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Buell Firebolt XB12R 2004 Manual Download Page 36

2-36

2004 Buell Firebolt: Chassis

HOME

6.

See 

Figure 2-50.

  Disconnect brake light connector

located under the seat.

7.

See 

Figure 2-51.

  Remove rear brake light switch (1)

(metric) and two copper crush washers (3) to detach
brake line (2) from master cylinder (4). Discard copper
crush washers.

8.

Remove right side rider footpeg mount. See 

2.29 FOOT-

PEG, HEEL GUARD AND MOUNT

.

9.

See 

Figure 2-51.

  Remove fasteners (11) (metric) to

detach master cylinder (4) from rider footpeg mount.

10. See 

Figure 2-52.

 Detach remote reservoir.

a. 

Remove top clamp (4) on hose connected to master
cylinder.

b. 

Remove fastener (2) to detach reservoir (1) from
frame if necessary.

Figure 2-50. Brake Line Switch Connector

Figure 2-51. Rear Master Cylinder Assembly

8442

b0983a2x

1.

Rear brake light switch assembly

2.

Brake line

3.

Copper washer

4.

Rear master cylinder body

5.

Clevis pin

6.

Pedal bearing

7.

Sleeve

8.

Brake pedal fastener

9.

Brake pedal

10. Cotter pin
11. Rear master cylinder mount screw

4

5

7

8

6

10

9

2

1

3

11

Figure 2-52. Remote Reservoir

8359

1.

Reservoir

2.

Fastener and washer

3.

Remote reservoir hose

4.

Clamp

3

4

2

1

Summary of Contents for Firebolt XB12R 2004

Page 1: ... WEIGHT U S MODELS LBS KG Wet weight 460 204 GVWR 850 386 GAWR front 325 147 GAWR rear 525 238 Load capacity 400 181 Table 2 3 Weight Specifications XB9R WEIGHT U S MODELS LBS KG Wet weight 450 204 GVWR 850 386 GAWR front 325 147 GAWR rear 525 238 Load capacity 400 181 Table 2 4 Capacities CAPACITIES U S LITERS Fuel tank inc reserve 3 7 gallons 14 0 Reserve Low fuel light at 0 7 gallons 2 6 Oil ta...

Page 2: ...lves 36 60 in lbs 4 7 Nm metric page 2 25 Caliper carrier rear 24 26 ft lbs 32 35 Nm page 2 17 Caliper fasteners front 15 19 ft lbs 20 26 Nm page 2 32 Caliper mounting fasteners front 35 37 ft lbs 47 50 Nm page 2 32 Caliper mounting large fastener rear 18 21 ft lbs 24 28 Nm page 2 42 Caliper mounting small fastener rear 14 18 ft lbs 19 24 Nm page 2 42 Chin fairing fasteners 36 48 in lbs 4 5 Nm pag...

Page 3: ...astener front 16 18 ft lbs 21 7 24 4 Nm page 2 73 Muffler mounting block fastener rear 32 36 ft lbs 43 49 Nm page 2 73 Muffler strap fastener front 108 120 in lbs 12 14 Nm page 2 73 Muffler strap fastener rear 48 60 in lbs 5 7 Nm page 2 73 Oil cooler air scoop 120 144 in lbs 14 16 Nm page 2 82 Oil drain plug 29 31 ft lbs 39 42 Nm page 2 57 Oil line fittings 29 31 ft lbs 39 42 Nm page 2 57 Passenge...

Page 4: ...ngarm pivot shaft 24 26 ft lbs 32 35 Nm page 2 58 Switch housing fasteners right 25 33 in lbs 3 4 Nm page 2 63 Tail body work lower 36 48 in lbs 4 5 Nm page 2 86 Tail body work upper 12 36 in lbs 1 4 Nm page 2 86 Tail frame to frame 21 23 ft lbs 28 31 Nm LOCTITE 272 red page 2 85 Torca clamp 40 45 ft lbs 54 61 Nm page 2 73 Valve stem nut 40 44 in lbs 4 5 Nm page 2 21 Wear Peg rider 36 48 in lbs 4 ...

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

Page 6: ...cation b0304x2x Figure 2 3 Vehicle Identification Number V I N 4 MZ AX 12 J 4 3 400001 Varies can be 0 9 or X Sample V I N as it appears on the steering head 4MZAX12J143400001 Sample abbreviated V I N as it appears on the left side crankcase AX124400001 Manufacturer Buell Motorcycle Company Horsepower Code Engine Model Year 2004 Sequential Number 400001 420000 XB9R Domestic 420001 425000 XB9R Cali...

Page 7: ...e recommended air pressure Always balance the wheel after replacing a tire 11WARNING 1WARNING Do not inflate any tire beyond its maximum inflation pres sure as specified on tire sidewall Overinflation may cause tire to suddenly deflate which could result in death or serious injury TROUBLESHOOTING See Figure 2 4 Check tire inflation pressure at least once each week At the same time inspect tire tre...

Page 8: ...le traction steering and han dling and could result in death or serious injury At regular intervals of 5000 miles 8000 km or whenever handling irregularities are noted perform the recommended service checks See Table 2 8 If tires must be replaced same as original equipment tires must be used Other tires may not fit correctly and may be hazardous to use Table 2 8 Wheel Service CHECK FOR REMEDY Loos...

Page 9: ...ners See 2 31 FEND ERS 3 See Figure 2 5 Loosen front axle pinch fasteners 2 metric on front fork 4 Remove axle 1 NOTE The front axle is left handed thread CAUTION To prevent cosmetic damage to the wheel center caliper between spokes before removal 5 See Figure 2 6 Raise the wheel up until the rotor clears the caliper and rotate the fork leg counterclockwise allowing wheel clearance for removal 6 R...

Page 10: ... from the WHEEL BEARING INSTALLER REMOVER HD 44060 4 See Figure 2 8 Insert the FRONT WHEEL BEARING REMOVER COLLET B 43993 7 into the wheel bearing until it fully seats against the bearing 5 Insert the ball bearing into the collet 6 See Figure 2 9 Thread the puller assembly 1 into the collet 2 7 Hold the collet 2 and turn the forcing screw 3 to expand the collet 8 See Figure 2 10 Place the bridge 1...

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

Page 12: ...ANT Part No J 23444 A to the threads of the long forcing screw 1 to prolong service life and ensure smooth operation 3 Insert a new wheel bearing 2 squarely into the hub with the lettered side pointing out away from the wheel 4 Slide the FRONT BEARING INSTALLER Part No B 43993 9 from kit Part No B 43993 50 3 onto the forc ing screw 1 with the smaller diameter toward the bear ing bore 5 Install a w...

Page 13: ...earing bore 13 Install a washer 4 Nice bearing 5 and nut 6 onto the forcing screw 3 NOTE See Figure 2 16 Center the spacer while installing the wheel bearing Failure to center the spacer could cause the bearing not to pull in straight 14 While holding the forcing screw 3 tighten the nut 6 until the bearing is seated firmly 15 Remove the nut bearing washer FRONT BEARING INSTALLER Part No B 43993 10...

Page 14: ...pat tern around the wheel to insure proper fitting between rotor fastener and bushing Tighten to 25 27 ft lbs 34 37 Nm 1CAUTION Rotor mounting fasteners must be seated into drive bushings and drive bushings must be fitted into rotor properly Failure to comply may affect braking ability and lead to brake failure which could result in death or seri ous injury Figure 2 18 Front Wheel Assembly 1 Front...

Page 15: ... Install front axle a Apply LOCTITE ANTI SEIZE LUBRICANT to axle b See Figure 2 20 With pinch fasteners metric loose insert threaded end of axle 1 through left side fork wheel hub and thread into right fork c Compress the front suspension to make sure it is free and not binding d Tighten axle 1 metric to 39 41 ft lbs 53 56 Nm NOTE The front axle is left handed thread 4 See Figure 2 20 Tighten the ...

Page 16: ...ring speeds can damage unlubricated bearings Spinning bearings with compressed air can also cause a bearing to fly apart which could result in death or seri ous injury 1 Inspect all parts for damage or excessive wear 2 Inspect brake rotor See 1 7 BRAKE SYSTEM MAINTE NANCE DISASSEMBLY 1 Remove sprocket a Remove sprocket fasteners and washers Discard fasteners b Remove sprocket from wheel 2 Remove r...

Page 17: ...ell Firebolt Chassis 2 17 HOME Figure 2 23 Rear Wheel Assembly 1 Rotor mounting fastener 6 2 Brake rotor 3 Wheel bearing 4 Wheel spacer 5 Wheel 6 Sprocket 7 Sprocket fastener 8 Axle b0936x2x 1 3 5 4 3 2 6 7 8 ...

Page 18: ...rotor 2 a Position rear brake rotor 2 on wheel 5 b Install brake rotor 2 with new rotor mounting fas teners 1 and tighten to 25 27 ft lbs 34 37 Nm INSTALLATION 1 Center rear wheel in the swingarm at the same time slid ing the drive belt onto the rear sprocket 2 With wheel centered in swingarm lower bike to align swingarm and wheel hub 3 Apply ANTI SEIZE LUBRICANT to hole in right side of swingarm ...

Page 19: ...llow the rotor to slide into the caliper Press on the brake pad from the outside of the caliper to straighten out the pad 11WARNING 1WARNING Always test motorcycle brakes at low speed after servic ing or bleeding system To prevent death or serious injury Buell recommends that all brake repairs be per formed by a Buell dealer or other qualified mechanic Figure 2 27 Rear Brake Caliper Carrier Fasten...

Page 20: ...nout exceeds specification shown in Table 2 9 Rim Radial Runout 1 See Figure 2 29 Install truing arbor in wheel hub and place wheel in WHEEL TRUING AND BALANCING STAND Part No HD 99500 80 2 Tighten arbor nuts so hub will turn on its bearings 3 Check radial runout as shown Replace wheel if runout exceeds specification shown in Table 2 9 Table 2 9 Wheel Rim Runout RUNOUT IN MM Maximum lateral 0 040 ...

Page 21: ...blue dot on inside of rim REMOVAL 1 Remove wheel from motorcycle See 2 5 FRONT WHEEL or 2 6 REAR WHEEL 2 Deflate tire 3 See Figure 2 30 Loosen both tire beads from rim flange 11WARNING 1WARNING Do not use excessive force when starting bead over rim Excessive force may damage tire or rim and adversely affect handling which could result in death or serious injury 4 If a bead breaker machine is not a...

Page 22: ...maged or leaking valve stems must be replaced 2 Install and tighten fastener to 40 44 in lbs 4 5 Nm 3 Thoroughly lubricate rim flanges and both beads of tire with tire lubricant 11WARNING 1WARNING The yellow circle on the sidewall is a balance mark and should be aligned 180 degrees from the balance mark blue dot on inside of rim 4 See Figure 2 32 Starting at the valve stem start first bead into th...

Page 23: ...ll tire and check again for tire tread lateral runout Checking Tire Radial Runout 1 See Figure 2 34 Turn wheel on axle and measure tread radial runout 2 Check tire tread for appropriate runout specification See Table 2 10 If runout is more then specification remove tire from rim 3 Check rim bead runout See 2 7 CHECKING CAST RIM RUNOUT Replace rims not meeting specifications 4 Install tire and chec...

Page 24: ...ed to within 1 4 oz 7 g at 60 MPH 97 KM H See Figure 2 35 Use only WHEEL WEIGHTS Part No 43692 94Y which have special self adhesive backings Apply WHEEL WEIGHTS to the flat surface of the wheel rim 1 Make sure that area of application is completely clean dry and free of oil and grease 2 Remove paper backing from weight For additional adhe sive strength apply three drops of LOCTITE SUPER BONDER 420...

Page 25: ...pedal 6 INSTALLATION 1 See Figure 2 36 Install pedal bushings 3 2 Install shift brake pedal sleeve 4 3 Install brake pedal 6 using LOCTITE 272 Red and tighten fastener 5 to 22 24 ft lbs 30 33 Nm 4 Install clevis pin 2 5 Install new cotter pin 7 Figure 2 36 Brake Pedal Assembly 1 Rear master cylinder body 2 Clevis pin 3 Pedal bushings 2 4 Shift brake pedal sleeve 5 Brake pedal fastener 6 Brake peda...

Page 26: ...s by carefully removing brake line components 2 See Figure 2 37 Remove the banjo bolt 13 metric and two copper washers 15 to disconnect brake line 14 from master cylinder 4 Discard copper washers 3 Unplug terminal 12 to detach brake lamp switch 11 NOTE The individual parts of the brake lamp switch are not service able Replace switch upon failure 4 Remove mounting clamp fasteners 5 metric to detach...

Page 27: ...hol Do not use mineral base cleaning solvents such as gasoline or paint thinner Use of mineral base solvents causes deterioration of rubber parts that continues after assembly This may result in improper brake operation which could result in death or serious injury 1 Clean all parts with denatured alcohol or D O T 4 BRAKE FLUID Do not contaminate with mineral oil or other solvents Wipe dry with a ...

Page 28: ...eration which could result in death or serious injury 4 See Figure 2 37 Insert piston assembly 6 spring first into master cylinder reservoir 4 5 See Figure 2 38 Secure piston assembly 1 with a new circlip 2 6 See Figure 2 39 Install ridge on boot 1 into groove on piston 3 Brake Hand Lever 1 See Figure 2 37 Lubricate pivot bolt 16 with LOCTITE ANTI SEIZE 2 Align hole in hand lever 8 with hole in ha...

Page 29: ...ylinder in a level posi tion add D O T 4 BRAKE FLUID Bring fluid level to within 1 8 in 3 2 mm of molded boss inside front mas ter cylinder reservoir 11WARNING 1WARNING Verify proper operation of the master cylinder relief port A plugged or covered relief port can cause brake drag or lockup which could result in loss of vehicle control which could result in death or serious injury 8 Verify proper ...

Page 30: ... CAUTION Damaged banjo bolt seating surfaces will leak when reassembled Prevent damage to seating surfaces by carefully removing brake line components 3 See Figure 2 37 Remove master cylinder banjo bolt 12 metric and two copper washers 14 to disconnect brake line from master cylinder 4 Discard copper washers 4 See Figure 2 42 Remove caliper banjo bolt 5 metric two copper washers and wire form 3 to...

Page 31: ... tighten banjo bolt 5 onto front caliper being careful not to pinch wire form 3 while tightening wire form should rotate around banjo bolt freely c Twist brake line 2 into wire form 3 spiral and clock wire form against bleeder valve 4 4 Tighten p clamp with fastener 1 on lower triple clamp to 36 60 in lbs 4 7 Nm 5 See Figure 2 37 Tighten master cylinder banjo bolt 12 metric to 16 20 ft lbs 22 27 N...

Page 32: ...e 2 44 Disconnect brake line at caliper See 2 11 FRONT BRAKE LINE 3 Remove caliper mounting fasteners 5 4 Slide caliper down the rotor to clear fork lower and then remove off rotor DISASSEMBLY 1 See Figure 2 45 Remove pin hanger set 1 caliper pad spring 2 and brake pads 2 Split caliper by removing caliper fasteners 3 3 See Figure 2 47 Remove and discard o rings 6 4 See Figure 2 46 Remove pistons u...

Page 33: ...ores with D O T 4 BRAKE FLUID b Install two new o rings 6 in grooves of each piston bore c Install pistons 5 in each piston bore 2 Install new o rings 8 between caliper halves 3 Clamp caliper together with caliper fasteners 11 and tighten to 15 19 ft lbs 20 26 Nm INSTALLATION 1 See Figure 2 47 Install brake pads 10 2 Install pin hanger set 1 and tighten to 11 14 ft lbs 15 19 Nm 3 Rotate front fork...

Page 34: ...igure 2 47 Front Caliper Assembly b0976x2x 1 Pin hanger set 2 Brake bleeder 3 Bleeder cap 4 Caliper 5 Piston 6 Piston o rings 7 Pad spring 8 Small o ring 9 Caliper mounting fasteners 10 Brake pads 11 Caliper fasteners 5 3 2 1 11 4 6 7 8 9 10 ...

Page 35: ...to 36 60 in lbs 4 7 Nm 2 Remove brake pedal See 2 9 BRAKE PEDAL 3 Remove heel guard See 2 29 FOOTPEG HEEL GUARD AND MOUNT CAUTION Damaged banjo bolt surfaces will leak when reassem bled Prevent damage to seating surfaces by carefully removing brake line components 4 See Figure 2 49 Remove brake reservoir hose at master cylinder 5 Remove seat See 2 38 SEAT Figure 2 48 Brake Bleeder Valve Rear Calip...

Page 36: ...m rider footpeg mount 10 See Figure 2 52 Detach remote reservoir a Remove top clamp 4 on hose connected to master cylinder b Remove fastener 2 to detach reservoir 1 from frame if necessary Figure 2 50 Brake Line Switch Connector Figure 2 51 Rear Master Cylinder Assembly 8442 b0983a2x 1 Rear brake light switch assembly 2 Brake line 3 Copper washer 4 Rear master cylinder body 5 Clevis pin 6 Pedal be...

Page 37: ...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 holes on master cylinder are com pletely open and free of dirt or debris 2 Inspect boot on front of master cylinder for cuts tears or general deterioration Replace if necessary ASSEMBLY 1 ...

Page 38: ... Nm b Attach hose 3 to rear brake reservoir using clamp 5 See Figure 2 50 Connect brake line switch connector under seat 6 Install heel guard See 2 29 FOOTPEG HEEL GUARD AND MOUNT 7 Install rear brake pedal See 2 9 BRAKE PEDAL 8 Adjust rear brake pedal See BRAKE PEDAL ADJUST MENT in 1 7 BRAKE SYSTEM MAINTENANCE 9 Install master cylinder to brake pedal See 2 9 BRAKE PEDAL 11WARNING 1WARNING Always ...

Page 39: ...luid according to local laws a Install a length of plastic tubing over caliper bleeder valve Place free end in a suitable container b Open bleeder valve metric about 1 2 turn c Pump brake foot pedal to drain brake fluid d Tighten bleeder valve to 36 60 in lbs 4 7 Nm 6 See Figure 2 55 Remove p clamp 3 and wire form 2 securing brake line 1 to the left side of swingarm CAUTION Damaged banjo bolt seat...

Page 40: ...MOUNT 6 Bleed brakes See BLEEDING BRAKES in 1 7 BRAKE SYSTEM MAINTENANCE 11WARNING 1WARNING Always connect the positive battery cable first If the pos itive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explo sion which could result in death or serious injury 7 Install negative battery cable and tighten to 72 96 in lbs 8 11 Nm See 1 5 BATTER...

Page 41: ... 7 Nm 2 Remove banjo bolt connecting brake line to rear caliper See 2 14 REAR BRAKE LINE 3 See Figure 2 57 Remove caliper mounting fasteners 6 and 7 DISASSEMBLY 1 See Figure 2 57 Remove pin plug 5 and pad hanger metric to free brake pads 2 See Figure 2 58 Remove spring clip 1 3 See Figure 2 59 Remove piston 3 using BRAKE CALI PER PISTON REMOVER 1 Part No B 42887 with adaptor 2 4 Remove two o rings...

Page 42: ...ever replace just one brake pad Fail ure to install brake pads as a set could result in death or serious injury 4 Inspect brake pads for damage or excessive wear Replace both pads as a set if the friction material of either pad is worn to 0 04 in 1 0 mm or less ASSEMBLY 1 See Figure 2 58 Place clip 1 inside caliper body as shown NOTE To ensure proper brake pad to brake rotor clearance when the cal...

Page 43: ... lic brake line and caliper bore are completely clean 3 See Figure 2 57 Connect brake line 1 to caliper using two new copper washers 3 and banjo bolt 2 metric Tighten to 16 20 ft lbs 22 27 4 Depress rear brake pedal several times to set brake pads to proper position within caliper Bleed brake system 5 See Figure 2 61 Verify proper fluid level in reservoir 11WARNING 1WARNING Always test motorcycle ...

Page 44: ...SPENSION DAMPING ADJUSTMENTS for more information REMOVAL 1 Remove front fender See 2 31 FENDERS 2 Remove front wheel See 2 5 FRONT WHEEL 3 Remove caliper mounting fasteners See 2 12 FRONT BRAKE CALIPER 4 Loosen upper 1 and lower 3 fork clamp pinch fasten ers 5 Remove fork from upper fork clamp 2 6 See Figure 2 63 Slide the stopper ring up and over the top of the fork 7 See Figure 2 62 Remove fork...

Page 45: ...e front fork in the holding tool 3 Remove snap ring 2 4 See Figure 2 65 Remove preload adjuster by turning counterclockwise NOTE After fully unthreading preload adjuster gently pull on adjuster 5 See Figure 2 66 Remove fork cap from outer tube Figure 2 64 Fork Tube Holder HD 41177 f1905x2x 1 Fork tube holder 2 Snap ring 3 Preload adjuster 4 Front fork assembly 1 1 2 3 4 8983 Figure 2 65 Removing P...

Page 46: ...ove fork cap 1 CAUTION Careful not to damage preload pins while holding damper rod assembly 8 Remove preload washer 4 and slider piston 5 9 See Figure 2 67 Uncompress fork and remove from FORK SPRING COMPRESING TOOL Figure 2 67 Fork Spring Compressing Tool HD 45966 b1145x1x Figure 2 68 Holding Damper Rod Assembly 8479 1 Fork cap 2 Preload pins 3 Damper rod assembly 4 Preload washer 5 Slider piston...

Page 47: ...nap ring 9 Rebound adjuster assembly 10 Damper locknut 11 Damper rod assembly 12 Centering plate 13 Ceiling washer 14 Center bolt 15 Collar 16 Spring 17 Spring joint 18 Outer tube 19 Stopper ring 20 Reflector assembly 21 Slide bushing 22 Guide bushing 23 Seal spacer 24 Oil seal 25 Oil seal stopper ring 26 Dust seal 27 Slider fork b0991x2x 1 2 3 4 5 6 7 8 9 10 11 12 13 14 20 15 17 18 21 22 23 24 25...

Page 48: ...4 stopper ring 25 and dust seal 26 Damper Rod Disassembly IMPORTANT NOTES See Figure 2 69 Disassembly of damper rod is not required unless damper locknut 10 has been moved If damper rod needs servicing refer to the Parts Catalog for kit information If damper locknut has been moved proceed with the following disassembly and assembly procedures for setting the correct range of motion 1 See Figure 2 ...

Page 49: ...nstall a new dust seal 26 and stopper ring 25 onto the slider fork 27 3 Coat the sealing lips of the new oil seal 24 with fork oil or sealing grease and install onto the slider fork with its marked side facing the dust seal 26 4 Remove the tape from the slider fork end 5 Install the seal spacer 23 the guide bushing 22 and the slide bushing 21 onto the slider fork 27 6 Coat the slide bushing 21 and...

Page 50: ... level with FRONT FORK OIL LEVEL GAUGE Part No B 59000A so that it is 4 6 in 118 mm from the top of the fork tube 18 See Figure 2 69 Install spring 16 and collar 15 19 Move fork assembly from holding tool to the FORK SPRING COMPRESSION TOOL 20 See Figure 2 68 Install preload washer 4 and slider piston 5 21 Hold damper rod assembly 3 and install fork cap 1 from damper rod assembly 3 tightening to 2...

Page 51: ...gure 2 74 Position fork with alignment lines 4 visible and reflector facing to the side and tighten the lower fork clamp 5 Repeat step 1 through 4 on second front fork 6 Temporarily install front axle to the fork assemblies to verify correct alignment 7 Use LOCTITE 272 on upper fork clamp fasteners and tighten to 17 19 ft lbs 23 26 Nm 8 Use LOCTITE 272 on lower fork clamp fasteners and tighten to ...

Page 52: ...2 52 2004 Buell Firebolt Chassis HOME NOTES ...

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