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Buell XB 2008 Series, Service Manual, Page: 505 / 688

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Buell XB 2008 Series Service Manual Download Page 505

2

3

4

5

1

6

sm00415

1.

Headlight support bracket

2.

Instrument module

3.

Grommet (3)

4.

Washer (3)

5.

Fastener (3)

6.

Instrument module connector [39]

Figure 7-85. Instrument Module Assembly: Firebolt

5

6

1

3

4

1

2

sm00463

1.

Front support module, left and right

2.

Instrument module

3.

Grommet (3)

4.

Washer (3)

5.

Fastener (3)

6.

Instrument module connector [39]

Figure 7-86. 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 7-87. Instrument Module Assembly: Ulysses

2008 XB Service:  Electrical  7-61

Summary of Contents for XB 2008 Series

Page 1: ...2008 Buell XB Models Service Manual 99490 08YA 2007 Buell Motorcycle Company ...

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

Page 3: ...2008 Buell XB Models Service Manual 2007 Buell Motorcycle Company ALL RIGHTS RESERVED 99490 08YA Printed in the U S A VISIT THE BUELL WEB SITE http www buell com ...

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: ...rty should 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 figu...

Page 8: ...s our continual goal Buell Motor cycle Company reserves the right to change specifications equipment or designs at any time without notice and without incurring obligation PRODUCT REFERENCES Read and follow warnings and directions on all products Failure to follow warnings and directions can result in death or serious injury 00470b When reference is made in this manual to a specific brand name pro...

Page 9: ...ons 1 10 Using a Battery Charger 1 10 Battery Installation and Connection 1 11 Storage 1 12 1 5 ENGINE OIL AND FILTER General 1 13 Engine Oil Level Check 1 13 Change Engine Oil and Filter 1 13 Drain Oil 1 13 Change Filter 1 14 Fill Engine With Oil 1 14 Clear Oil Cooler 1 14 Return to Service 1 15 1 6 BRAKE SYSTEM MAINTENANCE General 1 16 Bleeding Brakes 1 16 Bleeding Front Brake 1 17 Bleeding Rear...

Page 10: ... 49 Clutch Drags Or Does Not Release 1 49 Clutch Chatters 1 49 Clutch 1 49 Slips 1 49 Drags or Does Not Release 1 49 Chatters 1 49 Chassis 1 49 Irregular Inadequate Brake Action 1 49 Handling Irregularities 1 49 Suspension 1 50 CHASSIS 2 1 SPECIFICATIONS Firebolt 2 1 Lightning 2 1 Ulysses 2 2 2 2 VEHICLE IDENTIFICATION NUMBER V I N Vehicle Identification Number V I N 2 4 2 3 WHEELS General 2 6 Tro...

Page 11: ...l 2 48 Installation 2 48 Front Fender XB12X 2 48 Removal Upper Front Fender 2 48 Removal Lower Front Fender 2 48 Installing Upper Front Fender 2 48 Installing Lower Front Fender 2 48 2 16 FRONT FORK ALL MODELS EXCEPT XB12STT XB12X XB12XT General 2 49 Removal 2 49 Disassembly 2 50 Damper Rod Disassembly 2 52 Cleaning and Inspection 2 54 Assembly 2 54 Damper Rod Assembly 2 54 Fork Assembly 2 54 Inst...

Page 12: ...tallation 2 100 2 32 FRONT MODULES LIGHTNING ULYSSES Removal 2 101 Installation 2 102 2 33 HANDLEBARS FIREBOLT General 2 103 Removal 2 103 Right Clip On 2 103 Left Clip On 2 103 Installation 2 103 Right Clip On 2 103 Left Clip On 2 103 2 34 HANDLEBARS LIGHTNING ULYSSES Removal 2 104 Installation 2 104 2 35 MIRRORS Removal 2 106 Installation 2 106 2 36 FOOTPEG HEEL GUARD AND MOUNT FIREBOLT LIGHTNIN...

Page 13: ...2XT 2 138 Installation Ulysses XB12XT 2 139 2 51 NUMBER PLATES XB12STT General 2 140 Removal 2 140 Installation 2 141 2 52 AIR SCOOPS Ram Air Scoop 2 142 Removal 2 142 Installation 2 142 Engine Shroud Air Scoop 2 142 Removal 2 142 Installation 2 142 Oil Cooler Air Scoop 2 142 Removal 2 142 Installation 2 142 2 53 CHIN FAIRING Removal 2 144 Installation 2 144 2 54 SEAT Firebolt 2 145 Rider Seat 2 1...

Page 14: ...58 3 9 OIL PUMP General 3 59 Removal Disassembly 3 60 Cleaning and Inspection 3 62 Assembly Installation 3 63 3 10 OIL RESERVOIR AND OIL HOSE ROUTING General 3 65 3 11 OIL LINE FITTINGS Removal 3 67 Installation 3 67 3 12 OIL COOLER General 3 69 Removal 3 69 Installation 3 69 3 13 OIL PRESSURE INDICATOR SWITCH General 3 70 Oil Pressure Signal Light 3 70 Oil Pressure 3 70 3 14 CRANKCASE BREATHING S...

Page 15: ...gulator Replacement 4 21 Low Fuel Level Sensor Replacement 4 22 Fuel Filter Replacement 4 23 Fuel Pump Wire Harness Replacement 4 25 Installation 4 25 4 14 THROTTLE BODY General 4 27 Removal 4 27 Repair 4 30 Throttle Position Sensor 4 30 Fuel Injectors 4 30 Installation 4 30 Injector Leak Testing 4 31 4 15 INTAKE LEAK TEST General 4 32 Leak Tester 4 32 Parts List 4 32 Tester Assembly 4 32 Tester A...

Page 16: ... 29 Mainshaft Countershaft 6 33 Mainshaft Disassembly 6 33 Cleaning and Inspection 6 34 Countershaft Disassembly 6 34 Cleaning and Inspection 6 34 6 10 TRANSMISSION ASSEMBLY Mainshaft Assembly 6 36 Countershaft Assembly 6 36 6 11 MAIN DRIVE GEAR AND BEARING General 6 38 Removal 6 38 Main Drive Gear Bearing 6 39 Disassembly 6 40 Assembly 6 40 Installation 6 41 Main Drive Gear Ball Bearing 6 41 Main...

Page 17: ...NT TURN SIGNALS Bulbs 7 32 Repair 7 32 Connections and Wire Routing 7 32 Firebolt 7 32 Removal 7 32 Installation 7 35 Lightning 7 32 Removal 7 32 Installation 7 32 Ulysses 7 33 Removal 7 33 Installation 7 36 7 13 REAR TURN SIGNALS Bulbs 7 35 Connections and Wire Routing 7 35 Firebolt 7 35 Removal 7 35 Installation 7 35 Lightning 7 36 Removal 7 36 Installation 7 36 Ulysses 7 37 Remove 7 37 Installa...

Page 18: ...minals A 6 A 3 AUTOFUSE ELECTRICAL CONNECTORS Autofuse Connector Repair A 7 General A 7 Disassembly A 7 Assembly A 7 A 4 DELPHI CONNECTORS Delphi Connector Repair A 8 General A 8 Separating Pin and Socket Housings A 8 Mating Pin and Socket Housings A 8 Removing Socket Terminals A 8 Installing Socket Terminals A 8 A 5 DEUTSCH ELECTRICAL CONNECTORS Deutsch Connector Repair A 10 General A 10 Separati...

Page 19: ... PACKARD ECM CONNECTOR Packard 100W Connector Repair A 29 General A 29 Separating Socket Housing From ECM A 29 Mating Socket Housing To ECM A 29 Removing Socket Terminal A 29 Installing Socket Terminal A 29 Crimping Terminals A 29 A 16 PACKARD MICRO 64 CONNECTORS Packard Micro 64 Connector Repair A 31 General A 31 Separating Pin and Socket Housings A 31 Mating Pin and Socket Housings A 31 Removing...

Page 20: ...ngs E 1 WOT Check E 1 Cable E 1 Adjustment E 1 Throttle Stop Screw E 3 Removal E 4 Installation E 5 APPENDIX F GLOSSARY F 1 GLOSSARY Acronyms and Abbreviations F 1 REFERENCE MATERIAL TOOLS I TORQUE VALUES VII INDEX XXVII XIV TABLE OF CONTENTS TABLE OF CONTENTS ...

Page 21: ...ES AND WHEELS 1 23 1 8 CLUTCH TRANSMISSION PRIMARY FLUID 1 25 1 9 DRIVE BELT MAINTENANCE 1 28 1 10 PRIMARY CHAIN 1 31 1 11 STEERING HEAD BEARINGS 1 32 1 12 SPARK PLUGS 1 33 1 13 AIR CLEANER AND EXHAUST SYSTEM 1 35 1 14 THROTTLE CABLE 1 38 1 15 INTERACTIVE EXHAUST CABLE 1 39 1 16 HEADLIGHT 1 41 1 17 WINDSHIELD MAINTENANCE 1 45 1 18 STORAGE 1 46 1 19 TROUBLESHOOTING 1 47 MAINTENANCE ...

Page 22: ...NOTES ...

Page 23: ...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 l...

Page 24: ...ocking 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 bearings must be handled in a special way To keep out...

Page 25: ... 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 Use buffing crocus cloth on highly polished parts that ...

Page 26: ...river 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 extensio...

Page 27: ...used 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 ...

Page 28: ...l 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 ...

Page 29: ...gs X 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 stablizer 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 ...

Page 30: ...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 3 4 Nm Intake cover screw torque Intake cover assembly LUBIT 8 TUFOIL CHAIN AND CABLE LUBE Part No HD 94968 85TV Lubricant...

Page 31: ...h defects 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 4 BATTERY MAINTENANCE Charging Battery For testing inf...

Page 32: ...ed In 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 positiv...

Page 33: ...of 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 ...

Page 34: ...rged 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 ...

Page 35: ...esult 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 tan...

Page 36: ...uired 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 approximately 2 5 quarts 2 4 liters and includes the 4 0 ounces 0 12 liter ...

Page 37: ...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 53 CHIN FAIRING 5 Check hot oil level See 1 5 ENGINE OIL AND FILTER Engine Oil Level Check 2008 XB Service Maintenance 1 15 ...

Page 38: ...rake 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 ...

Page 39: ... D 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 bleede...

Page 40: ...holding brake pedal in the depressed 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 caliper bleeder valve metric to 30 60 in lbs 4 7 ...

Page 41: ... 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 Adjustment Typical BRAKE PAD THICKNESS Always replace ...

Page 42: ...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 outer pad 7 Remove ...

Page 43: ...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 See Figure 1 19 Ch...

Page 44: ...5 1 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 1 22 2008 XB Service Maintenance ...

Page 45: ...etters TWI on tire sidewalls pinpoint location of wear indicators bars Always remove tires from service before they reach the treadwear indicator bars Refer to Table 1 9 1 2 om00962 1 Tread wear indicator bar 2 Sidewall TWI marking Figure 1 21 Tread Wear Indicator Pirelli Scorpion Sync 2 1 om00963 1 Tread wear indicator bar 2 Sidewall TWI marking Figure 1 22 Tread Wear Indicator Pirelli Diablo T T...

Page 46: ...h or serious injury 00505b Check front and rear wheel bearings for wear Every time a wheel is removed When storing or removing the motorcycle for the season Check wheel bearings for wear and corrosion Excessive play or roughness indicates worn bearings Replace bearings in sets only 1 24 2008 XB Service Maintenance ...

Page 47: ...3 2 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...

Page 48: ... adjustment is within specific ations adjust clutch mechanism as described below 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 ad...

Page 49: ...sion 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 10 12 Nm 1 2 3 4 sm00090 1 Rubber boot 2 Cable end 3 Jam nut 4 Adjuster Figure 1 27 Clutch Cable Adjuster Mechanism 2 3 1 sm00091 1 Diaphragm spring 2 Lockplate 3 Adj...

Page 50: ...d 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 tran...

Page 51: ...inate 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 har...

Page 52: ...ocket 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 gu...

Page 53: ...red 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 1 31 Install primary chain inspection cover and new gasket to prima...

Page 54: ...leg pull front wheel to center position a The desired resistance to pull front wheel to center is between 1 7 lbs 0 5 3 2 kg b If steering head resistance measurement is not within specification see 1 11 STEERING HEAD BEARINGS Determining Proper Resistance 7 When adjustment is complete attach clutch cable and adjust See 1 8 CLUTCH TRANSMISSION PRIMARY FLUID sm00098 Figure 1 34 Measuring Steering H...

Page 55: ...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 combustion Clean off spark plug deposits at regular inter...

Page 56: ...all left side air scoop See 2 52 AIR SCOOPS 15 Install air cleaner assembly and intake cover See 2 40 INTAKE COVER and 4 2 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 seat sm00100 Figure 1 36 Rear Spark Plug Access 1 34 2...

Page 57: ...1 Remove seat 2 Remove intake cover assembly See 2 40 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 i...

Page 58: ...element 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 in...

Page 59: ...k entire 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 16 EXHAUST SYSTEM for exhaust system...

Page 60: ...uster 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 eac...

Page 61: ...el and bracket 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 Adjust cable as needed using cable adjuster 1 NOTES In this mode...

Page 62: ...king 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 1 40 2008 XB Service Maintenance ...

Page 63: ...ehicle with rider passenger cargo accessories Weight will compress vehicle suspension slightly 5 Stand motorcycle upright with headlamps aimed straight forward 6 Check LOW beam right lens for alignment a See Figure 1 49 Turn ignition switch to IGN Set handlebar headlamp switch to LOW beam position b Turn engine stop switch to the RUN position c Check that the correct pattern of light is a double r...

Page 64: ... adjuster right Figure 1 50 Headlamp Height Adjustment Firebolt ADJUSTMENT LIGHTNING Horizontal Alignment See Figure 1 51 and Figure 1 52 Loosen fasteners on right and left side of headlamp housing to adjust the horizontal alignment Vertical Alignment See Figure 1 53 Loosen fastener on the bottom of headlamp housing to adjust the vertical alignment NOTE Only loosen headlamp alignment fasteners eno...

Page 65: ...ertical Alignment See Figure 1 56 or Figure 1 57 Loosen fastener on the bottom of headlamp housing to adjust the vertical alignment The ver tical headlamp adjustment screw is located under the front upper fender NOTE Only loosen headlamp alignment fastener enough to adjust headlamp Once headlamps are aligned tighten fastener to 36 48 in lbs 4 5 Nm pd00200 Figure 1 54 Horizontal Headlamp Adjustment...

Page 66: ...sm05318 Figure 1 57 Vertical Headlamp Adjustment Fastener XB12XT 1 44 2008 XB Service Maintenance ...

Page 67: ...ndscreen 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 ...

Page 68: ...rely 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 b...

Page 69: ...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 partially fouled 2 Spark p...

Page 70: ... 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 not functioning 3 Restricted oil lines or fittings 4 Restricted ...

Page 71: ...ubricant 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 backwards Clutch Chatters 1 Friction discs or steel discs worn warped or dragging CLUTCH Slips 1 Clutch controls improperly adjusted 2 Worn friction plates Drags or Does Not Re...

Page 72: ...und quickly after bumps This is more pronounced over a series of bumps and is often referred to as packing down Increase compression damping The bike bottoms out or dips while cornering Bike has excessive brake dive Reduce compression damping Harsh ride particularly over washboard surfaces Bumps kick through handlebars or seat Suspension seems not to respond to bumps This is evidenced by tire chat...

Page 73: ...A good 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 2008 XB Service Maintenance 1 51 ...

Page 74: ...1 52 2008 XB Service Maintenance NOTES ...

Page 75: ...G SUPPORT BRACKET FIREBOLT 2 97 2 30 DEFLECTORS XB9SX XB12STT XB12X XB12XT 2 99 2 31 GRILLE XB9SX XB12STT XB12X 2 100 2 32 FRONT MODULES LIGHTNING ULYSSES 2 101 2 33 HANDLEBARS FIREBOLT 2 103 2 34 HANDLEBARS LIGHTNING ULYSSES 2 104 2 35 MIRRORS 2 106 2 36 FOOTPEG HEEL GUARD AND MOUNT FIREBOLT LIGHTNING 2 107 2 37 HEEL GUARD AND FOOTPEG MOUNTS ULYSSES MODELS 2 109 2 38 SPROCKET COVER 2 111 2 39 BEL...

Page 76: ...NOTES ...

Page 77: ...inates at 2 4 2 5 U S quarts Oil tank 0 9 1 0 U S quart Transmission LIGHTNING Table 2 4 Dimensions 2008 Lightning Models XB12STT XB12Ss XB12Scg XB12S XB9SX ITEM MM IN MM IN MM IN MM IN MM IN 1364 53 7 1372 54 0 1320 52 0 1320 52 0 1320 52 0 Wheel base without rider 798 31 4 775 30 5 726 28 6 765 30 1 797 31 4 Seat height with rider 140 5 50 118 4 66 90 3 55 110 4 35 110 4 35 Ground clearance with...

Page 78: ...le 2 8 Dimensions 2008 Ulysses Models XB12XT WITHOUT LUGGAGE BRACKETS XB12XT WITH LUGGAGE XB12X ITEM MM IN MM IN MM IN 2180 85 8 2320 91 3 2159 85 0 Overall length 892 35 1 1005 39 6 891 35 1 Overall width 1331 52 4 1331 52 4 1331 52 4 Overall height 1370 53 9 1370 53 9 1374 54 1 Wheel base without rider 780 30 7 780 30 7 808 31 8 Seat height with rider 151 5 94 151 5 94 171 6 75 Ground clearance ...

Page 79: ...s Axle Weight Ratings GAWR are given on an information decal located on the steering head Table 2 10 Capacities 2008 Ulysses Models LITERS U S ITEM 16 7 4 40 gallons Fuel tank total including reserve 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 inflate...

Page 80: ...e 2 11 Buell V I N Breakdown 2008 Models POSSIBLE VALUES DESCRIPTION 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 AX Firebolt Motorcycle type code 2 DX Ulysses XB12X FX Ulysses XB12XT HL 1125R JX Lightning Long KP Blast KX Lightning CityX SX Lightning...

Page 81: ...008 Models POSSIBLE VALUES DESCRIPTION POSITION 0 Blast Model 8 2 XB9SX 3 XB12R 4 XB12S 5 XB12Scg 6 XB12Ss 7 XB12X 8 XB12STT A XB12XT B 1125R D 1125R 105 HP France Varies Sequential number last five digits 9 2008 XB Service Chassis 2 5 ...

Page 82: ...or radial up and down play in wheel hubs Repair swingarm See 2 21 SWINGARM AND BRACE Alignment of rear wheel in frame or with front wheel Replace rims See 2 6 TIRES and 2 7 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 6 TIRES and 2 7 CHECKING CAST RIM RUNOUT Rims and tires out of round or eccentric with hub should not be m...

Page 83: ...injury 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 e...

Page 84: ...ore 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...

Page 85: ...1 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 ...

Page 86: ...ER 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 which are not intended to be d...

Page 87: ...3993 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 ...

Page 88: ...e 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 t...

Page 89: ... squarely 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 ...

Page 90: ...ws 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 insure 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 c...

Page 91: ...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 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 a...

Page 92: ...oper handling 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 6 BRAKE SYSTEM MAINTEN ANCE and 2 14 REAR BRAKE CALIPER DISASSEMBLY TOOL NAME PART NUMBE...

Page 93: ...5 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 2008 XB Service Chassis 2 17 ...

Page 94: ...993 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 4 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 ...

Page 95: ... Nm 9 Install lower belt guard See 2 39 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 XB12STT 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 th...

Page 96: ... 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 and handling which could result in death or serious injury Use onl...

Page 97: ... well on one side and insert tire tool underneath bead from opposite side Pry bead over rim edge Remove tire from rim 6 Remove valve stem if it is damaged or leaks sm00113 Figure 2 26 Loosening Beads from Rim Flange sm00114 Figure 2 27 Pry Bead Over Rim Edge CLEANING AND INSPECTION 1 Clean inside of tire with dry rag 2 If rim is dirty or corroded clean with a stiff wire brush 3 Inspect tire for we...

Page 98: ...re 2 28 Starting Bead on Rim Checking Tire Lateral Runout 1 See Figure 2 29 Turn wheel on axle and measure amount of displacement from a fixed point to tire sidewall 2 Refer to Table 2 14 Check tire tread for appropriate lateral 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 7 CHECKING CAST R...

Page 99: ...cial self adhesive backings Apply WHEEL WEIGHTS to the flat surface of the wheel rim Refer to Table 2 15 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...

Page 100: ... specification Refer to Table 2 16 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 16 Table 2 16 Wheel Rim Runout MM IN MAXIMUM RUNOUT 0 76 0 030 Lateral ...

Page 101: ...d 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 34 Remove the banjo bolt 14 metric and two copper washers 16 to disconnect brake line 15 from master cylinder 4 Discard copper washers 4 Unplug terminal 13 to detach brake lamp switch 12 N...

Page 102: ...lled 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 master cylinder housing for scoring pitting or corrosion Replace housing if any of these condi tions are found 3 Inspect outlet port that mates with brake line fitting As a critical sealing surface replace housing if any scratches dents or...

Page 103: ...ke 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 cylinder reservoir A plugged or covered relief port can cause brake drag or lock up which could lead to loss of control resulting in death or serious injury 00288a 8 Verify proper operation of the master cylinder relief port Actuate the brake ...

Page 104: ...nder Discard copper washers 6 See Figure 2 39 Remove caliper banjo bolt metric 2 two copper washers 3 and wire form 4 if equipped to disconnect brake line from caliper Discard copper washers 7 Carefully inspect the brake line for dents cuts chaffing or other defects Replace damaged brake lines 1 2 4 3 sm00532 1 Bleeder valve 2 Banjo bolt 3 Copper washers 4 Wire form Firebolt and Lightning models o...

Page 105: ... See Figure 2 40 Install and tighten p clamp 1 with fastener on lower triple clamp to 36 60 in lbs 4 7 Nm 7 See Figure 2 34 Tighten master cylinder banjo bolt 14 metric to 16 20 ft lbs 22 27 Nm 8 See Figure 2 39 Tighten brake caliper banjo bolt 2 metric to 16 20 ft lbs 22 27 Nm After repairing the brake system test brakes at low speed If brakes are not operating properly testing at high speeds can...

Page 106: ... B 42887 1 See Figure 2 42 Remove pin hanger set 1 brake pads and caliper pad spring 2 2 Split caliper by removing caliper fasteners 3 3 See Figure 2 44 Remove and discard o rings 8 4 See Figure 2 43 Remove pistons using a BRAKE CAL IPER PISTON REMOVER Part No B 42887 5 See Figure 2 44 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...

Page 107: ...3 Clamp caliper together with caliper fasteners 11 and tighten to 15 19 ft lbs 20 26 Nm INSTALLATION 1 See Figure 2 44 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 ...

Page 108: ...1 Caliper 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 44 Front Caliper Assembly 2 32 2008 XB Service Chassis ...

Page 109: ...e 2 45 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 45 Brake Pedal Asse...

Page 110: ...20a 4 See Figure 2 47 Remove brake reservoir hose 6 at master cylinder 5 Remove seat sm00488 Figure 2 46 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 47 Rear Master Cylinder Firebolt 6 See Figure 2 48 or Figure 2 49 Disconnect brake light connector loc...

Page 111: ...ote Reservoir Lightning REMOVAL ULYSSES 1 See Figure 2 52 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 si...

Page 112: ...crush 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 55 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 ...

Page 113: ...riorate 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 ve...

Page 114: ...rcycle 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 c...

Page 115: ...rcycle 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 2008 XB Service Chassis 2 39 ...

Page 116: ...r valve metric about 1 2 turn c Pump brake foot pedal to drain brake fluid d Tighten bleeder valve to 36 60 in lbs 4 7 Nm 7 See Figure 2 59 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 60 Remove brake light s...

Page 117: ...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 serious injury disconnect negative battery cable before proceeding 00048a 2 Disconnect battery by unthreading fastener removing negative cable black from battery first See 1 4 BATTERY MAINTENANCE 3 See Figure 2 61 Disco...

Page 118: ...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 REMOVAL ULYSSES 1 Remove seat To prevent accidental vehicle start up which could cause death or...

Page 119: ...ll negative battery cable and tighten to 72 96 in lbs 8 11 Nm See 1 4 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 9 Install seat Be sure that all lights and switches operate properly before operating motorcycle Low visibility of ride...

Page 120: ... banjo 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 65 Rear Brake Caliper DISASSEMBLY TOOL NAME PART NUMBER BRAKE CALILPER PISTON REMOVER B 42887 1 See Figu...

Page 121: ...ould 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 18 Rear Rotor Runout MM IN RUNOUT 0 45 0 0177 Rotor radial 0 39 0 0154 Rotor lateral ASSEMBLY 1 See Figure 2 66 Place clip 1 inside caliper body as shown NOTE To ensure proper brake pad to brake r...

Page 122: ... fluid 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...

Page 123: ...er 1 with fasteners and washers 2 and tighten to 36 48 in lbs 4 5 4 Nm REAR FENDER XB9SX XB12S XB12SCG Removal 1 See Figure 2 70 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 70 Align rear fender to the swingarm 2 Install rear fender with fasteners 6 and tighten to 12 36 in lbs 1 4 4 0 Nm NOTE It is necess...

Page 124: ...her 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 71 Align upper front fender 2 to fender mounts on lower triple clamp and install upper front fender fasteners and washers 1 and tighten to 1...

Page 125: ...Remove front fender See 2 15 FENDERS 2 Remove front wheel See 2 4 FRONT WHEEL 3 Remove caliper mounting fasteners See 2 10 FRONT BRAKE CALIPER 4 See Figure 2 100 Loosen upper and lower fork clamp pinch fasteners 1 4 5 See Figure 2 73 Remove fork from upper fork clamp and slide the stopper ring up and over the top of the fork 6 See Figure 2 100 Remove fork from lower fork clamp 3 7 Repeat steps 4 t...

Page 126: ...before disassembly 1 Remove front fork 2 1 3 4 1 sm00561 1 Fork holding tool 2 Snap ring 3 Preload adjuster 4 Front fork assembly Figure 2 74 Fork Holding Tool 2 See Figure 2 74 Clamp the FORK HOLDING TOOL Part No HD 41177 in a vise and install the upper part of the front fork in the holding tool 3 Remove snap ring 2 sm00562 Figure 2 75 Removing Preload Adjuster 2 50 2008 XB Service Chassis ...

Page 127: ...od Assembly 7 See Figure 2 78 Hold damper rod assembly 3 and remove fork cap 1 NOTE Be careful not to damage preload pins while holding damper rod assembly 8 Remove preload washer 4 and slider piston 5 9 See Figure 2 77 Expand fork and remove from FORK SPRING COMPRESSOR 10 See Figure 2 79 Over drain pan spring collar 15 remove spring 17 and drain fork oil 11 Drain remaining fork oil by pumping the...

Page 128: ...re 2 79 Disassembly of damper rod is not required unless damper locknut 10 has been moved If damper rod needs servicing refer to the Parts Catalog for kit information If damper locknut has been moved proceed with the fol lowing disassembly and assembly procedures for setting the correct range of motion 1 See Figure 2 79 Lightly turn the rebound adjuster screw on top of the rebound adjuster assembl...

Page 129: ...12 3 21 Centering plate Fork cap Slide bushing 22 13 4 Guide bushing Sealing washer Fork cap o ring 5 23 14 Preload washer Seal spacer Center bolt 15 6 24 Collar Slider piston Oil seal 25 16 7 Oil seal stopper ring Spring joint Inner slider piston o ring 8 26 17 Snap ring Dust seal Spring 18 9 27 Outer tube Rebound adjuster assembly Slider fork Figure 2 79 Front Fork Assembly 2008 XB Service Chass...

Page 130: ...orks to the exact same suspension settings 2 Adjust rebound assembly for proper range of motion a Lightly turn the rebound adjuster screw on top of the rebound adjuster assembly 9 counterclockwise till it stops b Turn the rebound adjuster screw three full turns clockwise 3 Fully thread rebound adjuster assembly 9 onto the damper rod assembly 11 until it lightly bottoms Do not tighten 4 Thread the ...

Page 131: ... or until resistance is felt 15 Place the damper rod in the fully bottomed position and compress fork completely 16 Pour 8 oz 236 5 cc more fork oil into the slider fork 17 See Figure 2 83 Adjust fork oil level with FRONT FORK OIL LEVEL GAUGE Part No B 59000A to the specified level below the top of the fork tube Refer to Table 2 20 Table 2 20 Fork Oil Levels MM IN MODEL 107 4 21 XB9R XB12R 107 4 2...

Page 132: ...isible and reflector facing to the side and tighten the lower fork clamp 5 Repeat previous steps on second front fork 6 Temporarily install front axle to the fork assemblies to verify correct alignment 7 Use LOCTITE 271 red on upper fork clamp fasteners and tighten to 23 25 ft lbs 31 2 33 8 Nm 8 Use LOCTITE 271 red on lower fork clamp fasteners and tighten to 20 22 ft lbs 27 2 20 Nm 9 Repeat torqu...

Page 133: ...20 FRONT FORK SLIDER PROTECTORS XB12STT 2 Remove front wheel See 2 4 FRONT WHEEL 3 Remove caliper mounting fasteners See 2 10 FRONT BRAKE CALIPER 4 See Figure 2 86 Loosen upper and lower fork clamp pinch fasteners 1 5 5 See Figure 2 85 Remove fork from upper fork clamp and slide the stopper ring up and over the top of the fork 6 See Figure 2 86 Remove fork from lower fork clamp 4 7 Repeat 4 throug...

Page 134: ... 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 89 Install the fork assembly in the FRONT FORK COMPRESSOR Part No HD 45966 sm03817 Figure 2 88 Fork Cap XB12STT XB12XT XB12X sm00564 Figure 2 ...

Page 135: ...emove 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 93 Push the damper rod 6 all the way down in order to seat it and prevent it from spinning in order to remove the center bolt 9 and washer 8 17 Remove dam...

Page 136: ...ar 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 93 Front Fork Assembly XB12STT XB12XT XB12X 2 60 2008 XB Service Chassis ...

Page 137: ...ure 2 95 For the XB12STT and XB12XT models use the FORK SEAL DRIVER AND DUST BOOT INSTALLER Part No B 42571 43mm For the XB12X use the FORK SEAL DRIVER AND DUST BOOT INSTALLER Part No B 48867 47mm Place the seal driver over the end of the slider fork 22 and the slide bushing channel to avoid damaging the oil seal lip when installing 3 Coat the sealing lips of the new oil seal 19 with fork oil or s...

Page 138: ...ring 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 92 Compress the fork spring until you have access to the damper rod assembly with jamnut 20 Remove the damper rod retrieval tool while holding onto the damp...

Page 139: ...rarily 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 2 20 Nm 8 Repeat torque sequence in previous two steps 9 Install front brake caliper onto caliper mount See 2 10 FRONT BRAKE CALIPER 10 Install front wheel...

Page 140: ...KEY SWITCH 8 See Figure 2 100 Hold or brace the lower fork clamp and remove steering stem capnut 1 9 Remove the upper fork clamp 4 10 Remove the stem 6 and lower fork clamp 8 as an assembly 11 Remove ignition switch See 7 3 IGNITION HEADLAMP KEY SWITCH 12 If steering head bearings need replacing see 2 19 STEERING HEAD BEARINGS 1 3 2 3 4 5 6 7 8 7 sm00573 1 Stem capnut 2 Stem pinch fastener 3 Upper...

Page 141: ...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 scissor jack under jacking point and raise front wheel off ground For location of jacking point see 4 16 ...

Page 142: ...ead to loss of control which could result in death or serious injury 00124b NOTE For additional information see 2 16 FRONT FORK ALL MODELS EXCEPT XB12STT XB12X XB12XT 9 See Figure 2 84 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 tighten to 23 25 ft lbs 31 34 Nm 11 Use LOCTI...

Page 143: ...s 5 a See Figure 2 102 Locate notches inside steering head stem bore upper bearing removed for clarity b Place a suitable tool in the notches of the steering stem bore and remove upper and lower steering head bearings NOTE Discard steering head bearings and replace with new Steering head bearings are not reusable sm00575 Figure 2 102 Lower Steering Head Bearing Notches Upper Bearing Removed For Cl...

Page 144: ...Insert the forcing screw from the steering head bearing race installer through the steering head bearing installation tool NOTE For ease of steering head bearing installation lubricate the outside of the steering head bearings sm00577 Figure 2 104 Steering Head Bearing Lip 1 3 2 5 4 6 sm00578 1 Forcing screw 2 Steering Head Bearing Installation Tool 3 Lower bearing 4 Bearing 5 Washer 6 Nut Figure ...

Page 145: ...t wheel and lower fork clamp steering stem as an assembly 10 Install upper fork clamp 11 Tighten steering stem capnut to 38 42 ft lbs 52 57 Nm 12 Install steering stem pinch bolt applying LOCTITE 271 red and tightening to 20 22 ft lbs 27 1 29 8 Nm 13 Apply LOCTITE 271 red to upper triple clamp fasteners and tighten to 23 25 ft lbs 31 2 33 8 Nm 14 On Lightning and Ulysses models install front modul...

Page 146: ...from left and right front fork slider protectors 1 and remove protectors 2 Install left and right fork slider protectors applying LOCTITE 271 red to fasteners and tighten to 12 36 in lbs 1 3 4 Nm 2 1 2 sm03835 1 Slider cover 2 Fastener Figure 2 107 Front Fork Slider Cover 2 70 2008 XB Service Chassis ...

Page 147: ...m 4 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 36 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 37 HEEL GUARD AND FOOTPEG MOUNTS ULYSSES MODELS 2 1 sm00302 1 Axle 2 Pinch bolt Figure 2 108 Rear...

Page 148: ...11 OIL LINE FITTINGS NOTE See Figure 2 109 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 2 109 Remove swingarm bearings 5 using SLIDE HAMMER Part No SNAP ON CJ1275 or equi valent and 3 4 in bearing remover and spacer 3 Remove shock mount bushings 3 and...

Page 149: ...TTINGS 4 See Figure 2 109 Install drain plug 8 Tighten to 26 29 ft lbs 35 39 Nm sm00585 Figure 2 110 Jiffy Tite Quick Disconnect Oil Line Fittings INSTALLATION SWINGARM 1 See Figure 2 109 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 46 ft lbs 59 62 Nm 3 Apply LOCTITE 271 red to pivot sh...

Page 150: ... 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 4 BATTERY MAINTENANCE After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift c...

Page 151: ...nstall upper snubber 1 tightening snubber fastener 2 to 12 36 in lbs 1 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...

Page 152: ...vaporate NOTE Do not sand or scuff the surface where the puck will be installed 2 See Figure 2 113 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 2 114 With a pencil outline the upper rear and lower r...

Page 153: ...tor fastener See 3 3 ENGINE ROTA TION FOR SERVICE 10 See Figure 2 116 Lift and remove frame from the motor cycle INSTALLATION 1 Place frame over the motorcycle 2 Install rear isolator fastener See 3 5 ENGINE INSTALLA TION 3 Install main wire harness See 7 23 MAIN WIRE HAR NESS 4 Install upper and lower fork clamps See 2 18 FORK CLAMPS UPPER AND LOWER 5 Install rear shock See 2 25 REAR SHOCK ABSORB...

Page 154: ...7 sm00588 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 2 117 Rear Shock Absorber Assembly Firebolt 2 78 2008 XB Servic...

Page 155: ...te reservoir 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 2 118 Rear Shock Absorber Assembly Lightning 2008 XB Service Chassis 2 79 ...

Page 156: ...astener 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 2 119 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 spark...

Page 157: ... the 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 reser voir clamp fastener 1 remove rear shock assembly and reservoir For XB9SX XB12S and XB12Scg The remote reser voir can be slid out of the clamp and the clamp left attached ...

Page 158: ...ct routing a Loosely install reservoir in clamp b See Figure 2 122 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 2 117 Verify compression adjuster screw is facing up 5 Install upper body work See 2 41 SUBFRAME TAIL ASSEMBL...

Page 159: ...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 36 60 in lbs 4 0 6 7 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 3 ELECTRONIC CONTROL MODULE ECM 7 Install cable strap securing preload adjuster hose to main harnes...

Page 160: ...inimum length 4 Remove fasteners 1 on right switch housing and separate housing from handlebar 5 See Figure 2 127 Remove cables 2 3 from notches in front housing 4 6 Remove cables 2 3 and ferrules 6 from cable wheel 7 smg03403 Figure 2 125 Throttle Cables Alignment Clip 1 2 5 4 3 sm00596 1 Right switch housing fasteners top fastener above brake lever 2 Cable adjuster lock 3 Adjusters 4 Throttle co...

Page 161: ... access the throttle cable jam nuts and the plug wires should be left in place without disturbing their connections if possible 3 Remove the old throttle cables Installation 1 Replace the new throttle cables by connecting them to the right hand grip first NOTE This is to ensure the cables can be routed correctly with no binding and maintain proper orientation 2 Route both cables along the handle b...

Page 162: ...ions and work the throttle to ensure there is no binding This is critical to the operation of the throttle control 9 Install the ignition coil and apply Loctite 272 red to the ignition coil fasteners and tighten to 120 144 in lbs 13 6 16 3 Nm NOTE Ensure that the spark plug wires were not disturbed and are tight on the coil and spark plug ends 10 Tighten the bolted joints that attach the front wir...

Page 163: ...ase 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 Adjuster sm04195 Figure 2 132 Front Tie Bar 7 1 3...

Page 164: ...scard 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 2 88 2008 XB Service Chassis ...

Page 165: ... 8 was removed for any reason apply LOCTITE 271 to fasteners and tighten to 36 60 in lbs 4 6 8 Nm Adjust to rider comfort 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 Flange head bolt 6 Chain adjuster screw 7 Locknut 8 Shift linkage assembly Figure 2 137 ...

Page 166: ... chin fairing See 2 53 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 00070b 20 Install seat 2 90 2008 XB Service Chassis ...

Page 167: ...pport 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 hea...

Page 168: ...upport bracket up 2 and tighten pivot fasteners 1 to 72 96 in lbs 8 11 Nm 7 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 49 FRONT FAIRING WI...

Page 169: ...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 openi...

Page 170: ...Horn 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 2 94 2008 XB Service Chassis ...

Page 171: ...ss 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 th...

Page 172: ...ten 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 6 7 Nm 7 Connect horn connectors 122 2 8 Adjust headlights See 1 16 HEADLIGHT 9 Install windshield and windscreen See 2 50 WINDSHIELD AND WINDSCREEN LIGHTNING AND ULYSSES Connect positive battery cable first If positive cable should contact grou...

Page 173: ...asteners 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 3 4 Nm See 7 22 INSTRUMENT MODULE 4 Install horn and tighten fasteners to 72 96 in lbs 8 10 Nm See 7 10 HORN 5 Install fuse block relay and p clamp tightening fasteners to 72 96 in lbs 8 11 Nm See 7 18 MAIN FUSE AND FUSES 6 Inst...

Page 174: ...port 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 2 98 2008 XB Service Chassis ...

Page 175: ...ot shafts 3 6 See 2 27 CLUTCH CONTROL and 2 8 FRONT BRAKE MASTER CYLINDER AND HAND LEVER 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...

Page 176: ...s to 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 2 100 2008 XB Service Chassis ...

Page 177: ...MP 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 7 12 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 ...

Page 178: ...le Tighten fasteners to 36 60 in lbs 4 1 6 8 Nm 8 Connect speedometer 9 On Ulysses model connect auxiliary outlet 10 Install headlamp assembly and support bracket See 2 28 HEADLAMP ASSEMBLY AND SUPPORT BRACKET 11 Install windshield and windscreen See 2 50 WINDSHIELD AND WINDSCREEN LIGHTNING AND ULYSSES Connect positive battery cable first If positive cable should contact ground with negative cable...

Page 179: ...emoved 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 26 THROTTLE CONTROL 5 Install end cap onto right clip on 6 Position brake hand...

Page 180: ...r screws in place after applying LOCTITE 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 27 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 181: ...p fasteners 4 Handlebar clamp 5 Left hand grip XB12X models are OEM equipped with heated handgrips 6 Handlebar XB12X XB12XT 7 Handlebar XB9SX XB12STT 8 Handlebar XB12S XB12Scg XB12Ss Figure 2 153 Handlebar Assembly Lightning Ulysses 2008 XB Service Chassis 2 105 ...

Page 182: ... than 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 Mirr...

Page 183: ... the non California vent clamp 2 Install heel guard 3 with fasteners 4 Tighten to 72 96 in lbs 8 11 Nm Footpeg Installation 1 See Figure 2 155 Position spring 6 in footpeg 8 2 Position footpeg 8 and spring in footpeg mount 1 3 Install footpeg pin 9 4 Install clip 5 Wear Peg Installation 1 See Figure 2 155 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 ...

Page 184: ...to 48 72 in lbs 5 8 Nm Footpeg Installation 1 See Figure 2 156 Position footpeg 8 detent plate 6 ball 5 and spring 4 on to footpeg mount 3 2 Install footpeg pin 9 3 Install clip 7 4 Check that 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 ...

Page 185: ... clicks 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 footpe...

Page 186: ...r Brake 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 2 110 2...

Page 187: ...stener 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 Nm 2 Install chin fairing See 2 53 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 2008 XB Service Cha...

Page 188: ...Figure 2 163 Install upper belt guard 1 to swingarm brace tightening fasteners 2 to 12 36 in lbs 1 4 Nm 2 Install stone guard 6 and tighten fasteners to 12 36 in lbs 1 4 Nm 3 Install lower belt guard 3 and tighten fasteners 4 to 12 36 in lbs 1 4 Nm 4 Tighten rear axle See 6 6 DRIVE BELT AND IDLER PULLEY 5 Tighten rear axle pinch fastener to 40 45 ft lbs 54 61 Nm 6 Install right side rider footrest...

Page 189: ...nylon washers 4 4 Remove intake cover assembly 2 INSTALLATION 1 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 190: ... fasteners 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 2 114 2008 XB Service Chassis ...

Page 191: ...049a 2 Disconnect battery by unthreading fastener removing negative cable black from battery first See 1 4 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 ...

Page 192: ...ork 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 2 116 2008 XB Service Chassis ...

Page 193: ... subframe 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 holdi...

Page 194: ...bly 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 1 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 195: ...erious injury 00068a 22 Connect battery cables to battery positive cable red first Tighten to 72 96 in lbs 8 11 Nm See 1 4 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 2008 XB Service Chassis 2 119 ...

Page 196: ...169 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 36 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 sectio...

Page 197: ...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 Seat Lightning CLEANING NOTE Do not use wheel care products or other compounds developed specifically for cleaning and polishing powdercoat These cleaners could potentially damage the tail section fin...

Page 198: ...ee 2 36 FOOTPEG HEEL GUARD AND MOUNT FIREBOLT LIGHTNING 8 Move rear main harness and shock absorber reservoir back to left side of vehicle Be sure that all lights and switches operate properly before operating motorcycle Low visibility of rider can result in death or serious injury 00316a 9 See Figure 2 169 Connect a Wire harness ground 2 GRD 2 b Rear brake light switch connector 5 121 c ECM conne...

Page 199: ...round 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 Assem...

Page 200: ...r 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 1 Nm Be sure that all lights and switches operate properly befor...

Page 201: ...s models apply LOCTITE 271 red and install battery tray fasteners and tighten to 48 72 in lbs 5 4 8 1 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 ft lbs 28 5 31 2 Nm 2 Insta...

Page 202: ...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 203: ...me 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 3 4 Nm 5 Install two fasteners securing the preload adjuster to the trunk pan and tighten to 36 60 in lbs 4 6 7 Nm 6 Install battery pan a Install fasteners securing battery tray to left and right tail sections and tighten to 72 96...

Page 204: ...her and nut to main frame fuel tank assembly 4 2 Right tail section 3 Left tail section 4 Battery pan 5 Front 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...

Page 205: ...NK 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 22 ...

Page 206: ...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 2 130 2008 XB Service Chassis ...

Page 207: ...aptured 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 ...

Page 208: ...r 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 0 6 8 Nm Connect positive battery cable first If positive cable should contact ground wi...

Page 209: ...TE 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 53 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 an...

Page 210: ...nsion 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 sides...

Page 211: ...ng 5 onto fairing support bracket and install turn signals 6 7 See 7 12 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 winds...

Page 212: ...r windscreen fasteners and washers 3 2 Remove windscreen 4 INSTALLATION LIGHTNING 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 Light...

Page 213: ...SES XB12X 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...

Page 214: ...g pins 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 Mouning grommet 2 Washer 2 6 13 Well nut 2 Windscreen sc...

Page 215: ...h the mounting 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 Figure 2 185Install mounting screws and tighten 8 10 revolutions into the well nuts pd00272 Figure 2 185 Turn Down 8 10 Turns 2008 XB Service Chassis 2 139 ...

Page 216: ...be removed when removing the left side number plate See Figure 2 186 When removing and installing the number plate screws 2 from the left and right tail sections place a shop rag over the swingarm to prevent cosmetic damage 2 Remove the screws 2 and sleeves 3 attaching the number plates 1 to the left and right tail sections and remove number plates 4 5 3 1 3 2 2 sm03839 1 Number plate 2 Screw 3 Sl...

Page 217: ...rews 2 and sleeves 3 and leave loose 2 Install screw 4 attaching the number plate 1 to the reflector bracket 5 and leave loose 3 Tighten the number plate screws 2 to 18 20 ft lbs 24 27 Nm 4 Tighten the number plate to reflector bracket screw 4 to 12 36 in lbs 1 4 4 Nm 2008 XB Service Chassis 2 141 ...

Page 218: ...36 in lbs 1 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 2 188 On right side of bike 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 2 188 Position engine shroud air scoop 6 ...

Page 219: ...ler 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 2 188 Ram Air Scoop Engine Shroud and Oil Cooler 2008 XB Service Chassis 2 143 ...

Page 220: ...EAD SETTER TOOL KIT Part No MAR39200HD 1 Apply LOCTITE 271 red on all fasteners 2 See Figure 2 189 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 ...

Page 221: ...Center Tab and Frame Slot Firebolt Pillion NOTE The trunk is located under the pillion 1 See Figure 2 192 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 tab ...

Page 222: ...n seat hooks 1 with mounting posts 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 2 199 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 ...

Page 223: ...ycle to remove om00576 Figure 2 200 Seat Lock Ulysses Models om00574 Figure 2 201 Seat Removal Ulysses Models Installation 1 See Figure 2 202 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 shi...

Page 224: ...1 2 1 1 1 3 pd00249 1 Seat hook 2 Seat lock latch 3 Front tab Figure 2 202 Seat Tab Hooks Ulysses Models 2 148 2008 XB Service Chassis ...

Page 225: ...through 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 lo...

Page 226: ... 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 Remove cable 5 from plate 2 INSTALLATION ULYSSES MODELS 1 See Figure 2 204 Install cable 5 into plate 2 2 Install the seat lock 1 into license p...

Page 227: ...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 sm03841 1 Seat lock 2 Plate 3 Retainer 4 Cable end 5 Cable 6 Cable end 7 Latch screw metric 2 8 Latch 9 Latch bracket 10 Trunk pan 11 Center tail lo...

Page 228: ...igning 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 w...

Page 229: ...move 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 fron...

Page 230: ...ghten 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 96 120 in lbs 11 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 0 Nm 4 5 4 6 8 9 2 1...

Page 231: ...ailsection 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 bellville washer rear mount side case bracket 2...

Page 232: ...cle 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 passenger footrest support bracket snug only 5 Tighten the three fasteners securing the passenger peg support bracket to the main fra...

Page 233: ...t this time 3 Tighten the two fasteners 6 attaching the top case mounting bracket 2 to the grab handles 5 to 19 20 ft lbs 26 27 Nm 4 Tighten all remaining fasteners to 96 120 in lbs 11 13 Nm LUGGAGE CASE LATCH MECHANISM Removal 1 Open desired case in order to access the latch mechanism for replacement 2 1 sm05219 1 Screw 2 2 Latch mechanism Figure 2 211 Side Case and Latch Mechanism 2 3 1 sm05230 ...

Page 234: ...large hex nut 2 Slide latch mechanism into luggage case 3 See Figure 2 211 or Figure 2 212 Install two new Phillips head screws into latch mechanism and tighten NOTE See Figure 2 212 On the top case it will be necessary to press lid gasket 1 back into place 2 158 2008 XB Service Chassis ...

Page 235: ... CYLINDER HEAD 3 34 3 7 CYLINDER AND PISTON 3 49 3 8 OILING SYSTEM 3 58 3 9 OIL PUMP 3 59 3 10 OIL RESERVOIR AND OIL HOSE ROUTING 3 65 3 11 OIL LINE FITTINGS 3 67 3 12 OIL COOLER 3 69 3 13 OIL PRESSURE INDICATOR SWITCH 3 70 3 14 CRANKCASE BREATHING SYSTEM 3 72 3 15 HYDRAULIC LIFTERS 3 74 3 16 GEARCASE AND CAM GEARS 3 76 3 17 CRANKCASE 3 80 ENGINE ...

Page 236: ...NOTES ...

Page 237: ...rk 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 0762 mm 0 001 0 003 in Fit in guide inta...

Page 238: ... 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 Specifications SERVICE WEAR LIMITS NEW COMPONENTS CYLINDER HEAD 0 0838 0 0508 mm 0 0033 0 0020 in Valve guide in head tight 0 0889 0 0254 mm 0 0035 0 0010 in Valve seat in head tight 0 152 mm total 0 006 in total 0 152 mm total 0 006 in total Head g...

Page 239: ...in 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 Flywheel Specifications SERVICE WEAR LIMITS NEW COMPONENTS FLYWHEEL 0 254 mm 0 010 in 0 000 0 254 mm 0 000 0 010 in Runout flywheels at rim 0 051 mm 0 002 in 0 000 0 051 mm 0 000 0 002 in Runout shaft at flywheel end Table 3 14 Sprocket Shaft Bearing Specifications SERVICE WEAR LIMITS NEW COMPONE...

Page 240: ...ring Specifications SERVICE WEAR LIMITS NEW COMPONENTS PINION SHAFT BEARINGS 0 003 0 022 mm 0 00012 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 3 4 2008 XB Service Engine ...

Page 241: ...ttle 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 strokes 4 Note gauge readings at the e...

Page 242: ...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 and or the Cylinder Leakage Test See 3 2 ENGINE Compression Test and 3 2 ENGINE Cylinder Leakage Test If further testing is needed remove the suspect cylinder heads and inspect the following V...

Page 243: ...k on 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 40 INTAKE COVER 4 Remove air filter base plate See 4 2 AIR CLEANER ASSEMBLY NOTE When removing the left air scoop ...

Page 244: ...yl inder head 13 Disconnect the following sensors a Temperature sensor 10 90 b Oxygen sensor 11 137 14 Remove idler pulley See 6 6 DRIVE BELT AND IDLER PULLEY NOTE See 7 14 INTERACTIVE EXHAUST SYSTEM for specific details on removal of interactive components 15 Remove muffler See 4 16 EXHAUST SYSTEM NOTE Secure right side rider footrest mount to the side to prevent cosmetic damage 16 Remove left an...

Page 245: ...or 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 2 Engine Mounting System 18 S...

Page 246: ...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 2 Install center tie bar 13 to engine and tigh...

Page 247: ...ition sensor connection 88 9 3 IAT sensor 89 Coil wire harness retaining clip 4 10 Throttle cables Engine temperature sensor connection 90 11 5 Oxygen sensor conection 137 Fuel injector connections 84 85 6 IAC sensor connection 87 Figure 3 5 Fuel Line Connections and Throttle Cables NOTE Remove shop towel from entrance of throttle body to ensure proper operation of induction module 16 Connect fuel...

Page 248: ...nsure that the voltage regulator and alternator wiring harnesses are not trapped between the air scoop and cylinder head 23 Install air scoops right and left sides See 2 52 AIR SCOOPS NOTE The connection for fuel pump is just above the pump located at the rear of the fuel tank on the left side of the vehicle 24 Connect fuel pump See 4 13 FUEL PUMP 25 Install intake cover See 2 40 INTAKE COVER 26 C...

Page 249: ...able before proceeding 00048a 3 Remove seat and disconnect battery negative cable black first 4 Remove intake cover and air cleaner assembly See 2 52 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 53 CHIN FAIRING 6 Remove ...

Page 250: ... 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 6 6 DRIVE BELT AND IDLER PULLEY 16 Remove transmission sprocket See 6 16TRANSMISSION SPROCKET NOTE For details on the interactive exhaust system see 7 14 IN...

Page 251: ... 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 25 Remove cable strap securing the positive cable from starter and the main harness to the tran...

Page 252: ...line 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 11 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 11 OIL LINE FITTINGS c Disc...

Page 253: ... to 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 9 Oil Lines and Connections 2008 XB Service Engine 3 17 ...

Page 254: ...ar 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 ...

Page 255: ...kets 32 See Figure 3 12 Remove two fasteners 2 and remove sidestand assembly 33 Support engine with wide scissors jack 1 2 sm03933 1 Sidestand asembly 2 Bracket fasteners 2 Figure 3 12 Sidestand Assembly Extended NOTE See Figure 3 13 At this point it is necessary to support main frame with overhead hoist in order to remove rear isolator bolt Failure to do this will result in main frame dropping sl...

Page 256: ...ched 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 15 Transmission Vent Line Firebolt sm00737 Figure 3 16 Transmissio...

Page 257: ...t c See Figure 3 19 Swingarm pivot shaft pinch bolt threaded insert d See Figure 3 20 Aluminum bushings from front exhaust mount e See Figure 3 21 Wire guard located under the sprocket cover sm00740 Figure 3 19 Threaded Insert 1 2 sm03745 1 Left side 2 Right side Figure 3 20 Front Exhaust Mount Bushings 2 piece sm02996 Figure 3 21 Wire Guard sm02979 Figure 3 22 Rear Isolator Assembly 2008 XB Servi...

Page 258: ... frame 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 24 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 23 S...

Page 259: ...owing items on the engine assembly as required a Shifter assembly See 6 2 PRIMARY COVER b See Figure 3 26 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 27 Apply LOCTITE 242 blue to swingarm pivot shaft pinc...

Page 260: ...ten 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 31 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...

Page 261: ...sion Vent Line Ulysses 6 See Figure 3 34 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 34 Rear Isolator Bolt 2008 XB Service Engine 3 25 ...

Page 262: ...sembly 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 35 Engine Mounting System 7 Rotate engine down and install exhaust header on...

Page 263: ...n 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 reinstalling 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 retaining clamp to engine and tighten to 25 27 ft lbs 33 9 36 6 Nm...

Page 264: ...ounting System 18 See Figure 3 37 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 38 The feed oil line is routed through the right side o...

Page 265: ... Figure 3 38 Oil Lines and Connections 20 Install the feed oil line 6 starting at the engine working towards the rear of the vehicle See 6 2 PRIMARY COVER 21 Install p clamps 8 on feed oil line 6 at crankcase and swingarm oil reservoir and tighten fastener to 48 72 in lbs 5 4 8 Nm 22 Install the return oil line 7 in the same manner as the feed 23 Install p clamp 8 on return oil line 7 at the swing...

Page 266: ... 5 Positive battery cable at starter Interactive exhaust cable 6 3 Oil pressure switch 120 Starter solenoid 128 Figure 3 39 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 harnesses are secured to the air scoop with 3 cable straps 27 Connect the alternator 46 and volt...

Page 267: ... Install rear belt and idler pulley See 6 6 DRIVE BELT AND IDLER PULLEY 33 Install left and right side rider footrests and support plates See 2 36 FOOTPEG HEEL GUARD AND MOUNT FIREBOLT LIGHTNING or 2 37 HEEL GUARD AND FOOTPEG MOUNTS ULYSSES MODELS 34 Install sprocket cover See 2 38 SPROCKET COVER 35 See Figure 3 42 Connect throttle cables 4 to induction module throttle body See 1 14 THROTTLE CABLE...

Page 268: ...operly before installing air box cover See 1 15 INTERACTIVE EXHAUST CABLE 42 Install air cleaner cover assembly See 4 2 AIR CLEANER ASSEMBLY 43 Install intake cover assembly Tighten fasteners to 12 36 in lbs 1 4 Nm See 2 40 INTAKE COVER 44 Install oil filter and fill oil tank See 1 5 ENGINE OIL AND FILTER NOTE The connection for fuel pump is just above the pump located at the rear of the fuel tank...

Page 269: ...6 in lbs 8 11 Nm See 1 4 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 49 Install seat 2008 XB Service Engine 3 33 ...

Page 270: ...r 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 45 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 ...

Page 271: ...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 45 Rocker Arm and Pushrod Cover Assemblies Cylinder Head Assemblies NOTE See Figure 3 46 Distortion to the head cylinder and crankcase studs may result if head screws are not loosened or tightened gradually in the sequence shown 1 Loosen each head screw 1 8...

Page 272: ...eir original locations 4 Use a fine tooth file to remove any burrs on the valve stem at the keeper groove 5 Mark valve to ensure that it will be reassembled in the same head Remove valve 15 valve stem seal and lower collar assembly by hand No special tools are required to remove valve stem seal and lower collar assembly 6 Repeat the above procedure for the other valves 3 5 1 2 4 3 1 2 4 6 sm00133 ...

Page 273: ...sm00134 Figure 3 47 Valve Spring Compressor 2008 XB Service Engine 3 37 ...

Page 274: ...15 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 48 Cylinder Head Cylinder and Piston Assembly 3 38 2008 XB Service Engine ...

Page 275: ...use 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 49 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 49 Checking Gasket Surface Rocker Arm Assemblies 1 Check each rocker arm at pad end and push rod end for unev...

Page 276: ...ished 1 Inspect seats for cracking chipping or burning Replace seats if any evidence of these conditions are found 2 See Figure 3 54 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 ope...

Page 277: ...g a 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 56 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 oppos...

Page 278: ...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 279: ...LVE 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 the pilot being careful not to drop the cutter onto ...

Page 280: ... 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 48 Insert valve into valve guide and bottom valve on valve seat 6 See Figure 3 61 Place a protective sleeve over the valve stem keeper groove NOTE Failure to use a protective sleeve on the valve ...

Page 281: ...steners 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 locations 2 Refer to Table 3 19 Identify push rod color coding length and respective push rod positions in engine Dip both ends of push rods in clean engine oil Place intake and exhaust push rods onto seat at top of ...

Page 282: ...all screws 7 After screws are loosened from initial torque tighten head screws in three stages Tighten fasteners in increasing numerical sequence i e 1 2 3 and 4 a Tighten screws to 96 120 in lbs 11 14 Nm b Tighten screws to 13 15 ft lbs 18 20 Nm c See Figure 3 62 Using a grease pencil mark a straight line on the cylinder head bolt continuing the line over onto the cylinder head d Using the marks ...

Page 283: ... screws to 120 168 in lbs 13 6 18 9 Nm 3 5 1 2 4 3 1 2 4 6 sm00133 1 Tighten loosen first 2 Tighten loosen second 3 Tighten loosen third 4 Tighten loosen fourth 5 Front cylinder 6 Rear cylinder Figure 3 67 Head Screw Loosening Tightening Sequence sm00154 Figure 3 68 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 69 Lower Ro...

Page 284: ...afts 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 70 Rocker Arm and Pushrod Cover Assemblies 3 48 2008 XB Service Engine ...

Page 285: ... 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 compressed in the ring groove and can fly ...

Page 286: ... 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 73 Piston Pin and Piston Identification NOTE See Figure 3 73 The arrows on the pistons must always point toward the front of the engine sm00158 Figure 3 74 Removing Piston Rings 9 See Figure 3 74 Using a piston ring expander to remove pis...

Page 287: ...et surface 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 gask...

Page 288: ... 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 NOTE After wiping the cylinder with a clean oiled paper towel the towel will be dark with contamination Repeat this process using...

Page 289: ...till 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 install either side up 2 Second compression ring install dot toward top 3 Oil control rings 4 Dot Figure 3 77 Piston Rings sm0016...

Page 290: ...de 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 85 Place new bushing between connecting rod and driver NOTE The driver must be attached facing the opposite direction as it was for removal of the bushing 7 Clean up...

Page 291: ...alled and then removed for any reason A loosely installed ring will come out of the piston groove and damage cylinder and piston beyond repair 4 See Figure 3 88 Install new piston pin retaining rings 1 using PISTON PIN RETAINING RING INSTALLER Part No HD 34623C Place new retaining ring on tool with gap pointing up NOTE Make sure the ring groove is clean Ring must be fully seated in the groove with...

Page 292: ...tion 2 1 sm00156 1 Piston pin retaining ring 2 Piston pin retaining ring installer Figure 3 88 Installing Piston Pin Circlip 4 2 1 3 4 sm00163 1 Front 2 Rear 3 Piston pin 4 Position ring end gaps at arrows minimum of 90 degrees apart Figure 3 89 Ring End Gap Position 3 56 2008 XB Service Engine ...

Page 293: ...1 sm00171 1 Piston ring compressor Figure 3 90 Compressing Piston Rings 2008 XB Service Engine 3 57 ...

Page 294: ...roperly 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 che...

Page 295: ...il 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 pin...

Page 296: ... line fittings Oil pump cover screws 7 7 O rings oil line fittings Figure 3 91 Oil Pump REMOVAL DISASSEMBLY NOTE Before vehicle is placed on the lift it will necessary to remove the chin fairing See 2 53 CHIN FAIRING 1 Remove seat See 2 54 SEAT To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 2 Disconnect ne...

Page 297: ...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 91 Carefully remove mountin...

Page 298: ...orking 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 2 See Figure 3 93 Inspect both gerotor sets for wear a Mesh pieces of each set together as shown b Use a feeler gauge to determine clearance c The SERVICE WEAR LIMIT between gerotors is 0 004 in 0 102 m...

Page 299: ... 3 15 HYDRAULIC LIFTERS Installation 10 Install rocker box assemblies See 3 6 CYLINDER HEAD Cylinder Head Installation NOTE Before attaching oil lines see 3 11 OIL LINE FITTINGS Installation 11 See Figure 3 92 Attach feed line connections on the bottom and right side of the oil pump body 12 Attach return line connections on the bottom and right side of the oil pump body 13 Attach the vent line con...

Page 300: ...8 6 2 4 10 3 5 1 11 9 7 sm03727 Figure 3 95 Oil Pump Body and Cover Mounting Screw Torque Sequence 3 64 2008 XB Service Engine ...

Page 301: ...run 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 crankcase...

Page 302: ... to 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 96 Oil Lines and Connections 3 66 2008 XB Service Engine ...

Page 303: ...he 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 97 Oil Line Remover sm00206 Figure 3 98 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 99 Push the correct flanged ...

Page 304: ...sm00207 Figure 3 99 Flanged Oil Line 3 68 2008 XB Service Engine ...

Page 305: ...l 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 cool...

Page 306: ...ump next to the oil filter mount unscrew and remove oil pressure switch from crankcase 2 See Figure 3 102 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 3 101 Oil Pressure Indicator Switch Table 3 22 Troubleshooting Oil Pressure Signal Light PROBABLE CAUSES OIL PRESSURE ...

Page 307: ...ITE 565 HIGH PERFORMANCE PIPE SEALANT with TEFLON Reinstall oil pressure switch and tighten switch snugly 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 ...

Page 308: ... in the cylinder head sm00209 Figure 3 103 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 3 104 Crankcase Breathing System REED VALVE REPLACEMENT NOTES Whenever the gearcase cover is removed inspect the reed valve for cracks chips and breakage See Figure 3 105 The reed valve 3 open...

Page 309: ...essary to replace the reed block apply LOCTITE 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 3 105 Reed Valve Assembly 1 2 1 2 3 3 sm00210 3 2 1 Stop screw Reed valve Reed valve stop Figure 3 106 Reed Valve Stop and Reed Valve 2008 XB Service Engine 3 73 ...

Page 310: ...ver 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 6 CYLINDER HEAD 3 See Figure 3 109 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 Remo...

Page 311: ...hers 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 c...

Page 312: ...itted 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 3 110 Oil Pump Body and Cam Assembly 3 76 2008 XB Service ...

Page 313: ...ate 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 3 111 Remove cam gears 1 2 3 and 4 NOTE Nut is secured by LOCTITE 271 red on the nut threads 9 See Figure 3 110 Remove pinion nut 9 Slide pinion gear 8 and pinion gear spacer 7 off pinion shaft NOTE See Figure 3 111 The timing marks are located on the front...

Page 314: ...ALLATION TOOL NAME PART NUMBER CRANKSHAFT LOCKING TOOL HD 43984 1 See Figure 3 113 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 Fi...

Page 315: ...m 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 n...

Page 316: ... rubber hose over cylinder studs Lifting or moving crankcase by grasping studs will cause cylinder stud damage 2 Remove cylinders and pistons See 3 7 CYLINDER AND PISTON 3 Remove oil pump See 3 9 OIL PUMP 4 Remove gearcase components See 3 16 GEARCASE AND CAM GEARS 5 Remove primary cover and primary drive clutch compon ents See 6 2 PRIMARY COVER 6 Remove starter motor See 5 2 STARTER 7 See Figure ...

Page 317: ...mount 1 See Figure 3 118 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 ...

Page 318: ...y LOCTITE 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 T...

Page 319: ...ning 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 3 121 Crankcase and Flywheel Assembly 2008 XB Service Engine 3 83 ...

Page 320: ... sprocket shaft oil seal retaining ring 5 See Figure 3 121 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 3 124 Removing Sprocket Shaft Bearing Retaining Ring 7 See Figure 3 124 Remove sprocket shaft bearing retaining ring from the inside of the left crankcase half sm00184 F...

Page 321: ...96 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 c...

Page 322: ... Table 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...

Page 323: ...s MM 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 3 130 and Figure 3 129 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 sl...

Page 324: ...Apply 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 3 132 Removing Pinion Bearing Inner Race NOTES For necessary dimensions for constructing a press on tool for the pinion bearing inner race see Figure 3 131 The new inner race must be ground by a competent machinist to OD dimension range for the finished lapped ID of ...

Page 325: ...igure 3 134 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 bu...

Page 326: ...5A Crankcase Halves NOTE Lubricate all parts with Harley Davidson 20W50 engine oil and proceed as follows 1 See Figure 3 137 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 ...

Page 327: ... Bearing Assembly 4 See Figure 3 138 Attach left crankcase half to engine stand 5 Install flywheel assembly using CRANKSHAFT GUIDE Part No HD 42326 B 6 See Figure 3 139 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 2008 XB Service Engine 3 91 ...

Page 328: ...bearing remover installer tool 3 Retaining ring Figure 3 137 Sprocket Shaft Bearing Installation sm03929 Figure 3 138 Installing Flywheel Assembly with CRANKSHAFT GUIDE sm00195 Figure 3 139 Pinion Shaft Bearing 3 92 2008 XB Service Engine ...

Page 329: ...steners See Figure 3 141 For model year 2008 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 4...

Page 330: ... Place the end of the stud without the shoulder into the head screw d Install the stud in the crankcase with the shoulder end down Use an air gun to drive the stud until the shoulder reaches the crankcase e Remove air gun Use a torque wrench to tighten stud to 10 20 ft lbs 14 27 Nm 3 4 1 2 sm00197 1 Head screw with ball inside 2 Cylinder stud 3 Shoulder on cylinder stud 4 Air gun Figure 3 142 Cyli...

Page 331: ...YGEN SENSOR 4 10 4 7 ENGINE TEMPERATURE SENSOR ET 4 11 4 8 BANK ANGLE SENSOR BAS 4 13 4 9 INTAKE AIR TEMPERATURE SENSOR IAT 4 16 4 10 COOLING FAN 4 17 4 11 FUEL TANK VENT VALVE 4 18 4 12 FUEL CAP RETAINING RING 4 19 4 13 FUEL PUMP 4 20 4 14 THROTTLE BODY 4 27 4 15 INTAKE LEAK TEST 4 32 4 16 EXHAUST SYSTEM 4 34 4 17 EVAPORATIVE EMISSIONS CONTROL CA MODELS 4 38 FUEL SYSTEM ...

Page 332: ...NOTES ...

Page 333: ...cator at XB9SX XB12S 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 engi...

Page 334: ...reather 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 ...

Page 335: ... sensor 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 Ensure rubber sealing ring on velocity stack completely engages baseplate Baseplate should be sandwiched between upper a...

Page 336: ...e exhaust 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 4 4 2008 XB Service Fuel System ...

Page 337: ...ed if the throttle position sensor or ECM have been replaced or if the ECM has been recalibrated See 4 4 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 pul...

Page 338: ...nt sm00857 Figure 4 7 Electronic Control Module ECM Lightning Typical sm00858 Figure 4 8 Electronic Control Module ECM Lightning XB12Ss REMOVAL ULYSSES 1 Remove seat Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explosion which could result in death or serious injury 00049a 2 Disconnect batter...

Page 339: ...e 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 TECHNICIAN Part No HD 48650 and perform the TPS zero procedure After installing seat pull upward on seat to b...

Page 340: ...rottle body See 4 14 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 p...

Page 341: ...ct 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 2 AIR CLEANER ASSEMBLY 6 Install intake cover assembly See 2 40 INTAKE COVER 7 Connect negative battery cable tightening to 72 96 in lbs 8 11 Nm...

Page 342: ...occurred 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 ANT...

Page 343: ...s 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 Figure 4 18 For 2008 Model Year all Buell engines wi...

Page 344: ... the 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 2 AIR CLE...

Page 345: ...e 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...

Page 346: ...e 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 eng...

Page 347: ...t Tighten fasteners to 60 96 in lbs 6 9 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 a...

Page 348: ...ery cable 2 See Figure 4 25 Remove air cleaner cover and filter 3 Remove fasteners securing base See 4 2 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 o...

Page 349: ...an 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 cool...

Page 350: ... Remove 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 lb...

Page 351: ...scard 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 n...

Page 352: ...the 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 54 SEAT 2 Drain fuel tank See 4 13 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 n...

Page 353: ...he 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 adequate clearan...

Page 354: ... tank See 4 13 FUEL PUMP Removal in this section 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 13 FUEL PUMP Installation in this section 4 22 20...

Page 355: ...ng 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 conn...

Page 356: ...l 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 4 24 2008 XB Service Fuel System ...

Page 357: ... seated 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 13 FUEL PUMP Installation in this section 4 5 3 5 1 2 sm00223 1 Connector 86...

Page 358: ...ts 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 1 70 5 Nm 13 Tighten rear axle pinch fastener to 40 45 ft lbs 54 61 Nm 14 Install front sprocket cover See 2 38 SPROCKET COVER 15 Install chin fairing after vehicle has been removed from the lift See 2 53 CHIN FAIRING 16 Install lower belt guard See 2 39 BELT ...

Page 359: ...ee 2 26 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 52 AIR SCOOPS 7 Remove ignition coil See 4 5 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 connect...

Page 360: ...1 2 sm00885 1 Manifold to cylinder brace fastener 2 Intake flange fastener 2 Figure 4 40 Intake Manifold Primary Side 4 28 2008 XB Service Fuel System ...

Page 361: ... idle 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 Assemb...

Page 362: ... the 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 ...

Page 363: ...er assembly See 2 40 INTAKE COVER 2 Remove air cleaner cover See 4 2 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 2 AIR CLEANER ASSE...

Page 364: ...2 Screw valve assembly 5 onto propane bottle 1 Tester Adjustment 1 See Figure 4 45 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 45 Leak Teste...

Page 365: ...5 When test is finished close valve knob turn knob fully clockwise sm00251 Figure 4 46 Checking for Intake Leak 2008 XB Service Fuel System 4 33 ...

Page 366: ...d for replacement without removing the exhaust header 8 Remove muffler Front Muffler Mount 1 Remove muffler 2 See Figure 4 47 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 5 ENGINE OIL AND FILTER 3 Remove feed oil line ...

Page 367: ...fastener Symbol for jacking point on muffler located on both sides of muffler 7 Front muffler mount Figure 4 47 Muffler and Mounting System ASSEMBLY AND INSTALLATION Exhaust Header 1 See Figure 4 48 Install exhaust ring 4 exhaust retaining ring 5 and new exhaust port gasket 6 NOTE Tighten header nuts gradually alternating between studs to insure that exhaust rings are flush with engine 2 Install e...

Page 368: ...he chin fairing and the CKP and Torca clamp 1 Install muffler and new Torca clamp onto header NOTES If necessary use a fiber hammer to fit muffler on header For details on installing components on XB12 models with interactive exhaust systems see 7 14 INTERACTIVE EXHAUST SYSTEM Installation 2 Install interactive exhaust cable to muffler NOTE Never re use front muffler strap Always replace front muf...

Page 369: ...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 48 Exhaust Header 2008 XB Service Fuel System 4 37 ...

Page 370: ...If necessary label fuel tank vent hose 2 at canister fitting and remove Canister 1 Remove upper tail body work See 2 41 SUBFRAME TAIL ASSEMBLY AND BODY WORK FIREBOLT 2 See Figure 4 49 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 50 Remove rear shock absorber reservoir fastene...

Page 371: ...er Mounting 1 2 sm00905 1 Adjuster screw 2 Adjuster screw alignment hole Figure 4 51 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 7 14 INTERACTIVE EXHAUST SYSTEM 1 Install vent valve See...

Page 372: ...Air Cleaner Cover Fuel Vent Tube and Fuel Vapor Valve XB12 Translucid models sm00910 Figure 4 54 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...

Page 373: ...SUBJECT PAGE NO 5 1 SPECIFICATIONS 5 1 5 2 STARTER 5 2 5 3 STARTER SOLENOID 5 9 ELECTRIC STARTER ...

Page 374: ...NOTES ...

Page 375: ... Free speed 90 amp max 11 5 V Free current 400 amp max 2 4 V Stall current 8 1 ft lbs 11 Nm min 2 4 V Stall torque Table 5 2 Service Wear Specifications MM IN SERVICE WEAR LIMITS 11 0 0 433 Brush length minimum 28 981 1 141 Commutator diameter min imum 2008 XB Service Electric Starter 5 1 ...

Page 376: ...n access to the starter mounting bolts 5 See Figure 5 1 Remove two starter mounting bolts and washers 1 6 See Figure 5 2 Remove fastener with washer 1 metric a Remove protective boot b Remove positive battery cable 2 c Detach solenoid wire 3 7 Remove starter and gasket from the gearcase cover side 2 1 1 sm00257 1 Mounting bolts and washers 2 Starter Figure 5 1 Starter Mounting 1 2 sm00258 1 Positi...

Page 377: ...thin hacksaw blade After undercutting lightly sand the com mutator with crocus cloth to remove any burrs Mica must not be left with a thin edge next to segments Mica must be cut away clean between segments 9 Check depth of mica on commutator If undercut is less than 0 008 in 0 203 mm use an undercutting machine to undercut the mica to 1 32 in 0 794 mm deep The slots should then be cleaned to remov...

Page 378: ...l cause the steel strip to vibrate and be attracted to the core Replace shorted arma tures 11 See Figure 5 8 Check for a GROUNDED ARMATURE with an ohmmeter or continuity tester a Touch one probe to any commutator segment 1 b Touch the other probe to the armature core 2 c There should be no continuity infinite ohms If there is continuity then the armature is grounded Replace grounded armatures 12 S...

Page 379: ...uch one probe to the field wire 1 b Touch the other probe to each of the brushes attached to the field coil s 2 c There should be continuity 0 ohms If there is no continuity at either brush then the field coil s are open and the field frame must be replaced 15 See Figure 5 12 Test BRUSH HOLDER INSULATION with an ohmmeter or continuity tester a Touch one probe to holder plate 1 b Touch the other pr...

Page 380: ...y components open end of idler bearing cage 15 faces toward solenoid 3 When installing drive housing 10 to solenoid housing 11 use new o ring 16 Be sure to install return spring 17 and ball 18 4 Lubricate armature bearings 8 with high temperature grease such as LUBRIPLATE 110 Install armature 6 and field frame 7 to solenoid housing 11 5 Install brushes and brush holder 4 6 Install o rings 23 Attac...

Page 381: ... Idler gear roller 5 15 7 24 Idler gear bearing cage Field frame Field wire nut with washer metric 16 8 O ring Armature bearing 2 Figure 5 13 Starter Assembly INSTALLATION 1 Install starter and starter gasket from the gearcase cover side 2 See Figure 5 15 Install both starter mounting bolts and washers Tighten to 13 20 ft lbs 18 27 Nm 3 See Figure 5 14 Connect wiring to starter a Connect solenoid ...

Page 382: ...e terminal of battery Tighten to 72 96 in lbs 8 11 Nm 7 Connect negative battery cable Tighten 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 1 2 sm00258 1 Positive battery cable 2 Solenoid wire Figure 5 14 Starter Wi...

Page 383: ...1 See Figure 5 16 Remove screws 1 and clip 2 2 Remove cover 3 and gasket 4 Discard gasket 3 Remove plunger 5 from solenoid housing 6 Assembly 1 See Figure 5 16 Replace wire connection hardware as necessary 2 Apply a light coat of LUBRIPLATE 110 to plunger shaft Install plunger 5 in solenoid housing 6 3 Install new gasket 4 onto cover 3 4 Position cover with gasket onto solenoid housing Install cli...

Page 384: ...5 10 2008 XB Service Electric Starter NOTES ...

Page 385: ... 7 TRANSMISSION 6 25 6 8 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL 6 26 6 9 TRANSMISSION DISASSEMBLY 6 29 6 10 TRANSMISSION ASSEMBLY 6 36 6 11 MAIN DRIVE GEAR AND BEARING 6 38 6 12 TRANSMISSION RIGHT CASE BEARINGS 6 45 6 13 TRANSMISSION LEFT CASE BEARINGS 6 47 6 14 TRANSMISSION INSTALLATION 6 48 6 15 SHIFTER SHAFT 6 52 6 16 TRANSMISSION SPROCKET 6 54 DRIVE TRANSMISSION ...

Page 386: ...NOTES ...

Page 387: ...135 teeth Secondary drive belt XB12Ss XB12STT XB12XT XB12X Table 6 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 6 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 mm...

Page 388: ...tch inspection cover 3 11 See Figure 6 2 Remove the outer ramp and hook 1 from the cable end 3 and coupling 2 Remove cable end from slot in coupling See 6 3 CLUTCH RELEASE MECHANISM 12 See Figure 6 1 Remove screws which secure primary cover 2 Remove cover and gasket 13 Discard gasket 14 See Figure 6 3 Remove and discard shifter lever oil seal 19 15 Clean all parts in a non volatile cleaning soluti...

Page 389: ...d Shifter Assembly PRIMARY CHAIN ADJUSTER REPLACEMENT 1 See Figure 6 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...

Page 390: ...seal 19 2 3 1 4 5 sm00272 1 Cable end 2 Coupling 3 Outer ramp and hook 4 Lockplate 5 Spring Figure 6 6 Clutch Release Mechanism 6 See Figure 6 6 Fit coupling 2 over cable end 1 with rounded side inboard and the ramp connector button out board With retaining ring side of ramp assembly facing inward place hook of ramp 3 around coupling button and rotate assembly counterclockwise until tang on inner ...

Page 391: ... 5 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 6 8 Nm 16 If the shift linkage assembly 2 was removed for any reaso...

Page 392: ...rd 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 R...

Page 393: ...se until resistance is felt c Adjust clutch release mechanism See 1 8 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 9 5 12 2 Nm 5 Adjust clutch cable See 1 8 CLUTCH TRANSMIS SION PRIMARY FLUID 6 Connect negative ...

Page 394: ... trans 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 ...

Page 395: ...asher 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 6 12 Clutch Assembly ...

Page 396: ...ng 3 and washer 2 d Thread the tool handle 1 onto end of forcing screw NOTE See Figure 6 14 Turn compressing tool handle only the amount required to release spring seat and remove snap ring 7 Excessive compression of diaphragm spring could damage clutch pressure plate 5 See Figure 6 14 Remove pressure plate assembly a Place a wrench on the clutch spring forcing screw 5 flats to prevent the forcing...

Page 397: ...eck 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 ...

Page 398: ...ining ring 2 Bearing and release plate 3 Retaining ring 4 Adjusting screw Figure 6 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 6 19 Install narrow friction plate o...

Page 399: ... to 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...

Page 400: ... DAVIDSON FORMULA TRANSMISSION AND PRIMARY CHAINCASE LUB RICANT Part No 99851 05 See 6 4 CLUTCH 10 Connect negative battery cable to battery terminal Tighten fastener to 72 96 in lbs 8 6 10 9 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 sea...

Page 401: ...uid 3 Remove primary cover See 6 2 PRIMARY COVER 4 Loosen engine sprocket a See Figure 6 24 Install SPROCKET LOCKING LINK Part No HD 38362 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...

Page 402: ...om clutch shell Inspect primary chain sprocket and the starter ring gear on the clutch shell 7 Inspect slots that mate with the clutch plates on both clutch shell and hub 8 See Figure 6 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 flo...

Page 403: ...from clutch shell 3 See Figure 6 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 6 33 Place clutch shell on support blocks with sprocket side facing up 6 Press be...

Page 404: ... hand 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 6 4 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 ...

Page 405: ...KING LINK 8 Install the pressure plate assembly See 6 4 CLUTCH 9 Install adjusting screw assembly into pressure plate a See Figure 6 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 6 2 PRIMARY COVER 11 Adjust clutch See 1 8 CLUTCH TRANSMIS SION PRIMARY FLUID 12...

Page 406: ...3 1 2 sm00288 1 Adjusting screw assembly 2 Retaining ring 3 Tab recesses Figure 6 38 Clutch Adjusting Screw Assembly and Retaining Ring 6 20 2008 XB Service Drive Transmission ...

Page 407: ...elt 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 6 39 Proper Drive Be...

Page 408: ...2 Pinch bolt Figure 6 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 21 SWINGARM AND BRACE NOTE See Figure 6 4...

Page 409: ...move 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 6 43 Rear Axle IDLER PULLEY INSTALLATION 1 See Figure 6 44 Install new or existing pulley wheel 1 if removed and tighten washer and nut 2 to wheel fastener 6 to 20 23 ft lbs 27 1 31 2 Nm 2...

Page 410: ...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 6 44 Idler Pulley Assembly 6 24 2008 XB Service Drive Transmission ...

Page 411: ...haft 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 lig...

Page 412: ...D 5 Disassemble gearcase See 3 16 GEARCASE AND CAM GEARS 6 Remove primary cover See 6 2 PRIMARY COVER 7 Remove clutch assembly primary chain and engine sprocket See 6 5 PRIMARY CHAIN and 6 4 CLUTCH sm00306 Figure 6 46 Hex Fastener Countershaft Retainer 8 See Figure 6 46 Place transmission in first gear Remove hex fastener sm00307 Figure 6 47 Shifter Drum Neutral Detent 9 See Figure 6 47 Place tran...

Page 413: ...ee Figure 6 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 5 2 STARTER sm02979 Figure 6 51 Rear Isolator Assembly 14 See Figure 6 51 Remove rear isolator assembly by removing the forward two fasteners first and then the two rear fasteners re install with new fasteners 2008 XB Service Drive Transmission 6...

Page 414: ...ers sm00312 Figure 6 53 Separating Crankcase Halves 16 See Figure 6 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 6 54 Removing Flywheels from Left Crankcase 17 See Figure 6 54 Remove the flywheel assembly from left crankcase half 6 28 2008 XB Service Drive Transmission ...

Page 415: ...drum right side 5 Shifter fork shaft 6 Shifter fork 2nd 3rd 7 Shifter fork 1st Figure 6 55 Shifter Forks Drum and Shafts 1 See Figure 6 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 6 57 Remove shifter drum 1 and shifter fork...

Page 416: ... lever 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 6 58 ...

Page 417: ... pliers and could be propelled with enough force to cause serious eye injury 00312a 3 See Figure 6 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 transmissi...

Page 418: ... Dog 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 integr...

Page 419: ...t assemblies 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 ex...

Page 420: ...th enough force to cause serious eye injury 00312a 1 See Figure 6 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 e...

Page 421: ...haft 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 6 63 Transmission Countershaft 2008 XB Service Drive Transmission 6 35 ...

Page 422: ...haft 2nd gear integral to shaft Figure 6 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 correct tips Verify th...

Page 423: ... 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 Countershaft 2nd gear 19 9 Spa...

Page 424: ... CROSS 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 6 8 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL 2 Remove transmission as an assembly See 6 9 TRANS MISSION DISASSEMBLY 3 See Figure 6 67 From inside case tap out seal 3 at end of mainshaft 5th gear Discard seal 4 Obtain MAIN DRIVE GEAR REMOVER AND INSTALLER S...

Page 425: ... pliers and correct tips Verify that tips are not excessively worn or damaged 1 See Figure 6 66 At outside of case remove and discard oil seal 10 Remove and discard main drive gear bearing retaining ring 9 2 See Figure 6 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 driver and bearing 4 At...

Page 426: ...ment for claw puller 4 Press ram Figure 6 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 correct depth is reached...

Page 427: ...earing bore 4 2 See Figure 6 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...

Page 428: ...ure 6 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 6 66 Make sure to install new o ring 5 onto main drive gear before installing main drive gear into crankcase 3 See Figure 6 76 Insert 8 IN BOLT Part No HD 35316 4A 1 through WASHER Part No HD 35316 7 2 and main drive gear ...

Page 429: ...ng so could make it difficult to remove adapter after seal has been installed 5 See Figure 6 80 Slide INSTALLER Part No HD 47856 1 over adapter until cupped end of installer is flat against seal 6 See Figure 6 81 Thread NUT Part No HD 47856 5 onto end of adapter until it tightens against installer 7 See Figure 6 82 Place CROWFOOT WRENCH Part No HD 47856 7 1 with 1 2 inch drive breaker bar 2 on lar...

Page 430: ...00337 Figure 6 80 Place Installer over Adapter Typical sm00338 Figure 6 81 Install Nut Typical 2 1 3 sm00339 1 Crowfoot wrench 2 1 2 inch breaker bar 3 Adjustable wrench Figure 6 82 Press Seal Into Crankcase 6 44 2008 XB Service Drive Transmission ...

Page 431: ...STALLATION 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 diameter 2 See Figure 6 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...

Page 432: ...Bearing 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 6 83 Transmission Assembly Right Crankcase Half 6 46 2008 XB Service Drive Transmission ...

Page 433: ...haft 4 Bearing countershaft Figure 6 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 should...

Page 434: ... 6 86 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 6 87 Place left case half over transmission assembly and install transmission remover installer tool INSTALLER Part No B 43985 3 1 into crankcase 4 Press crankcase onto transmission assem...

Page 435: ...er 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 forks and into left crankcase half 4 Install 4th 5th gear shifter fork onto sliding gear with dogs located o...

Page 436: ...t and countershaft with HARLEY DAVIDSON SPECIAL PURPOSE GREASE Part No 99857 97 5 See Figure 6 92 Assemble crankcase halves together a Apply a thin coat of GRAY HIGH PERFORMANCE SEALANT Part No 99650 02 to crankcase joint faces b See Figure 6 93 Apply several drops of LOCTITE 271 red to last few threads and tighten crankcase fasteners 1 2 to 15 19 ft lbs 20 3 25 0 Nm c Remove GEAR DETENT ASSEMBLY ...

Page 437: ...D 1 1 1 1 2 sm00176 1 Crankcase fasteners 2 Crankcase fastener behind shifter mechanism Figure 6 93 Crankcase Fasteners 2008 XB Service Drive Transmission 6 51 ...

Page 438: ...1 red 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 6 16 TRANSMISSION SPROCKET 6 Continue assembling engine See the following 3 17 CRANKCASE Assembly 3 6 CYLINDER HEAD Assembly 3 6 CYLINDER HEAD Cylinder Head Installation 3 7 CYLINDER AND PI...

Page 439: ...sm00309 Figure 6 97 Installing Shifter Shaft Assembly sm00306 Figure 6 98 Hex Fastener Countershaft Retainer 2008 XB Service Drive Transmission 6 53 ...

Page 440: ...sion 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 Firebolt SPROCKET LOCKING TOOL Part No B 45659 to hold the sprocket 8 See Figure 6 101 Place transmission in neutral In...

Page 441: ... 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 canno...

Page 442: ...Transmission sprocket nut 2 Transmission sprocket 3 Line scribed on nut and sprocket Figure 6 102 Aligning Transmission Sprocket 2 1 sm00302 1 Axle 2 Pinch bolt Figure 6 103 Rear Axle 6 56 2008 XB Service Drive Transmission ...

Page 443: ... 7 12 FRONT TURN SIGNALS 7 32 7 13 REAR TURN SIGNALS 7 35 7 14 INTERACTIVE EXHAUST SYSTEM 7 39 7 15 HEADLIGHT 7 43 7 16 TAIL LAMP 7 48 7 17 LICENSE PLATE LAMP ASSEMBLY 7 50 7 18 MAIN FUSE AND FUSES 7 52 7 19 NEUTRAL INDICATOR SWITCH 7 55 7 20 CRANKSHAFT POSITION SENSOR CKP 7 56 7 21 VEHICLE SPEED SENSOR VSS 7 58 7 22 INSTRUMENT MODULE 7 59 7 23 MAIN WIRE HARNESS 7 62 7 24 INTERACTIVE EXHAUST HARNE...

Page 444: ...NOTES ...

Page 445: ...fications AMPERES ELECTRICAL SYSTEM 30 Main fuse battery fuse 15 Ignition fuse 15 Light fuse 10 Accessory fuse 10 Brake horn active muffler fuse XB12 models only 10 ECM fuse 15 Key switch fuse 10 Cooling fan fuse 10 Auxiliary fuse Table 7 7 Bulb Chart 2008 Firebolt Models PART NUMBER AMPS WATTS BULBS REQUIRED BULBS 68918 98 4 58 55 2 Bulb H3 Headlamps Y0026 02A8 0 25 3 1 Position lamp European Jap...

Page 446: ...5 0 7 1 Replace instrument cluster if low fuel warning lamp fails Low fuel Table 7 9 Bulb Chart 2008 Ulysses Models PART NUMBER AMPS WATTS BULBS REQUIRED BULB Y0148 1AD 4 58 55 2 Bulb H7 Headlamps 53436 97 0 37 5 1 Position lamp European models only Y0401 1AKC Replace tail lamp assembly if lamp fails Tail stop lamp Marker lamps Y0042 K 0 74 10 4 Front and rear turn signal lamps 1 bulb each 53436 9...

Page 447: ...ition 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 up to operating temperature the fuel m...

Page 448: ... 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 7 1 Ignition Components 7 4 2008 XB Service Electrical ...

Page 449: ... European 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 REMOVAL FIREBOLT TOOL NAME PART NUMBER SNAP ON TAMPER RESISTANT T45 TORX DRIVER FTXR45E 1 Remove seat To prevent accidental ...

Page 450: ...ove ignition switch body fasteners 1 Separate ignition switch body 2 from ignition switch 4 ASSEMBLY FIREBOLT NOTE See Figure 7 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...

Page 451: ...ht 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 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 ti...

Page 452: ...e SNAP 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...

Page 453: ...ch body 2 from ignition switch 4 ASSEMBLY LIGHTNING NOTE See Figure 7 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 ignition switch body 2 If ignition switch does not easily slide into ignition switch body rotate slot in ign...

Page 454: ...77 1 Body fastener 2 2 Body 3 Spacer 4 Housing 5 Ignition switch 6 Socket head fastener 7 Tamper resistant Torx fasteners 2 8 Ignition switch connector 33 Figure 7 9 Ignition Switch Assembly 7 10 2008 XB Service Electrical ...

Page 455: ...ottle cables 3 to your left the right side of the vehicle slide the ignition switch assembly in to your right the left side of the vehicle 2 Install the ignition switch 4 with the fork stop pin 5 pointing down and once in place roll the assembly toward you and insert the fork stop pin into the upper triple clamp 3 See Figure 7 9 Apply LOCTITE 271 red to ignition switch fasteners 6 7 4 Install spac...

Page 456: ...m 1 2 3 sm00478 1 Ignition key switch 2 Fork stop pin 3 Ignition key switch connector 33 Figure 7 11 Ignition Key Switch REMOVAL ULYSSES TOOL NAME PART NUMBER SNAP ON TAMPER RESISTANT T45 TORX DRIVER FTXR45E 1 Remove 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 ...

Page 457: ...n switch 5 by prying tabs on side of housing 2 Remove body fasteners 1 Separate body 2 from ignition switch 5 ASSEMBLY ULYSSES NOTE See Figure 7 13 In next step be sure wide slot in housing 4 is installed over wide boss on ignition switch 5 1 Push housing 4 on to ignition switch 5 NOTE In next step do not force ignition switch 5 into body 2 If ignition switch does not easily slide into ignition sw...

Page 458: ...le 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 ignition switch 6 Install negative battery cable to battery terminal Tighten fastener to 72 96 in lbs 8 11 Nm The automatic on headlamp feature provides in...

Page 459: ...k for 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 7 15 Check spark plug cable resistance with an ohmmeter 4 Replace cables not meeting resistance specifications Table 7 13 Spark Plug Cable Resistance RESISTANCE OHMS CABLE LENGTH POSITION 1 350 3 465 5 7 in 145 m...

Page 460: ...sm00366 Figure 7 16 Boot Gap 7 16 2008 XB Service Electrical ...

Page 461: ...the engine sprocket shaft The stator which bolts to the engine crankcase Voltage Regulator NOTE For troubleshooting and diagnostic see Electrical Diagnostic Manual See 7 7 VOLTAGE REGULATOR The voltage regulator is a series regulator with shunt control The voltage regulator combines the functions of rectifying converting AC voltage to DC and regulating controlling voltage output GND 1 R 46B Stator...

Page 462: ...lock 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 7 18 Charging System Circuit Ulysses Lightning 7 18 2008 XB Service Electrical ...

Page 463: ...ely 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 464: ...8 Negative battery cable 9 To frame 10 To starter Figure 7 19 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 7 20 Battery Lightning Ulysses sm00394 Figure 7 21 Negative Battery Cable Typical 7 20 2008 XB Service Electrical ...

Page 465: ...1 2 sm00258 1 Positive battery cable 2 Solenoid wire Figure 7 22 Starter Wires Protective Boot Not Shown 2008 XB Service Electrical 7 21 ...

Page 466: ... 7 24 Attach new voltage regulator 4 to bracket 3 Tighten fasteners 5 to 30 60 in lbs 3 5 6 9 Nm NOTE When installing the left side side air scoop it is necessary to ensure that the voltage regulator and alternator wiring har nesses are not trapped between the air scoop and cylinder head 2 Connect stator connector 46 1 and voltage regulator connector 77 2 located under left ram air scoop See 7 25 ...

Page 467: ... the 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 7 27 Disconnect stator wiring 4 from voltage regulator wiring at connector 5 46 under the left ram air scoop See 7 25 SPROCKET COVER WIRING 2 Remove cable straps holding stator wire to the left ram air scoop NOTE Stator fas...

Page 468: ...nkcase 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 ensure that the voltage regulator and alternator wiring harnesses are not trapped between the air scoop and cylinder head 5 See Figure 7 27 Route stator wiring 4 behind ...

Page 469: ...d hand grip 11 Remove right side heated hand grip See 2 26 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 26 THROTTLE CONTROL NOTES See Figure 7 29 The paint mark needs to be lined up visually with the inside edge of the right and left hand control See Figure 7 30 The han...

Page 470: ...ion of Cable Strap Securing the Right Side Hand Grip Wire Below the Instrument Cluster 7 See Figure 7 34 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...

Page 471: ...g 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 2008 XB...

Page 472: ... 96 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 7 10 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 fairin...

Page 473: ...c 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 7 39 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 Figu...

Page 474: ...n fastener to 36 60 in lbs 4 6 7 Nm 3 Install front fairing or windshield windscreen See 2 49 FRONT FAIRING WINDSHIELD AND MIRRORS FIREBOLT Firebolt or 2 50 WINDSHIELD AND WIND SCREEN LIGHTNING AND ULYSSES Lightning and Ulysses Be sure that all lights and switches operate properly before operating motorcycle Low visibility of rider can result in death or serious injury 00316a 4 Check turn signals ...

Page 475: ...1 2 sm00407 1 Left turn signal 2 Right turn signal Figure 7 44 Turn Signal Controls 2008 XB Service Electrical 7 31 ...

Page 476: ...rn 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 7 45 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 s...

Page 477: ...nnectors on turn signal wires 3 See Figure 7 48 Remove jam nut and lockwasher 2 from inside of front module 3 4 Pull bullet connectors and wiring through hole in front module 3 and remove turn signal 1 Installation 1 See Figure 7 48 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 Attac...

Page 478: ...1 5 2 3 4 1 2 3 sm03811 1 Turn signal 2 Jam nut and lockwasher 3 Front module left and right 4 Windshield 5 Windscreen Figure 7 48 Front Turn Signals Ulysses 7 34 2008 XB Service Electrical ...

Page 479: ...3 sm00458 1 Left turn signal 2 Tail lamp 3 Right turn signal Figure 7 50 Rear Turn Signal Connections Ulysses FIREBOLT Removal 1 Remove seat See 2 54 SEAT 2 Remove tail frame upper body work See 2 41 SUBFRAME TAIL ASSEMBLY AND BODY WORK FIREBOLT 3 See Figure 7 49 Disconnect bullet connectors on turn signal wires 4 See Figure 7 51 Remove fastener 6 and lockwasher 5 5 Remove turn signal from tail se...

Page 480: ... OFF 6 Install tail frame upper bodywork See 2 41 SUBFRAME TAIL ASSEMBLY AND BODY WORK FIREBOLT 7 Install seat See 2 54 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 7 51 Rear Turn Signals Firebolt LIGHTNING Removal 1 Remove seat See 2 54 SEAT 2 See Figure 7 49 Disconnect bullet connectors 1...

Page 481: ...00455 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 7 52 Rear Turn Signals Lightning ULYSSES Remove 1 Remove seat See 2 54 SEAT 2 See 7 17 LICENSE PLATE LAMP ASSEMBLY Ulysses Remove rear wire cover 3 See Figure 7 50 Separate left turn signal connector 18 and right turn signal connector 19 4 See Figure 7 53 Remove jam n...

Page 482: ...lebar Front and rear left turn signals must flash c Activate right turn signals using switch on left handlebar Front and rear right turn signals must flash d Turn ignition key switch to OFF 6 Install seat See 2 54 SEAT 4 5 1 1 3 2 3 sm00457 5 3 1 License plate bracket Reflector Turn signal 2 2 4 Turn signal bulb Jam nut and lockwasher 2 Figure 7 53 Rear Turn Signals Ulysses 7 38 2008 XB Service El...

Page 483: ...re so the engine can gain RPM quickly The exhaust enters 2 the muffler and flows 3 through the open valve 1 into chamber C 7 and then exits 8 2 In the mid range the valve is closed to increase 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...

Page 484: ...rness 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 7 55 Interactive Control System XB12 Models 7 40 2008 XB Service Electrical ...

Page 485: ... and support muffler until interactive exhaust cable is removed 11 Remove cable strap above starter securing actuator cable vent line main harness and positive battery cable 1 3 2 sm03744 1 Neutral switch connection 131 2 Oil pressure indicator switch wire 3 Interactive exhaust cable Figure 7 56 Electrical Connectors and Interactive Exhaust Cable Under Sprocket Cover 12 Remove cable strap securing...

Page 486: ...6 40 in lbs 4 1 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 15 INTERACTIVE EXHAUST CABLE 7 Install cable strap above starter securing actuator cable vent line main harness and positive battery cable 8 Install cable strap securin...

Page 487: ...b the bulb with paper or a clean dry cloth Failure to do so could result in bulb damage 00210a 2 See Figure 7 60 Disconnect headlight connection 1 3 Remove rubber boot from headlight housing 4 Release wire retaining latch 5 from headlight housing clips 5 Pull bulb housing from headlight housing Installation NOTE Not using the specified bulb may cause charging system problems Handle bulb carefully ...

Page 488: ... 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 3 Remove windscreen See 2 50 WINDSHIELD AND WINDSCREEN LIGHTNING AND ULYSSES 4 Remove headlight housing fasteners 5 Disconnect headlight connector 3...

Page 489: ... Connect 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 7 61 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 cast...

Page 490: ...h 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 i...

Page 491: ...sm00447 Figure 7 62 Headlight Housing 20 Degree Alignment Marks for Rubber Boot Wiring Harness Guides or Spigots 2008 XB Service Electrical 7 47 ...

Page 492: ...n 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 br...

Page 493: ... 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 brake pedal e Turn ignition key switch to OFF After insta...

Page 494: ...ng jam nuts and washers 1 and tighten to 12 36 in lbs 1 4 4 1 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 switch to OFF After inst...

Page 495: ... section using washers and jam nuts 1 and tighten to 12 36 in lbs 1 4 4 1 Nm d See Figure 7 67 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 Turn ignit...

Page 496: ...der 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 7 68 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 ...

Page 497: ...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 7 71 Fuse Block Lightning sm00470 Figure 7 72 Fuse Block and Main Fuse Location Ulysses 2008 XB Service Electrical 7 53 ...

Page 498: ... 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 7 73 Fuse Block Ulysses 1 3 2 sm00424 1 Negative battery cable 2 Main fuse holder 3 Rear brake fluid reservoir Figure 7 74 30A Main Fuse Location Firebolt 7 54 2008 XB Service Electrical ...

Page 499: ...fter testing and repair connect wire lead to indicator switch 4 Install sprocket cover See 2 38 SPROCKET COVER REMOVAL AND INSTALLATION 1 Verify that the ignition key switch is turned to OFF 2 Remove sprocket cover See 2 38 SPROCKET COVER NOTE If replacing neutral indicator switch wiring see 7 25 SPROCKET COVER WIRING for correct wire routing 3 See Figure 7 76 Remove neutral indicator switch wire ...

Page 500: ...ee Figure 7 77 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 7 77 Crank Position CKP Sensor INSTALLATION NOTE The CKP...

Page 501: ...E 7 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 2008 XB Service Electrical 7 57 ...

Page 502: ...nsor 2 from crankcase INSTALLATION 1 See Figure 7 78 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 38 SPROCKET COVER 3 2 1 sm00410 1 Fastener 2 Vehicle speed sensor 3 Rear isolator assembly Figure 7 78 Speedo...

Page 503: ...ashers 6 See Figure 7 85 Firebolt Figure 7 86 Lightning or Figure 7 87 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 wil...

Page 504: ...EADLAMP ASSEMBLY AND SUPPORT BRACKET 5 For Lightning install windscreen and for Ulysses install windscreen windshield See 2 28 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 s...

Page 505: ...pport module left and right 2 Instrument module 3 Grommet 3 4 Washer 3 5 Fastener 3 6 Instrument module connector 39 Figure 7 86 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 7 87 Instrument Module Assembly Ulysses 2008 XB Servi...

Page 506: ...7 88 Disconnect positive battery cable 1 and starter solenoid connection 128 3 from starter 9 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 10 On Firebolt models remove the main fuse case lo...

Page 507: ...gative 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 7 89 Main Harness and Electrical Connectors Under...

Page 508: ... voltage 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 7 90 Main Harness and Electrical Connectors Under Seat Lightning XB12Ss 7 64 2008 XB Service Electrical ...

Page 509: ...ument 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 7 91 Electrical Connectors Behind Windscreen Ulysses 2008 XB Service Electrical 7 65 ...

Page 510: ...or Firebolt see 2 49 FRONT FAIRING WIND SHIELD AND MIRRORS FIREBOLT b For Lightning Ulysses see 2 50 WINDSHIELD AND WINDSCREEN LIGHTNING AND ULYSSES 16 See Lightning Figure 7 96 Ulysses Figure 7 91Figure 7 94 Disconnect a Ignition switch 33 6 b Turn signal flasher connector 30 1 c Instrument module connector 39 2 d Left handlebar connector 24 4 and right handlebar connector 22 3 e Turn signal conn...

Page 511: ...sor 137 d Temperature sensor 90 e Fuel injectors 84 85 f Fuel pump connector 86 g Idle air control 87 25 Disconnect and remove ignition coil 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 26 Remove left side air scoop See 2 52 AIR SCOOPS 27 Disconnect alternator connector 46 1 a...

Page 512: ...gnal 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 7 93 Fairing Wiring Viewed From Beneath Fairing Firebolt 7 68 2008 XB Service Electrical ...

Page 513: ... 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 ...

Page 514: ...switch 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 ...

Page 515: ...d 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 1 Nm 11 Connect a Throttle position sensor 88 b Intake air temperature sensor 89 c O2 sensor 137 d Temperature sensor 90 e Fuel injectors 84 and 85 f Idle air control 87 g Ulysses models rear auxiliary power outlet 1...

Page 516: ...s models install wire harness guide on steering neck and tighten to 36 60 in lbs 4 6 7 Nm 28 On Firebolt models install steering head clamp around wire harness and secure clamp to fairing support bracket with loop facing vehicle Tighten fastener to 16 18 ft lbs 21 7 2404 Nm 29 Verify that front forks can be turned from full left to full right lock without wire harness binding or pinching NOTE The ...

Page 517: ...gative 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 7 97 Main Harness and Electrical Connectors Under...

Page 518: ... voltage 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 7 98 Main Harness and Electrical Connectors Under Seat Lightning XB12Ss 7 74 2008 XB Service Electrical ...

Page 519: ...0 3 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 7 99 Main Harness and Electrical Components Under Seat Ulysses 2008 XB Service Electrical 7 75 ...

Page 520: ...nal 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 7 100 Fairing Wiring Viewed From Beneath Fairing Firebolt 7 76 2008 XB Service Electrical ...

Page 521: ...ure 7 101 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 7 102 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 w...

Page 522: ...onnector 161B 2 at main harness 5 Figure 7 104 Remove the exhaust actuator ground 4 6 Pull actuator harness through frame 7 See Figure 7 105 Disconnect connector 161B 2 from actuator NOTE For actuator or actuator cable replacement see 7 14 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 7 104 Harness an...

Page 523: ...rt up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 3 See Figure 7 107 Remove negative battery cable 3 from battery See 1 4 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 7 107 Separate exhaust actuator harness connector 165 beneath t...

Page 524: ... Install 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 0 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 Insta...

Page 525: ... connector 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 7 109 Route the interactive exhaust cable behind the oil pump body beside the neutral switch...

Page 526: ... position 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 50 WINDSHIELD AND WIND SCREEN LIGHTNI...

Page 527: ...I TERMINAL REPAIR A 15 A 8 DEUTSCH MINI TERMINAL REPAIR A 17 A 9 MOLEX CONNECTORS A 18 A 10 PACKARD 150 METRI PACK CONNECTORS A 22 A 11 PACKARD 280 METRI PACK RELAY AND FUSE BLOCK CONNECTORS A 24 A 12 PACKARD 480 METRI PACK CONNECTORS A 25 A 13 PACKARD 630 METRI PACK CONNECTORS A 26 A 14 PACKARD METRI PACK TERMINALS A 27 A 15 PACKARD ECM CONNECTOR A 29 A 16 PACKARD MICRO 64 CONNECTORS A 31 A 17 SE...

Page 528: ...NOTES ...

Page 529: ...handle 5 Holding the socket housing while keeping the tool firmly bottomed 5 depress the plunger 6 The terminal 7 pops out the wire end of the connector NOTE If the terminal is not released from the socket housing then the terminal was not pushed forward far enough before place ment of the tool or the tool was not bottomed in the connector housing Installing Socket Terminal 1 Note the lip at the m...

Page 530: ... the pin housing then the terminal was not pushed forward far enough before placement of the tool or the tool was not bottomed in the connector housing Installing Pin Terminal 1 Push the lead into the pin housing until it stops A click is heard when the terminal is properly seated 2 Gently tug on the lead to verify that the terminal is locked in place 1 3 4 5 6 2 sm00012 1 Pin housing 2 Barrel 3 B...

Page 531: ...ngs 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 3 AMP Multilock Connector Removing...

Page 532: ...op 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...

Page 533: ...ition 1 2 Raise locking bar by pushing up on bottom flange 2 NOTE See Figure A 6 and Figure A 7 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 8 With the insulation crimp tail facing up...

Page 534: ... crimped terminal Figure A 8 AMP Multilock Connector Terminal Crimping Procedure Inspecting Crimped Terminals See Figure A 9 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 9 AMP Multilock Connector Terminal Crimp A 6 2008 XB Service Appendix A Connector Repair ...

Page 535: ...ach 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 u...

Page 536: ...to 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 pu...

Page 537: ...2 3 1 sm00015 1 Remove wire lock 2 Remove terminal lock 3 Pry tang outward Figure A 13 Delphi Connector Removing Socket Terminals 2008 XB Service Appendix A Connector Repair A 9 ...

Page 538: ...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 nector until that latch engages then press on the opposite side to en...

Page 539: ...edge of the 3 place connector must be installed with the arrow 1 pointing toward the external latch If the secondary locking wedge does not slide into the installed position easily verify that all terminals are fully installed in the socket housing The lock indicates when terminals are not properly installed by not entering its fully installed position sm00009 Figure A 15 Deutsch Connector Remove ...

Page 540: ...ck 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 18 Deutsch Connector Depress Terminal Latch and Back Out Pin Installing Pin Terminals 1 See Figure A 19 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 ...

Page 541: ...ith 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 6 DEUTSCH STANDARD TERMINAL REPAIR Standard with crimp tails A 7 DEUTSCH SOLID BARREL MINI TERMINAL REPAIR Mini Terminal solid barrel A 8 DEUTSCH MINI TERMINAL REPAIR Mini Terminal with crimp tails 2008 XB Service Appendix ...

Page 542: ... that 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 unt...

Page 543: ...t 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 cri...

Page 544: ...UCTS 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 22 Deutsch Solid Barrel A 16 2008 XB Service Appendix A Connector Repair ...

Page 545: ...ert 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...

Page 546: ...art 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 28 From the wiring diagram match the wire colo...

Page 547: ...auges 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 are released 3 See Figure A 29 Hold fully open tool at approximately 45 degrees NOTE Do NOT tighten the locknut holding the locator bars T...

Page 548: ...unch and the die sm02855 Figure A 31 Square Openings in Socket Locator Bar Insert Stripped Lead See Figure A 34 Insert the stripped end wire core between the crimp tails at an up angle until the wire core touches the face of the socket locator bar above the square opening NOTES The insulation must extend through the insulation crimp tails Insert the wire with little or no pressure Pressing on the ...

Page 549: ... 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 3 without piercing or cutting the insulation d Distortion should be minimal 2 Test Crimp Hold the terminal and pull the lead 1 3 2 sm02859 1 Core crimp 2 Wire strands 3 Insu...

Page 550: ...NOTE 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 cl...

Page 551: ...emove 4 Raise tang to install Figure A 36 150 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 37 150 Metri Pack Connector Push to Seat 2008 XB Service Appendix A Connector Repair A 23 ...

Page 552: ...am 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 th...

Page 553: ... 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 depress the tang 4 Remove the pin and then pull terminal out of the wire end of connector housing 5 If necessary crimp new terminals on wires See A 14 PACKARD METRI PACK TERMINALS Installing Socket...

Page 554: ...rminal 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 t...

Page 555: ...tion and expose 5 32 in 4 0 mm of wire core Crimping Wire Core NOTE Metri Pack terminal crimps require two steps Always perform Crimping Wire Core before Crimping Insulation Seal 1 Squeeze and release handles until ratchet automatically opens 2 Identify the corresponding sized nest for the core crimp 3 Position the core crimp in the die Be Sure the core crimp tails are facing the forming jaws 4 Ge...

Page 556: ...igure A 42 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 42 Metri Pack Connector Inspect Core and Insulation Seal Crimps A...

Page 557: ... to free strain relief collar 4 from conduit 5 3 See Figure A 45 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 cau...

Page 558: ...ck 3 Cable strap 4 Strain relief collar 5 Conduit Figure A 44 Packard 100W Connector 2 1 1 1 sm00039 1 Pins 2 Socket terminal Figure A 45 Packard 100W Connector Separate Halves of Socket Housing A 30 2008 XB Service Appendix A Connector Repair ...

Page 559: ... Part No HD 45928 5 See Figure A 47 Push the adjacent terminals all the way into the connector housing and then insert tool into hole until it bottoms 6 Leaving the tool installed gently tug on wires to pull either one or both terminals from wire end of connector Remove tool sm00046 Figure A 46 Packard Micro 64 Terminal Remover HD 45928 sm00048 Figure A 47 Packard Micro 64 Connector Insert Tool an...

Page 560: ...osition of contact When correctly positioned the locking bar fits snugly in the space at the front of the core crimp tails and the closed side of the terminal rests on the outer nest of the crimp tool 6 Insert wires between crimp tails until ends make contact with locking bar Verify that wire is positioned so that wide pair of crimp tails squeeze bare wire strands while the narrow pair folds over ...

Page 561: ...3 1 2 4 sm00049 1 Open position 2 Raising locking bar 3 Insert terminal 4 Crimp terminal Figure A 50 Packard Micro 64 Connector Terminal in Crimper 2008 XB Service Appendix A Connector Repair A 33 ...

Page 562: ...ze the handles until the connector is held in the jaws 4 See Figure A 52 Feed the stripped end of a wire into the connector until the wire stops inside the metal insert 1 5 Squeeze the handles tightly closed to crimp the lead in the insert 2 The tool automatically opens when the crimping is complete 6 Slide the connector to the other half of the metal insert Insert the stripped wire lead 1 until i...

Page 563: ...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 52 Sealed Splice Connector 2008 XB Service Appendix A Connector Repair A 35 ...

Page 564: ...A 36 2008 XB Service Appendix A Connector Repair NOTES ...

Page 565: ...SUBJECT PAGE NO B 1 WIRING DIAGRAMS B 1 APPENDIX B WIRING ...

Page 566: ...NOTES ...

Page 567: ...ray 11 Under sprocket cover 3 place Deutsch Cam position sensor 14 Under rear wire cover Under seat Under tail sec tion 2 1 place bullet Right rear turn signal 18 Under rear wire cover Under seat Under tail sec tion 2 1 place bullet Left rear turn signal 19 Behind windscreen Beneath right side of fairing 4 place Multilock Right hand controls 22 Behind windscreen Beneath left side of fairing 8 plac...

Page 568: ...light 2 place spade Tail light 93 1 place spade ground Ulysses Only 3 place Amp Underside of clutch lever assembly 2 place Multilock Clutch switch 95 Behind rear cylinder under seat 2 place Multilock Cooling fan 97 Crankcase above oil filter Post terminal Oil pressure switch 120 Underside of front master cylinder assembly 2 place Multilock Front brake switch 121 Under seat 2 place Multilock Rear b...

Page 569: ...ntifies a pin housing B Socket The letter B after a connector number and the socket symbol 5 identifies a socket housing Other symbols found on the wiring diagrams include the symbol for a diode 7 a symbol for a wire to wire connection 8 a symbol that verifies that no connection 9 between two wire traces exists and a symbol identifying two wires that are twisted together 10 9 10 1 2 1 2 8 7 6 5 3 ...

Page 570: ... Figure B 5 Lighting Circuit Ulysses and Lightning Figure B 6 Lighting Circuit Firebolt Figure B 7 Horn and Instruments Circuit All Models Figure B 8 Horn and Instruments Circuit Firebolt Figure B 9 Starting Circuit Ulysses and Lightning Figure B 10 Starting Circuit Firebolt Figure B 11 Charging Circuits All Models Figure B 12 Heated Hand Grips Ulysses B 4 2008 XB Service Appendix B Wiring ...

Page 571: ...O W 1 2 TN V 3 GN Y 1 PK Y V GY 1 V BN 1 2 BK 4 BK 1 1 BK 1 1 1 2 1 2 1 1 2 3 1 2 3 1 2 1 2 1 1 BK 165A 120A 77B 65A 65B 131B 131A 128A 128B 97A 97B 86A 86B 178 18B 93B 45B 19B 134B 62B 85B 84B 88B 88A 89B 83B 83A 90B 90A 137B 137A 30B 87B 95B 24A 31B 39A 39B 31B 22A 121A 121B 15A 15A 10A 15A 10A 10A 15A 10A 10A 30A BK TN LGN 11 9 13 14 22 21 17 16 10 9 8 3 2 1 23 24 15 16 17 34 33 32 31 30 29 28 ...

Page 572: ...Figure B 2 Figure B 2 Main Harness Ulysses and Lightning Main Harness Ulysses and Lightning ...

Page 573: ...V Y R W R W LGN GY 4 5 BK W 6 BK W LGN Y 1 2 Y BE GY BE O O W 1 2 TN V 3 1 2 4 1 2 3 1 2 3 165A 134B 88B 88A 89B 83B 83A 30B GY V R BK W LGN R 91A 121B 121A 160A TN W BK W R W 133B GY GY O GN GY BK O 1 2 3 4 V BN O W BK Key Switch Accessary Igniton Brake Horn EVA Cooling Fan ECM Lights 6 5 4 3 23 16 18 12 11 10 9 17 22 24 Auxiliary 21 15 Fuel Pump R BK Y BN O W O R GY O R GY Y BE R R R BK R R R R ...

Page 574: ...Figure B 3 Figure B 3 Main Harness Firebolt Main Harness Firebolt ...

Page 575: ...IAGRAM Japan only CONNECTING WIRE SECT MM WIRE COLOR ON OFF LOCK V Y 4 TN Y 8 TN V 9 PK Y 11 W 13 LGN Y 14 LGN R 15 V R 16 LGN GY 17 GN W 18 BK W 19 R W 24 R W 25 BK BE 26 BK W 27 BK W 28 V GY 32 TN W 34 W 1 BK O 2 BK O 3 BK 8 GY 9 GY O 10 BK 16 Y 17 W 21 BK Y 23 BK 24 BE O 25 BN Y 27 BN Y 28 W Y 29 GN GY 30 Y BE Y BE 31 BE O 32 BK 33 34 2 4 8 9 11 13 14 15 16 17 18 19 24 25 26 27 28 32 34 1 2 3 8...

Page 576: ...Figure B 4 Figure B 4 Engine Management Circuit All Models Engine Management Circuit All Models ...

Page 577: ... USER USER 1 R BK R GY BATTERY BATTERY 1 R 0 0 0 PARK KEY POSITION IGNITION SWITCH WIRING DIAGRAM CONNECTING WIRE SECT MM WIRE COLOR ON OFF LOCK Speedometer 39A Ground Ignition Oil pressure Check engine High beam Right turn Left turn Neutral Battery 2 4 5 6 13 12 2 4 5 6 13 12 39B 10 Amp 30 Amp 15 Amp 15 Amp 10 Amp GRD 5 GRD 4 1 2 4 BK BE BK BK BK BN BK BK BN BK GRD 1 BK R Y R Y R Y R Y O W O W R ...

Page 578: ...Figure B 5 Figure B 5 Lighting Circuit Ulysses and Lightning Lighting Circuit Ulysses and Lightning ...

Page 579: ...N SWITCH WIRING DIAGRAM CONNECTING WIRE SECT MM WIRE COLOR ON OFF LOCK Speedometer 39A Ground Ignition Oil pressure Check engine High beam Right turn Left turn Neutral Battery 2 4 5 6 13 12 2 4 5 6 13 12 39B GRD 4 GRD 4 1 2 4 BE BK BK BK BK BK BN BN BK BN BK BK R Y R Y O W R Y R Y O V O R Y O R R R R R R R GY R BK R BK R GY R BK BK BK BN BE BE BN BE BE BE BK BK O W O W BK BN R Y R Y V V O W O W O ...

Page 580: ...Figure B 6 Figure B 6 Lighting Circuit Firebolt Lighting Circuit Firebolt ...

Page 581: ...R BK R GY BATTERY BATTERY 1 R 0 0 0 0 0 PARK KEY POSITION IGNITION SWITCH WIRING DIAGRAM CONNECTING WIRE SECT MM WIRE COLOR ON OFF LOCK Tachometer output System ground 2 7 7 Start relay System ground 1 Vehicle speed sensor Sensor ground Sidestand switch 5V sensor power Speedometer 39A VSS in Low fuel Tach in Ground Ignition Oil pressure Neutral Battery 8 3 2 12 16 15 14 13 8 3 2 12 16 15 14 13 39B...

Page 582: ...Figure B 7 Figure B 7 Horn and Instruments Circuit All Models Horn and Instruments Circuit All Models ...

Page 583: ... 24 4 8 2 2 1 1 1 1 IGN 3 3 3 3 4 4 1 2 3 1 1 2 2 Brake Horn EVA Key Switch 131A 1 0 2 4 3 1 1 R 1 USER 1 R BK R GY BATTERY BATTERY 1 R 0 0 0 0 0 PARK KEY POSITION IGNITION SWITCH WIRING DIAGRAM CONNECTING WIRE SECT MM WIRE COLOR ON OFF LOCK Tachometer output System ground B 7 7 Start relay System ground A Vehicle speed sensor Sensor ground Sidestand switch 5V sensor power Speedometer 39A VSS in L...

Page 584: ...Figure B 8 Figure B 8 Horn and Instruments Circuit Firebolt Horn and Instruments Circuit Firebolt ...

Page 585: ...GY GY R R 10 5 87 87A 30 85 86 Ignition Key Sw Start 4 7 15 6 9 14 2 19 11 1 2 3 1 2 3 4 1 1 2 Ignition Key Switch 131A 1 Male Female 0 0 0 2 4 3 1 1 R 1 1 R BK R GY BATTERY BATTERY 1 R 0 0 0 PARK KEY POSITION IGNITION SWITCH WIRING DIAGRAM CONNECTING WIRE SECT MM WIRE COLOR ON OFF LOCK 15 Amp 37 43 BE R BK Lights 15 Amp 29 23 O R BK Brake Horn EVA 10 Amp 15 Amp R R Y R Y 87 87A 30 85 86 87 87A 30...

Page 586: ...Figure B 9 Figure B 9 Starting Circuit Ulysses and Lightning Starting Circuit Ulysses and Lightning ...

Page 587: ... V W GN O GY GY R R 10 5 87 87A 30 85 86 Ignition Key Sw Start 4 7 6 9 2 1 2 3 1 2 3 4 1 1 2 Ignition Key Switch 131A 1 Male Female 0 0 0 2 4 3 1 1 R 1 USER 1 R BK R GY BATTERY BATTERY 1 R 0 0 0 PARK KEY POSITION IGNITION SWITCH WIRING DIAGRAM CONNECTING WIRE SECT MM WIRE COLOR ON OFF LOCK 15 Amp 17 23 BE R BK Lights 15 Amp 9 3 O R BK Brake Horn EVA 10 Amp 15 Amp R R Y R Y 87 87A 30 85 86 87 87A 3...

Page 588: ...Figure B 10 Figure B 10 Starting Circuit Firebolt Starting Circuit Firebolt ...

Page 589: ...77B To Voltage Regulator Starter Motor Battery 2 1 1 2 2 2 1 1 41 35 Fuse Relay Assembly Battery 30 Amp Ulysses Lightning Firebolt OR 61B BK BK BK BK BK BK BK BK R Y R 1 2 Fuse Relay Assembly Battery 30 Amp J FUSE 5 R Y R GRD2 et00005 Figure B 11 Charging Circuits All Models ...

Page 590: ...Figure B 11 Figure B 11 Charging Circuits All Models Charging Circuits All Models ...

Page 591: ...ontrols Left Hand Controls 24B 189LA 189LB 189RA 189RB R Heat Grip L Heat Grip 1 2 3 1 2 3 1 2 3 2 3 4 5 6 7 8 1 1 2 3 1 2 3 To Heated Grips Switch Right Side Left Side 4 BK R W BK W BK O R BK BN BE BK BN BE BK O R BK BK BN BN BE BE O O BN PK P BN Y BK BE Y W et00087 Figure B 12 Heated Hand Grips Ulysses ...

Page 592: ...Figure B 12 Figure B 12 Heated Hand Grips Ulysses Heated Hand Grips Ulysses ...

Page 593: ...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 594: ...NOTES ...

Page 595: ...2 1 535 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 03...

Page 596: ...e measurements in this Service Manual do not include the British Imperial Imp system equivalents The fol lowing conversions exist in the British Imperial system 1 pint Imp 20 fluid ounces Imp 1 quart Imp 2 pints Imp 1 gallon Imp 4 quarts Imp Although the same unit of measure terminology as the U S system is used in the British Imperial Imp system the actual volume of each British Imperial unit of ...

Page 597: ...lbs X 0 08333 foot pounds ft lbs METRIC SYSTEM All metric torque specifications are written in Newton meters Nm To convert metric to United States units and United States to metric use the following equations Newton meters Nm X 0 737563 foot pounds ft lbs Newton meters Nm X 8 85085 inch pounds in lbs foot pounds ft lbs X 1 35582 Newton meters Nm inch pounds in lbs X 0 112985 Newton meters Nm 2008 ...

Page 598: ...C 4 2008 XB Service Appendix C Conversions NOTES ...

Page 599: ...SUBJECT PAGE NO D 1 APPENDIX D HOSE AND WIRE ROUTING D 1 APPENDIX D HOSE AND WIRE ROUTING ...

Page 600: ...NOTES ...

Page 601: ...D 1 APPENDIX D HOSE AND WIRE ROUTING FIREBOLT 2008 XB Service Appendix D Hose and Wire Routing D 1 ...

Page 602: ...sm04328 Figure D 1 Front and Rear Brake Systems Right Side View D 2 2008 XB Service Appendix D Hose and Wire Routing ...

Page 603: ...sm04332 Figure D 2 Rear Brake Systems Top View 2008 XB Service Appendix D Hose and Wire Routing D 3 ...

Page 604: ...sm04334 Figure D 3 Rear Brake Systems Left Side View D 4 2008 XB Service Appendix D Hose and Wire Routing ...

Page 605: ...1 sm04337 1 Carbon canister Figure D 4 Evaporative Emissions Control California Models Top View 2008 XB Service Appendix D Hose and Wire Routing D 5 ...

Page 606: ... From 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 D 6 2008 XB Service Appendix D Hose and Wire Routing ...

Page 607: ... 4 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 2008 XB Service Appendix D Hose and Wire Routing D 7 ...

Page 608: ...ector 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 D 8 2008 XB Service Appendix D Hose and Wire Routing ...

Page 609: ...speed 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 2008 XB Service Appendix D Hose and Wire Routing D 9 ...

Page 610: ...4 5 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 D 10 2008 XB Service Appendix D Hose and Wire Routing ...

Page 611: ...1 2 sm04367 1 Exhaust valve actuator 2 Muffler valve Figure D 10 Clutch Cable and Exhaust Valve Actuator Right Side View 2008 XB Service Appendix D Hose and Wire Routing D 11 ...

Page 612: ...m04371 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 D 12 2008 XB Service Appendix D Hose and Wire Routing ...

Page 613: ... 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 LIGHTNING 2008 XB Service Appendix D Hose and Wire Routing D 13 ...

Page 614: ...sm04329 Figure D 13 Front and Rear Brake Systems Right Side View D 14 2008 XB Service Appendix D Hose and Wire Routing ...

Page 615: ...sm04331 Figure D 14 Rear Brake Systems Top View 2008 XB Service Appendix D Hose and Wire Routing D 15 ...

Page 616: ...sm04335 Figure D 15 Rear Brake Systems Left Side View D 16 2008 XB Service Appendix D Hose and Wire Routing ...

Page 617: ...1 sm04338 1 Carbon canister Figure D 16 Evaporative Emissions Control California Models Top View 2008 XB Service Appendix D Hose and Wire Routing D 17 ...

Page 618: ...From 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 D 18 2008 XB Service Appendix D Hose and Wire Routing ...

Page 619: ... 4 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 2008 XB Service Appendix D Hose and Wire Routing D 19 ...

Page 620: ...7 1 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 D 20 2008 XB Service Appendix D Hose and Wire Routing ...

Page 621: ...peed 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 2008 XB Service Appendix D Hose and Wire Routing D 21 ...

Page 622: ... 5 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 D 22 2008 XB Service Appendix D Hose and Wire Routing ...

Page 623: ...1 2 sm04369 1 Exhaust valve actuator 2 Muffler valve Figure D 22 Clutch Cable and Exhaust Valve Actuator XB12 Models Right Side View 2008 XB Service Appendix D Hose and Wire Routing D 23 ...

Page 624: ... 1 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 D 24 2008 XB Service Appendix D Hose and Wire Routing ...

Page 625: ...k 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 ULYSSES 2008 XB Service Appendix D Hose and Wire Routing D 25 ...

Page 626: ...sm04330 Figure D 25 Front and Rear Brake Systems Right Side View D 26 2008 XB Service Appendix D Hose and Wire Routing ...

Page 627: ...sm04333 Figure D 26 Rear Brake Systems Top View 2008 XB Service Appendix D Hose and Wire Routing D 27 ...

Page 628: ...sm04336 Figure D 27 Rear Brake Systems Left Side View D 28 2008 XB Service Appendix D Hose and Wire Routing ...

Page 629: ...1 sm04339 Figure D 28 Evaporative Emissions Control California Models Top View 2008 XB Service Appendix D Hose and Wire Routing D 29 ...

Page 630: ...From 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 D 30 2008 XB Service Appendix D Hose and Wire Routing ...

Page 631: ... 1 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 2008 XB Service Appendix D Hose and Wire Routing D 31 ...

Page 632: ...8 1 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 D 32 2008 XB Service Appendix D Hose and Wire Routing ...

Page 633: ...Vehicle 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 2008 XB Service Appendix D Hose and Wire Routing D 33 ...

Page 634: ...d 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 D 34 2008 XB Service Appendix D Hose and Wire Routing ...

Page 635: ...2 1 sm04370 1 Exhaust valve actuator 2 Muffler valve Figure D 34 Clutch Cable and Exhaust Valve Actuator Right Side View 2008 XB Service Appendix D Hose and Wire Routing D 35 ...

Page 636: ...m04373 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 D 36 2008 XB Service Appendix D Hose and Wire Routing ...

Page 637: ... lock 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 2008 XB Service Appendix D Hose and Wire Routing D 37 ...

Page 638: ...D 38 2008 XB Service Appendix D Hose and Wire Routing NOTES ...

Page 639: ...SUBJECT PAGE NO E 1 ACTIVE INTAKE SYSTEM JAPANESE MODELS ONLY E 1 APPENDIX E ACTIVE INTAKE JAPANESE MODELS ...

Page 640: ...NOTES ...

Page 641: ...Check 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 clea...

Page 642: ... in 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 ...

Page 643: ...ss 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 A...

Page 644: ...ical 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 6 Remove the two fasteners at the front on the solenoid bracket ...

Page 645: ...e in baseplate first and then insert active cable and then grommet Follow next step only if solenoid was removed 2 Install solenoid 8 into bracket 9 and tighten pinch fastener to 48 60 in lbs 5 4 6 7 Nm and bracket to solenoid fasteners to 20 24 in lbs 2 3 2 7 Nm 3 Install active cable 2 into bracket 4 and leave jam nut 5 loose until the setting can be verified 4 Connect active cable 2 to solenoid...

Page 646: ...E 6 2008 XB Service Appendix E Active Intake Japanese Models NOTES ...

Page 647: ...SUBJECT PAGE NO F 1 GLOSSARY F 1 APPENDIX F GLOSSARY ...

Page 648: ...NOTES ...

Page 649: ... 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 GAL Gross ...

Page 650: ... 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 Reserve RES Revolutions Per Minute RPM Cubic Feet per Hour at Standard Conditions SCFH Throttle Control Actuator TCA Top Dead Center TDC Twist Grip Sensor TGS Throttle Positi...

Page 651: ...Table F 1 Acronyms and Abbreviations DESCRIPTION ACRONYM OR ABBREVIATION Vehicle Identification Number VIN Vehicle Speed Sensor VSS 2008 XB Service Appendix F Glossary F 3 ...

Page 652: ...F 4 2008 XB Service Appendix F Glossary NOTES ...

Page 653: ...ET HOLDING TOOL B 43982 6 16 TRANSMISSION SPROCKET Installation SPROCKET HOLDING TOOL B 43982 6 14 TRANSMISSION INSTALLATION Installation INSTALLER B 43985 3 6 14 TRANSMISSION INSTALLATION Installation GUIDE B 43985 4 6 14 TRANSMISSION INSTALLATION Installation GUIDE B 43985 4 2 4 FRONT WHEEL Assembly FRONT WHEEL BEARING INSTALLER B 43993 10 2 5 REAR WHEEL Assembly FRONT WHEEL BEARING INSTALLER B ...

Page 654: ...ON Installation TRANSMISSION FIXTURE B 46285 4 2 17 FRONT FORK XB12STT XB12X XB12XT Assembly FORK SEAL DRIVER AND DUST BOOT INSTALLER B 48867 47MM 2 16 FRONT FORK ALL MODELS EXCEPT XB12STT XB12X XB12XT Assembly FRONT FORK OIL LEVEL GAUGE B 59000A 2 17 FRONT FORK XB12STT XB12X XB12XT Assembly FRONT FORK OIL LEVEL GAUGE B 59000A 3 17 CRANKCASE Piston Jets SNAP ON BODY DENT PULLER CJ114 7 3 IGNITION ...

Page 655: ...Leakage Test CYLINDER LEAKDOWN TESTER HD 35667A 3 6 CYLINDER HEAD Procedure For Using The Neway Valve Seat Cutter NEWAY VALVE SEAT CUTTER SET HD 35758 C A 14 PACKARD METRI PACK TERMINALS Metri Pack Terminal Crimps PACKARD TERMINAL CRIMP TOOL HD 38125 6 A 1 AMP 1 PLACE CONNECTORS AMP 1 Place Con nector Repair PACKARD TERMINAL CRIMPER HD 38125 7 A 8 DEUTSCH MINI TERMINAL REPAIR Deutsch Mini Terminal...

Page 656: ...P MULTILOCK CONNECTORS AMP Multilock Connector Repair AMP MULTILOCK CRIMPER HD 41609 6 8 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL Right Crankcase Removal ENGINE SUPPORT STAND HD 42310 HD 43646 OR HD 43682 3 7 CYLINDER AND PISTON Assembly Installation PISTON SUPPORT PLATE HD 42322 3 17 CRANKCASE Assembly CRANKSHAFT GUIDE HD 42326 B 6 14 TRANSMISSION INSTALLATION Installing Right Crankcase CRANKSHA...

Page 657: ...H HD 94660 37B 6 16 TRANSMISSION SPROCKET Installation MAINSHAFT LOCKNUT WRENCH HD 94660 37B 3 7 CYLINDER AND PISTON Connecting Rod Bushing REAMER HD 94800 26A 3 6 CYLINDER HEAD Replacing Rocker Arm Bushings ROCKER ARM BUSHING REAMER HD 94804 57 3 17 CRANKCASE Piston Jets CLAW PULLER HD 95635 46 3 17 CRANKCASE Pinion Shaft Bearing CLAW PULLER HD 95635 46 6 11 MAIN DRIVE GEAR AND BEARING Disassembl...

Page 658: ...ation MARSON THREAD SETTER TOOL KIT MAR39200HD 2 21 SWINGARM AND BRACE Disassembly SLIDE HAMMER SNAP ON CJ1275 2 13 REAR BRAKE LINE Installation Lightning FLARE NUT SOCKET SNAP ON FRXB14 2 13 REAR BRAKE LINE Installation Firebolt FLARE NUT SOCKET SNAP ON FRXM14 4 7 ENGINE TEMPERATURE SENSOR ET Removal ENGINE TEMPERATURE SENSOR SOCKET SNAP ON M3503B 6 13TRANSMISSION LEFT CASE BEARINGS Removal SNAP ...

Page 659: ...6 Nm 39 41 ft lbs Axle front 2 5 REAR WHEEL Installation Follow special instructions ANTI SEIZE 65 1 70 5 Nm 48 52 ft lbs Axle rear final torque 2 5 REAR WHEEL Installation Follow special instructions ANTI SEIZE 31 2 36 6 Nm 23 27 ft lbs Axle rear initial torque 2 39 BELT GUARDS Installation 54 61 Nm 40 45 ft lbs Axle pinch fastener rear 6 6 DRIVE BELT AND IDLER PULLEY Drive Belt Installation 54 6...

Page 660: ...erminal fasteners 2 25 REAR SHOCK ABSORBER Installation Ulysses 8 11 Nm 72 96 in lbs Battery terminal fasteners 2 27 CLUTCH CONTROL Assembly and Installa tion 8 11 Nm 72 96 in lbs Battery terminal fasteners 2 28 HEADLAMP ASSEMBLY AND SUPPORT BRACKET Installation Firebolt 8 11 Nm 72 96 in lbs Battery terminal fasteners 2 28 HEADLAMP ASSEMBLY AND SUPPORT BRACKET Installation Lightning Ulysses 8 11 N...

Page 661: ...TARTER Installation 8 11 Nm 72 96 in lbs Battery terminal fasteners 5 2 STARTER Installation 8 11 Nm 72 96 in lbs Battery terminal fasteners 7 3 IGNITION HEADLAMP KEY SWITCH Installa tion Firebolt 8 11 Nm 72 96 in lbs Battery terminal fasteners 7 3 IGNITION HEADLAMP KEY SWITCH Installa tion Lightning 8 11 Nm 72 96 in lbs Battery terminal fasteners 7 3 IGNITION HEADLAMP KEY SWITCH Installa tion Uly...

Page 662: ... cylinder banjo bolt rear 2 13 REAR BRAKE LINE Installation Ulysses 22 27 Nm 16 20 ft lbs Brake light switch master cylinder banjo bolt rear 2 9 FRONT 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 Installation Lightning 4 7 Nm 36 60 in lbs Brake line ...

Page 663: ...ENGINE INSTALLATION Assembly 40 6 44 7 Nm 30 33 ft lbs Center tie bar mount to engine fasteners 1 3 MAINTENANCE SCHEDULE General 27 34 Nm 20 25 ft lbs Chain tensioner nut 2 53 CHIN FAIRING Installation 4 5 Nm 36 48 in lbs Chin fairing fasteners 6 6 DRIVE BELT AND IDLER PULLEY Idler Pulley Installation LOCTITE 271 red 4 5 Nm 36 48 in lbs Chin fairing fasteners 2 22 FRONT AND REAR ISOLATORS Front Is...

Page 664: ...120 in lbs Cylinder head screws initial tightening 3 17 CRANKCASE Assembly Special method required to tighten 14 27 Nm 10 20 ft lbs Cylinder studs 2 17 FRONT FORK XB12STT XB12X XB12XT Assembly 30 41 Nm 22 30 ft lbs damper rod jamnut 2 30 DEFLECTORS XB9SX XB12STT XB12X XB12XT Assembly and Installation 2 7 4 1 Nm 24 36 in lbs Deflector fasteners 2 30 DEFLECTORS XB9SX XB12STT XB12X XB12XT Assembly an...

Page 665: ...sembly LOCTITE 271 red 34 38 Nm 25 28 ft lbs Footpeg mount Firebolt and Lightning 2 39 BELT GUARDS Installation 15 16 3 Nm 132 144 in lbs Footpeg mount fasteners rider 2 36 FOOTPEG HEEL GUARD AND MOUNT FIREBOLT LIGHTNING Rider 14 9 16 2 Nm 132 144 in lbs Footpeg mount fasteners rider Firebolt and Lightning 2 57 LUGGAGE XB12XT Installation Side Case 14 9 16 2 Nm 132 144 in lbs Footpeg support brack...

Page 666: ... FENDERS Front Fender XB12STT 1 4 4 0 Nm 12 36in lbs Front fender fasteners and washers 2 15 FENDERS Front Fender XB12STT 4 0 5 4 Nm 36 48in lbs Front fender fasteners and washers 2 20 FRONT FORK SLIDER PROTECTORS XB12STT Replacement XB12STT 1 3 4 Nm 12 36 in lbs Front fork protectors fasteners 2 22 FRONT AND REAR ISOLATORS Front Isol ator 66 69 Nm 49 51 ft lbs Front isolator bolt 3 3 ENGINE ROTAT...

Page 667: ...rew 2 34 HANDLEBARS LIGHTNING ULYSSES Installation LOCTITE 271 red Tighten front screws first 14 16 Nm 10 12 ft lbs Handlebar clamp screws Lightning and Ulysses 2 34 HANDLEBARS LIGHTNING ULYSSES Installation LOCTITE 271 red Tighten front screws first 14 16 Nm 10 12 ft lbs Handlebar clamp screws Lightning and Ulysses 2 33 HANDLEBARS FIREBOLT Installation 33 35 Nm 24 26 ft lbs Handlebar clip on fast...

Page 668: ...ation 45 47 Nm 33 35 ft lbs Idler pullye assembly 2 26 THROTTLE CONTROL Throttle Cable Replacement 13 6 16 3 Nm 120 144 in lbs Ignition coil fasteners 3 3 ENGINE ROTATION FOR SER VICE Assembly 13 6 16 3 Nm 120 144 in lbs Ignition coil fasteners 3 5 ENGINE INSTALLATION Assembly 13 6 16 3 Nm 120 144 in lbs Ignition coil fasteners 4 5 IGNITION COIL Installation 13 6 16 3 Nm 120 144 in lbs Ignition co...

Page 669: ...17 FRONT FORK XB12STT XB12X XB12XT Installation 27 2 20 Nm 20 22 ft lbs Lower fork clamp fasteners 7 15 HEADLIGHT Headlight Bulbs Lightning and Ulysses 4 5 5 Nm 36 48 in lbs Lower headlight fastener 3 6 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 6 CYLINDER HEAD Cylinder Head Installation 24 30 Nm 18 22 ft lbs Lower rocker box bolts 5 ...

Page 670: ...attery cable at battery terminal 6 4 CLUTCH Assembly and Installation 8 6 10 9 Nm 72 96 in lbs Negative battery cable at battery terminal 6 5 PRIMARY CHAIN Installation 8 1 10 9 Nm 72 96 in lbs Negative battery cable at battery terminal 7 14 INTERACTIVE EXHAUST SYSTEM Installa tion 8 11 Nm 72 96 in lbs Negative battery cable at battery terminal 7 15 HEADLIGHT Headlight Bulbs Firebolt 8 11 Nm 72 96...

Page 671: ...s Pinch fastener E 1 ACTIVE INTAKE SYSTEM JAPANESE MODELS ONLY Installation 5 4 6 7 Nm 48 60 in lbs Pinch fastener 3 16 GEARCASE AND CAM GEARS Assembly and Installation Plus an additional 15 to 19 rotation 26 29 Nm 19 21 ft lbs Pinion shaft nut 3 17 CRANKCASE Piston Jets TORX LOCTITE LOW STRENGTHTHREADLOCKER 222 purple 2 8 4 0 Nm 25 35 in lbs Piston jet assembly screws 2 25 REAR SHOCK ABSORBER Rem...

Page 672: ... 4 4 0 Nm 12 36 in lbs Rear fender fasteners 2 21 SWINGARM AND BRACE Installation Swingarm 1 4 4 Nm 12 36 in lbs Rear fender fasteners 3 5 ENGINE INSTALLATION Assembly 33 9 36 6 Nm 25 27 ft lbs Rear isolator assembly fasteners 3 3 ENGINE ROTATION FOR SER VICE Assembly 33 9 36 6 Nm 25 27 ft lbs Rear isolator bolt 3 5 ENGINE INSTALLATION Assembly 33 9 36 6 Nm 25 27 ft lbs Rear isolator bolt 3 5 ENGI...

Page 673: ...lbs Rotor mounting fasteners front 2 5 REAR WHEEL Assembly Replace with new 34 37 Nm 25 27 ft lbs Rotor mounting fasteners rear 1 3 MAINTENANCE SCHEDULE General 10 12 Nm 84 108 in lbs Screw primary chain inspection cover 2 55 SEAT LOCKS Installation Ulysses Models 6 7 10 8 Nm 60 96 in lbs Seat lock bracket fasteners Ulysses 2 55 SEAT LOCKS Installation Lightning 6 7 8 Nm 60 72 in lbs Seat lock lat...

Page 674: ... in lbs Stator TORX mounting screws 7 23 MAIN WIRE HARNESS Installation 21 7 2404 Nm 16 18 ft lbs Steering head clamp fastener 7 23 MAIN WIRE HARNESS Installation 21 7 24 4 Nm 16 18 ft lbs Steering head wiring clamp 7 3 IGNITION HEADLAMP KEY SWITCH Installa tion Firebolt 52 57 Nm 38 42 ft lbs Steering stem cap 1 11 STEERING HEAD BEARINGS Determining Proper Resistance 52 57 Nm 38 42 ft lbs Steering...

Page 675: ... Tail sections to main frame fuel tank assembly Ulysses 2 47 RIGHT TAIL SECTION XB12X XB12XT Assembly LOCTITE 271 red 28 5 31 2 Nm 21 23 ft lbs Tail sections to main frame fuel tank assembly Ulysses 2 46 CENTER TAIL LOOP XB12X XB12XT Assembly 27 30 Nm 20 22 ft lbs Tail sections to tail loop Ulysses 2 47 RIGHT TAIL SECTION XB12X XB12XT Assembly 27 1 29 8 Nm 20 22 ft lbs Tail sections to tail loop U...

Page 676: ...lbs Turn signal fasteners front 7 11 TURN SIGNAL FLASHER Installation 4 6 7 Nm 36 60 in lbs Turn signal flasher fastener 7 12 FRONT TURN SIGNALS Bulbs 0 5 0 6 Nm 4 4 4 3 in lbs Turn signal housing screw 7 13 REAR TURN SIGNALS Bulbs 0 5 0 6 Nm 4 4 4 3 in lbs Turn signal housing screw 2 17 FRONT FORK XB12STT XB12X XB12XT Installation 31 2 33 8 Nm 23 25 ft lbs Upper fork clamp fasteners 2 15 FENDERS ...

Page 677: ...1 4 Nm 10 12 in lbs Windscreen fasteners Ulysses 7 17 LICENSE PLATE LAMP ASSEMBLY Ulysses 4 1 5 4 Nm 36 48 in lbs Wire cover front fasteners 7 17 LICENSE PLATE LAMP ASSEMBLY Ulysses 1 4 4 1 Nm 12 36 in lbs Wire cover rear fasteners 2 46 CENTER TAIL LOOP XB12X XB12XT Assembly 4 5 4 Nm 36 48 in lbs Wire cover screws Ulysses 2 55 SEAT LOCKS Installation Ulysses Models 4 5 4 Nm 36 48 in lbs Wire cover...

Page 678: ...XXVI TORQUE VALUES NOTES ...

Page 679: ...ng Battery 1 10 Cleaning and Inspection 1 10 Disconnection and Removal 1 10 Installation and Connection 1 11 Storage 1 12 Battery Cables Installation 7 19 Removal 7 19 Battery Maintenance 1 9 Battery Pan Assembly Lightning 2 122 Assembly Ulysses 2 127 Cleaning Lightning 2 121 Cleaning Ulysses 2 126 Disassembly Lightning 2 120 Disassembly Ulysses 2 126 Bearings Steering Head 1 32 Belt Gaurds Instal...

Page 680: ...nspection 3 39 Disassembly 3 36 Installation 3 46 Removal 3 34 Cylinder Leakage Test 3 5 D Deflectors Handlebars Assembly and Installation 2 99 Removal and Disassembly 2 99 Deglazing Cylinder 3 52 Delphi Connector Repair A 8 Deutsch Connector Crimping Mini Terminals A 17 Crimping Solid Barrel Terminals A 15 Crimping Standard Terminals A 14 Repair A 10 Digital Dynamic Fuel Injection 4 16 Throttle P...

Page 681: ...llation 2 76 Removal 2 76 Front Brake Caliper Assembly 2 31 Cleaning and Inspection 2 30 Disassembly 2 30 Installation 2 31 Removal 2 30 Front Brake Hand Lever Assembly 2 26 Cleaning and Inspection 2 26 Disassembly 2 25 Installation 2 27 Removal 2 25 Front Brake Line Removal 2 28 Front Brake Master Cylinder Assembly 2 26 Cleaning and Inspection 2 26 Disassembly 2 25 Installation 2 27 Removal 2 25 ...

Page 682: ...roubleshooting 7 29 Hose and Wire Routing Firebolt D 1 Lightning D 13 Ulysses D 25 Hydraulic Lifters 3 74 Cleaning and Inspection 3 74 Installation 3 75 Removal 3 74 I Idler Pulley Inspection 1 28 Replacement 6 23 Ignition Headlamp Key Switch Installation Lightning 7 11 Ignition Headlight Key Switch Assembly Firebolt 7 6 Assembly Lightning 7 9 Assembly Ulysses 7 13 Disassembly Firebolt 7 6 Disasse...

Page 683: ...62 Metric System C 2 Metri Pack Terminals Crimping A 27 Mirrors Installation 2 106 Installation Firebolt 2 135 Removal 2 106 Removal Firebolt 2 135 Molex Connector Repair A 18 Terminal Crimps A 19 N Neutral Indicator Switch General 7 55 Removal and Installation 7 55 Testing 7 55 Neway Valve Seat Cutter How To Use 3 43 Number Plates XB12STT General 2 140 Number Plates XB12STT Only Installation 2 14...

Page 684: ...rdware and Threaded Parts 1 2 Lip Type Seals 1 2 O Rings Preformed Packings 1 3 Part Replacement 1 3 Shafts 1 3 Threadlocking Agents 1 2 Wiring Hoses and Lines 1 2 Right Tail Section Assembly Lightning 2 125 Assembly Ulysses 2 132 Disassembly Lightning 2 125 Disassembly Ulysses 2 131 Rim Runout 2 24 Rocker Arm Cleaning and Inspection 3 39 Rocker Arms and Bushings 3 41 S Safe Operating Maintenance ...

Page 685: ...ral 4 27 Installation 4 30 Removal 4 27 Repair 4 30 Throttle Cable Adjustment 1 38 Throttle Cables Installation 2 85 Removal 2 85 Throttle Control Cleaning and Inspection 2 85 Throttle Position Sensor 4 8 Installation 4 8 Removal 4 8 Tires Adjustment 2 23 Cleaning and Inspection 2 21 General 2 20 Inflation 1 23 Installation 2 21 Lateral Runout 2 22 Pressure 1 23 Radial Runout 2 22 Removal 2 21 Rep...

Page 686: ...Service Wear Limits table 3 42 Vehicle Identification Number 2 4 Vehicle Speed Sensor Installation 7 58 Removal 7 58 Voltage Regulator General 7 22 Installation 7 22 Removal 7 22 W Wheel Balancing 2 23 Wheel Runout table 2 24 Wheels Bearings 1 24 Cleaning and Inspection 2 10 Cleaning and Inspection 2 16 Front Wheel Assembly 2 11 Front Wheel Disassembly 2 8 Front Wheel Installation 2 14 Front Wheel...

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