER ROCKER ARM BUSHING REAMER HD 94804 57 1 See Figure 3 55 To replace worn bushings press or drive them from the rocker arm NOTE If bushing is difficult to remove thread a 9 16 18 tap into bushing From opposite...

Page 297: ...ntil the tool touches the machined surface surrounding the guide At this point the correct guide height has been reached 5 Ream guides to final size or within 0 0010 in 0 0254 mm of final size using VALVE GUIDE REAMER Part No B 45523 Use REAMER LUBRICANT Part No HD 39964 or liberal amounts of suitable cutting oil to prevent reamer chatter NOTE The hone is not intended to remove material 6 Apply th...

Page 298: ...fy the inside of the valve guide is clean by using VALVE GUIDE CLEANING BRUSH Part No HD 34751 6 Install the valve seat cutter pilot 7 02 MM VALVE SEAT CUTTER PILOT Part No B 35758 52A into the valve guide hole and securely seat the pilot by pushing down and turning using the installation tool supplied in the tool set 7 Choose the proper 46 cutter intake or exhaust and gently slide the cutter onto...

Page 299: ...ebris from compressed air could cause serious eye injury Wear safety glasses when working with compressed air Never use your hand to check for air leaks or to determine air flow rates 00061a 3 Blow dry with compressed air 4 Apply a liberal amount of engine oil to the valve stem 5 See Figure 3 47 Insert valve into valve guide and bottom valve on valve seat 6 See Figure 3 60 Place a protective sleev...

Page 300: ... pushrod cover be sure to apply a small amount of clean engine oil to each o ring b Install new push rod cover gasket 5 onto bottom of each push rod cover c Install each push rod cover assembly and start the fasteners 4 securing the bottom of each cover to the crankcase d Tighten fasteners to 30 40 in lbs 3 4 4 5 Nm NOTE If installing original parts be sure to install them in their original locati...

Page 301: ...ds and covers must be installed prior to installing cylinder heads Short head screws will be installed in the 1 and 2 positions and long head screws in the 3 and 4 positions Thoroughly clean and lubricate the threads of the cylinder head screws before installation Friction caused by dirt and grime will result in a false torque indication 1 Thoroughly clean and dry the gasket surfaces of cylinders ...

Page 302: ...ush rod sockets of rocker arms with clean engine oil NOTE Turn engine over so that both lifters from the rocker box to be installed are on the base circle of the cam the lowest position 10 See Figure 3 68 Install new gaskets Place lower rocker box assembly with rocker arms and shafts into position Place push rods in rocker arm sockets 11 See Figure 3 68 Install hardware attaching lower rocker cove...

Page 303: ...m00154 Figure 3 67 Tightening Head Screws 2 3 1 2 3 1 1 1 2 sm00131 1 Screws and washers 2 Bolts and washers 3 Rocker arm fasteners Figure 3 68 Lower Rocker Box Fasteners HOME 2009 XB Service Engine 3 49 ...

Page 304: ...ts 12 3 21 Screw 2 Screw 4 Push rod cover 22 13 4 Screw 4 Washer 2 Washer 4 5 23 14 Fiber seal 4 O ring push rod cover 2 Rocker cover lower 15 6 24 Rocker arm 2 Rocker cover top Push rod 25 16 7 Washer 4 Bushing rocker arm 4 Bolt 3 8 26 17 Washer 3 Bolt 4 Gasket lower rocker cover 18 9 Hydraulic lifter Gasket inner Figure 3 69 Rocker Arm and Pushrod Cover Assemblies HOME 3 50 2009 XB Service Engin...

Page 305: ...OTE With cylinder removed be careful not to bend the cylinder studs The slightest bend could cause a stress riser and lead to stud failure 7 Install a 6 in 152 mm length of 1 2 in 12 7 mm ID plastic or rubber hose over each cylinder stud This will protect the studs and the piston Wear safety glasses or goggles when removing or installing piston pin retaining rings Piston pin retaining rings are co...

Page 306: ...Leave the second circlip in the pin bore Since the piston pin is a loose fit in the piston the pin will easily slide out The pin has tapered ends to help seat the round retaining rings sm00157 Figure 3 72 Piston Pin and Piston Identification NOTE See Figure 3 72 The arrows on the pistons must always point toward the front of the engine sm00158 Figure 3 73 Removing Piston Rings 9 See Figure 3 73 Us...

Page 307: ...face for flatness a Lay a straightedge across the surface b Try to insert a feeler gauge between the straightedge and the gasket surface c If cylinder head gasket surface is not flat within 0 006 in 0 152 mm replace cylinder and piston 2 Check cylinder base gasket surface for flatness a Lay a straightedge across the surface b Try to insert a feeler gauge between the straightedge and the gasket sur...

Page 308: ...horoughly wash the cylinder bore with liquid dishwashing soap and warm water to remove all abrasive particles and residual grit Continue cleaning until a clean cloth shows no evidence or dirt or debris 6 Hot rinse the cylinder and dry with moisture free com pressed air 7 Immediately apply a thin film of clean engine oil to a clean white paper towel and thoroughly wipe the inside of the cylinder NO...

Page 309: ... side clearance with thickness gauge as shown See 3 2 SPECIFICATIONS NOTE If the ring grooves are clean and the side play is still not correct replace the rings the piston or both Table 3 21 Piston Ring End Gap MM IN RING TYPE 0 18 0 51 0 007 0 020 Top compression ring 0 18 0 51 0 007 0 020 2nd compression ring 0 23 1 32 0 009 0 052 Oil control ring rails 4 1 3 2 sm00161 1 Top compression ring ins...

Page 310: ...ver cup fits on one side of the rod while the driver fits on the opposite side as shown 3 Use two box wrenches and push worn bushing from con necting rod 4 Remove piston pin bushing tool from connecting rod 5 Remove bushing from receiver cup 6 See Figure 3 84 Place new bushing between connecting rod and driver NOTE The driver must be attached facing the opposite direction as it was for removal of ...

Page 311: ... RING INSTALLER HD 34623C PISTON SUPPORT PLATE HD 42322 PISTON RING COMPRESSOR HD 96333 51E 1 See Figure 3 85 Place PISTON SUPPORT PLATE Part No HD 42322 in position as shown 2 Install piston assembly over connecting rod NOTE See Figure 3 86 Piston must be installed with the arrows pointing towards the front of the engine 3 Liberally lube piston pin with clean engine oil and install piston pin NOT...

Page 312: ...te 7 Lubricate cylinder wall and piston with engine oil 8 Remove protective sleeves from cylinder studs Install a new cylinder base gasket Make sure the piston does not bump the studs or crankcase 9 See Figure 3 89 Compress the piston rings using PISTON RING COMPRESSOR Part No HD 96333 51E 10 Install cylinder over piston 11 Remove the ring compressor NOTE Push rods and covers must be installed pri...

Page 313: ...nt 2 Rear 3 Piston pin 4 Position ring end gaps at arrows minimum of 90 degrees apart Figure 3 88 Ring End Gap Position 1 sm00171 1 Piston ring compressor Figure 3 89 Compressing Piston Rings HOME 2009 XB Service Engine 3 59 ...

Page 314: ...perly lubricate the rod bearing assembly 10 Oil flow then continues to the main feed galley at the top of the oil pump body Passages in the crankcase intersect the main feed galley and carry oil to all hydraulic lifters and piston jets The piston jets which receive a supply of oil from the intake lifter bores spray the underside of the pistons for cooling of the piston crown and skirt area A check...

Page 315: ... from the flywheel compartment gearcase is drawn back into the pump and is forced by the gerotor scavenge set back to the oil reservoir The oil pump seldom needs servicing Before you disassemble an oil pump suspected of not producing adequate oil pressure be sure that all possible related malfunctions have been elim inated 1 Make sure all oil line connections are tight and that lines are not pinch...

Page 316: ...erotor gear set 6 13 Oil line fittings Oil pump cover screws 7 7 O rings oil line fittings Figure 3 90 Oil Pump REMOVAL DISASSEMBLY NOTE Before vehicle is placed on the lift it will necessary to remove the chin fairing See 2 50 CHIN FAIRING 1 Remove seat See 2 51 SEAT To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceedin...

Page 317: ...d oil line connection 1 from the bottom and left side of the oil pump body 8 Disconnect return oil line connection 2 from the bottom and left side of the oil pump body 9 Disconnect the vent oil line connection 4 from the top left side of the oil pump body 10 Disconnect the oil cooler return line from the oil pump 11 Remove oil pressure switch 8 12 Remove pressure relief valve 9 13 See Figure 3 90 ...

Page 318: ...y Figure 3 91 Oil Pump Connections CLEANING AND INSPECTION Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury Wear safety glasses when working with compressed air Never use your hand to check for air leaks or to determine air flow rates 00061a 1 Clean all parts in cleaning solvent Blow out holes and oil passages with compressed air HOME 3 64 200...

Page 319: ...ure relief valve assembly and tighten plug to 108 156 in lbs 12 2 17 6 Nm 8 Install oil pressure switch and tighten to 96 120 in lbs 11 13 8 Nm 9 Install hydraulic lifters and push rods See 3 16 HYDRAULIC LIFTERS Installation 10 Install rocker box assemblies See 3 7 CYLINDER HEAD Cylinder Head Installation NOTE Before attaching oil lines see 3 12 OIL LINE FITTINGS Installation 11 See Figure 3 91 A...

Page 320: ...8 6 2 4 10 3 5 1 11 9 7 sm03727 Figure 3 94 Oil Pump Body and Cover Mounting Screw Torque Sequence HOME 3 66 2009 XB Service Engine ...

Page 321: ... to the rear of the oil pump body 1 Three rubberized clamps 8 and one plastic clamp 12 secure the lines in place The oil cooler feed line 3 exits the front of the oil pump and routes across the front of the engine to the oil cooler on the left front side of the crankcases The oil cooler return line 2 then exits the oil cooler and connects to the oil pump on the right front side of the crankcases F...

Page 322: ... crankcase Rear muffler bracket 10 3 Swingarm Oil reservoir Oil cooler feed line from oil pump 4 11 Oil filter Vent oil line 12 5 Oil line clamp Front muffler mount 6 13 Feed oil line Cable interactive exhaust 14 7 Drain plug Return oil line Figure 3 95 Oil Lines and Connections HOME 3 68 2009 XB Service Engine ...

Page 323: ... oil line and the tool from the fitting 5 Repeat to remove the remaining oil lines 6 Remove oil line fittings and plug the holes until they can be replaced sm00205 Figure 3 96 Oil Line Remover sm00206 Figure 3 97 Oil Line Fitting with Spring Clip INSTALLATION 1 Install oil line fittings with o ring into swingarm and tighten to 108 156 in lbs 12 17 6 Nm 2 See Figure 3 98 Push the correct flanged oi...

Page 324: ...sm00207 Figure 3 98 Flanged Oil Line HOME 3 70 2009 XB Service Engine ...

Page 325: ...cooler feed line 1 at oil cooler 5 Remove two fasteners 8 securing the oil cooler scoop 7 and remove scoop NOTE Place protective covering over primary cover to prevent cos metic damage when removing and installing fastener for stabil izer bracket 6 Remove fastener 6 securing oil cooler to stabilizer bracket 5 7 Remove the fasteners 4 holding the oil cooler 3 to mounting bracket 8 Remove oil cooler...

Page 326: ...re switch from crankcase 2 See Figure 3 101 Install adapter 2 from OIL PRESSURE GAUGE SET Part No HD 96925 52B in oil pressure indicator lamp switch mounting hole Tighten adapter snugly DO NOT OVERTIGHTEN sm03000 Figure 3 100 Oil Pressure Indicator Switch Table 3 22 Troubleshooting Oil Pressure Signal Lamp PROBABLE CAUSES OIL PRESSURE SIGNAL LAMP Stays on at speeds above idle Empty oil reservoir G...

Page 327: ...nugly to 96 120 in lbs 10 8 13 6 Nm 7 Plug in electrical connector 3 by pushing elbow connector straight onto stud on oil pressure switch NOTE If an appreciable amount of oil leaked out when oil pressure switch was removed it will have to be replaced with fresh oil 8 Check oil level in oil tank See 1 6 ENGINE OIL AND FILTER 9 Start engine and test oil pressure switch for proper opera tion Check oi...

Page 328: ...n the cylinder head sm00209 Figure 3 102 Reed Valve Assembly in Gearcase 4 1 3 2 5 6 sm00216 1 Base plate air box 2 Breather hose rear 3 Breather hose front 4 PCV Valves 2 5 Grommet 6 Rocker cover 2 Figure 3 103 Crankcase Breathing System REED VALVE REPLACEMENT NOTES Whenever the gearcase cover is removed inspect the reed valve for cracks chips and breakage See Figure 3 104 The reed valve 3 opens ...

Page 329: ...ary to replace the reed block apply LOC TITE 222 purple install the fasteners and tighten to 25 35 in lbs 2 8 4 0 Nm 1 2 3 sm02944 3 1 Reed valve Reed valve fastener 2 4 Reed valve stop Reed block Figure 3 104 Reed Valve Assembly 1 2 1 2 3 3 sm00210 3 2 1 Stop screw Reed valve Reed valve stop Figure 3 105 Reed Valve Stop and Reed Valve HOME 2009 XB Service Engine 3 75 ...

Page 330: ... use your hand to check for air leaks or to determine air flow rates 00061a 1 Clean all dirt from around crankcase Blow loose particles from area with compressed air 2 Remove cylinder head assemblies See 3 7 CYLINDER HEAD 3 See Figure 3 108 Remove push rod covers a Remove screws 4 b Remove push rod covers 3 c Remove gaskets and o rings 6 2 Discard parts 4 Remove valve hydraulic lifters 7 a Remove ...

Page 331: ...rs 8 in the holes in lifter block b Tighten anti rotation screws to 55 65 in lbs 6 7 Nm NOTE Before installing o rings on the top of each pushrod cover be sure to apply a small amount of clean engine oil to each o ring 5 Install push rod cover a Place new push rod cover gasket 6 over bottom of pushrod cover b Position push rod cover 3 onto crankcase c Install screws 4 through holes in push rod cov...

Page 332: ...ed and matched Changing one component can affect many others It is important to know and understand all inspection procedures and how components interact 1 2 3 4 9 8 7 6 10 5 sm02934 6 1 Key Oil pump body 2 7 Oil pump body gasket Pinion gear spacer 8 3 Pinion gear K cam gear set 4 9 Right crankcase half Nut 10 5 Screw 4 Dowel pin Figure 3 109 Oil Pump Body and Cam Assembly HOME 3 78 2009 XB Servic...

Page 333: ...e crankshaft until all timing marks 7 8 are aligned as shown NOTE DO NOT rotate camshafts or crankshaft while gears are removed 8 See Figure 3 110 Remove cam gears 1 2 3 and 4 NOTE Nut is secured by LOCTITE 271 red on the nut threads 9 See Figure 3 109 Remove pinion nut 9 Slide pinion gear 8 and pinion gear spacer 7 off pinion shaft NOTE See Figure 3 110 The timing marks are located on the front i...

Page 334: ...LATION TOOL NAME PART NUMBER CRANKSHAFT LOCKING TOOL HD 43984 1 See Figure 3 112 Install pinion gear spacer and pinion gear on pinion shaft a Install shaft key into pinion shaft slot b Slide pinion gear spacer over pinion shaft Pinion gear spacer must align with shaft key c Align keyway in ID of pinion gear with shaft key d Slide pinion gear over shaft key and against pinion gear spacer 2 See Figu...

Page 335: ...gear being checked is pointing toward its respective tappet guide hole b Gently pry the cam gear toward the oil pump body using a flat blade screwdriver c Measure gap between bore in crankcase half and cam gear shaft thrust face shoulder using a feeler gauge This is cam gear end play d Compare cam gear end play measurements with the SERVICE WEAR LIMITS Make repairs as required if end play does not...

Page 336: ...over cylinder studs Lifting or moving crankcase by grasping studs will cause cylinder stud damage 2 Remove cylinders and pistons See 3 8 CYLINDER AND PISTON 3 Remove oil pump See 3 10 OIL PUMP 4 Remove gearcase components See 3 17 GEARCASE AND CAM GEARS 5 Remove primary cover and primary drive clutch compon ents See 5 3 PRIMARY COVER 6 Remove starter motor See MISSING_XREF_C18 sec tionC18S6 7 See ...

Page 337: ...nt 1 See Figure 3 117 Remove the oil filter adapter from the oil filter mount 2 Clean and replace components as necessary 3 Apply several drops of LOCTITE 243 blue to last few threads on end of the oil filter adapter that is installed into filter mount NOTE Do not apply LOCTITE to adapter threads on filter element side 4 Thread oil filter adapter into filter mount 5 Tighten to 96 144 in lbs 11 16 ...

Page 338: ...OCTITE LOW STRENGTHTHREADLOCKER 222 purple to threads of TORX screws With the jet pointed upward install TORX screws to secure piston jet to crankcase Tighten screws to 25 35 in lbs 2 8 4 0 Nm Removing Cylinder Base Studs If cylinder base studs require replacement proceed as follows 1 Thread a 3 8 16 nut onto cylinder base stud 2 Thread a second nut onto stud until it contacts the first nut 3 Tigh...

Page 339: ...ng ring oil seal Connecting rod and flywheel assembly 11 3 Inner race Oil seal 4 12 Thrust washer Pinion shaft bearing 13 5 Retaining ring Crankcase half 6 14 Bearing sprocket shaft Outer bearing race 15 7 Crankshaft case Bearing retaining ring 8 Inner race sprocket shaft bearing Figure 3 120 Crankcase and Flywheel Assembly HOME 2009 XB Service Engine 3 85 ...

Page 340: ...procket shaft oil seal retaining ring 5 See Figure 3 120 Remove sprocket shaft oil seal 3 from crankcase using SNAP ON BODY DENT PULLER Part No CJ114 6 Remove outer thrust washer 4 next to sprocket shaft bearing 6 sm00183 Figure 3 123 Removing Sprocket Shaft Bearing Retaining Ring 7 See Figure 3 123 Remove sprocket shaft bearing retaining ring from the inside of the left crankcase half sm00184 Fig...

Page 341: ...Inner race OD 39 76 1 5656 Outer race ID NOTE Pinion shaft bearing selection at the factory during engine build or replacement of crankcase set or flywheel assembly is based on the largest measured outside diameter OD of the inner race and the smallest measured inside diameter ID of the outer race crankcase bushing A running clearance of 0 0002 0 0008 in 0 0051 0 0203 mm is established during cran...

Page 342: ...ble 3 29 Pinion Shaft Bearing Selection BEARING SIZE AS IDENTIFIED BY COLOR CODING OUTER RACE ID FACTORY STAMPED NO Red 1 5654 1 5656 in 39 761 39 766 mm Blue Red 1 5652 1 5654 in 39 756 39 761 mm White Gray Blue Red 1 5650 1 5652 in 39 751 39 756 mm 3 Green White Gray Blue 1 5648 1 5650 in 39 746 39 751 mm 2 Green White Gray 1 5646 1 5648 in 39 741 39 746 mm 1 1 2500 1 2502 in 1 2498 1 2500 in 1 ...

Page 343: ...M IN 39 8069 1 5672 Largest ID measured 0 0051 0 0002 Roundness of ID 0 0051 0 0002 Taper 5 Press the outer race from the right crankcase 6 Press new outer race into crankcase flush with inside edge of cast in insert NOTE See Figure 3 129 and Figure 3 128 Dimensions are shown for fabrication of tools used in pressing the outer race into or out of crankcase 7 The new outer race must be lapped sligh...

Page 344: ...ly heat to race to aid removal 3 1 2 sm00189 1 Bearing race remover installer 2 End cap 3 Wedge attachment for claw puller Figure 3 131 Removing Pinion Bearing Inner Race NOTES For necessary dimensions for constructing a press on tool for the pinion bearing inner race see Figure 3 130 The new inner race must be ground by a competent machinist to OD dimension range for the finished lapped ID of the...

Page 345: ...ure 3 133 Obtain CRANKCASE MAIN BEARING LAPPING TOOL Part No HD 96710 40D Assemble CRANKCASE MAIN BEARING LAP Part No HD 96718 87 to lapping handle Assemble guide sleeve to sprocket shaft bearing bushing Sleeves for use with tapered bearing are assembled to case with bearings and small spacer collar Finger tighten the sleeve parts 3 Insert lap shaft with arbor assembled through pinion bearing bush...

Page 346: ... Crankcase Halves NOTE Lubricate all parts with Harley Davidson 20W50 engine oil and proceed as follows 1 See Figure 3 136 Using CRANKCASE BEARING REMOVER INSTALLER WITH ADAPTER Part No B 45655 HD 42720 2 and HD 46663 install sprocket shaft bearing into left crankcase half from the inside NOTE Make sure that the bearing assembly bottoms against the machined shoulder in the left crankcase half 2 In...

Page 347: ...earing Assembly 4 See Figure 3 137 Attach left crankcase half to engine stand 5 Install flywheel assembly using CRANKSHAFT GUIDE Part No HD 42326 B 6 See Figure 3 138 Install pinion shaft bearing a Lubricate pinion shaft bearing with engine oil b Slip bearing on pinion shaft c Install new retaining ring in groove of pinion shaft bearing inner race HOME 2009 XB Service Engine 3 93 ...

Page 348: ...aring remover installer tool 3 Retaining ring Figure 3 136 Sprocket Shaft Bearing Installation sm03929 Figure 3 137 Installing Flywheel Assembly with CRANKSHAFT GUIDE sm00195 Figure 3 138 Pinion Shaft Bearing HOME 3 94 2009 XB Service Engine ...

Page 349: ...asteners See Figure 3 140 Kent Moore has developed additional tools to be used with SPROCKET SHAFT BEARING INSTALLER Part No HD 42579 You will need SPROCKET SHAFT ADAPTER Part No B 42579 6 and COLLAR Part No B 42579 7 The addition of these tools will update HD 42579 SPROCKET SHAFT BEARING INSTALLER to HD 42579 A In addition you will need SPROCKET SHAFT SEAL INSTALLER Part No B 45676 A to use with ...

Page 350: ...nd of the stud without the shoulder into the head screw d Install the stud in the crankcase with the shoulder end down Use an air gun to drive the stud until the shoulder reaches the crankcase e Remove air gun Use a torque wrench to tighten stud to 10 20 ft lbs 14 27 Nm 3 4 1 2 sm00197 1 Head screw with ball inside 2 Cylinder stud 3 Shoulder on cylinder stud 4 Air gun Figure 3 141 Cylinder Studs 1...

Page 351: ... 11 4 7 OXYGEN SENSOR 4 12 4 8 ENGINE TEMPERATURE SENSOR ET 4 13 4 9 BANK ANGLE SENSOR BAS 4 15 4 10 INTAKE AIR TEMPERATURE SENSOR IAT 4 18 4 11 COOLING FAN 4 19 4 12 FUEL TANK VENT VALVE 4 20 4 13 FUEL CAP RETAINING RING 4 21 4 14 FUEL PUMP 4 22 4 15 THROTTLE BODY 4 29 4 16 FUEL PRESSURE TEST 4 34 4 17 INTAKE LEAK TEST 4 36 4 18 EXHAUST SYSTEM 4 38 4 19 EVAPORATIVE EMISSIONS CONTROL CA MODELS 4 4...

Page 352: ...NOTES ...

Page 353: ... MODULE ECM ULYSSES 8 11 Nm 72 96 in lbs Battery terminal fasteners 4 6 IGNITION COIL Installation 8 11 Nm 72 96 in lbs Battery terminal fasteners 4 8 ENGINE TEMPERATURE SENSOR ET Installation 8 11 Nm 72 96 in lbs Battery terminal fasteners 4 9 BANK ANGLE SENSOR BAS Installation 8 11 Nm 72 96 in lbs Battery terminal fasteners 4 10 INTAKE AIR TEMPERATURE SENSOR IAT Installation 8 11 Nm 72 96 in lbs...

Page 354: ...T SYSTEM Assembly and Installa tion LOCTITE 27 red 43 49 Nm 32 36 ft lbs Muffler mounting block fastener rear 4 18 EXHAUST SYSTEM Assembly and Installa tion 12 14 Nm 108 120 in lbs Muffler strap fastener front 4 18 EXHAUST SYSTEM Assembly and Installa tion 12 14 Nm 108 120 in lbs Muffler strap fastener front 4 18 EXHAUST SYSTEM Assembly and Installa tion You need to alternately tighten the fastene...

Page 355: ...r at XB9SX XB12Scg XB12R Table 4 2 Fuel System Specifications TYPE FUEL SYSTEM 45 mm downdraft manifold ram air Intake XB9 models 49 mm downdraft manifold ram air Intake XB12 models DDFI fuel injection Fuel delivery 49 51 PSI 338 352 kPa Fuel pressure 91 octane Recommended fuel Table 4 3 Idle Speed XB Models VALUE SPECIFICATION 320 F 160 C Operating temperature 1050 1150 RPM Regular engine idle sp...

Page 356: ...ather hose from baseplate pull out from bottom c Disconnect shorter breather hose from PVC valve located on top of rear cylinder d Remove IAT sensor 6 from grommet on bottom of baseplate e Lift baseplate off of frame carefully disengaging baseplate from velocity stack sealing ring 5 on velocity stack 4 f Remove baseplate from motorcycle 3 4 2 1 sm00894 1 Cover air cleaner 2 Fuel tank vent valve 3 ...

Page 357: ...ensor tower If hoses extend past tower damage to sensor may occur 3 Insert longer breather hose into right baseplate grommet from underside 4 Attach shorter breather hose onto crankcase breather located on top of rear cylinder 5 Carefully lower baseplate into mounting position verify rubber sealing ring on velocity stack completely engages baseplate Baseplate should be sandwiched between upper and...

Page 358: ...xhaust Air cleaner seal 9 3 Shoulder screw 4 Cable bracket 4 10 Interactive exhaust cable Base plate assembly 11 5 Breather hoses front and rear Mounting fasteners actuator 6 Cover air cleaner Figure 4 5 Air Cleaner Assembly with Interactive Exhaust XB12 Models Typical HOME 4 6 2009 XB Service Fuel System ...

Page 359: ... throttle position sensor or ECM have been replaced or if the ECM has been recalibrated See 4 5 THROTTLE POSITION SENSOR TPS The throttle body has a throttle plate stop screw that is preset at the factory and has tamper proof paint applied to the head of the screw Do NOT attempt to adjust this screw Tampering with this screw will require throttle body replacement After installing seat pull upward ...

Page 360: ... Do NOT attempt to adjust this screw Tampering with this screw will require throttle body replacement sm00857 Figure 4 7 Electronic Control Module ECM Lightning Typical sm00858 Figure 4 8 Electronic Control Module ECM Lightning XB12Ss ULYSSES TOOL NAME PART NUMBER DIGITAL TECHNICIAN HD 48650 Removal 1 Remove seat Disconnect negative battery cable first If positive cable should contact ground with ...

Page 361: ...4 5 THROTTLE POSITION SENSOR TPS The throttle body has a throttle plate stop screw that is preset at the factory and has tamper proof paint applied to the head of the screw Do NOT attempt to adjust this screw Tampering with this screw will require throttle body replacement If the ECM was replaced with a new component it will be necessary to download the correct calibration using D T DIGITAL TECHNI...

Page 362: ...tle body See 4 15 THROTTLE BODY NOTE The Throttle Position Sensor Zero Procedure should be per formed if the throttle position sensor or ECM are replaced or if the ECM has been recalibrated 5 To zero the TPS a Set the Run Stop switch to the Run position b Turn the ignition key to the On position c With the engine off rotate the throttle grip from closed throttle position to wide open throttle posi...

Page 363: ...spark plug cables to ignition coil 2 See Figure 4 12 Attach coil to frame with fasteners 2 Tighten to 120 144 in lbs 13 6 16 3 Nm 3 Attach front and rear spark plug cables to ignition coil posts 4 Attach connector 83 3 5 Install air cleaner cover See 4 3 AIR CLEANER ASSEMBLY 6 Install intake cover assembly See 2 38 INTAKE COVER 7 Connect negative battery cable tightening to 72 96 in lbs 8 11 Nm 1 ...

Page 364: ...urred Replacement sensor assemblies have threads coated with anti seize lubricant and new seal rings If reinstalling O2 sensor apply a thin coat of anti seize Part No 98960 97 to threads of each O2 sensor prior to installing in header Do not use any other grease or sealant product on sensor threads The electrical connector must also be clean and free of any dielectric grease 1 Apply LOCTITE ANTI S...

Page 365: ...de access to sensor NOTES Lightning Ulysses models Remove fastener securing rear wire guide to underside of frame to provide access to temperature sensor Do not pull on engine temperature sensor wiring Excess strain to sensor wiring will cause sensor damage 6 See Figure 4 17 Disconnect engine temperature sensor connector 90 above rear cylinder head NOTE See Figure 4 18 All Buell engines come equip...

Page 366: ...he boot is towards the left side of the motorcycle 3 Push rubber boot down sensor wire towards cylinder head until it seats in hole on top of ET sensor 4 See Figure 4 17 Connect ET sensor connector 90 to wiring harness 5 Install rear wire harness guide Tighten fastener 6 Install right upper tie bar fastener Tighten fastener to 25 27 ft lbs 33 9 36 6 Nm 7 Install air cleaner cover See 4 3 AIR CLEAN...

Page 367: ...seat To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 2 Disconnect negative battery cable 3 See Figure 4 21 Remove screws and washers to detach sensor from seat latch bracket 4 Unplug bank angle sensor connector 134 and remove 4 4 2 2 1 1 3 3 sm00864 1 Bank angle sensor 2 Fuse block and electrical relays 3 S...

Page 368: ...sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 6 Install seat 1 2 sm00862 1 Bank angle sensor 2 Headlights Figure 4 22 Bank Angle Sensor Firebolt Lightning 1 See Figure 4 23 Install bank angle sensor connector 134 2 Position bank angle sensor on seat latch bracket Make sure locating post on sensor engag...

Page 369: ...Tighten fasteners to 60 96 in lbs 7 11 Nm 3 Install bank angle sensor connector 134 4 Connect negative battery cable and tighten fastener to 72 96 in lbs 8 11 Nm After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 5 Install seat 1 2 3 sm00865 1 Fuse block and e...

Page 370: ...y cable 2 See Figure 4 25 Remove air cleaner cover and filter 3 Remove fasteners securing base See 4 3 AIR CLEANER ASSEMBLY 4 Raise base and pull IAT sensor from sensor grommet 5 Disconnect connector 89 from intake air temperature sensor 6 Inspect sensor grommet for damage and replace as required INSTALLATION 1 Connect IAT sensor connector 89 to wiring harness 2 Install IAT sensor into grommet on ...

Page 371: ... connector 97 INSTALLATION 1 See Figure 4 27 Connect cooling fan connector 97 NOTES See Figure 4 26 When installing cooling fan 3 be sure wiring transmission vent hose and fuel line are routed through notch 2 in fan body On California models both fuel tank and canister vent hoses are routed through notch in fan body 2 Install cooling fan and rotate counter clockwise into posi tion 3 Install coolin...

Page 372: ...emove bracket 4 fuel tank vent valve 3 and o ring 2 from fuel tank frame 1 INSTALLATION 1 See Figure 4 28 Install new o ring 2 2 Install fuel tank vent valve 3 into fuel tank frame Vent valve nozzle should be at approximately the 7 o clock position 3 Install bracket over vent valve Slot in bracket should line up with notch in valve 4 Loosely install fasteners 5 5 Tighten fasteners to 39 41 in lbs ...

Page 373: ...ard o ring INSTALLATION 1 Coat new o ring 2 with thin film of clean engine oil 2 Place o ring into groove in underside of fuel cap retaining ring 3 NOTE Be sure o ring remains in groove of fuel cap retaining ring during installation 3 Insert fuel cap retaining ring into fuel filler neck 4 Install fasteners 4 Tighten to 62 71 in lbs 7 8 Nm 5 Install fuel filler cap 4 1 3 2 sm00877 1 Fuel filler nec...

Page 374: ...wheel vise in order to successfully perform this procedure Place a scissor jack under jacking point and raise until vehicle weight is removed from rear wheel 1 Remove seat See 2 51 SEAT 2 Drain fuel tank See 4 14 FUEL PUMP Draining Fuel Tank To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 3 Disconnect negat...

Page 375: ...he bolt Hold the bolt stationary and turn nut clockwise until fuel pump is pulled free from frame 16 Remove tool from fuel pump NOTE When pivoting the swingarm rear wheel assembly it is neces sary to note the location of the oil lines Excessive movement may damage the oil lines 17 Raise the scissor jack until the lower shock clevis clears the swingarm mount Pivot the swingarm rear wheel to gain ad...

Page 376: ...assembly from tank See 4 14 FUEL PUMP Removal 2 See Figure 4 34 Disconnect low fuel level sensor con nector 10 3 Remove screw 8 securing low fuel level sensor 7 in place 4 Install new sensor 5 Install screw 8 securing sensor and tighten to 18 22 in lbs 2 0 2 5 Nm 6 Attach low fuel level sensor wire connector 10 7 Install fuel pump assembly See 4 14 FUEL PUMP Installation HOME 4 24 2009 XB Service ...

Page 377: ...3 and fuel pump 8 with bracket 9 6 Remove fuel filter 2 NOTE Remove the rubber seals from each end of the original fuel filter to be used on the new fuel filter 7 Install rubber seals on new fuel filter and install filter into pump housing 11 8 See Figure 4 35 Install regulator housing 3 and fuel pump 8 assembly 9 Install E clip 7 in bottom groove on shaft 10 Install ground fastener 12 and connect...

Page 378: ...filter 10 3 Overflow hose Pressure regulator housing 4 11 Low fuel level sensor Fuel pump housing 12 5 Ground fastener Fuel pump connectors 6 13 Low fuel level sensor connector Protective sleeve 7 Pressure regulator E clip 1 Figure 4 35 Fuel Pump Assembly Left and Right Sides HOME 4 26 2009 XB Service Fuel System ...

Page 379: ...ated If necessary bend tab on terminal to aid in seating wire 9 Install terminals into proper locations of fuel pump con nector 86 Install connector clips 10 See Figure 4 35 Connect low fuel level sensor connector 6 11 Connect fuel pump connectors 5 Connectors are two different sizes 12 Install fuel pump assembly See 4 14 FUEL PUMP Installation 4 5 3 5 1 2 sm00223 1 Connector 86 2 Fuel supply fitt...

Page 380: ... to 33 35 ft lbs 45 47 Nm 12 Tighten rear axle to 23 27 ft lbs 31 2 36 6 Nm back off two full turns and then retighten to 48 52 ft lbs 65 70 5 Nm 13 Tighten rear axle pinch fastener to 40 45 ft lbs 54 61 Nm 14 Install front sprocket cover See 2 36 SPROCKET COVER 15 Install chin fairing after vehicle has been removed from the lift See 2 50 CHIN FAIRING 16 Install lower belt guard See 2 37 BELT GUAR...

Page 381: ...4 THROTTLE CONTROL 4 Remove coil wire retaining clip attached to throttle cable bracket 5 See Figure 4 39 On California models pull EVAP hose from fitting 1 6 Remove left and right air scoops See 2 49 AIR SCOOPS 7 Remove ignition coil See 4 6 IGNITION COIL 8 See Figure 4 41 Remove fuel line from fuel rail 14 9 Disconnect a TPS connector 88 21 b Fuel injector connectors 84 85 12 c IAC connector 87 ...

Page 382: ...1 2 sm00885 1 Manifold to cylinder brace fastener 2 Intake flange fastener 2 Figure 4 40 Intake Manifold Primary Side HOME 4 30 2009 XB Service Fuel System ...

Page 383: ...dle air control Nylock nut 6 18 Cable wheel Actuator idle air control 19 7 Screw 2 Screw 4 8 20 Throttle cable retention clip Washer flat 2 21 9 Throttle position sensor Cable bracket 10 22 Throttle body manifold assembly 45mm 984 49mm 1203 Clamp wire spring 23 Velocity stack 11 O ring fuel injector outlet 12 Fuel injector 1 front 1 rear Figure 4 41 One Piece Throttle Body Intake Manifold Assembly...

Page 384: ...e fuel rail assembly 14 11 Install fasteners 7 and tighten to 25 30 in lbs 2 9 3 5 Nm INSTALLATION NOTES The intake flanges have been extended to improve clamp load distribution Intake flanges are interchangeable 1 See Figure 4 41 Install flanges onto throttle body with the counterbore 2 facing out 2 Place a new seal in each intake flange with the beveled side against the counterbore 3 Install thr...

Page 385: ... assembly See 2 38 INTAKE COVER 2 Remove air cleaner cover See 4 3 AIR CLEANER ASSEMBLY 3 Conduct test a Turn key ON for two seconds b Turn key OFF for two seconds c Repeat Steps A and B five consecutive times d Open throttle and look for raw fuel in manifold Replace fuel injectors if there is any evidence of raw fuel in throttle body manifold 4 Install air cleaner cover See 4 3 AIR CLEANER ASSEMB...

Page 386: ...of rags in a suitable manner 00277a 3 See Figure 4 46 Press button 2 of fuel line connector and disconnect the fuel line 3 from throttle body inlet 1 4 See Figure 4 47 Attach FUEL PRESSURE GAUGE ADAPTER Part No B 45522 2 to throttle body inlet 1 5 Connect the fuel line 3 to fuel pressure gauge adapter NOTE See Figure 4 48 Verify that fuel valve 2 and air bleed petcock 5 on the gauge are closed 6 A...

Page 387: ...r 00277a 10 See Figure 4 48 Turn engine off Detach pressure gauge 4 from adapter 1 a Open the air bleed petcock 5 to relieve fuel system pressure and purge the pressure gauge of gasoline b Remove pressure gauge from adapter 11 Detach adapter from vehicle 12 Connect fuel line to throttle body inlet 1 2 3 sm06168 1 Throttle body inlet 2 Fuel pressure gauge adapter 3 Fuel line Figure 4 47 Fuel Pressu...

Page 388: ...crew valve assembly 5 onto propane bottle 1 Tester Adjustment 1 See Figure 4 49 Press and hold trigger button 8 2 Slowly open valve knob 6 until pellet in flow gauge 7 rises to between 5 and 10 SCFH on gauge 3 Release trigger button 1 8 5 9 3 2 7 4 6 sm02629 1 Propane bottle 2 Nozzle 3 Copper tube 4 Hose 5 Valve assembly 6 Valve knob 7 Flow gauge 8 Trigger button 9 Hanger Figure 4 49 Leak Tester P...

Page 389: ...5 When test is finished close valve knob turn knob fully clockwise sm00251 Figure 4 50 Checking for Intake Leak HOME 2009 XB Service Fuel System 4 37 ...

Page 390: ...for replacement without removing the exhaust header 8 Remove muffler Front Muffler Mount 1 Remove muffler 2 See Figure 4 51 Remove front muffler mount fastener 8 3 Remove front muffler strap 5 from front muffler mount 7 4 Remove front muffler mount bushings 9 by punching out with suitable tool Rear Muffler Bracket 1 Remove muffler 2 Drain oil See 1 6 ENGINE OIL AND FILTER 3 Remove feed oil line p ...

Page 391: ...stener Symbol for jacking point on muffler located on both sides of muffler 7 Front muffler mount Figure 4 51 Muffler and Mounting System ASSEMBLY AND INSTALLATION Exhaust Header 1 See Figure 4 52 Install exhaust ring 4 exhaust retaining ring 5 and new exhaust port gasket 6 NOTE Tighten header nuts gradually alternating between studs to verify that exhaust rings are flush with engine 2 Install exh...

Page 392: ...If necessary use a fiber hammer to fit muffler on header For details on installing components on XB12 models with interactive exhaust systems see 6 17 INTERACTIVE EXHAUST SYSTEM Installation 2 Install interactive exhaust cable to muffler NOTE Never re use front muffler strap Always replace front muffler strap with a new strap when removed from system 3 See Figure 4 51 Loosely install new front and...

Page 393: ...3 4 6 5 2 1 sm00638 1 Torca clamp 2 Header 3 Header mount fastener 4 Exhaust ring 5 Exhaust retaining ring 6 Exhaust port gasket Figure 4 52 Exhaust Header HOME 2009 XB Service Fuel System 4 41 ...

Page 394: ... necessary label fuel tank vent hose 2 at canister fitting and remove Canister 1 Remove upper tail body work See 2 39 SUBFRAME TAIL ASSEMBLY AND BODY WORK FIREBOLT 2 See Figure 4 53 The canister 1 mounts behind the bat tery in the tail section 3 Label and disconnect the fuel tank vent hose 2 and canister vent hose 3 from the canister 4 See Figure 4 54 Remove rear shock absorber reservoir fasteners...

Page 395: ... Mounting 1 2 sm00905 1 Adjuster screw 2 Adjuster screw alignment hole Figure 4 55 Adjuster Screw Alignment INSTALLATION LIGHTNING ULYSSES Vent Valve Keep vent and vapor valve lines away from exhaust and engine Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00263a NOTE For XB12 models See 6 17 INTERACTIVE EXHAUST SYSTEM 1 Install vent valve See 4...

Page 396: ...r Cleaner Cover Fuel Vent Tube and Fuel Vapor Valve XB12 Translucid models sm00910 Figure 4 58 Canister Mounting Bracket HOSE ROUTING Both fuel tank and canister vent hoses are routed through notch in fan body NOTE For information on vent hose routing See D 1 APPENDIX D HOSE AND WIRE ROUTING 1 4 2 3 5 sm00888 1 EVAP hose fitting 2 Throttle control cable attachment 3 Idle control cable attachment 4...

Page 397: ...T AND IDLER PULLEY 5 23 5 8 TRANSMISSION 5 27 5 9 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL 5 28 5 10 TRANSMISSION DISASSEMBLY 5 31 5 11 TRANSMISSION ASSEMBLY 5 38 5 12 MAIN DRIVE GEAR AND BEARING 5 40 5 13 TRANSMISSION RIGHT CASE BEARINGS 5 47 5 14 TRANSMISSION LEFT CASE BEARINGS 5 49 5 15 TRANSMISSION INSTALLATION 5 51 5 16 SHIFTER SHAFT 5 55 5 17 TRANSMISSION SPROCKET 5 57 DRIVE TRANSMISSION ...

Page 398: ...NOTES ...

Page 399: ... 108 in lbs Clutch inspection cover fasteners 5 4 CLUTCH RELEASE MECHANISM Assembly 10 12 Nm 84 108 in lbs Clutch inspection cover fasteners 5 6 PRIMARY CHAIN Installation LOCTITE 271 red if using original mainshaft nut 94 9 108 5 Nm 70 80 ft lbs Clutch mainshaft nut 5 16 SHIFTER SHAFT Installation LOCTITE 271 red 44 8 50 Nm 33 37 ft lbs Countershaft retaining screw 5 15 TRANSMISSION INSTALLATION ...

Page 400: ...tallation LOCTITE 271 red 4 0 7 Nm 36 60 in lbs Shift linkage fasteners 5 3 PRIMARY COVER Installation LOCTITE 271 red 30 0 32 5 Nm 22 24 ft lbs Shift pedal flange head bolt 5 7 DRIVE BELT AND IDLER PULLEY Drive Belt Installation 34 37 Nm 25 27 ft lbs Swingarm brace mounting fasteners 5 17 TRANSMISSION SPROCKET Installa tion Follow special torque procedure left hand threads LOCTITE 272 red 67 8 Nm...

Page 401: ...t 135 teeth XB12Ss XB12XT XB12X XB12XP Secondary drive belt Table 5 3 Transmission Specifications XB Models XB12 MODELS XB9SX OVERALL GEAR RATIOS 9 563 10 688 First gear low 6 831 7 635 Second gear 5 080 5 678 Third gear 4 211 4 706 Fourth gear 3 611 4 036 Fifth gear Table 5 4 Wet Clutch Multiple Disc Clutch Plate Thickness SERVICE WEAR LIMITS NEW COMPONENTS ITEM N A 0 0866 0 0031 in 2 200 0 079 m...

Page 402: ... inspection cover 3 11 See Figure 5 2 Remove the outer ramp and hook 1 from the cable end 3 and coupling 2 Remove cable end from slot in coupling See 5 4 CLUTCH RELEASE MECHANISM 12 See Figure 5 1 Remove screws which secure primary cover 2 Remove cover and gasket 13 Discard gasket 14 See Figure 5 3 Remove and discard shifter lever oil seal 19 15 Clean all parts in a non volatile cleaning solution ...

Page 403: ...Shifter Assembly PRIMARY CHAIN ADJUSTER REPLACEMENT 1 See Figure 5 4 Remove locknut 3 from adjuster screw 2 Turn adjuster screw out of threaded boss in primary cover 4 2 Remove chain adjuster as an assembly 3 Inspect primary chain adjuster shoe 1 If badly worn or damaged it must be replaced 4 Replace adjuster shoe as an assembly 5 Position adjuster inside primary cover 4 with closed side of shoe a...

Page 404: ...al 19 2 3 1 4 5 sm00272 1 Cable end 2 Coupling 3 Outer ramp and hook 4 Lockplate 5 Spring Figure 5 6 Clutch Release Mechanism 6 See Figure 5 6 Fit coupling 2 over cable end 1 with rounded side inboard and the ramp connector button out board With retaining ring side of ramp assembly facing inward place hook of ramp 3 around coupling button and rotate assembly counterclockwise until tang on inner ra...

Page 405: ... Nm Lightning and Firebolt models do not have a shifter bracket 13 Install rubber washer and engine shift lever assembly 1 14 After applying LOCTITE 271 red install flange bolt 5 and shift pedal 6 and tighten to 22 24 ft lbs 30 0 32 5 Nm 15 After applying LOCTITE 271 red tighten engine shift lever pinch screw to 48 60 in lbs 5 4 7 Nm 16 If the shift linkage assembly 2 was removed for any reason ap...

Page 406: ...Unscrew nut 6 from end of adjusting screw 7 Remove hook of ramp from cable end coupling 10 Remove cable end from slot in coupling 8 Remove and discard retaining ring from ramp assembly to separate inner and outer halves Remove three balls from ramp sockets 2 1 3 4 5 6 7 10 11 8 9 sm00275 9 5 1 Primary cover Lockplate TORX screw with washers 3 2 10 6 Clutch inspection cover Coupling Nut 7 3 11 Ramp...

Page 407: ...e until resistance is felt c Adjust clutch release mechanism See 1 9 CLUTCH TRANSMISSION PRIMARY FLUID d Fit nut hex into recess of outer ramp e Install clutch adjusting lockplate 5 and spring 4 Install clutch inspection cover and new gasket with three TORX screws with washers Tighten to 84 108 in lbs 10 12 Nm 5 Adjust clutch cable See 1 9 CLUTCH TRANSMIS SION PRIMARY FLUID 6 Connect negative batt...

Page 408: ...ans mitted to the rear wheel When the clutch is disengaged clutch lever pulled to left handlebar grip the pressure plate is pulled outward by clutch cable action against the diaphragm spring thereby com pressing the diaphragm spring With the pressure plate retracted strong inward force no longer squeezes the clutch plates together The fiber plates are now free to rotate at a different relative spe...

Page 409: ...er Retaining ring Outer ramp 5 25 15 Coupling Clutch hub Bearing 16 6 26 Adjusting screw Ball 3 Inner thrust washer 27 17 7 Needle bearing inner race Pressure plate Inner ramp 8 28 18 Retaining ring Needle bearing Friction plate fiber 7 19 9 29 Steel plate 7 Retaining ring Clutch shell and sprocket 30 20 10 Outer thrust washer Friction plate narrow fiber Spring seat Figure 5 12 Clutch Assembly HOM...

Page 410: ... 3 and washer 2 d Thread the tool handle 1 onto end of forcing screw NOTE See Figure 5 14 Turn compressing tool handle only the amount required to release spring seat and remove snap ring 7 Excessive compression of diaphragm spring could damage clutch pressure plate 5 See Figure 5 14 Remove pressure plate assembly a Place a wrench on the clutch spring forcing screw 5 flats to prevent the forcing s...

Page 411: ...k fiber plates for thickness a Wipe the lubricant from the eight fiber plates 7 regular and 1 narrow and stack them on top of each other b Measure the thickness of the eight stacked fiber plates with a dial caliper or micrometer The minimum thickness must be 0 661 in 16 789 mm c If the thickness is less than specified discard the fiber plates and steel plates Install a new set of both fric tion an...

Page 412: ...ing ring 2 Bearing and release plate 3 Retaining ring 4 Adjusting screw Figure 5 18 Adjusting Screw Assembly ASSEMBLY AND INSTALLATION TOOL NAME PART NUMBER SPRING COMPRESSING TOOL HD 38515 A 1 Submerge and soak all friction and steel plates in GENUINE HARLEY DAVIDSON FORMULA TRANSMIS SION AND PRIMARY CHAINCASE LUBRICANT for at least five minutes 2 See Figure 5 19 Install narrow friction plate on ...

Page 413: ... install new retaining ring into the groove in clutch hub prongs f With retaining ring fully seated in groove of clutch hub carefully loosen and remove compression tool NOTE When the compressing tool is removed the diaphragm spring will move outward forcing the spring seat up into the inside of the retaining ring The spring seat provides an operating surface for the diaphragm spring at the same ti...

Page 414: ...DAVIDSON FORMULA TRANSMISSION AND PRIMARY CHAINCASE LUB RICANT Part No 99851 05 See 5 5 CLUTCH 10 Connect negative battery cable to battery terminal Tighten fastener to 72 96 in lbs 8 11 Nm After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 11 Install seat HOM...

Page 415: ... 3 Remove primary cover See 5 3 PRIMARY COVER 4 Loosen engine sprocket a See Figure 5 24 Install SPROCKET LOCKING LINK Part No HD 38362 for XB9 models or SPROCKET LOCKING LINK Part No HD 46283 for XB12 models b Remove the engine sprocket bolt c Loosen but do not remove engine sprocket If neces sary use the slotted portion of TWO CLAW PULLER Part No HD 97292 61 and two bolts to loosen the engine sp...

Page 416: ... clutch shell Inspect primary chain sprocket and the starter ring gear on the clutch shell 7 Inspect slots that mate with the clutch plates on both clutch shell and hub 8 See Figure 5 27 Inspect the clutch shell compensating spring set NOTE As you proceed around the back of the clutch shell the com pensating springs go from being loaded to unloaded so it is possible for the clutch springs to float...

Page 417: ...m clutch shell 3 See Figure 5 32 Remove bearing guide from end of CLUTCH SHELL BEARING REMOVER INSTALLER Part No B 45926 4 Place new needle bearing onto installer end of tool and insert the bearing guide to prevent the bearing from falling off during installation and to align bearing with clutch shell 5 See Figure 5 33 Place clutch shell on support blocks with sprocket side facing up 6 Press beari...

Page 418: ...and No tools are required 2 Submerge and soak all friction and steel plates in FOR MULA PRIMARY TRANSMISSION LUBRICANT for at least five minutes and assemble clutch pack in sequence in the clutch hub See 5 5 CLUTCH General 3 Verify that outer thrust washer 4 is installed on transmis sion shaft 4 Install the engine sprocket clutch assembly and primary chain as a unit into primary chaincase 5 See Fi...

Page 419: ...KING LINK 8 Install the pressure plate assembly See 5 5 CLUTCH 9 Install adjusting screw assembly into pressure plate a See Figure 5 38 Align two tabs on perimeter of release plate with corresponding recesses 3 in pressure plate b Secure the adjusting screw assembly with new retaining ring 10 Install primary cover See 5 3 PRIMARY COVER 11 Adjust clutch See 1 9 CLUTCH TRANSMIS SION PRIMARY FLUID 12...

Page 420: ...3 1 2 sm00288 1 Adjusting screw assembly 2 Retaining ring 3 Tab recesses Figure 5 38 Clutch Adjusting Screw Assembly and Retaining Ring HOME 5 22 2009 XB Service Drive Transmission ...

Page 421: ... will result in premature failure For maximum strength integrity and longevity avoid over bending twisting crimping pinching kinking or prying the drive belt 1 3 3 2 4 5 6 sm00301 1 Forward bend must not be less than 5 in 127 mm 2 Reverse bend must not be less than 10 in 254 mm 3 Minimum diameter 4 Do not twist belt 5 Do not crimp pinch or kink belt 6 Do not pry belt Figure 5 39 Proper Drive Belt ...

Page 422: ... 1 sm00302 1 Axle 2 Pinch bolt Figure 5 41 Rear Axle DRIVE BELT INSTALLATION NOTES When removing or installing belt do not bend or twist belt Partially slide belt onto sprocket and rotate wheel or belt damage will occur Never tighten rear axle with swingarm brace removed 1 Slide belt onto sprocket 2 Install swingarm brace and tighten fasteners to 25 27 ft lbs 34 37 Nm See 2 19 SWINGARM AND BRACE N...

Page 423: ... Inspection 8 If pulley wheel needs replacement remove fastener 6 washer and nut 2 from idler pulley bracket 4 and discard wheel Replace with new pulley wheel 1 NOTE The pulley wheel bearings can not be replaced separately 2 1 sm00302 1 Axle 2 Pinch bolt Figure 5 43 Rear Axle IDLER PULLEY INSTALLATION 1 See Figure 5 44 Install new or existing pulley wheel 1 if removed and tighten washer and nut 2 ...

Page 424: ... 2 to 40 45 ft lbs 54 61 Nm 3 1 2 4 5 6 sm00304 1 Wheel 2 Wheel nut 3 Stud 2 4 Idler pulley bracket 5 Idler pulley bracket nut and washer 2 6 Wheel fastener Figure 5 44 Idler Pulley Assembly HOME 5 26 2009 XB Service Drive Transmission ...

Page 425: ...t The shifter shaft actuates a pawl and a shifter fork drum The shifter fork drum moves shifter forks which slide a series of shifter dogs on the mainshaft and countershaft into and out of mesh with the other gears 2 3 4 1 5 2 3 4 1 5 2 3 4 1 5 2 3 4 1 5 2 3 4 1 5 2 3 4 1 5 7 6 8 1 2 4 3 5 9 10 11 12 sm00305 9 5 1 Sliding members dark gray Fifth gear First gear 2 10 6 Second gear Power flow light ...

Page 426: ... Disassemble gearcase See 3 17 GEARCASE AND CAM GEARS 6 Remove primary cover See 5 3 PRIMARY COVER 7 Remove clutch assembly primary chain and engine sprocket See 5 6 PRIMARY CHAIN and 5 5 CLUTCH sm00306 Figure 5 46 Hex Fastener Countershaft Retainer 8 See Figure 5 46 Place transmission in first gear Remove hex fastener sm00307 Figure 5 47 Shifter Drum Neutral Detent 9 See Figure 5 47 Place transmi...

Page 427: ...50 Depress ratchet arms 3 in order to clear the shifter drum and remove shifter shaft assembly from left crankcase half 13 Remove starter See MISSING_XREF_C18 sec tionC18S6 sm02979 Figure 5 51 Rear Isolator Assembly 14 See Figure 5 51 Remove rear isolator assembly by removing the forward two fasteners first and then the two rear fasteners re install with new fasteners HOME 2009 XB Service Drive Tr...

Page 428: ... sm00312 Figure 5 53 Separating Crankcase Halves 16 See Figure 5 53 Separate crankcase halves NOTE Flywheel assembly slides out of the left main bearing by hand No tools are required for this operation sm02981 Figure 5 54 Removing Flywheels from Left Crankcase 17 See Figure 5 54 Remove the flywheel assembly from left crankcase half HOME 5 30 2009 XB Service Drive Transmission ...

Page 429: ...um right side 5 Shifter fork shaft 6 Shifter fork 2nd 3rd 7 Shifter fork 1st Figure 5 55 Shifter Forks Drum and Shafts 1 See Figure 5 56 Remove shifter fork shafts by inserting a small flat punch in the slots and tapping on the end of each shaft until it falls free NOTE Carefully tap on alternate sides of the shaft using the provided slots 2 See Figure 5 57 Remove shifter drum 1 and shifter forks ...

Page 430: ...ever assembly 2 Fork assembly shifter 2nd 3rd 6 18 Fork assembly shifter 1st Shift lever 19 7 Bolt linkage assembly Shifter cam assembly 8 20 Fork assembly shifter 4th 5th Sleeve shift brake lever 21 9 Bolt shift lever Pin shifter stop 10 22 Spring shifter return Pad rubber shift lever 23 11 Linkage assembly shifter Spring extension 12 24 Shifter lever assembly Bolt linkage assembly Figure 5 58 Sh...

Page 431: ...liers and could be propelled with enough force to cause serious eye injury 00312a 3 See Figure 5 59 Remove left crankcase half and transmis sion assembly 4 from engine stand a Place crankcase half 3 and transmission assembly 4 on arbor press 1 and support transmission assembly on parallel supports 5 b Press transmission assembly using TRANSMISSION REMOVER Part No B 43895 1 2 to remove transmission...

Page 432: ...g ring 23 7 Countershaft 4th gear Mainshaft 5th gear 8 24 Mainshaft 1st gear Countershaft 3rd gear 25 9 Dog ring Retaining ring 4 10 26 Thrust washer 4 Thrust washer 27 11 Countershaft 2nd gear Mainshaft 4th gear 12 28 Split bearing 4 Spacer 29 13 Countershaft bearing Mainshaft 14 30 Mainshaft 3rd gear integral to shaft Retaining ring 31 15 Countershaft retaining screw Mainshaft 2nd gear integral ...

Page 433: ...ssemblies can be serviced separately All thrust washers are one common part number This transmission requires no shimming Wear safety glasses or goggles when removing or installing retaining rings Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury 00312a NOTE Use correct retaining ring pliers and correct tips Verify that tips are not exces...

Page 434: ...enough force to cause serious eye injury 00312a 1 See Figure 5 63 Remove spacer 19 and 2nd gear 18 from the end of the of the countershaft 2 Remove and discard split bearing 17 2 Remove spacer 16 NOTE When removing the dog ring 15 it is important to mark the direction of the ring on the shaft as parts establish wear pat terns 3 Remove dog ring 15 4 Using RETAINING RING PLIERS Part No J 5586 A expa...

Page 435: ...ft 3rd gear 13 3 Thrust washer Split bearing 4 14 Countershaft 1st gear Retaining ring 15 5 Dog ring Thrust washer 6 16 Retaining ring Spacer 17 7 Split bearing Dog ring 8 18 Countershaft 4th gear Countershaft 2nd gear 19 9 Spacer Retaining ring 10 Thrust washer Figure 5 63 Transmission Countershaft HOME 2009 XB Service Drive Transmission 5 37 ...

Page 436: ...al to shaft 8 Mainshaft 2nd gear integral to shaft Figure 5 64 Transmission Mainshaft COUNTERSHAFT ASSEMBLY TOOL NAME PART NUMBER RETAINING RING PLIERS J 5586 A Wear safety glasses or goggles when removing or installing retaining rings Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury 00312a NOTES Use correct retaining ring pliers and cor...

Page 437: ...ready to be pressed into the left crankcase half 1 2 3 4 5 6 9 10 13 14 7 8 11 12 15 16 18 19 17 sm00321 11 1 Split bearing Countershaft 5th gear integral to shaft 2 12 Countershaft Countershaft 3rd gear 13 3 Thrust washer Split bearing 4 14 Countershaft 1st gear Retaining ring 15 5 Dog ring Thrust washer 6 16 Retaining ring Spacer 17 7 Split bearing Dog ring 8 18 Countershaft 4th gear Countershaf...

Page 438: ...ROSS PLATE B 45847 RECEIVER CUP HD 35316 11 8 IN BOLT HD 35316 4A WASHER HD 35316 7 BEARING DRIVER HD 35316 9 1 Split crankcases in half See 5 9 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL 2 Remove transmission as an assembly See 5 10 TRANSMISSION DISASSEMBLY 3 See Figure 5 67 From inside case tap out seal 3 at end of mainshaft 5th gear Discard seal 4 Obtain MAIN DRIVE GEAR REMOVER AND INSTALLER SET...

Page 439: ... correct retaining ring pliers and correct tips Verify that tips are not excessively worn or damaged 1 See Figure 5 66 At outside of case remove and discard oil seal 10 Remove and discard main drive gear bearing retaining ring 9 2 See Figure 5 69 From inside crankcase position BEARING DRIVER Part No HD 35316 9 2 over main drive gear bearing 3 Insert 8 IN BOLT Part No HD 35316 4A 1 through bearing ...

Page 440: ...his photo 3 Wedge attachment for claw puller 4 Press ram Figure 5 70 Removing Inner Bearing Race from Main Drive Gear ASSEMBLY TOOL NAME PART NUMBER INNER OUTER MAIN DRIVE GEAR NEEDLE BEARING INSTALLATION TOOL HD 47855 1 Use INNER OUTER MAIN DRIVE GEAR NEEDLE BEARING INSTALLATION TOOL Part No HD 47855 for assembly Assemble parts The installation tool will automatically bottom on the gear when the ...

Page 441: ...e 4 2 See Figure 5 74 Insert 8 IN BOLT Part No HD 35316 4A 2 through cross plate 1 and main drive gear bearing bore 3 At outside of case place main drive gear ball bearing 3 BEARING DRIVER Part No HD 35316 8 4 nice bearing 5 flat washer 6 and nut 7 over end of bolt NOTE Do not continue to tighten nut after ball bearing bottoms against lip in crankcase bearing bore Tightening nut too much can break...

Page 442: ...e 5 66 Install new o ring 5 into groove in main drive gear 2 Lubricate o ring with GENUINE HARLEY DAVIDSON FORMULA TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT NOTE See Figure 5 66 Make sure to install new o ring 5 onto main drive gear before installing main drive gear into crankcase 3 See Figure 5 76 Insert 8 IN BOLT Part No HD 35316 4A 1 through WASHER Part No HD 35316 7 2 and main drive gear 3 ...

Page 443: ... so could make it difficult to remove adapter after seal has been installed 5 See Figure 5 80 Slide INSTALLER Part No HD 47856 1 over adapter until cupped end of installer is flat against seal 6 See Figure 5 81 Thread NUT Part No HD 47856 5 onto end of adapter until it tightens against installer 7 See Figure 5 82 Place CROWFOOT WRENCH Part No HD 47856 7 1 with 1 2 inch drive breaker bar 2 on large...

Page 444: ...337 Figure 5 80 Place Installer over Adapter Typical sm00338 Figure 5 81 Install Nut Typical 2 1 3 sm00339 1 Crowfoot wrench 2 1 2 inch breaker bar 3 Adjustable wrench Figure 5 82 Press Seal Into Crankcase HOME 5 46 2009 XB Service Drive Transmission ...

Page 445: ...LLATION TOOL NAME PART NUMBER SNAP ON BUSHING DRIVER 1 2 INCH ADAPTER A157 8 SNAP ON BUSHING DRIVER SET A157C Countershaft Needle Bearing 1 Find a suitable bearing driver 1 1 4 in 31 75 mm in dia meter 2 See Figure 5 83 From the outside of the case place the closed end needle bearing 11 open end first next to the bearing bore Hold the driver squarely against the closed end of the bearing and tap t...

Page 446: ...aring inner Ball bearing with spacer 9 3 Retaining ring Fifth gear mainshaft 4 10 Bearing outer Oil seal 11 5 Bearing closed end countershaft O ring 6 12 Oil seal Bushing shifter drum Figure 5 83 Transmission Assembly Right Crankcase Half HOME 5 48 2009 XB Service Drive Transmission ...

Page 447: ...t 4 Bearing countershaft Figure 5 84 Ball Bearing Assembly INSTALLATION Mainshaft and Countershaft Bearings 1 Place crankcase on press with inside surface of crankcase downward 2 Lay bearing squarely over bore with printed side of bearing upward Place a pressing tool slightly smaller than outside diameter of bearing against outer race Press bearing into bore until bearing bottoms against shoulder ...

Page 448: ...3 4 1 2 sm01370 1 Retaining ring 2 Retaining ring 3 Mainshaft bearing 4 Countershaft bearing Figure 5 86 Ball Bearing Assembly HOME 5 50 2009 XB Service Drive Transmission ...

Page 449: ... shaft Gear could be damaged if it strikes a hard sur face 1 See Figure 5 87 Place transmission assembly onto TRANSMISSION FIXTURE Part No B 46285 4 on arbor press 1 2 Install transmission remover installer tool GUIDE Part No B 43985 4 2 over the end of the countershaft 3 See Figure 5 88 Place left case half over transmission assembly and install transmission remover installer tool INSTALLER Part ...

Page 450: ... 12 o clock position This will place shifter drum in neutral position NOTE See Figure 5 90 Install shifter fork shafts in the left case half by lightly tapping on the end of the shaft with a brass or hard plastic hammer until shaft is seated in bore 3 Place 1st gear shifter fork onto dog ring between counter shaft 1st and 4th gear gears Install shifter fork shaft through two installed shifter fork...

Page 451: ... and the mating surfaces of the mainshaft and countershaft with HARLEY DAVIDSON SPECIAL PURPOSE GREASE Part No 99857 97 5 See Figure 5 93 Assemble crankcase halves together a Apply a thin coat of GRAY HIGH PERFORMANCE SEALANT Part No 99650 02 to crankcase joint faces b See Figure 5 94 Apply several drops of LOCTITE 271 red to last few threads and tighten crankcase fasteners 1 2 to 15 19 ft lbs 20 ...

Page 452: ...sm00312 Figure 5 93 Crankcase Halves D 1 1 1 1 2 sm00176 1 Crankcase fasteners 2 Crankcase fastener behind shifter mechanism Figure 5 94 Crankcase Fasteners HOME 5 54 2009 XB Service Drive Transmission ...

Page 453: ...ed to last few threads of countershaft retaining screw Thread screw into end of shaft 4 Place transmission in gear and tighten hex head fastener to 33 37 ft lbs 44 8 50 Nm 5 Install transmission sprocket See 5 17 TRANSMISSION SPROCKET 6 Continue assembling engine See the following 3 18 CRANKCASE Assembly 3 7 CYLINDER HEAD Assembly 3 7 CYLINDER HEAD Cylinder Head Installation 3 8 CYLINDER AND PISTO...

Page 454: ...sm00309 Figure 5 98 Installing Shifter Shaft Assembly sm00306 Figure 5 99 Hex Fastener Countershaft Retainer HOME 5 56 2009 XB Service Drive Transmission ...

Page 455: ...n in first gear Remove two socket head screws 1 and lockplate 2 NOTES Transmission sprocket nut has left hand threads Turn nut clockwise to loosen and remove from main drive gear shaft Use the P3 Blast SPROCKET HOLDING TOOL Part No B 43982 with the spacer and fastener from the Fire bolt SPROCKET LOCKING TOOL Part No B 45659 to hold the sprocket 8 See Figure 5 102 Place transmission in neutral Inst...

Page 456: ...to align the screw holes The lockplate has four screw holes and can be turned to either side so you should be able to find a position without having to additionally tighten the nut If you cannot align lock plate and sprocket screw holes nut may be additionally tightened to 45 as specified above Tightening too much or too little may cause the nut to come loose during vehicle operation If you cannot...

Page 457: ...ansmission sprocket nut 2 Transmission sprocket 3 Line scribed on nut and sprocket Figure 5 103 Aligning Transmission Sprocket 2 1 sm00302 1 Axle 2 Pinch bolt Figure 5 104 Rear Axle HOME 2009 XB Service Drive Transmission 5 59 ...

Page 458: ...5 60 2009 XB Service Drive Transmission NOTES ...

Page 459: ...L FLASHER 6 40 6 15 FRONT TURN SIGNALS 6 42 6 16 REAR TURN SIGNALS 6 44 6 17 INTERACTIVE EXHAUST SYSTEM 6 50 6 18 HEADLIGHT 6 54 6 19 TAIL LAMP 6 59 6 20 LICENSE PLATE LAMP ASSEMBLY 6 61 6 21 MAIN FUSE AND FUSES 6 63 6 22 NEUTRAL INDICATOR SWITCH 6 66 6 23 SIDESTAND SWITCH HDI 6 67 6 24 CRANKSHAFT POSITION SENSOR CKP 6 68 6 25 VEHICLE SPEED SENSOR VSS 6 70 6 26 INSTRUMENT MODULE 6 71 6 27 MAIN WIR...

Page 460: ...NOTES ...

Page 461: ...TION HEADLAMP KEY SWITCH ULYSSES 8 11 Nm 72 96 in lbs Battery terminal fasteners 6 10 VOLTAGE REGULATOR Installation 8 11 Nm 72 96 in lbs Battery terminal fasteners 6 11 ALTERNATOR Assembly and Installation 8 11 Nm 72 96 in lbs Battery terminal fasteners 6 13 HORN Installation 8 11 Nm 72 96 in lbs Battery terminal fasteners 6 24 CRANKSHAFT POSITION SENSOR CKP Installation 8 11 Nm 72 96 in lbs Batt...

Page 462: ...ver fasteners 6 20 LICENSE PLATE LAMP ASSEMBLY Light ning 1 4 4 Nm 12 36 in lbs License plate lamp assembly fastener Lightning 6 9 STARTER SOLENOID Solenoid Contacts 7 3 9 0 Nm 65 80 in lbs Long post jam nut 6 18 HEADLIGHT Headlight Bulbs Lightning and Ulysses 4 5 5 Nm 36 48 in lbs Lower headlight fastener 6 29 INTERACTIVE EXHAUST HARNESS XB12 MODELS Lightning 5 4 8 Nm 48 72 in lbs Main battery gr...

Page 463: ...bs Turn signal fastener rear Ulysses 6 16 REAR TURN SIGNALS Firebolt 2 8 3 2 Nm 25 28 in lbs Turn signal fastener rear 6 15 FRONT TURN SIGNALS Firebolt 2 8 3 2 Nm 25 28 in lbs Turn signal fasteners front 6 14 TURN SIGNAL FLASHER Installation 4 7 Nm 36 60 in lbs Turn signal flasher fastener 6 14 TURN SIGNAL FLASHER Installation 1 4 4 Nm 12 36 in lbs Turn signal flasher fastener 6 14 TURN SIGNAL FLA...

Page 464: ...lacement 79 0 ft lbs 107 2 Nm 3500 RPM 51 0 ft lbs 69 2 Nm 4300 RPM Torque 9 7 1 8 9 1 Compression ratio 2 8 qt 2 65 Liters 2 8 qt 2 65 Liters Oil tank capacity with filter Table 6 4 Service Wear Specifications MM IN SERVICE WEAR LIMITS 11 0 0 433 Brush length minimum 28 981 1 141 Commutator diameter min imum Table 6 5 Alternator Specifications ALTERNATOR 20 28 VAC per 1000 engine RPM AC voltage o...

Page 465: ...97 0 37 5 1 Position lamp Lightning Ulysses Europe Japan Australia models only 68169 90A 0 42 1 75 5 21 1 Tail stop lamp Firebolt Lightning Marker lamps Illuminated with LEDs Replace entire assembly upon failure Tail stop lamp Ulysses Y0042 K 0 74 10 4 Front and rear turn signal lamps 1 bulb each 53436 97 0 37 5 1 License plate illumination lamp Lightning Ulysses only Y0163 02A8 0 08 1 12 1 Turn s...

Page 466: ...ne The ECM also mon itors the crank position sensor to determine the exact position of both cylinders in the combustion cycle and the engine speed The ET sensor provides the ECM the current engine temper ature Proper fuel and spark delivery are dependent on the temperature of the engine The ECM will provide a richer fuel mixture on start up and a higher degree of spark advance As the vehicle warms...

Page 467: ...10 sm00241 9 5 1 Crank position sensor CKP Mounting fastener Electronic control module ECM 10 6 O ring Ignition coil 2 7 Connector interactive exhaust system Front spark plug cable 8 Cylinder brace 3 Spark plug 2 4 Rear spark plug cable Figure 6 1 Ignition Components HOME 2009 XB Service Electrical 6 7 ...

Page 468: ...ropean models only Can be activated Off Headlight high beam On Off Headlight low beam On Off Instrument module illumination lamps Can be activated Off Stop lamp Can be activated Front and rear turn signals Can be activated Cannot be activated Horn On Off Aux power outlets FIREBOLT TOOL NAME PART NUMBER SNAP ON TAMPER RESISTANT T45 TORX DRIVER FTXR45E Removal 1 Remove seat To prevent accidental veh...

Page 469: ...e ignition switch body fasteners 1 Separate igni tion switch body 2 from ignition switch 4 Assembly NOTE See Figure 6 6 In next step be sure wide slot in ignition switch housing 5 is installed over wide boss on ignition switch 4 1 Push ignition switch housing 5 on to ignition switch 4 NOTE In next step do not force ignition switch 4 into ignition switch body 2 If ignition switch does not easily sl...

Page 470: ...switch and brake line wires to upper fork clamp b Install cable strap to the left of ignition switch securing left hand switch and clutch cable wires to upper fork clamp 8 Install negative battery cable to battery terminal Tighten fastener to 72 96 in lbs 8 11 Nm The automatic on headlamp feature provides increased visibility of the rider to other motorists Be sure headlamp is on at all times Poor...

Page 471: ...NAP ON TAMPER RESISTANT T45 TORX DRIVER Part No FTXR45E to remove the two tamper resistant Torx fasteners 2 securing ignition switch to upper fork clamp 8 Remove the final ignition switch fastener 1 along with spacer located behind the ignition switch 9 While holding the throttle cables 3 to your left the right side of the vehicle pull the ignition switch 4 toward you and roll the assembly away fr...

Page 472: ...tion switch 4 by prying tabs on side of housing 2 Remove ignition switch body fasteners 1 Separate igni tion switch body 2 from ignition switch 4 Assembly NOTE See Figure 6 9 In next step be sure wide slot in ignition switch housing 5 is installed over wide boss on ignition switch 4 1 Push ignition switch housing 4 on to ignition switch 5 NOTE In next step do not force ignition switch 5 into ignit...

Page 473: ...ar ness connectors c Turn signal connectors 31 5 d Turn signal flasher connector 30 1 9 Loosely install cable strap around the main wiring harness and the ignition switch 10 Install negative battery cable to battery terminal Tighten fastener to 72 96 in lbs 8 11 Nm The automatic on headlamp feature provides increased visibility of the rider to other motorists Be sure headlamp is on at all times Po...

Page 474: ... harness 9 3 Horn fastener Right handlebar connector 22 4 10 Left handlebar connector 24 Horn mount 11 5 Horn connector 122 Turn signal connectors 31 6 12 Ignition switch Horn Figure 6 10 Electrical Connectors Behind Windscreen Ulysses Disassembly 1 See Figure 6 11 Remove housing 4 from ignition switch 5 by prying tabs on side of housing 2 Remove body fasteners 1 Separate body 2 from igni tion swi...

Page 475: ...u and insert the fork stop pin into the upper triple clamp 3 See Figure 6 11 After applying LOCTITE 271 red attach ignition switch assembly to upper triple clamp using ignition switch fasteners 7 6 install spacer 3 onto fastener 6 and tighten to 18 20 ft lbs 24 4 27 1 Nm 4 Connect ignition switch connector 33 to wiring harness 5 Loosely install cable strap around the main wiring harness and the ig...

Page 476: ...or loose fit on ignition coil and spark plugs 2 Check cable boots caps for cracks or tears Replace boots caps that are worn or damaged NOTE Both cables are the same length 3 See Figure 6 13 Check spark plug cable resistance with an ohmmeter 4 Replace cables not meeting resistance specifications Table 6 13 Spark Plug Cable Resistance RESISTANCE OHMS CABLE LENGTH POSITION 1 350 3 465 5 7 in 145 mm F...

Page 477: ...sm00366 Figure 6 14 Boot Gap HOME 2009 XB Service Electrical 6 17 ...

Page 478: ...r battery post fasteners Install wiring between battery cable and fastener Alternator The alternator consists of two main components The rotor which mounts to the engine sprocket shaft The stator which bolts to the engine crankcase Voltage Regulator NOTE For troubleshooting and diagnostic see Electrical Diagnostic Manual See 6 10 VOLTAGE REGULATOR The voltage regulator is a series regulator with s...

Page 479: ...1 1 J Fuse 30 Amp To fuse and relay block BK BK BK BK BK BK BK R Y R 46A BK 6 5 3 2 1 4 sm04729 5 3 1 Voltage regulator J fuse 30A Battery 2 6 4 Battery cable Stator H D 1 phase To voltage regulator Figure 6 15 Charging System Circuit Firebolt HOME 2009 XB Service Electrical 6 19 ...

Page 480: ...ck Battery Fuse 30 Amp To fuse and relay block BK BK BK BK BK BK BK R Y R R 46A BK sm04730 4 1 To voltage regulator Battery 2 5 Battery cable Voltage regulator 6 3 Stator H D 1 phase 30A battery fuse Figure 6 16 Charging System Circuit Ulysses Lightning HOME 6 20 2009 XB Service Electrical ...

Page 481: ...ly 6 in 152 4 mm above the point where it enters the main harness bundle INSTALLATION 1 Clean cable connectors and battery terminals using a wire brush or sandpaper to remove any oxidation Connect positive battery cable first If positive cable should contact ground with negative cable connected the resulting sparks can cause a battery explosion which could result in death or serious injury 00068a ...

Page 482: ...Negative battery cable 9 To frame 10 To starter Figure 6 17 Battery Firebolt 1 8 4 3 7 6 2 5 sm00445 1 Battery 2 Battery boot 3 Positive battery cable 4 Negative battery cable 5 To frame 6 To starter 7 Red yellow wires 14 gauge to be spliced 8 Battery strap Figure 6 18 Battery Lightning Ulysses sm00394 Figure 6 19 Negative Battery Cable Typical HOME 6 22 2009 XB Service Electrical ...

Page 483: ...1 2 sm00258 1 Positive battery cable 2 Solenoid wire Figure 6 20 Starter Wires Protective Boot Not Shown HOME 2009 XB Service Electrical 6 23 ...

Page 484: ...death or serious injury 00049a 2 Disconnect battery See 1 5 BATTERY MAINTENANCE 3 Drain transmission lubricant and remove primary cover See 2 36 SPROCKET COVER 4 Remove sprocket cover See 2 36 SPROCKET COVER NOTE A ball hex driver may be required to gain access to the starter mounting bolts 5 See Figure 6 21 Remove two starter mounting bolts and washers 1 6 See Figure 6 22 Lift rubber boot remove ...

Page 485: ... use an undercutting machine to undercut the mica to 1 32 in 0 79 mm deep The slots should then be cleaned to remove any dirt or copper dust NOTES See Figure 6 23 If an undercutting machine is not avail able undercutting can be done satisfactorily using a thin hacksaw blade After undercutting lightly sand the arma ture with crocus cloth to remove any burrs Do not use sandpaper or emery cloth on co...

Page 486: ...hex nut with captive lockwasher Tighten hex nut to 70 90 in lbs 7 9 10 2 Nm Cover field wire ring terminal with rubber boot 10 Install end cover bracket onto threaded end of thru bolts if equipped For proper orientation be sure that the longest end of the bracket before the bend is on the field wire side Install two Keps nuts and alternately tighten until snug 11 Install allen head screw to fasten...

Page 487: ...stall return spring on solenoid plunger shaft 9 Mate the solenoid and drive housings and install two hex screws using a 9 mm socket Alternately tighten hex screws until snug 10 Lubricate armature bearing with LUBRIPLATE 110 Seating armature bearing in counterbore mate field coil and solenoid housings For proper assembly a nub on the field coil housing flange must engage the slot on solenoid housin...

Page 488: ...nstall field coil See 6 8 STARTER Field Coil Assembly SOLENOID PLUNGER Disassembly 1 Remove three hex screws to release solenoid cover 2 Remove rubber gasket from solenoid cover flange 3 Remove plunger and return spring Assembly 1 Apply a light film of LUBRIPLATE 110 to plunger shaft and install return spring Install plunger in solenoid 2 Install new rubber gasket on solenoid cover flange 3 Instal...

Page 489: ...lenoid housing d At outside of solenoid housing install round bushing O ring and wave washer onto end of post Install jam nut but do not tighten 2 Assemble long post battery a On inside of solenoid housing align hole in paper insulator washer with hole in solenoid housing Insert sleeve on square bushing into holes b With the foot inboard against solenoid winding align hole in contact plate with ho...

Page 490: ...s 7 3 9 0 Nm Verify that contact plates have not rotated out of alignment with plunger 5 Install new rubber gasket on solenoid cover flange 6 Install three hex screws to secure solenoid cover Altern ately tighten hex screws until snug HOME 6 30 2009 XB Service Electrical ...

Page 491: ... 4 Remove fasteners 5 and voltage regulator 4 from bracket 3 INSTALLATION 1 See Figure 6 27 Attach new voltage regulator 4 to bracket 3 Tighten fasteners 5 to 36 60 in lbs 3 5 7 Nm NOTE When installing the left side air scoop it is necessary to verify that the voltage regulator and alternator wiring harnesses are not trapped between the air scoop and cylinder head 2 Connect stator connector 46 1 a...

Page 492: ...5 2 1 4 sm00392 1 Voltage regulator connector 77 2 Stator connector 46 3 Voltage regulator mount bracket 4 Voltage regulator 5 Fastener 3 Figure 6 27 Voltage Regulator HOME 6 32 2009 XB Service Electrical ...

Page 493: ...he alternator and voltage regulator are routed on the left side of the vehicle under the air scoop The harnesses are secured to the air scoop with 3 cable straps 1 See Figure 6 30 Disconnect stator wiring 4 from voltage regulator wiring at connector 5 46 under the left ram air scoop See 6 30 SPROCKET COVER WIRING 2 Remove cable straps holding stator wire to the left ram air scoop NOTE Stator faste...

Page 494: ...case half Secure stator using four new stator fasteners 1 Tighten to 30 40 in lbs 3 4 Nm 4 Install retainer plate with new fasteners and tighten to 56 in lbs 6 3 Nm NOTE When installing the left side air scoop it is necessary to verify that the voltage regulator and alternator wiring harnesses are not trapped between the air scoop and cylinder head 5 See Figure 6 30 Route stator wiring 4 behind re...

Page 495: ...rip 11 Remove right side heated hand grip See 2 24 THROTTLE CONTROL Installation 1 Install the left heated grip and tighten fasteners to 14 16 in lbs 1 6 1 8 Nm 2 Install the right side heated hand grip to the handlebar See 2 24 THROTTLE CONTROL NOTES See Figure 6 32 The paint mark needs to be lined up visually with the inside edge of the right and left hand control See Figure 6 33 The hanging loo...

Page 496: ...n of Cable Strap Securing the Right Side Hand Grip Wire Below the Instrument Cluster 7 See Figure 6 37 On the left side install a cable strap securing the hand grip wire to the instrument module connector under the left hand side of the instrument cluster 8 Connect the two black 3 way connectors for the heated grip leads 2 1 1 sm04637 1 Black 3 way connector for heated hand grips 2 2 Cable strap s...

Page 497: ...wire on the heated grip does not make contact with anything when the throttle is rotated 10 Connect negative battery cable to battery terminal Tighten fastener to 72 96 in lbs 8 11 Nm After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 11 Install seat HOME 2009...

Page 498: ... in lbs 8 1 10 8 Nm 3 Install negative battery cable to battery terminal Tighten fastener to 72 96 in lbs 8 11 Nm 4 Check horn operation If horn does not sound or fails to function satisfactorily see 6 13 HORN Troubleshooting a Turn ignition key switch ON b Press horn switch to activate horn c Turn ignition key switch OFF 5 For Firebolt install headlight support bracket and install front fairing S...

Page 499: ...Verify horn is not making contact with wiring or other components 2 If battery has a satisfactory charge and wiring appears to be in good condition test horn ground and switch using voltmeter a See Figure 6 42 RemoveY BK power and BK ground wires from terminal clips b Connect voltmeter positive lead to Y BK wire c Connect voltmeter negative lead to ground d Turn ignition key switch ON 3 See Figure...

Page 500: ...ule Lightning Tighten fastener to 12 36 in lbs 1 4 4 Nm 4 Install turn signal flasher to front headlight module Ulysses Tighten fastener to 36 60 in lbs 4 7 Nm 5 Install front fairing or windshield windscreen See 2 47 FRONT FAIRING WINDSHIELD AND MIRRORS FIREBOLT Firebolt or 2 48 WINDSHIELD AND WIND SCREEN LIGHTNING AND ULYSSES Lightning and Ulysses Be sure that all lights and switches operate pro...

Page 501: ...sm00459 Figure 6 46 Turn Signal Flasher Ulysses 1 2 sm00407 1 Left turn signal 2 Right turn signal Figure 6 47 Turn Signal Controls HOME 2009 XB Service Electrical 6 41 ...

Page 502: ... signal 1 using lockwasher 2 and fastener 3 Tighten fastener to 25 28 in lbs 2 8 3 2 Nm 3 Attach bullet connectors on turn signal wires as shown in Figure 6 48 4 Check turn signals for proper operation If operation fails reread procedure and verify that all steps were performed a Turn ignition key switch to ON b Activate left turn signals using switch on left handlebar Front and rear left turn sig...

Page 503: ... Figure 6 51 Insert bullet connectors and wiring through hole in front module 2 Install turn signal using lockwasher and jam nut Tighten fastener to 25 28 in lbs 2 8 3 2 Nm 3 Attach bullet connectors on turn signal wires as shown in Figure 6 48 Be sure that all lights and switches operate properly before operating motorcycle Low visibility of rider can result in death or serious injury 00316a 4 Ch...

Page 504: ...sm00458 1 Left turn signal 2 Tail lamp 3 Right turn signal Figure 6 53 Rear Turn Signal Connections Ulysses FIREBOLT Removal 1 Remove seat See 2 51 SEAT 2 Remove tail frame upper body work See 2 39 SUBFRAME TAIL ASSEMBLY AND BODY WORK FIREBOLT 3 See Figure 6 52 Disconnect bullet connectors on turn signal wires 4 See Figure 6 54 Remove fastener 6 and lockwasher 5 5 Remove turn signal from tail sect...

Page 505: ...y switch to OFF 6 Install tail frame upper bodywork See 2 39 SUBFRAME TAIL ASSEMBLY AND BODY WORK FIREBOLT 7 Install seat See 2 51 SEAT 1 6 2 3 4 7 5 sm00404 7 4 1 Tail section License plate bracket Turn signal 2 5 Turn signal bulb Lockwasher 2 6 3 Fastener 2 Reflector bracket Figure 6 54 Rear Turn Signals Firebolt LIGHTNING Removal 1 Remove seat See 2 51 SEAT 2 See Figure 6 52 Disconnect bullet c...

Page 506: ...ash d Turn ignition key switch to OFF 6 Install seat See 2 51 SEAT 2 4 3 5 6 1 1 3 6 sm00455 5 3 1 Center tail section Reflector bracket Turn signal 2 2 6 4 Turn signal bulb Bungee hooks Jam nut and lockwasher 2 Figure 6 55 Rear Turn Signals Lightning ULYSSES Remove 1 Remove seat See 2 51 SEAT 2 See 6 20 LICENSE PLATE LAMP ASSEMBLY Ulysses Remove rear wire cover 3 See Figure 6 53 Separate left tur...

Page 507: ...55 LUGGAGE XB12XP 2 See Figure 6 57 Remove turn signal relocation bracket 1 and let hang by the wires 3 Remove rear reflector bracket 7 4 Remove grommet for the emergency light connector wires from wire cover 6 5 Disconnect emergency light connectors at the rear of the lighting siren control module and pull connectors through hole in rear wire cover 6 one connector at a time 6 Remove license plate...

Page 508: ...tall the rear reflector bracket 7 and tighten to 48 72 in lbs 5 4 8 Nm 6 Install turn signal relocation bracket 1 and tighten to 60 72 in lbs 7 8 Nm 7 Install side cases HOME 6 48 2009 XB Service Electrical ...

Page 509: ...oop 3 Turn signal left rear 4 Bracket license plate illuminationn center tail section 5 Turn signal right rear 6 Cover rear wires 7 Rear reflector bracket 8 License plate lamp Figure 6 57 Rear Turn Signal Relocation Bracket XB12XP HOME 2009 XB Service Electrical 6 49 ...

Page 510: ... engine can gain RPM quickly The exhaust enters 2 the muffler and flows 3 through the open valve 1 into chamber C 7 and then exits 8 2 In the mid range the valve is closed to increase accelera tion torque The exhaust flows 4 through chamber A around to chamber B and then through chamber C and exits 3 At high RPM the valve opens again to maximize horsepower The exhaust enters 2 the muffler and flow...

Page 511: ...ess with connector 161B Actuator cover Lightning XB12 models with translucid cover only 3 Interactive exhaust cable bracket 7 4 Screws Lightning XB12 models with translucid cover only Actuator Figure 6 59 Interactive Control System XB12 Models HOME 2009 XB Service Electrical 6 51 ...

Page 512: ...d support muffler until interactive exhaust cable is removed 11 Remove cable strap above starter securing actuator cable vent line main harness and positive battery cable 1 3 2 sm03744 1 Neutral switch connection 131 2 Oil pressure indicator switch wire 3 Interactive exhaust cable Figure 6 60 Electrical Connectors and Interactive Exhaust Cable Under Sprocket Cover 12 Remove cable strap securing in...

Page 513: ... 40 in lbs 4 4 5 Nm 4 Attach interactive exhaust cable to cable wheel on actu ator 5 Connect interactive exhaust harness to actuator 161B 6 Attach interactive exhaust cable to bracket and cable wheel on actuator and adjust See 1 16 INTERACTIVE EXHAUST CABLE 7 Install cable strap above starter securing actuator cable vent line main harness and positive battery cable 8 Install cable strap securing a...

Page 514: ...ear eye protection Bulb con tains gas under pressure which if not handled carefully could cause serious eye injury 00062b Never touch the quartz bulb Fingerprints will etch the glass and decrease bulb life Grab the bulb with paper or a clean dry cloth Failure to do so could result in bulb damage 00210a 2 See Figure 6 64 Disconnect headlight connection 1 3 Remove rubber boot from headlight housing ...

Page 515: ... cause death or serious injury disconnect negative battery cable before proceeding 00048a 2 Disconnect negative battery cable Handle bulb carefully and wear eye protection Bulb con tains gas under pressure which if not handled carefully could cause serious eye injury 00062b Never touch the quartz bulb Fingerprints will etch the glass and decrease bulb life Grab the bulb with paper or a clean dry c...

Page 516: ...onnect the headlight bulb connector 3 4 NOTE If the rubber boots are not installed correctly the wiring har nesses can contact the edge of the forward frame mount The wiring harness guides must be installed at a 20 degree angle 4 See Figure 6 65 Install rubber boot a When installing the rubber boots on the back of the headlight housing be sure to align the harness guides or spigots with the castin...

Page 517: ...to ON b Check headlight LOW beam 3 and HIGH beam 2 settings c Set headlight to LOW beam Press passing lamp switch 1 Headlight should flash HIGH beam for as long as the switch is pressed d Turn ignition key switch to OFF After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious inj...

Page 518: ...sm00447 Figure 6 66 Headlight Housing 20 Degree Alignment Marks for Rubber Boot Wiring Harness Guides or Spigots HOME 6 58 2009 XB Service Electrical ...

Page 519: ...result in death or serious injury 00316a 4 Check tail lamp for proper operation If operation fails reread procedure and verify that all steps were performed a Turn ignition key switch to ON b Check for tail lamp illumination c Squeeze front brake hand lever Check for brake lamp illumination Release front brake hand lever d Press rear brake pedal Check for brake lamp illumin ation Release rear brak...

Page 520: ...amp for proper operation If operation fails reread procedure and verify that all steps were performed a Turn ignition key switch to ON b Check for tail lamp illumination c Squeeze front brake hand lever Check for brake lamp illumination Release front brake hand lever d Press rear brake pedal Check for brake lamp illumin ation Release rear brake pedal e Turn ignition key switch to OFF After install...

Page 521: ...y to tail section using jam nuts and washers 1 and tighten to 12 36 in lbs 1 4 4 Nm c Attach the two connectors 45 from license plate lamp wiring harness and connectors 2 to main harness 2 Check lamp for proper operation If operation fails reread procedure and verify that all steps were performed a Turn ignition key switch to ON b Check for license plate lamp illumination c Turn ignition key switc...

Page 522: ...5 to tail section using washers and jam nuts 1 and tighten to 12 36 in lbs 1 4 4 Nm d See Figure 6 71 Attach front of wire cover by installing remaining fasteners 6 and tightening to 36 48 in lbs 4 1 5 4 Nm 2 Check lamp for proper operation If operation fails reread procedure and verify that all steps were performed a Turn ignition key switch to ON b Check for license plate lamp illumination c Tur...

Page 523: ... the seat immediately behind the rear brake fluid reservoir To disable the motorcycle s ignition system pull the main fuse Lightning and Ulysses The 30 amp main fuse is located under the seat in the fuse block To disable the motorcycle s ignition system pull the main fuse sm00423 Figure 6 72 Fuse Block Firebolt 19 20 21 22 23 24 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 ...

Page 524: ... 24 25 26 27 28 29 30 31 32 1 2 3 4 5 6 7 8 9 10 11 12 sm00467 1 Fuel pump 10 amp 2 Auxiliary 10 amp 3 Main 30 amp 4 ECM 10 amp 5 Lamps 15 amp 6 Key switch 15 amp 7 Ignition 15 amp 8 Accessories 10 amp 9 Brake horn interactive exhaust 10 amp 10 Cooling fan 10 amp 11 Spare 15 amp 12 Spare 10 amp Figure 6 75 Fuse Block Lightning HOME 6 64 2009 XB Service Electrical ...

Page 525: ...ary 10amp 3 Battery 30 amp 4 ECM 10 amp 5 Lamps 15 amp 6 Key switch 15 amp 7 Ignition 15 amp 8 Accessory 10 amp 9 Brake horn interactive exhaust 10 amp 10 Fan 10 amp 11 Spare 15 amp 12 Spare 10 amp Figure 6 77 Fuse Block Ulysses 1 3 2 sm00424 1 Negative battery cable 2 Main fuse holder 3 Rear brake fluid reservoir Figure 6 78 30A Main Fuse Location Firebolt HOME 2009 XB Service Electrical 6 65 ...

Page 526: ...r testing and repair connect wire lead to indicator switch 4 Install sprocket cover See 2 36 SPROCKET COVER REMOVAL AND INSTALLATION 1 Verify that the ignition key switch is turned to OFF 2 Remove sprocket cover See 2 36 SPROCKET COVER NOTE If replacing neutral indicator switch wiring see 6 30 SPROCKET COVER WIRING for correct wire routing 3 See Figure 6 80 Remove neutral indicator switch wire lea...

Page 527: ...racket and remove sidestand switch and har ness Installation 1 Install fastener through the sidestand switch into the sidestand bracket and tighten to 96 120 in lbs 11 13 6 Nm 2 Route the switch wire harness through the re closeable tree fastener clip on the muffler in order to secure the switch harness from damage 3 Continue routing the sidestand switch harness along the front contour of the prim...

Page 528: ... Figure 6 81 Remove screw 2 securing the CKP wire bracket 3 and sensor 1 to the left crankcase Carefully remove CKP sensor 1 and o ring along with the harness bracket 3 from engine crankcase 6 Remove the plastic clip securing the CKP wire to the har ness bracket 1 2 3 sm02442 1 Crank position CKP sensor 2 Screw 3 CKP harness bracket Figure 6 81 Crank Position CKP Sensor INSTALLATION NOTE The CKP s...

Page 529: ... Connect negative battery cable tightening to 72 96 in lbs 8 11 Nm After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 8 Install seat HOME 2009 XB Service Electrical 6 69 ...

Page 530: ...r 2 from crankcase INSTALLATION 1 See Figure 6 82 Lubricate o ring with engine oil and install fastener 1 to attach vehicle speed sensor 2 to crank case and tighten to 90 110 in lbs 10 0 12 4 Nm 2 Connect vehicle speed sensor connector 65 to wiring harness 3 Install sprocket cover See 2 36 SPROCKET COVER 3 2 1 sm00410 1 Fastener 2 Vehicle speed sensor 3 Rear isolator assembly Figure 6 82 Speedomet...

Page 531: ...hers 6 See Figure 6 89 Firebolt Figure 6 90 Lightning or Figure 6 91 Ulysses Pull instrument module from support 1 Bulb Replacement 1 Once the instrument module has been removed from the vehicle place face down on a work surface 2 Remove the nine fasteners securing the back of the module housing to the display and remove back cover NOTE Do not turn display over The speedometer and tachometer will ...

Page 532: ...LAMP ASSEMBLY AND SUPPORT BRACKET 5 For Lightning install windscreen and for Ulysses install windscreen windshield See 2 26 HEADLAMP ASSEMBLY AND SUPPORT BRACKET 6 Install negative battery cable After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 7 Install seat...

Page 533: ...ort module left and right 2 Instrument module 3 Grommet 3 4 Washer 3 5 Fastener 3 6 Instrument module connector 39 Figure 6 90 Instrument Module Assembly Lightning 5 7 3 4 2 1 6 sm00464 1 Fairing support center 2 Instrument module 3 Grommet 3 4 Washer 3 5 Fastener 3 6 Instrument module connector 39 7 Front support module left and right Figure 6 91 Instrument Module Assembly Ulysses HOME 2009 XB Se...

Page 534: ...cable 1 and starter solenoid connection 128 3 from starter 6 Disconnect vehicle speed sensor 65 2 NOTES On Firebolt models the rear brake switch connector is located under the seat in front of the rear break reservoir hose On Firebolt models the fuse block and relay block are attached to the fairing support bracket 7 On Firebolt models remove the main fuse case located to the right of the battery ...

Page 535: ...ive cable 4 12 Battery positive cable License plate lamp connector 45 13 5 Tail light connectors 93 Rear brake light switch connector 121 6 14 Ground terminals GRD1 and GRD3 Left and right trunk pan fasteners 15 7 Center tail section fastener to rear tail section ECM connectors 10 and 11 8 16 Fuse block and relay center Right tail section Figure 6 93 Main Harness and Electrical Connectors Under Se...

Page 536: ...oltage ground wire ECM connectors 10 and 11 8 3 Fuse block and relay center Battery negative cable 4 9 Battery positive cable Bank angle sensor BAS connector 134 5 Rear brake light switch connector 121 Figure 6 94 Main Harness and Electrical Connectors Under Seat Lightning XB12Ss HOME 6 76 2009 XB Service Electrical ...

Page 537: ...ent cluster connector 39 Main harness 9 3 Horn fastener Right handlebar connector 22 4 10 Left handlebar connector 24 Horn mount 11 5 Horn connector 122 Turn signal connectors 31 6 12 Ignition switch Horn Figure 6 95 Electrical Connectors Behind Windscreen Ulysses HOME 2009 XB Service Electrical 6 77 ...

Page 538: ...4 Horn connector 122 11 5 Horn Turn signal connectors 31 6 Ignition switch 33 Figure 6 96 Electrical Connectors Behind Windscreen Lightning 12 Remove fairing and windscreen a For Firebolt see 2 47 FRONT FAIRING WIND SHIELD AND MIRRORS FIREBOLT b For Lightning Ulysses see 2 48 WINDSHIELD AND WINDSCREEN LIGHTNING AND ULYSSES 13 See Lightning Figure 6 100 Ulysses Figure 6 95 HOME 6 78 2009 XB Service...

Page 539: ...emove connector from oil pressure switch 120 See 3 14 OIL PRESSURE INDICATOR SWITCH 21 Disconnect a Intake air temperature sensor 89 b Throttle position sensor 88 c O2 sensor 137 d Temperature sensor 90 e Fuel injectors 84 85 f Fuel pump connector 86 g Idle air control 87 22 Disconnect and remove ignition coil NOTE When removing the left air scoop the alternator and voltage regulator harnesses and...

Page 540: ...l connectors Cable strap 9 3 Right switch housing connector 22 Data link 91 4 10 Left switch housing connector 24 Ignition switch connector 33 11 5 Cable strap Cable strap 6 Headlight connector 38 Figure 6 97 Fairing Wiring Viewed From Beneath Fairing Firebolt HOME 6 80 2009 XB Service Electrical ...

Page 541: ...they are installed the harness will not be twisted For more information on wire harness and hose routing see D 1 APPENDIX D HOSE AND WIRE ROUTING 1 On Lightning and Ulysses models install the new harness from the rear of the vehicle working towards the front 2 Feed front and center portion of harness between the trunk pan and tire through opening at rear of frame fuel tank assembly 3 On Firebolt m...

Page 542: ...itch 121 from right switch housing b Clutch switch 95 from left switch housing c Horn connector 122 11 d Headlight connector 38 e Turn signal connectors 31 5 f Left handlebar connector 24 4 and right handlebar connector 22 3 g Instrument module connector 39 2 h Turn signal flasher connector 30 1 i Install electronic control module 2 3 4 5 1 sm00428 1 Mounting strap and guide 2 Transmission vent ho...

Page 543: ... 22 4 10 Left handlebar connector 24 Horn connector 122 11 5 Horn Turn signal connectors 31 6 Ignition switch 33 Figure 6 100 Electrical Connectors Behind Windscreen Lightning 9 Install cable strap loosely around main harness 7 and ignition switch 6 10 Install ground terminal on front of steering head and tighten to 48 72 in lbs 5 4 8 Nm HOME 2009 XB Service Electrical 6 83 ...

Page 544: ...eft turn signal connector 19 11 d Right turn signal connector 18 10 e Bank angle sensor BAS connector 134 9 f ECM connectors 10 and 11 7 164 on XB12 models g Rear brake light switch connector 121 h Main harness ground GRD 2 2 i Front auxiliary power outlet 160 25 Install starter side of positive battery cable and starter solenoid connector 128 to starter 26 Connect vehicle speed sensor 65 27 On Li...

Page 545: ...nstall windscreen windshield See 2 48 WINDSHIELD AND WINDSCREEN LIGHTNING AND ULYSSES 39 Install air cleaner assembly See 2 36 SPROCKET COVER After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 40 Install seat HOME 2009 XB Service Electrical 6 85 ...

Page 546: ...ive cable 4 12 Battery positive cable License plate lamp connector 45 13 5 Tail light connectors 93 Rear brake light switch connector 121 6 14 Ground terminals GRD1 and GRD3 Left and right trunk pan fasteners 15 7 Center tail section fastener to rear tail section ECM connectors 10 and 11 8 16 Fuse block and relay center Right tail section Figure 6 101 Main Harness and Electrical Connectors Under S...

Page 547: ...ltage ground wire ECM connectors 10 and 11 8 3 Fuse block and relay center Battery negative cable 4 9 Battery positive cable Bank angle sensor BAS connector 134 5 Rear brake light switch connector 121 Figure 6 102 Main Harness and Electrical Connectors Under Seat Lightning XB12Ss HOME 2009 XB Service Electrical 6 87 ...

Page 548: ... Seat lock cable ECM connectors 10 and 11 4 11 Fuse block and relay center Bank angle sensor BAS connector 134 12 5 Auxiliary power outlet Main harness ground wire GRD2 6 13 Main harness with plastic grommet Trunk pan 14 7 Left tail section Battery ground cable Figure 6 103 Main Harness and Electrical Components Under Seat Ulysses HOME 6 88 2009 XB Service Electrical ...

Page 549: ...l connectors Cable strap 9 3 Right switch housing connector 22 Data link 91 4 10 Left switch housing connector 24 Ignition switch connector 33 11 5 Cable strap Cable strap 6 Headlight connector 38 Figure 6 104 Fairing Wiring Viewed From Beneath Fairing Firebolt HOME 2009 XB Service Electrical 6 89 ...

Page 550: ...Pull back terminal cover boot on battery positive cable red 5 Disconnect battery positive cable from battery positive terminal 6 Remove battery 7 Remove electronic control module See 4 4 ELECTRONIC CONTROL MODULE ECM 8 Remove windscreen and windshield See 2 48 WIND SHIELD AND WINDSCREEN LIGHTNING AND ULYSSES 9 Remove left side air scoop See 2 49 AIR SCOOPS sm06002 Figure 6 105 V Bracket with Siren...

Page 551: ...eft side of vehicle to the rear of the coil 4 Near fuel rail and idle air control actuator 5 Rear of fuel tank next to fan Figure 6 106 Auxiliary Harness Cable Strap Locations 16 See Figure 6 106 Remove five cable straps securing auxiliary harness and main harness to frame HOME 2009 XB Service Electrical 6 91 ...

Page 552: ... to lighting siren control module Figure 6 109 Lighting Siren Control Module and Connectors Installation NOTE Make sure to properly install the bundle components in the auxiliary harness in order to maintain component clearances 1 Install auxiliary harness starting at the seat area and guiding and pulling it towards the front of vehicle NOTE When routing the harness through the shock tower the sir...

Page 553: ... alternator wiring harnesses are not trapped between the air scoop and cylinder head 14 Install left side air scoop See 2 49 AIR SCOOPS 15 Install windscreen and windshield See 2 48 WINDSHIELD AND WINDSCREEN LIGHTNING AND ULYSSES 16 Install electronic control module See 4 4 ELECTRONIC CONTROL MODULE ECM 17 Install battery a Connect battery positive cable from battery positive terminal b Install te...

Page 554: ...re 6 110 Left Side Subframe Hose and Wire Routing Firebolt 1 2 3 sm00433 1 Main battery ground 2 Wire harness ground 3 Main fuse case Figure 6 111 Battery and Harness Ground Battery Removed for Clarity Installation 1 Mate actuator connector 161B to actuator 2 Route harness along channel in air cleaner under frame and under main wiring harness NOTE If cable is routed in front of the frame lug it wi...

Page 555: ...ctor 161B 2 at main harness 5 See Figure 6 113 Remove the exhaust actuator ground 4 6 Pull actuator harness through frame 7 See Figure 6 114 Disconnect connector 161B 2 from actuator NOTE For actuator or actuator cable replacement see 6 17 INTER ACTIVE EXHAUST SYSTEM 1 2 3 4 sm00911 1 ECM connector 10 2 ECM connector 11 3 Negative battery cable 4 Battery and actuator ground Figure 6 113 Harness an...

Page 556: ...p which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 3 See Figure 6 116 Remove negative battery cable 3 from battery See 1 5 BATTERY MAINTENANCE 4 Remove the fuse block from the battery tray to access the actuator harness ground 5 5 Remove the exhaust actuator ground 5 6 See Figure 6 116 Separate exhaust actuator harness connector 165 beneath the m...

Page 557: ...stall fuse block on the battery tray 7 Connect negative battery cable to battery terminal Tighten fastener to 72 96 in lbs 8 11 Nm 8 Install intake cover Tighten fasteners to 12 36 in lbs 1 4 4 Nm After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 9 Install se...

Page 558: ...nnector and the oil pres sure switch wire is located under the sprocket cover 3 Route oil pressure switch wiring from main harness to oil pressure switch located on the bottom front of the oil pump body and connect to the oil pressure switch 4 Connect the neutral safety switch single bullet 5 See Figure 6 118 Route the interactive exhaust cable behind the oil pump body beside the neutral switch co...

Page 559: ...osition with the engine OFF RUN switch in the RUN position The 12 volt auxiliary power outlet circuit contains a 10 amp fuse to protect overloading of the circuit Verify that the com bined accessory load of both power outlets does not exceed the amperage rating of the circuit Remove the windscreen to access the forward power outlet electrical connector See 2 48 WINDSHIELD AND WIND SCREEN LIGHTNING...

Page 560: ...6 100 2009 XB Service Electrical NOTES ...

Page 561: ...INAL REPAIR A 13 A 7 DEUTSCH MINI TERMINAL REPAIR A 15 A 8 MOLEX CONNECTORS A 16 A 9 PACKARD 150 METRI PACK CONNECTORS A 20 A 10 PACKARD 280 METRI PACK RELAY AND FUSE BLOCK CONNECTORS A 22 A 11 PACKARD 480 METRI PACK CONNECTORS A 23 A 12 PACKARD 630 METRI PACK CONNECTORS A 24 A 13 PACKARD METRI PACK TERMINALS A 25 A 14 PACKARD ECM CONNECTOR A 27 A 15 PACKARD MICRO 64 CONNECTORS A 29 A 16 SEALED SP...

Page 562: ...NOTES ...

Page 563: ...s 1 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 T...

Page 564: ... of 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 R...

Page 565: ...on 1 2 Raise locking bar by pushing up on bottom flange 2 NOTE See Figure A 4 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 upwar...

Page 566: ...rimped 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 HOME A 4 2009 XB Service Appendix A Connector Repair ...

Page 567: ... side of terminal simultaneously 3 Gently pull on wire to remove terminal from wire end of socket housing 4 If necessary crimp new terminals on wires Assembly 1 Using a thin flat blade like that on a hobby knife carefully bend tang on each side of terminal outward away from terminal body 2 With the open side of the terminal facing rib on wire end of socket housing insert terminal into chamber unti...

Page 568: ...pry colored 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 purpo...

Page 569: ...2 3 1 sm00015 1 Remove wire lock 2 Remove terminal lock 3 Pry tang outward Figure A 11 Delphi Connector Removing Socket Terminals HOME 2009 XB Service Appendix A Connector Repair A 7 ...

Page 570: ...or together the latch on the socket side must be aligned with the latch 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 nec...

Page 571: ... not require a special orientation the conical secondary locking wedge 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 full...

Page 572: ... may be mated with the gray since the alignment tabs are absent and the orientation of the external latch is the same sm00019 Figure A 16 Deutsch Connector Depress Terminal Latch and Back Out Pin Installing Pin Terminals 1 See Figure A 17 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 in...

Page 573: ... 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 5 DEUTSCH STANDARD TERMINAL REPAIR Standard with crimp tails A 6 DEUTSCH SOLID BARREL MINI TERMINAL REPAIR Mini Terminal solid barrel A 7 DEUTSCH MINI TERMINAL REPAIR Mini Terminal with crimp tails HOME 2009 XB Service Appendi...

Page 574: ...hat the 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...

Page 575: ...2 Turn adjusting screw counterclockwise out until contact is flush with bottom of depression in indentor cover Tighten knurled locknut 3 Slowly squeeze handles of crimp tool until contact is centered between the four indentor points 3 4 Insert bare wire core strands of stripped wire lead 4 into contact barrel Squeeze handle of crimp tool until tightly closed Tool automatically opens when the crimp...

Page 576: ...TS DIVISIO N HDT 48 00 JDG360 1 HEMET RYAN AIRPORT P O BOX 878 HEMET CA 92343 0161 714 929 1200 IN DUSTRIAL PRODUCTS DIVISIO N 2 1 3 4 3 sm00024 1 Contact barrel 2 Indentor cover 3 Indentor point 4 Stripped wire lead Figure A 20 Deutsch Solid Barrel HOME A 14 2009 XB Service Appendix A Connector Repair ...

Page 577: ... stripped wire core stands between crimp tails Pos ition wire so that short pair of crimp tails squeeze bare wire strands while long pair squeeze over the insulation 5 Squeeze handle of crimper until tightly closed Tool auto matically opens when the crimping sequence is complete NOTE If the crimper does not open it can be opened by squeezing the ratchet trigger 2 6 Position the insulation crimp on...

Page 578: ...NECTOR TERMINAL REMOVER Part No HD 48114 into the pin hole next to the terminal until the tool bottoms a Socket Housing The pin holes are inside the ter minal openings b Pin Housing The pin holes are outside the pins 3 Pressing the terminal remover to the bottom of the pin hole gently pull on the wire to remove wire terminal from its cavity Installing Terminals 1 See Figure A 26 From the wiring di...

Page 579: ...0 5 60 mm of insulation from the end of the wire lead NOTE The strip length is the same for both pin and socket terminals and for wire gauges from 22 to 14 Prepare Tool 1 Identify the punch die in the jaws of the ELECTRICAL CRIMP TOOL Part No HD 48119 for the wire gauge Refer to Table A 4 2 Squeeze and release the handles to open the tool NOTE The crimp tool automatically opens when the handles ar...

Page 580: ...et locator bar 1 b Pin Terminal See Figure A 30 The tip of a pin ter minal passes through the socket locator bar and stops in the notch in the face of the pin locator bar 2 See Figure A 31 Ratchet the handles together until the crimp tails are held in vertical alignment between the punch and the die sm02855 Figure A 29 Square Openings in Socket Locator Bar Insert Stripped Lead See Figure A 32 Inse...

Page 581: ...force the handles open or closed sm02858 Figure A 32 Stripped Lead at Up Angle Inspect Crimp 1 Inspect Crimp Inspect the core and insulation crimp a See Figure A 33 The core tails should be creased into the wire strands at the core crimp 1 b Strands 2 of wire should be visible beyond the core crimp but not forward into the terminal shell c The insulation tails should be folded into the insulation ...

Page 582: ...E The click 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...

Page 583: ...ve 4 Raise tang to install Figure A 34 150 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 35 150 Metri Pack Connector Push to Seat HOME 2009 XB Service Appendix A Connector Repair A 21 ...

Page 584: ...for fuse block terminal cavity coordinates 2 With the open side of the socket terminal facing the tang push lead into chamber at the wire end of the fuse block A click is heard when the terminal is properly engaged 3 Gently tug on the wire to verify that the terminal is locked in place and will not back out of the chamber 4 Install the secondary locks With the locking wedges positioned above the t...

Page 585: ... the tang in the square shaped opening centered next to the 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 press 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...

Page 586: ...nal 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 SNAP ON 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 ...

Page 587: ...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 ta...

Page 588: ...s complete Inspecting Crimps 1 See Figure A 40 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 40 Metri Pack Connector Inspe...

Page 589: ...ree strain relief collar 4 from conduit 5 3 See Figure A 43 Using a thin blade gently pry at seam at back of socket housing to release three plastic pins 1 from slots in housing Separate and spread halves of socket housing 4 Push on wire lead to free terminal from chamber Installing Socket Terminal 1 From inside socket housing gently pull on wire to draw terminal into chamber 2 Exercising caution ...

Page 590: ... 3 Cable strap 4 Strain relief collar 5 Conduit Figure A 42 Packard 100W Connector 2 1 1 1 sm00039 1 Pins 2 Socket terminal Figure A 43 Packard 100W Connector Separate Halves of Socket Housing HOME A 28 2009 XB Service Appendix A Connector Repair ...

Page 591: ...ocate the head of the secondary lock 1 on one side of the connector housing 2 Insert the blade of a small screwdriver between the center ear of the lock and the connector housing and gently pry out lock When partially removed pull lock from connector housing 3 Locate pin hole 2 between terminals on mating end of connector 4 See Figure A 44 Obtain the PACKARD MICRO 64 TER MINAL REMOVER Part No HD 4...

Page 592: ...ry 2 See Figure A 48 Squeeze the handles of the PACKARD MICRO 64 TERMINAL CRIMPER Part No HD 45929 to cycle the tool to the fully open position 1 3 Raise locking bar and barrel holder by pushing up on bottom tab with index finger 2 4 With the crimp tails facing upward insert terminal through locking bar into front hole in barrel holder 20 22 gauge wire 3 5 Release locking bar to lock position of c...

Page 593: ...3 1 2 4 sm00049 1 Open position 2 Raising locking bar 3 Insert terminal 4 Crimp terminal Figure A 48 Packard Micro 64 Connector Terminal in Crimper HOME 2009 XB Service Appendix A Connector Repair A 31 ...

Page 594: ...s and insert one end of the sealed connector 3 Gently squeeze the handles until the connector is held in the jaws 4 See Figure A 50 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 ...

Page 595: ...ellow connector die Figure A 49 Packard Crimping Tool HD 38125 8 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 50 Sealed Splice Connector HOME 2009 XB Service Appendix A Connector Repair A 33 ...

Page 596: ...A 34 2009 XB Service Appendix A Connector Repair NOTES ...

Page 597: ...TABLE OF CONTENTS SUBJECT PAGE NO B 1 CONNECTORS B 1 B 2 WIRING DIAGRAMS B 3 APPENDIX B WIRING ...

Page 598: ...NOTES ...

Page 599: ...t Under rear wire cover Ulysses 2 1 place bullet Left rear turn signal 19 Under seat Lightning Under tail section Firebolt Behind windscreen Ulysses Lightning 4 place Amp Multilock Right hand controls 22 Beneath fairing Firebolt Behind windscreen Ulysses Lightning 8 place Amp Multilock Left hand controls 24 Beneath fairing Firebolt Behind windscreen Ulysses Lightning 5 place Amp Flasher 30 Beneath...

Page 600: ...Firebolt Underside of clutch lever assembly 2 place Sumitomo Clutch switch 95 Behind rear cylinder under seat 2 place Amp Multilock Cooling fan 97 Bottom of oil pump Post terminal Oil pressure switch 120 Under seat 2 place Amp Multilock Rear brake switch 121 Behind windscreen Ulysses Lightning Spade terminals Horn 122 In fairing Firebolt Top of starter Spade terminal Starter solenoid 128 Under spr...

Page 601: ...ing diagrams include the symbol for a diode 7 a symbol for a wire to wire connection 8 a symbol verifying that no connection 9 between two wire traces exists symbols for actual 10 and virtual 11 splices and a symbol identifying two wires that are twisted together 12 Actual splices 10 are splices where two wires are connected together at a specific location along a wire Virtual splices 11 are splic...

Page 602: ...on Accessory Power 2009 XB Model Firebolt Figure B 6 Chassis Grounds 2009 XB Model Ulysses Lightning Figure B 7 Chassis Grounds 2009 XB Model Firebolt Figure B 8 Main Harness 2009 XB Model Ulysses and Lightning Figure B 9 Main Harness 2009 XB Model Firebolt Figure B 10 Engine Management Circuit 2009 XB Model Figure B 11 Component Wiring Diagrams 2009 XB Model Figure B 12 Police Harness 2009 XB Mod...

Page 603: ...7 30 86 85 5 3 2 1 4 5 9 1 40 34 Battery 30A 41 35 Fuel Pump 10A 39 33 ECM 10A 42 36 Ignition 15A 21 27 Key Switch 15A 38 44 Cooling Fan 10A 30 24 4 1 4 1 On Park Lock Off Ignition Switch R R R R R On Park Lock Off 33B 33A 128A O GY O GY GY O Y BN Y BN GY O R Y R Y R Y R Y R R R R R R R R R Y Y R R BK BK BK Battery Cable Starter Solenoid Starter Motor em00366 Figure B 2 Battery Power 2009 XB Model...

Page 604: ...3 15 87 30 86 85 5 3 2 1 4 5 9 1 1 2 Auxiliary 10A 21 15 Fuel Pump 10A 7 1 ECM 10A 22 16 Ignition 15A 5 11 Key Switch 15A 18 24 Cooling Fan 10A 10 4 4 1 4 1 On Park Lock Off Ignition Switch R R R R R On Park Lock Off 33B 33A O GY O GY GY O Y BN Y BN GY O R Y R Y R Y R Y R R R R R R R R R Y Y R R BK BK 128A BK Battery Cable Starter Solenoid Starter Motor em00429 Figure B 3 Battery Power 2009 XB Mod...

Page 605: ...ces sory 10A Battery Power In Wiring Diagrams 2 2 8 4 2 4 3 3 2 8 165B 165A License Plate Lamp 1 1 1 1 45A 45B Tail Light Headlight 1 1 93A 93B Flasher 2 2 38B 38A 22B 22A 170B 170A 91A 30B 30A 121A 121B Front Brake Switch 1 1 Rear Brake Switch 1 1 84B 84A Front Injector Rear Injector 1 1 85B 85A 1 1 10B 10A ECM 9 9 83B 83A Ignition Coil 2 2 24A 24B 39A 39B Engine Stop Switch Start Switch 87 86 1 ...

Page 606: ...s sory 10A Battery Power In Wiring Diagrams 2 2 8 4 2 4 3 3 2 8 165B 165A License Plate Lamp 1 1 1 1 3 3 45A 45B Tail Light Headlight 1 1 93A 93B Flasher 2 2 38B 38A 22B 22A 170B 170A 91A 30B 30A 121A 121B Front Brake Switch 1 1 Rear Brake Switch 1 1 84B 84A Front Injector Rear Injector 1 1 85B 85A 1 1 10B 10A ECM 9 9 83B 83A Ignition Coil 2 2 24A 24B 39A 39B Engine Stop Switch Start Switch 87 86 ...

Page 607: ...1 39A 39B Instrument Cluster 13 13 95A 95B 31A 31B Clutch Switch Left Front Turn Signal 2 2 2 2 4 4 1 1 31A 31B Right Front Turn Signal Rear 12V Auxiliary Power Outlet Ulysses Only Front 12V Auxiliary Power Outlet 2 2 2 2 85 2 9 85 2 19 BK BK BK BK BK BK BK BK BK BK BK BK BK 4 4 1 1 Flasher Horn Marker Lamp Low Beam Headlamp High Beam Headlamp BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK ...

Page 608: ...utch Switch Left Front Turn Signal 2 2 2 2 2 2 1 1 1 2 2 1 1 1 1 1 1 1 31A 31B Right Front Turn Signal Front 12V Auxiliary Power Outlet Horn 2 2 85 2 9 85 2 19 BK BK BK BK BK BK BK BK BK BK BK BK BK BK 13 13 Instrument Cluster BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK Left Marker Lamp 1 1 BK Low Beam Headlamp 1 1 BK High Beam Headlamp 1 1 BK Right Marker Lamp 1 1 BK BK BK 39A 39B 122A 122B 4 4 ...

Page 609: ...p Output Rear Ignition Coil System Ground 1 Front Ignition Coil Engine Temp Input Auxiliary 10A 1 2 1 2 Throttle Position Sensor 8 3 Neutral Switch Starter Relay 5v Sensor Power Oxygen Sensor Sensor GND 2 Sensor GND 1 Sidestand Sensor Fuel Pump 10A 133B 7 1 2 1 2 1 1 1 1 2 3 4 1 2 3 4 4 91A BATT NEUT TRNL TRNR HIB ENG Oil IGN GND TACH Fuel SPD 1 2 Clutch Switch 2 19 26 Crank Position Sensor 18 Cra...

Page 610: ...Figure B 8 Figure B 8 Main Harness 2009 XB Model Ulysses and Lightning Main Harness 2009 XB Model Ulysses and Lightning ...

Page 611: ...emp Input Throttle POS Sensor 8 Clutch Switch Neutral Switch 5V Sensor Power 1 Oxygen Sensor Sensor GND 2 Sensor GND 1 Sidestand Sensor 4 20 21 22 23 Idle Air Control Motor Idle Air Control Motor Idle Air Control Motor Idle Air Control Motor 1 2 1 2 Gray 4 key J1 J2 Black 3 key 2 3 4 5 6 7 8 12 13 14 15 16 2 3 4 5 6 7 8 12 13 14 15 16 BATT NEUT TRNL TRNR HiB ENG Oil IGN GRD TACH Fuel SPD Speedomet...

Page 612: ...Figure B 9 Figure B 9 Main Harness 2009 XB Model Firebolt Main Harness 2009 XB Model Firebolt ...

Page 613: ... Rear Fuel Injector Output Active Muffler Feedback Bank Angle Sensor Fan Control Active Intake System GND 3 Battery Vehicle Speed System GND 2 Fuel Pump Output Rear Coil System GND 1 Front Ignition Coil Engine Temp Input Throttle Position Sensor Neutral Switch 5v Sensor Power Oxygen Sensor Sensor GND 2 Sensor GND 1 Sidestand Sensor Clutch Switch Crank Position Sensor Crank Position Sensor Sensor G...

Page 614: ...Figure B 10 Figure B 10 Engine Management Circuit 2009 XB Model Engine Management Circuit 2009 XB Model ...

Page 615: ...ain Harness To Main Harness Ulysses Fuel Pump RH Turn Signals LH Turn Signals 1 2 Rear Auxiliary Outlet Ulysses Only Front Auxiliary Outlet 1 2 Tail Light LIC Plate Lamp Tail Sub Harness Left Turn Signal Right Turn Signal 1 1 1 1 1 1 1 1 1 2 3 4 5 1 1 2 1 2 Heated Grips Sub Harness Connector 12V Auxiliary Outlet Connector Right Hand Controls Left Hand Controls R Heat Grip L Heat Grip 1 2 3 1 2 3 1...

Page 616: ...Figure B 11 Figure B 11 Component Wiring Diagrams 2009 XB Model Component Wiring Diagrams 2009 XB Model ...

Page 617: ...ar Channel 2 Rear Channel 1 Rear Channel 2 Rear Channel 1 17 16 19 4 14 2 12 5 6 18 7 8 22 23 3 1 13 15 21 17 16 19 4 14 2 12 5 6 18 7 8 22 23 3 1 13 15 J9A J9B J7B J6B J4B J5B J2B J2A J3B J1B J8B BE BK GN BK BE BK GN BK BE BK BE BK BE BK GN BK GN BK GN BK BE W GN W BE W GN W BE W BE W BE W GN W GN W GN W GY BE BN BN BK BK GY BE BN GN R W R W O BN O Y Y R R BK R R Y W GN R Y W GN BK GN BK BE BK BE...

Page 618: ...B 20 2009 XB Service Appendix B Wiring NOTES ...

Page 619: ...TABLE OF CONTENTS SUBJECT PAGE NO C 1 LENGTH CONVERSION C 1 C 2 FLUID CONVERSION C 2 C 3 TORQUE CONVERSION C 3 APPENDIX C CONVERSIONS ...

Page 620: ...NOTES ...

Page 621: ... 535 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 7...

Page 622: ...easurements 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 mea...

Page 623: ...s 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 HOME 20...

Page 624: ...C 4 2009 XB Service Appendix C Conversions NOTES ...

Page 625: ...TABLE OF CONTENTS SUBJECT PAGE NO D 1 APPENDIX D HOSE AND WIRE ROUTING D 1 APPENDIX D HOSE AND WIRE ROUTING ...

Page 626: ...NOTES ...

Page 627: ...D 1 APPENDIX D HOSE AND WIRE ROUTING FIREBOLT HOME 2009 XB Service Appendix D Hose and Wire Routing D 1 ...

Page 628: ...sm04328 Figure D 1 Front and Rear Brake Systems Right Side View HOME D 2 2009 XB Service Appendix D Hose and Wire Routing ...

Page 629: ...sm04332 Figure D 2 Rear Brake Systems Top View HOME 2009 XB Service Appendix D Hose and Wire Routing D 3 ...

Page 630: ...sm04334 Figure D 3 Rear Brake Systems Left Side View HOME D 4 2009 XB Service Appendix D Hose and Wire Routing ...

Page 631: ...1 sm04337 1 Carbon canister Figure D 4 Evaporative Emissions Control California Models Top View HOME 2009 XB Service Appendix D Hose and Wire Routing D 5 ...

Page 632: ...om induction module California 3 From fuel tank California 4 From fuel tank to atmosphere 49 state Figure D 5 Evaporative Emissions Control California and 49 State Models Left Side View HOME D 6 2009 XB Service Appendix D Hose and Wire Routing ...

Page 633: ...5 sm04344 1 Active intake solenoid Japan only 2 Ignition coil 3 Fuel pump 4 Crank position sensor CKP 5 To ECM Figure D 6 Wiring Harness Left Side View HOME 2009 XB Service Appendix D Hose and Wire Routing D 7 ...

Page 634: ...or 2 2 Idle air control IAC 3 Throttle position sensor TPS 4 Intake air temperature sensor IAT 5 Oxygen sensor O2 6 Engine temperature sensor Figure D 7 Wiring Harness Top View HOME D 8 2009 XB Service Appendix D Hose and Wire Routing ...

Page 635: ...ed sensor VSS 2 Cable starter to battery positive 3 Solenoid 4 Voltage regulator 5 Oil pressure switch 6 Neutral switch 7 Relay terminal Figure D 8 Wiring Harness Right Side View HOME 2009 XB Service Appendix D Hose and Wire Routing D 9 ...

Page 636: ... 3 2 1 sm04322 1 Feed oil line 2 Return oil line 3 Vent line 4 Oil cooler return line 5 Oil cooler feed line Figure D 9 Oil Lines Right Side View HOME D 10 2009 XB Service Appendix D Hose and Wire Routing ...

Page 637: ...1 2 sm04367 1 Exhaust valve actuator 2 Muffler valve Figure D 10 Clutch Cable and Exhaust Valve Actuator Right Side View HOME 2009 XB Service Appendix D Hose and Wire Routing D 11 ...

Page 638: ...4371 1 Muffler valve 2 Exhaust valve actuator 3 Cable seat lock Figure D 11 Clutch Throttle Seat Release Cable and Exhaust Valve Actuator Left Side View HOME D 12 2009 XB Service Appendix D Hose and Wire Routing ...

Page 639: ...ck 2 Exhaust valve actuator mounted to top of functional air cleaner cover Figure D 12 Clutch Throttle Seat Release Cable and Exhaust Valve Actuator XB12 Models Top View HOME 2009 XB Service Appendix D Hose and Wire Routing D 13 ...

Page 640: ...LIGHTNING sm04329 Figure D 13 Front and Rear Brake Systems Right Side View HOME D 14 2009 XB Service Appendix D Hose and Wire Routing ...

Page 641: ...sm04331 Figure D 14 Rear Brake Systems Top View HOME 2009 XB Service Appendix D Hose and Wire Routing D 15 ...

Page 642: ...sm04335 Figure D 15 Rear Brake Systems Left Side View HOME D 16 2009 XB Service Appendix D Hose and Wire Routing ...

Page 643: ...1 sm04338 1 Carbon canister Figure D 16 Evaporative Emissions Control California Models Top View HOME 2009 XB Service Appendix D Hose and Wire Routing D 17 ...

Page 644: ...m induction module California 3 From fuel tank California 4 From fuel tank to atmosphere 49 state Figure D 17 Evaporative Emissions Control California and 49 State Models Left Side View HOME D 18 2009 XB Service Appendix D Hose and Wire Routing ...

Page 645: ... 2 1 sm04327 1 Active Intake Solenoid Japan only 2 Ignition coil 3 Fuel pump 4 Crank position sensor CKP Figure D 18 Wiring Harness Left Side View HOME 2009 XB Service Appendix D Hose and Wire Routing D 19 ...

Page 646: ... Fuel injector 2 2 Idle air control IAC 3 Throttle position sensor TPS 4 Intake air temperature sensor IAT 5 Oxygen sensor 02 Figure D 19 Wiring Harness Top View HOME D 20 2009 XB Service Appendix D Hose and Wire Routing ...

Page 647: ...d sensor VSS 2 Cable starter to battery positive 3 Solenoid 4 Voltage regulator 5 Oil pressure switch 6 Neutral switch 7 Relay terminal Figure D 20 Wiring Harness Right Side View HOME 2009 XB Service Appendix D Hose and Wire Routing D 21 ...

Page 648: ... 1 2 3 sm04325 1 Feed oil line 2 Return oil line 3 Vent line 4 Oil cooler return line 5 Oil cooler feed line Figure D 21 Oil Lines Right Side View HOME D 22 2009 XB Service Appendix D Hose and Wire Routing ...

Page 649: ...1 2 sm04369 1 Exhaust valve actuator 2 Muffler valve Figure D 22 Clutch Cable and Exhaust Valve Actuator XB12 Models Right Side View HOME 2009 XB Service Appendix D Hose and Wire Routing D 23 ...

Page 650: ... Muffler valve 2 Exhaust valve actuator 3 Cable seat lock Figure D 23 Clutch Throttle Seat Release Cable and Exhaust Valve Actuator XB12 Models Left Side View HOME D 24 2009 XB Service Appendix D Hose and Wire Routing ...

Page 651: ...ck 2 Exhaust valve actuator mounted to top of functional air cleaner cover Figure D 24 Clutch Throttle Seat Release Cable and Exhaust Valve Actuator XB12 Models Top View HOME 2009 XB Service Appendix D Hose and Wire Routing D 25 ...

Page 652: ...ULYSSES sm04330 Figure D 25 Front and Rear Brake Systems Right Side View HOME D 26 2009 XB Service Appendix D Hose and Wire Routing ...

Page 653: ...sm04333 Figure D 26 Rear Brake Systems Top View HOME 2009 XB Service Appendix D Hose and Wire Routing D 27 ...

Page 654: ...sm04336 Figure D 27 Rear Brake Systems Left Side View HOME D 28 2009 XB Service Appendix D Hose and Wire Routing ...

Page 655: ...1 sm04339 Figure D 28 Evaporative Emissions Control California Models Top View HOME 2009 XB Service Appendix D Hose and Wire Routing D 29 ...

Page 656: ...m induction module California 3 From fuel tank California 4 From fuel tank to atmosphere 49 state Figure D 29 Evaporative Emissions Control California and 49 State Models Left Side View HOME D 30 2009 XB Service Appendix D Hose and Wire Routing ...

Page 657: ... 2 4 sm04326 1 Active intake solenoid Japan only 2 Ignition coil 3 Fuel pump 4 Crank position sensor CKP Figure D 30 Wiring Harness Left Side View HOME 2009 XB Service Appendix D Hose and Wire Routing D 31 ...

Page 658: ... Fuel injector 2 2 Idle air control IAC 3 Throttle position sensor TPS 4 Intake air temperature sensor IAT 5 Oxygen sensor O2 Figure D 31 Wiring Harness Top View HOME D 32 2009 XB Service Appendix D Hose and Wire Routing ...

Page 659: ...icle speed sensor VSS 2 Cable starter to battery positive 3 Solenoid 4 Oil pressure switch 5 Neutral switch 6 Relay terminal Figure D 32 Wiring Harness Right Side View HOME 2009 XB Service Appendix D Hose and Wire Routing D 33 ...

Page 660: ...oil line 3 Return oil line 4 Feed oil line from the oil pump to the oil cooler 5 Return oil line from the oil cooler to the oil filter housing Figure D 33 Oil Lines Right Side View HOME D 34 2009 XB Service Appendix D Hose and Wire Routing ...

Page 661: ...2 1 sm04370 1 Exhaust valve actuator 2 Muffler valve Figure D 34 Clutch Cable and Exhaust Valve Actuator Right Side View HOME 2009 XB Service Appendix D Hose and Wire Routing D 35 ...

Page 662: ...4373 1 Muffler valve 2 Exhaust valve actuator 3 Cable seat lock Figure D 35 Clutch Throttle Seat Release Cable and Exhaust Valve Actuator Left Side View HOME D 36 2009 XB Service Appendix D Hose and Wire Routing ...

Page 663: ...ck 2 Exhaust valve actuator mounted to top of functional air cleaner cover Figure D 36 Clutch Throttle Seat Release Cable and Exhaust Valve Actuator XB12 Models Top View HOME 2009 XB Service Appendix D Hose and Wire Routing D 37 ...

Page 664: ...D 38 2009 XB Service Appendix D Hose and Wire Routing NOTES ...

Page 665: ...TABLE OF CONTENTS SUBJECT PAGE NO E 1 ACTIVE INTAKE SYSTEM JAPANESE MODELS ONLY E 1 APPENDIX E ACTIVE INTAKE JAPANESE MODELS ...

Page 666: ...NOTES ...

Page 667: ...eck that when the throttle plate reaches WOT TPS should read above 82 b If not see WOT CHECK listed below 5 While holding the throttle wide open activate the active intake tab on Digital Technician a Verify that the TPS setting is between 10 4 10 9 degrees b If settings are not correct proceed to cable adjustment procedure WOT CHECK 1 Remove cosmetic intake cover assembly and functional air cleane...

Page 668: ... the shaft loosen jam nuts 2 and adjust cable housing 4 towards the solenoid bracket 3 until freeplay is achieved NOTE You should be able to move the solenoid shaft slightly outward until the shaft is fully extended This slight travel will be the freeplay which should be 1 32 in 0 79 mm or greater 4 See E 1 ACTIVE INTAKE SYSTEM JAPANESE MODELS ONLY Verify Settings Once freeplay has been set it wil...

Page 669: ... set screw 3 Activate Active Intake System using DIGITAL TECHNI CIAN 4 Adjust stop screw while reading the TPS on Digital Technician until setting is between the range of 10 4 to 10 9 a If the reading is below 10 4 adjust screw clockwise b If the reading is above 10 9 adjust screw counterclock wise 5 Confirm the TPS setting Repeat process if needed 6 Adjust active intake cable assembly See E 1 ACT...

Page 670: ...the baseplate 1 See Figure E 4 Disconnect electrical connector 178 1 2 Hold solenoid shaft by flat spot provided and break cable connector 6 loose 3 Unthread cable connector and disconnect cable from solenoid 8 4 Loosen jam nut 5 and disconnect active cable 2 from cable bracket 4 NOTE Follow next step only is solenoid is to be replaced 5 Loosen pinch fastener on solenoid bracket 9 HOME E 4 2009 XB...

Page 671: ...re 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 7 Nm and bracket to solenoid fasteners to 20 24 in lbs 2 3 2 7 Nm 3 Install active cable 2 into bracket 4 and leave jam nut 5 loose until the setting can b...

Page 672: ...E 6 2009 XB Service Appendix E Active Intake Japanese Models NOTES ...

Page 673: ...TABLE OF CONTENTS SUBJECT PAGE NO F 1 GLOSSARY F 1 APPENDIX F GLOSSARY ...

Page 674: ...NOTES ...

Page 675: ...meter cm Direct 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 GA...

Page 676: ...iter ml millimeter mm Miles 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 Pulse Width Modulated signal PWM signal Reserve RES Revolutions Per Minute RPM Cubic Feet per Hour at Standard Conditions SCFH Throttle Control Actuator TCA...

Page 677: ... and Abbreviations DESCRIPTION ACRONYM OR ABBREVIATION Volts of Alternating Current VAC Volts of Direct Current VDC Vehicle Identification Number VIN Vehicle Speed Sensor VSS HOME 2009 XB Service Appendix F Glossary F 3 ...

Page 678: ...F 4 2009 XB Service Appendix F Glossary NOTES ...

Page 679: ...NG TOOL B 43982 5 17 TRANSMISSION SPROCKET Installation SPROCKET HOLDING TOOL B 43982 5 15 TRANSMISSION INSTALLATION Installation INSTALLER B 43985 3 5 15 TRANSMISSION INSTALLATION Installation GUIDE B 43985 4 5 15 TRANSMISSION INSTALLATION Installation GUIDE B 43985 4 2 5 FRONT WHEEL Assembly FRONT WHEEL BEARING INSTALLER B 43993 10 2 6 REAR WHEEL Assembly FRONT WHEEL BEARING INSTALLER B 43993 10...

Page 680: ...HELL BEARING REMOVER INSTALLER B 45926 5 15 TRANSMISSION INSTALLATION Installation TRANSMISSION FIXTURE B 46285 4 2 16 FRONT FORKS ALL MODELS Assembly FORK SEAL DRIVER AND DUST BOOT INSTALLER B 48867 47MM 2 16 FRONT FORKS ALL MODELS Assembly FRONT FORK OIL LEVEL GAUGE B 59000A 3 18 CRANKCASE Piston Jets SNAP ON BODY DENT PULLER CJ114 6 4 IGNITION HEADLAMP KEY SWITCH FIREBOLT SNAP ONTAMPER RESISTAN...

Page 681: ...er NEWAY VALVE SEAT CUTTER SET HD 35758 C A 13 PACKARD METRI PACK TERMINALS Metri Pack Terminal Crimps PACKARD TERMINAL CRIMP TOOL HD 38125 6 A 7 DEUTSCH MINI TERMINAL REPAIR Deutsch Mini Terminal Crimps PACKARD TERMINAL CRIMPER HD 38125 7 A 13 PACKARD METRI PACK TERMINALS Metri Pack Terminal Crimps PACKARD TERMINAL CRIMPER HD 38125 7 A 13 PACKARD METRI PACK TERMINALS Metri Pack Terminal Crimps PA...

Page 682: ...43984 2 19 SWINGARM AND BRACE Assembly BEARING INSTALLER HD 44060 6 2 5 FRONT WHEEL Disassembly WHEEL BEARING REMOVER INSTALLER HD 44060A 2 5 FRONT WHEEL Assembly WHEEL BEARING INSTALLER REMOVER HD 44060A 2 6 REAR WHEEL Disassembly WHEEL BEARING REMOVER AND INSTALLER HD 44060A 3 18 CRANKCASE Piston Jets FLYWHEEL SUPPORT FIXTURE HD 44358 A 15 PACKARD MICRO 64 CONNECTORS Packard Micro 64 Connector R...

Page 683: ...TON Connecting Rod Bushing PISTON PIN BUSHING TOOL HD 95970 32D 3 8 CYLINDER AND PISTON Assembly Installation PISTON RING COMPRESSOR HD 96333 51E 3 18 CRANKCASE Pinion Shaft Bearing CRANKCASE MAIN BEARING LAPPING TOOL HD 96710 40D 3 18 CRANKCASE Pinion Shaft Bearing CRANKCASE MAIN BEARING LAP HD 96718 87 3 14 OIL PRESSURE INDICATOR SWITCH Oil Pressure OIL PRESSURE GAUGE SET HD 96925 52B 3 18 CRANK...

Page 684: ...RT NUMBER A 12 PACKARD 630 METRI PACK CONNECTORS 630 Metri Pack Connector Repair SNAP ON PICK SNAP ON TT600 3 4 7 OXYGEN SENSOR Removal OXYGEN SENSOR SOCKET SNAP ON YA8875 2 16 FRONT FORKS ALL MODELS Assembly FORK BLEED TOOL SET TBFT 02S VI TOOLS ...

Page 685: ...6 Nm 39 41 ft lbs Axle front 2 6 REAR WHEEL Installation Follow special instructions ANTI SEIZE 65 70 5 Nm 48 52 ft lbs Axle rear final torque 2 6 REAR WHEEL Installation Follow special instructions ANTI SEIZE 31 2 36 6 Nm 23 27 ft lbs Axle rear initial torque 2 37 BELT GUARDS Installation 54 61 Nm 40 45 ft lbs Axle pinch fastener rear 5 7 DRIVE BELT AND IDLER PULLEY Drive Belt Installation 54 61 ...

Page 686: ...LAMP ASSEMBLY AND SUPPORT BRACKET Installation Firebolt 8 11 Nm 72 96 in lbs Battery terminal fasteners 2 26 HEADLAMP ASSEMBLY AND SUPPORT BRACKET Installation Lightning Ulysses 8 11 Nm 72 96 in lbs Battery terminal fasteners 2 27 FAIRING SUPPORT BRACKET FIRE BOLT Installation 8 11 Nm 72 96 in lbs Battery terminal fasteners 2 30 FRONT MODULES LIGHT NING ULYSSES Installation 8 11 Nm 72 96 in lbs Ba...

Page 687: ...1 Nm 72 96 in lbs Battery terminal fasteners 6 29 INTERACTIVE EXHAUST HARNESS XB12 MODELS Lightning 8 11 Nm 72 96 in lbs Battery terminal fasteners 6 29 INTERACTIVE EXHAUST HARNESS XB12 MODELS Ulysses 8 11 Nm 72 96 in lbs Battery terminal fasteners 2 45 RIGHT TAIL SECTION ULYSSES MODELS Assembly 8 11 Nm 72 96 in lbs Battery tray and ground wire fasteners Ulysses 2 42 RIGHT TAIL SECTION LIGHT NING ...

Page 688: ...Brake line p clamp fastener rear 2 19 SWINGARM AND BRACE Installation Swingarm 4 7 Nm 36 60 in lbs Brake line p clamp fastener rear 2 30 FRONT MODULES LIGHT NING ULYSSES Installation 4 7 Nm 36 60 in lbs Brake line p clamp fastener on inside of lighting module 2 10 FRONT BRAKE SIX PISTON CAL IPER Brake Line Installation 4 7 Nm 36 60 in lbs Brake line P clamp on inside of front module Lightning and ...

Page 689: ...BRAKE CALIPER Removal 4 7 Nm 36 60 in lbs Caliper bleeder valves 2 14 REAR BRAKE CALIPER Assembly 4 7 Nm 36 60 in lbs Caliper bleeder valves 2 9 FRONT BRAKE EIGHT PISTON CAL IPER Master Cylinder Reservoir Removal 4 7 Nm 36 60 in lbs Caliper bleeder valves front 2 6 REAR WHEEL Installation 32 35 Nm 24 26 ft lbs Caliper carrier rear 2 9 FRONT BRAKE EIGHT PISTON CALIPER Cal iper Repair 24 5 29 4 Nm 1...

Page 690: ...2 36 in lbs Cooling fan fasteners 5 16 SHIFTER SHAFT Installation LOCTITE 271 red 44 8 50 Nm 33 37 ft lbs Countershaft retaining screw 5 15 TRANSMISSION INSTALLATION Installing Right Crankcase Apply several drops of LOCTITE 271 red to last few threads 20 3 25 0 Nm 15 19 ft lbs Crankcase 5 16 in fasteners 3 18 CRANKCASE Assembly LOCTITE 272 20 26 Nm 15 19 ft lbs Crankcase 5 16 in screws 6 24 CRANKS...

Page 691: ...g nut 3 4 ENGINE ROTATION FOR SERVICE Assembly 8 1 10 8 Nm 72 96 in lbs Exhaust header nuts 3 6 ENGINE INSTALLATION Assembly 8 1 10 8 Nm 72 96 in lbs Exhaust header nuts 2 27 FAIRING SUPPORT BRACKET FIRE BOLT Installation 22 26 Nm 16 18 ft lbs Fairing support bracket fasteners Fire bolt 2 15 FENDERS Rear Fender XB12Ss XB12XT XB12X 1 4 4 Nm 12 36 in lbs Fender fasteners 4 14 FUEL PUMP Installation ...

Page 692: ...E 271 red 4 0 5 4 Nm 36 48 in lbs Front fender fasteners 2 15 FENDERS Front Fender XB12XP 1 4 4 Nm 12 36 in lbs Front fender fasteners and washers 2 15 FENDERS Front Fender XB12XP 4 0 5 4 Nm 36 48 in lbs Front fender fasteners and washers 2 20 FRONT AND REAR ISOLATORS Front Isol ator 66 69 Nm 49 51 ft lbs Front isolator bolt 3 4 ENGINE ROTATION FOR SERVICE Assembly 66 4 69 1 Nm 49 51 ft lbs Front ...

Page 693: ...lamp screws Lightning and Ulysses 2 32 HANDLEBARS LIGHT NING ULYSSES Installation LOCTITE 271 red Tighten front screws first 14 16 Nm 10 12 ft lbs Handlebar clamp screws Lightning and Ulysses 2 31 HANDLEBARS FIREBOLT Installation 33 35 Nm 24 26 ft lbs Handlebar clip on fastener Firebolt 2 31 HANDLEBARS FIREBOLT Installation 33 35 Nm 24 26 ft lbs Handlebar clip on fastener Firebolt 1 4 MAINTENANCE ...

Page 694: ...tle Cable Replacement 13 6 16 3 Nm 120 144 in lbs Ignition coil fasteners 3 4 ENGINE ROTATION FOR SERVICE Assembly 13 6 16 3 Nm 120 144 in lbs Ignition coil fasteners 3 6 ENGINE INSTALLATION Assembly 13 6 16 3 Nm 120 144 in lbs Ignition coil fasteners 4 6 IGNITION COIL Installation 13 6 16 3 Nm 120 144 in lbs Ignition coil mounting screws 6 4 IGNITION HEADLAMP KEY SWITCH FIRE BOLT 1 4 4 Nm 12 36 i...

Page 695: ...S ALL MODELS Installation 27 30 Nm 20 22 ft lbs Lower fork clamp fasteners 6 18 HEADLIGHT Headlight Bulbs Lightning and Ulysses 4 5 5 Nm 36 48 in lbs Lower headlight fastener 3 7 CYLINDER HEAD Cylinder Head Installation 15 17 5 Nm 135 155 in lbs Lower rocker box bolts 1 4 20 x 1 1 4 3 7 CYLINDER HEAD Cylinder Head Installation 24 30 Nm 18 22 ft lbs Lower rocker box bolts 5 16 18 x 2 1 2 3 7 CYLIND...

Page 696: ...ve battery cable at battery terminal 5 4 CLUTCH RELEASE MECHANISM Assembly 8 11 Nm 72 96 in lbs Negative battery cable at battery terminal 5 5 CLUTCH Assembly and Installation 8 11 Nm 72 96 in lbs Negative battery cable at battery terminal 5 6 PRIMARY CHAIN Installation 8 11 Nm 72 96 in lbs Negative battery cable at battery terminal 6 17 INTERACTIVE EXHAUST SYSTEM Installa tion 8 11 Nm 72 96 in lb...

Page 697: ...in lbs Pinch fastener E 1 ACTIVE INTAKE SYSTEM JAPANESE MODELS ONLY Installation 5 4 7 Nm 48 60 in lbs Pinch fastener 3 17 GEARCASE AND CAM GEARS Assembly and Installation Plus an additional 15 to 19 rota tion 26 29 Nm 19 21 ft lbs Pinion shaft nut 3 18 CRANKCASE Piston Jets TORX LOCTITE LOW STRENGTHTHREADLOCKER 222 purple 2 8 4 0 Nm 25 35 in lbs Piston jet assembly screws 2 23 REAR SHOCK ABSORBER...

Page 698: ...RACE Installation Swingarm 1 4 4 0 Nm 12 36 in lbs Rear fender fasteners 3 6 ENGINE INSTALLATION Assembly 33 9 36 6 Nm 25 27 ft lbs Rear isolator assembly fasteners 3 4 ENGINE ROTATION FOR SERVICE Assembly 33 9 36 6 Nm 25 27 ft lbs Rear isolator bolt 3 6 ENGINE INSTALLATION Assembly 33 9 36 6 Nm 25 27 ft lbs Rear isolator bolt 3 6 ENGINE INSTALLATION Assembly LOCTITE 271 red 43 4 48 8 Nm 32 36 ft ...

Page 699: ...eners front 2 6 REAR WHEEL Assembly Replace with new 34 37 Nm 25 27 ft lbs Rotor mounting fasteners rear 1 4 MAINTENANCE SCHEDULE General 9 5 12 Nm 84 108 in lbs Screw primary chain inspection cover 2 45 RIGHT TAIL SECTION ULYSSES MODELS Assembly 7 11 Nm 60 96 in lbs Seat latch fastener 2 52 SEAT LOCKS Installation Ulysses Models 7 11 Nm 60 96 in lbs Seat lock bracket fasteners Ulysses 2 52 SEAT L...

Page 700: ...ket fasteners 3 13 OIL COOLER Installation 7 5 8 8 Nm 66 78 in lbs Stabilizer bracket fastener 6 8 STARTER Field Coil Assembly 10 2 12 4 Nm 90 110 in lbs Starter end cover screw 6 8 STARTER Installation 17 6 27 1 Nm 13 20 ft lbs Starter mounting bolt 6 8 STARTER Installation 7 9 6 Nm 60 85 in lbs Starter positive terminal nut 6 8 STARTER Field Coil Assembly 4 4 7 3 Nm 39 65 in lbs Starter thru bol...

Page 701: ... 24 THROTTLE CONTROL Assembly and Installation 3 4 Nm 25 33 in lbs Switch housing fasteners right 2 39 SUBFRAME TAIL ASSEMBLY AND BODY WORK FIREBOLT Assembly 1 4 4 Nm 12 36 in lbs Tail body work lower Firebolt 2 39 SUBFRAME TAIL ASSEMBLY AND BODY WORK FIREBOLT Assembly 1 4 4 Nm 12 36 in lbs Tail body work upper Firebolt 2 39 SUBFRAME TAIL ASSEMBLY AND BODY WORK FIREBOLT Assembly LOCTITE 271 red 28...

Page 702: ...front Lightning 6 15 FRONT TURN SIGNALS Ulysses 2 8 3 2 Nm 25 28 in lbs Turn signal fastener front Ulysses 6 16 REAR TURN SIGNALS Lightning 2 8 3 2 Nm 25 28 in lbs Turn signal fastener rear Lightning 6 16 REAR TURN SIGNALS Ulysses 2 8 3 2 Nm 25 28 in lbs Turn signal fastener rear Ulysses 6 16 REAR TURN SIGNALS Firebolt 2 8 3 2 Nm 25 28 in lbs Turn signal fastener rear 2 39 SUBFRAME TAIL ASSEMBLY A...

Page 703: ...Windscreen fasteners 2 47 FRONT FAIRING WINDSHIELD AND MIR RORS FIREBOLT Installation 1 1 4 Nm 10 12 in lbs Windscreen fasteners Firebolt 2 48 WINDSHIELD AND WINDSCREEN LIGHT NING AND ULYSSES LIGHTNING 1 1 1 4 Nm 10 12 in lbs Windscreen fasteners Lightning 2 48 WINDSHIELD AND WINDSCREEN LIGHT NING AND ULYSSES ULYSSES XB12X 1 1 1 4 Nm 10 12 in lbs Windscreen fasteners Ulysses 6 20 LICENSE PLATE LAM...

Page 704: ...XXVI TORQUE VALUES NOTES ...

Page 705: ...1 14 Battery Cables Installation 6 21 Removal 6 21 Battery Maintenance Charging Battery 1 12 Battery Pan Assembly Lightning 2 137 Assembly Ulysses 2 142 Cleaning Lightning 2 137 Cleaning Ulysses 2 141 Disassembly Lightning 2 135 Disassembly Ulysses 2 141 Bearings Steering Head 1 35 Belt Gaurds Installation Firebolt Lightning 2 127 Belt Guards Removal Firebolt Lightning 2 127 Bottom End Overhaul Di...

Page 706: ...ection 3 53 Removal Disassembly 3 51 Cylinder Base Studs Removing 3 84 Cylinder Head 3 35 Assembly 3 45 Cleaning and Inspection 3 40 Disassembly 3 37 Installation 3 47 Removal 3 35 Cylinder Leakage Test 3 7 D Deflectors Handlebars Assembly and Installation 2 114 Removal and Disassembly 2 114 Deglazing Cylinder 3 54 Delphi Connector Repair A 6 Deutsch Connector Crimping Mini Terminals A 15 Crimping...

Page 707: ...rebolt 2 80 Fork Clamps Lightning Ulysses Installation 2 81 Removal 2 81 Frame Installation 2 92 Removal 2 92 Frame Pucks Installation 2 91 Removal 2 91 Front Brake Caliper Removal and Installation 2 45 Caliper Repair 2 46 Fluid Line Removal and Installation 2 44 Hand Lever 2 40 Master Cylinder Reservoir Installation 2 43 Master Cylinder Reservoir Removal 2 40 Master Cylinder Reservoir Repair 2 41...

Page 708: ...moval Firebolt Lightning 2 122 Replacement Ulysses 2 125 Horn Installation 6 38 Removal 6 38 Troubleshooting 6 39 Hose and Wire Routing Firebolt D 1 Lightning D 14 Ulysses D 26 Hydraulic Lifters 3 76 Cleaning and Inspection 3 76 Installation 3 77 Removal 3 76 I Idler Pulley Inspection 1 30 Replacement 5 25 Ignition Headlamp Key Switch Installation Lightning 6 13 Ignition Headlight Key Switch Assem...

Page 709: ...8 Main Wire Harness General Lightning 6 74 Installation Lightning 6 81 Removal Lightning 6 74 Metric System C 2 Metri Pack Terminals Crimping A 25 Mirrors Installation 2 121 Installation Firebolt 2 151 Removal 2 121 Removal Firebolt 2 151 Molex Connector Repair A 16 Terminal Crimps A 17 N Neutral Indicator Switch General 6 66 Removal and Installation 6 66 Testing 6 66 Neway Valve Seat Cutter How T...

Page 710: ...rdware and Threaded Parts 1 4 Lip Type Seals 1 4 O Rings Preformed Packings 1 5 Part Replacement 1 5 Shafts 1 5 Threadlocking Agents 1 4 Wiring Hoses and Lines 1 4 Right Tail Section Assembly Lightning 2 140 Assembly Ulysses 2 148 Disassembly Lightning 2 140 Disassembly Ulysses 2 147 Rim Runout 2 39 Rocker Arm Cleaning and Inspection 3 40 Rocker Arms and Bushings 3 42 S Safe Operating Maintenance ...

Page 711: ...uspension Settings 2 15 Swingarm and Brace Assembly 2 88 Cleaning and Inspection 2 88 Disassembly 2 87 General 2 86 Installation 2 88 Removal 2 86 T Tail Lamp Assembly Firebolt Lightning 6 59 Installation Ulysses 6 60 Removal Firebolt Lightning 6 59 Removal Ulysses 6 60 Throttle Body General 4 29 Installation 4 32 Removal 4 29 Repair 4 32 Throttle Cable Adjustment 1 41 Throttle Cables Installation...

Page 712: ...alves Cleaning and Inspection 3 41 Valve Seats Cleaning and Inspection 3 41 Valve Springs Cleaning and Inspection 3 42 Valve Stems Valve Stem Clearances and Service Wear Limits table 3 43 Vehicle Identification Number 2 19 Vehicle Speed Sensor Installation 6 70 Removal 6 70 Voltage Regulator General 6 31 Installation 6 31 Removal 6 31 W Wheel Balancing 2 38 Wheel Runout table 2 39 Wheels Bearings ...

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Summary of Contents for 2009 XB Series

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Buell 2009 XB Series, Service Manual, Page: 1 / 712

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Summary of Contents for 2009 XB Series

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