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1.20

WINDSHIELD MAINTENANCE

GENERAL

Polycarbonate windscreens/windshields require proper
attention and care to maintain. Failure to maintain
polycarbonate properly can result in damage to the wind-
screen/windshield. (00483d)

Buell recommends using Harley Softcloths with the following
products to clean your windscreen. To minimize swirl marks,
cleaning should be done when motorcycle is cool and parked
in the shade.

•

HARLEY-DAVIDSON BUG REMOVER (Part No. 94657-
98).

•

HARLEY-DAVIDSON SUNWASH (PART No. 94659-98).

•

NOVUS 1 CLEANER/PROTECTANT (Part No. 99837-
94T).

•

NOVUS 2 SCRATCH REMOVER (Part No. 99836-94T).

•

HARLEY GLAZE (Part No. 99701-84) to polish and seal
after cleaning.

NOTE

Faint swirl marks are normal and may be more visible on tinted
than on clear windshields.

sm03605

Figure 1-59. Windshield: Firebolt

2010 XB Service: Maintenance 1-49

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Summary of Contents for XB 2010

Page 1: ...2010 Buell XB Models Service Manual 99490 10Y 2009 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: ...2010 Buell XB Models Service Manual 2009 Buell Motorcycle Company ALL RIGHTS RESERVED 99490 10Y 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: ... be cleaned before work starts Cleaning will occasionally uncover sources of trouble Tools instruments and any parts needed for the job should be gathered before work is started Interrupting a job to locate tools or parts is a distraction and causes needless delay NOTES To avoid unnecessary disassembly carefully read all rel ative service information before repair work is started In figure legends...

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

Page 9: ...1 11 Engine Oil Level 1 11 Cold Check Pre Ride 1 11 Hot Check 1 11 Change Engine Oil and Filter 1 12 Drain Oil 1 12 Change Filter 1 12 Fill Engine With Oil 1 12 Clear Oil Cooler 1 13 Return to Service 1 13 1 7 AIR CLEANER AND EXHAUST SYSTEM Removal 1 14 Cleaning and Inspection 1 15 Installation 1 15 Exhaust System Leak Check 1 16 1 8 TIRES AND WHEELS Tire Inflation 1 17 Tire Wear 1 17 Wheel Bearin...

Page 10: ...ctrical System 1 53 Alternator Does Not Charge 1 53 Alternator Charge Rate Is Below Normal 1 53 Speedometer Operates Erratically 1 53 Transmission 1 53 Shifts Hard 1 53 Jumps Out Of Gear 1 53 Clutch Slips 1 53 Clutch Drags Or Does Not Release 1 53 Clutch Chatters 1 53 Clutch 1 53 Slips 1 53 Drags or Does Not Release 1 53 Chatters 1 53 Chassis 1 53 Irregular Inadequate Brake Action 1 53 Handling Ir...

Page 11: ...Brake Caliper Removal 2 62 Brake Caliper Disassembly 2 63 Brake Caliper Cleaning and Inspection 2 63 Brake Caliper Assembly 2 64 Installation 2 64 2 11 BRAKE PEDAL Removal 2 66 Installation 2 66 2 12 REAR BRAKE MASTER CYLINDER Removal Firebolt Lightning 2 67 Removal Ulysses 2 68 Disassembly 2 70 Cleaning and Inspection 2 70 Assembly 2 70 Installation Firebolt Lightning 2 71 Installation Ulysses 2 ...

Page 12: ...113 Removal and Disassembly 2 113 Clutch Cable 2 113 Assembly and Installation 2 115 Clutch Cable 2 115 2 26 HEADLAMP ASSEMBLY AND SUPPORT BRACKET Removal Firebolt 2 117 Disassembly Firebolt 2 117 Assembly Firebolt 2 117 Installation Firebolt 2 118 Removal Lightning Ulysses 2 119 Disassembly Lightning Ulysses 2 121 Assembly Lightning Ulysses 2 121 Installation Lightning Ulysses 2 122 2 27 FAIRING ...

Page 13: ...L LOOP ULYSSES MODELS Disassembly 2 156 Assembly 2 156 2 45 TRUNK AND BATTERY PAN ULYSSES MODELS Disassembly Trunk and Battery Pan 2 158 Assembly Trunk Pan and Battery Pan 2 158 2 46 SIDESTAND General 2 159 Removal 2 159 Disassembly 2 159 Assembly 2 160 Installation 2 160 2 47 FRONT FAIRING WINDSHIELD AND MIRRORS FIREBOLT Removal 2 161 Installation 2 161 2 48 WINDSHIELD AND WINDSCREEN LIGHTNING AN...

Page 14: ...n 3 24 Installing Engine in Frame 3 25 3 7 CYLINDER HEAD Removal 3 35 Rocker Box Assemblies 3 35 Cylinder Head Assemblies 3 37 Disassembly 3 37 Cleaning and Inspection 3 40 Cylinder Heads 3 40 Rocker Arm Assemblies 3 40 Valves 3 41 Valve Seats 3 41 Valve Guides 3 41 Valve Springs 3 42 Spark Plug Threads 3 42 Push Rods 3 42 Replacing Rocker Arm Bushings 3 42 Replacing Valve Guides 3 43 Procedure Fo...

Page 15: ...llation 4 5 4 4 ELECTRONIC CONTROL MODULE ECM Firebolt 4 7 Removal 4 7 Installation 4 7 Lightning 4 7 Removal 4 7 Installation 4 7 Ulysses 4 8 Removal 4 8 Installation 4 8 4 5 THROTTLE POSITION SENSOR TPS Removal 4 10 Installation 4 10 4 6 IGNITION COIL Removal 4 11 Installation 4 11 4 7 OXYGEN SENSORS O2 General 4 12 Removal 4 12 Installation 4 13 4 8 ENGINE TEMPERATURE SENSOR ET General 4 15 Rem...

Page 16: ...RIMARY COVER Removal 5 4 Primary Chain Adjuster Replacement 5 5 Installation 5 6 5 4 CLUTCH RELEASE MECHANISM Disassembly 5 8 Cleaning and Inspection 5 8 Assembly 5 9 5 5 CLUTCH General 5 10 Removal 5 12 Clutch Pack Cleaning and Inspection 5 13 Adjusting Screw Disassembly Assembly 5 13 Assembly and Installation 5 14 5 6 PRIMARY CHAIN General 5 17 Removal 5 17 Clutch Shell Hub Inspection 5 18 Clutc...

Page 17: ...6 9 Installation 6 10 Ulysses 6 10 Removal 6 10 Disassembly 6 11 Assembly 6 11 Installation 6 12 6 4 SPARK PLUG CABLES General 6 13 Removal 6 13 Inspection 6 13 Installation 6 13 6 5 CHARGING SYSTEM General 6 15 Alternator 6 15 Voltage Regulator 6 15 6 6 BATTERY CABLES Removal 6 18 Installation 6 18 6 7 STARTER General 6 21 Wiring Diagrams 6 21 Paint Touch Up 6 21 Removal 6 21 Field Coil Assembly ...

Page 18: ...P ASSEMBLY Firebolt 6 58 Removal 6 58 Installation 6 58 Lightning 6 58 Removal 6 58 Installation 6 58 Ulysses 6 59 Removal and Disassembly 6 59 Assembly and Installation 6 59 6 20 MAIN FUSE AND FUSES General 6 60 Fuses 6 60 Main Fuse 6 60 6 21 NEUTRAL INDICATOR SWITCH General 6 63 Testing 6 63 Removal and Installation 6 63 6 22 SIDESTAND SWITCH HDI Sidestand Switch HDI 6 64 Removal 6 64 Installati...

Page 19: ... Preparing Wire Leads For Crimping A 13 Adjusting Crimper Tool A 13 Crimping a Barrel Contact To Wire Lead A 13 Inspecting Crimps A 13 A 7 DEUTSCH MINI TERMINAL REPAIR Deutsch Mini Terminal Crimps A 15 Preparing Wire Leads for Crimping A 15 Crimping a Mini Terminal to Wire Lead A 15 Inspecting Crimps A 15 A 8 PACKARD 150 METRI PACK CONNECTORS 150 Metri Pack Connector Repair A 16 General A 16 Separ...

Page 20: ...ghtning D 14 Ulysses D 26 APPENDIX E ACTIVE INTAKE JAPANESE MODELS E 1 ACTIVE INTAKE SYSTEM JAPANESE MODELS ONLY General E 1 Active Intake System E 1 Diagnostic Notes E 1 Verify Settings E 1 WOT Check E 1 Cable E 1 Adjustment E 1 Throttle Stop Screw E 3 Removal E 4 Installation E 5 APPENDIX F GLOSSARY F 1 GLOSSARY Acronyms and Abbreviations F 1 REFERENCE MATERIAL TOOLS I TORQUE VALUES VII INDEX XX...

Page 21: ...AND WHEELS 1 17 1 9 CLUTCH TRANSMISSION PRIMARY FLUID 1 19 1 10 PRIMARY CHAIN 1 22 1 11 DRIVE BELT MAINTENANCE 1 24 1 12 THROTTLE CABLE 1 27 1 13 INTERACTIVE EXHAUST CABLE 1 28 1 14 BRAKE SYSTEM MAINTENANCE 1 30 1 15 SPARK PLUGS 1 37 1 16 BATTERY MAINTENANCE 1 39 1 17 STEERING HEAD BEARINGS 1 44 1 18 FRONT FORK OIL REPLACEMENT 1 45 1 19 HEADLAMP 1 46 1 20 WINDSHIELD MAINTENANCE 1 49 1 21 STORAGE 1...

Page 22: ...NOTES ...

Page 23: ...aliper bleeder valve 1 14 BRAKE SYSTEM MAINTENANCE Brake Pad Replacement 14 9 19 Nm 132 168 in lbs Front caliper pin hanger 1 14 BRAKE SYSTEM MAINTENANCE Bleeding Brakes 1 1 5 Nm 9 13 in lbs Front master cylinder reservoir cover fasteners 1 14 BRAKE SYSTEM MAINTENANCE Brake Pad Replacement 1 1 5 Nm 9 13 in lbs Front master cylinder reservoir cover fasteners 1 19 HEADLAMP Headlamp Adjustment Lightn...

Page 24: ...Replacement 14 9 19 Nm 132 168 in lbs Rear caliper pin hanger 1 14 BRAKE SYSTEM MAINTENANCE Brake Pad Replacement 2 7 Nm 24 in lbs Rear caliper pin plug 1 15 SPARK PLUGS Inspection 16 3 24 7 Nm 12 18 ft lbs Spark plug 1 17 STEERING HEAD BEARINGS Determining Proper Resistance 51 5 56 9 Nm 38 42 ft lbs Steering stem capnut 1 17 STEERING HEAD BEARINGS Determining Proper Resistance 27 1 29 8 Nm 20 22 ...

Page 25: ...sider 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 lifting operation...

Page 26: ...nd compressed air Always use the recommended threadlocking agent for the 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 damaged or defective instruments and gauges Bearings Anti friction bearings must be handled in a special way To keep out dirt and abrasives cover the bear...

Page 27: ...able petroleum cleaning solution Never use a solution that contains chlorine Knock out packed lubricant by tapping the bearing against a wooden block Wash bearings again Using compressed air to spin dry bearings can cause bearing to fly apart which could result in death or serious injury 00505b Cover bearings with a clean shop towel and allow to air dry Do not spin bearings while they are drying N...

Page 28: ...h the entire contents of service kit Never hammer on a ratchet or put a pipe extension on a ratchet handle for added leverage Always support the ratchet head when using socket extensions but do not put your hand on the head or you may interfere with the action of its reversing mechanism When breaking a fastener loose apply a small amount of pressure as a test to be sure the ratchet s gear wheel is...

Page 29: ...cally 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 cleaner air in our environment Some gasoline blen...

Page 30: ...rval 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 allowed to th...

Page 31: ...e Japan Australia models only Illuminated with LEDs Replace entire assembly upon failure Tail stop lamp All models Marker lamps Y0042 K 0 74 10 4 Front and rear turn signal lamps 1 bulb each 53436 97 0 37 5 1 License plate illumination lamp Lightning Ulysses only Y0163 02A8 0 08 1 12 1 Turn signal indicator Instruments Y0163 02A8 0 08 1 12 1 Check engine Y0162 02A8 0 05 0 7 1 High beam Y0163 02A8 ...

Page 32: ...levels and condition Brake fluid X X X X X X Inspect for wear Brake pads and discs 1 X X Replace Spark plugs X X X X X X Check operation Electrical equipment and switches 1 X X Replace Front fork oil 1 X X X X X Perform resistance test Steering head bearings X X X X X X Clean Oil cooler fins 1 3 X X X X X X Inspect for leaks contact and abra sion Brake system oil lines front forks rear shock exhau...

Page 33: ...e engine at normal operating temperature Hot Check 1 See Figure 1 1 Remove the oil filler plug dipstick and visually check for oil in the tank NOTE If the oil pressure lamp stays lit after starting the engine immediately shut the engine off 2 If oil is not visible in the tank screw the dipstick back in and start the engine 3 Let the engine idle for 30 seconds then shut the engine off 4 Remove the ...

Page 34: ...imately 1 2 full 6 Screw filter onto adapter until filter gasket touches crank case surface 7 By hand turn filter an additional 1 2 to 3 4 turn Be sure that no lubricants or fluids get on tires wheels or brakes when changing fluid Traction can be adversely affected which could result in loss of control of the motorcycle and death or serious injury 00047d 2 1 3 3 3 3 pd00227 1 Oil filter 2 Oil pres...

Page 35: ...leaks or to determine air flow rates 00061a 2 Blow out any debris from fins with compressed air from the inside of the oil cooler outward Inspect cooler fins for debris or damage 3 Install oil cooler scoop See 2 49 AIR SCOOPS Return to Service 1 Wipe up any spilled oil on muffler 2 Start engine Verify that oil pressure signal light on instru ment cluster turns off after a few seconds when engine s...

Page 36: ... Remove seat 2 Remove intake cover assembly See 2 38 INTAKE COVER 3 See Figure 1 6 or Figure 1 7 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 8 Unlatch six latching tabs and remove air cleaner cover from baseplate 5 See Figure 1 9 Remove the filter element 1 from base plate 2 Inspect and replace if ne...

Page 37: ...ment 1 on baseplate 2 2 Position air cleaner cover over baseplate Make sure air filter remains correctly positioned 3 Install air cleaner cover by latching latch tabs to baseplate 4 For XB12 models verify that the actuator cable and har ness are located in the grooves in the air cleaner cover NOTE The vent tube is now a larger outer diameter than previous and requires extra effort to install into ...

Page 38: ...ntire exhaust system for loose or missing fasteners broken pipe clamps or brackets and obvious signs of leakage carbon tracks at pipe joints etc 2 Check for loose or broken heat shields Repair or replace as necessary 3 Start engine cover muffler ends with clean dry shop towels and listen for audible signs of exhaust leakage 4 Correct any leaks detected See 4 19 EXHAUST SYSTEM for exhaust system re...

Page 39: ... 180 55 ZR 17 Pirelli Diablo Corsa III Rear 234 34 120 70 ZR 17 Pirelli Scorpion SYNC Front XB9SX XB12SX 248 36 180 55 ZR 17 Pirelli Scorpion SYNC Rear XB12X XB12XP 234 34 120 70 ZR 17 Pirelli Scorpion SYNC Front XB12Ss XB12Scg 248 36 180 55 ZR 17 Pirelli Scorpion SYNC Rear 234 34 120 70 ZR 17 Pirelli Diablo Angel ST Front XB12XT 248 36 180 55 ZR 17 Pirelli Diablo Angel STE Rear TIRE WEAR See Figu...

Page 40: ...cause bearing to fly apart which could result in death or serious injury 00505b Check front and rear wheel bearings for wear Every time a wheel 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 HOME 1 18 2010 XB Service Maintenance ...

Page 41: ...2 4 sm01388 1 Adjusting screw 2 Cable end 3 Coupling 4 Correct fluid level Figure 1 15 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 t...

Page 42: ...escribed below When necessary lubricate cable with Harley Lube Part No HD 94968 09 1 Position the vehicle upright and level This will prevent lubricant from draining out when clutch inspection cover is removed 2 See Figure 1 18 Slide rubber boot 1 upward to expose adjuster mechanism Loosen jam nut 3 from adjuster 4 Turn adjuster to shorten cable housing until there is a large amount of free play a...

Page 43: ... adjuster 4 d Thread jam nut 3 against adjuster 4 and tighten to 120 in lbs 13 6 Nm e Slide boot 1 over cable adjuster mechanism 7 Change or add transmission fluid if necessary NOTE Each time the clutch inspection cover is removed the gasket must be replaced 8 See Figure 1 16 Install clutch inspection cover and new gasket using three fasteners and washers and tighten to 84 108 in lbs 9 5 12 2 Nm 1...

Page 44: ... at the absolute tightest point in the drive as measured with special ized factory equipment If a chain has less than 1 4 in 6 4 mm vertical tension with a cold engine adjust tension to the field specification of 3 8 1 2 in 9 5 12 7 mm The looser specification will avoid overtightening which might otherwise occur during adjustment using non factory equipment and methods 5 See Figure 1 21 Install p...

Page 45: ...3 Tighten locknut 1 to 20 25 ft lbs 27 1 33 9 Nm 1 2 sm00096 1 Locknut 2 Adjusting fastener Figure 1 23 Chain Tension Adjusting Fastener Typical HOME 2010 XB Service Maintenance 1 23 ...

Page 46: ...utside 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 transmi...

Page 47: ...ssing guards Eliminate 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 Inform operator Aggressive riding ha...

Page 48: ... Excessive drive noise Replace damaged or missing 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 Replace damaged or missing belt guards ...

Page 49: ...er on throttle control cable 2 until throttle cam stop touches stop plate Tighten cable adjuster lock 5 on throttle control cable adjuster release throttle control grip 5 Turn handlebars fully to right Turn adjuster on idle control cable 3 until end of cable housing just touches the cable guide 6 Twist and release throttle control grip a few times Throttle plate must return to idle position each t...

Page 50: ...ket 8 Tighten jam nut NOTE Do not overtighten jam nut on interactive exhaust cable 9 See Figure 1 27 Adjust interactive exhaust cable as fol lows a Move cable with your fingers from side to side There should be no more than 1 8 in 3 2 mm side play in cable in either direction with 1 4 in 6 4 mm max imum overall side play b See Figure 1 26 Adjust cable as needed using cable adjuster 1 NOTES In this...

Page 51: ...g For 1 8 in 3 2 mm Maximum Free Play In Either Direction For Proper Adjustment 2 1 sm00506 1 Interactive exhaust cable 2 Frame lug Figure 1 28 Correct Cable Routing Behind Frame Lug Typical HOME 2010 XB Service Maintenance 1 29 ...

Page 52: ...ake 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 adjustment BLEEDING BRAKES Direct contact of D O T 4 brake fluid with eyes can cause irritation Avoid eye contact In case of eye contact flush with large amounts of water and get medical attention Swallowing large am...

Page 53: ... O T 4 BRAKE FLUID to master cylinder reservoir Bring fluid level to within 1 8 in 3 2 mm of molded boss level indicator inside front master cylinder NOTE Do not reuse brake fluid b Slowly squeeze and release brake lever several times to build up hydraulic pressure then squeeze or apply pressure to brake lever c Open bleeder valve about 1 2 turn counterclockwise Brake fluid will flow from bleeder ...

Page 54: ...sed 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 36 60 in lbs 4 6 8 Nm and replace rubber cap on va...

Page 55: ...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 34 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 35 Brake Pedal Pushrod Adjustment Typical BRAKE PAD THICKNESS Always replace brake pads in complete sets for...

Page 56: ...e 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 outer pad from right side 8 Remove inner pad from le...

Page 57: ...move pin hanger 4 7 See Figure 1 41 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 ...

Page 58: ... Rear caliper mounting fasteners 2 Brake pad retainer 3 Rear caliper pin plug 4 Rear caliper pin hanger Figure 1 40 Rear Brake Caliper sm00496 Figure 1 41 Rear Brake Pad Spring Installed HOME 1 36 2010 XB Service Maintenance ...

Page 59: ...ctrodes and is caused by an air fuel mixture that is too lean a hot running engine valves not seating or improper ignition timing The glassy deposit on the spark plug is a conductor when hot and may cause high speed misfiring A plug with eroded electrodes heavy deposits or a cracked insulator must be replaced d A plug with a white yellow tan or rusty brown powdery deposit 4 indicates balanced comb...

Page 60: ... coil and spark plugs See 6 4 SPARK PLUG CABLES 14 Install left side air scoop See 2 49 AIR SCOOPS 15 Install air cleaner assembly and intake cover See 2 38 INTAKE COVER and 4 3 AIR CLEANER ASSEMBLY After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 16 Install...

Page 61: ...cts 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 16 BATTERY MAINTENANCE Charging Battery For testing informat...

Page 62: ...th batteries KEEP BATTERIES AWAY FROM CHILDREN 00063a Never remove warning label attached to top of battery Failure to read and understand all precautions contained in warning could result in death or serious injury 00064a Voltmeter Test The voltmeter test provides a general indicator of battery con dition Check the voltage of the battery to verify that it is fully charged If the open circuit disc...

Page 63: ...before connecting charger cables to battery Connecting cables with charger ON can cause a spark and battery explosion which could result in death or serious injury 00066a Do not reverse the charger connections described in the following steps or the charging system of the motorcycle could be damaged 00214a 2 Connect red battery charger lead to the positive ter minal and black battery charger lead ...

Page 64: ...g when working with batteries KEEP BATTERIES AWAY FROM CHILDREN 00063a 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 46 A battery that is removed from the vehicle is affected by self discharge A battery that is stored in the vehicle is affected by self discharge and more significantly ...

Page 65: ...sm06717 Figure 1 47 Battery Tender Connector Lightning sm06716 Figure 1 48 Battery Tender Connector Firebolt sm06730 Figure 1 49 Battery Tender Connector Ulysses HOME 2010 XB Service Maintenance 1 43 ...

Page 66: ...eg 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 17 STEERING HEAD BEARINGS Determining Proper Resistance 7 When adjustment is complete attach clutch cable and adjust See 1 9 CLUTCH TRANSMISSION PRIMARY FLUID sm00098 Figure 1 50 Measuring Steering He...

Page 67: ...ssembly PROCEDURE 1 Remove front fork assembly from motorcycle See 2 16 FRONT FORKS Removal 2 Partially disassemble and drain front forks See Initial Disassembly under 2 16 FRONT FORKS Disassembly 3 Refill and assemble fork assembly See Final Assembly under 2 16 FRONT FORKS Assembly 4 Install fork assembly onto motorcycle See 2 16 FRONT FORKS Installation HOME 2010 XB Service Maintenance 1 45 ...

Page 68: ...he same as that of the principal rider sit on the motorcycle 5 With the vehicle laden and upright point the front wheel straight forward at wall and measure the distance 4 from the floor to the center of the HIGH BEAM bulb 6 Draw a horizontal line 5 through the vertical line on the wall that is 2 1 in 53 3 mm lower than the measured bulb centerline 2 3 5 4 1 om00029 1 Perpendicular line 2 Vertical...

Page 69: ...enough to adjust headlamp Once headlamps are aligned tighten fasteners to 48 72 in lbs 5 8 Nm pd00197 Figure 1 53 Horizontal Headlamp Adjustment Fastener Locations Lightning pd00326 Figure 1 54 Horizontal Headlamp Adjustment Fastener Lightning pd00199 Figure 1 55 Vertical Headlamp Adjustment Fastener Lightning Models HEADLAMP ADJUSTMENT ULYSSES Horizontal Alignment See Figure 1 56 Loosen fasteners...

Page 70: ...r 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 56 Horizontal Headlamp Adjustment Fastener Locations Ulysses pd00202 Figure 1 57 Vertical Headlamp Adjustment Fastener Ulysses XB12X XB12XP sm05318 Figure 1 58 Vertical Headlamp Adjustment Fastener XB12XT HOME 1 48 2010 XB Service Maint...

Page 71: ...creen To minimize swirl marks cleaning should be done when motorcycle is cool and parked in the shade HARLEY DAVIDSON BUG REMOVER Part No 94657 98 HARLEY DAVIDSON SUNWASH PART No 94659 98 NOVUS 1 CLEANER PROTECTANT Part No 99837 94T NOVUS 2 SCRATCH REMOVER Part No 99836 94T HARLEY GLAZE Part No 99701 84 to polish and seal after cleaning NOTE Faint swirl marks are normal and may be more visible on ...

Page 72: ...ly support the motorcycle so that all weight is off the tires Be sure that brake fluid or other lubricants do not contact brake pads or discs Such contact can adversely affect braking ability which could cause loss of control resulting in death or serious injury 00290a 8 Wash and polish molded in color painted and chrome plated surfaces 9 If motorcycle is to be covered use a material that will bre...

Page 73: ...timing incorrect due to faulty coil ECM or faulty sensors 8 Bank Angle Sensor tripped and ignition switch not cycled OFF then ON 9 Fuel filter clogged 10 Sticking or damaged valve or wrong length push rod 11 Cam primary gear key sheared or missing the spacer 12 Fuel pump inoperative 13 Plugged fuel injectors 14 Fuse blown Starts Hard 1 Spark plugs in bad condition or have improper gap or are parti...

Page 74: ...puts poorly tuned engine 6 Internal engine problem 7 Broken frame 8 Stabilizer links worn or loose or stabilizer link brackets loose or broken Check Engine Light Illuminates During Operation 1 Fault detected See the Electrical Diagnostic Manual for this motorcycle LUBRICATION SYSTEM TOOL NAME PART NUMBER BLACK LIGHT LEAK DETECTOR HD 35457 Oil Does Not Return To Oil Tank 1 Oil tank empty 2 Oil pump...

Page 75: ...r forks bent 4 Damaged gears Clutch Slips 1 Clutch controls improperly adjusted 2 Insufficient clutch spring tension 3 Worn friction discs Clutch Drags Or Does Not Release 1 Lubricant level too high in primary chaincase 2 Clutch controls improperly adjusted 3 Primary chain badly misaligned 4 Insufficient clutch spring tension 5 Clutch discs excessively warped 6 Clutch spacer missing or installed b...

Page 76: ...go after passing over a bump This is noticeable by watching the motorcycle continue to bounce as it travels over multiple bumps Reduce rebound damping Wheel responds to bump but doesn t return to ground quickly after bumps This is more pronounced over a series of bumps and is often referred to as packing down Increase compression damping The motorcycle bottoms out or dips while cornering Motorcycl...

Page 77: ...ood suspension is a balance between damping and track condition Finding this balance requires exploring all possible compression settings Not absorbing bumps Increase compression damping Lack of tire feedback Decrease compression damping Tire slides HOME 2010 XB Service Maintenance 1 55 ...

Page 78: ...1 56 2010 XB Service Maintenance NOTES ...

Page 79: ... XB12XP XB12SX 2 126 2 30 FRONT MODULES LIGHTNING AND ULYSSES MODELS 2 127 2 31 HANDLEBARS FIREBOLT 2 129 2 32 HANDLEBARS LIGHTNING AND ULYSSES MODELS 2 130 2 33 MIRRORS 2 132 2 34 FOOTPEG HEEL GUARD AND MOUNT FIREBOLT AND LIGHTNING MODELS 2 133 2 35 HEEL GUARD AND FOOTPEG MOUNTS ULYSSES MODELS 2 135 2 36 SPROCKET COVER 2 137 2 37 BELT GUARDS 2 138 2 38 INTAKE COVER 2 139 2 39 SUBFRAME TAIL ASSEMB...

Page 80: ...NOTES ...

Page 81: ...tery terminal fasteners 2 23 REAR SHOCK ABSORBER Installation Firebolt 6 8 7 9 Nm 60 70 in lbs Battery terminal fasteners 2 25 CLUTCH CONTROL Assembly and Installa tion 6 8 7 9 Nm 60 70 in lbs Battery terminal fasteners 2 26 HEADLAMP ASSEMBLY AND SUPPORT BRACKET Installation Firebolt 6 8 7 9 Nm 60 70 in lbs Battery terminal fasteners 2 26 HEADLAMP ASSEMBLY AND SUPPORT BRACKET Installation Lightnin...

Page 82: ...er Reservoir Installation 0 8 1 Nm 7 10 in lbs Brake light switch fastener front 2 9 FRONT BRAKE EIGHT PISTON CAL IPER Front Brake Fluid Line 4 6 8 Nm 36 60 in lbs Brake line P clamp front 2 10 FRONT BRAKE SIX PISTON CAL IPER Brake Line Installation 4 6 8 Nm 36 60 in lbs Brake line p clamp fastener front 2 13 REAR BRAKE LINE Installation Firebolt 4 6 8 Nm 36 60 in lbs Brake line p clamp fastener r...

Page 83: ...12 REAR BRAKE MASTER CYL INDER Removal Firebolt Lightning 4 6 8 Nm 36 60 in lbs Caliper bleeder valves 2 12 REAR BRAKE MASTER CYL INDER Removal Ulysses 4 6 8 Nm 36 60 in lbs Caliper bleeder valves 2 13 REAR BRAKE LINE Removal Firebolt 4 6 8 Nm 36 60 in lbs Caliper bleeder valves 2 13 REAR BRAKE LINE Removal Lightning 4 6 8 Nm 36 60 in lbs Caliper bleeder valves 2 13 REAR BRAKE LINE Removal Ulysses...

Page 84: ...ACKET Assembly Firebolt 4 6 8 Nm 36 60 in lbs Flasher fastener 2 35 HEEL GUARD AND FOOTPEG MOUNTS ULYSSES MODELS Mount Installation 15 16 Nm 132 144 in lbs Footpeg mount 2 34 FOOTPEG HEEL GUARD AND MOUNT FIREBOLT AND LIGHTNING MODELS Pas senger LOCTITE 271 red 33 9 38 Nm 25 28 ft lbs Footpeg mount Firebolt and Lightning 2 39 SUBFRAME TAIL ASSEMBLY AND BODY WORK FIREBOLT Assembly LOCTITE 271 red 33...

Page 85: ... 3 Nm 120 144 ft lbs Handlebar clamp screws Lightning and Ulysses 2 32 HANDLEBARS LIGHTNING AND ULYSSES MODELS Installation LOCTITE 271 red Tighten front screws first 13 6 16 3 Nm 120 144 ft lbs Handlebar clamp screws Lightning and Ulysses 2 31 HANDLEBARS FIREBOLT Installation 32 5 35 3 Nm 24 26 ft lbs Handlebar clip on fastener Firebolt 2 31 HANDLEBARS FIREBOLT Installation 32 5 35 3 Nm 24 26 ft ...

Page 86: ... BRAKE SIX PISTON CAL IPER Brake Line Installation 21 7 27 1 Nm 16 20 ft lbs Master cylinder banjo bolt front 2 10 FRONT BRAKE SIX PISTON CAL IPER Master Cylinder Installation 1 0 1 5 Nm 9 13 in lbs Master cylinder cover fasteners front 2 12 REAR BRAKE MASTER CYLINDER Installa tion Firebolt Lightning 8 10 8 Nm 72 96 in lbs Master cylinder mounting fasteners rear 2 12 REAR BRAKE MASTER CYLINDER Ins...

Page 87: ...CTION ULYSSES MODELS Assembly 4 6 8 Nm 36 60 in lbs Rear ECM fastener 2 15 FENDERS Rear Fender XB12R XB9SX XB12SX XB12Scg 1 4 4 Nm 12 36 in lbs Rear fender fasteners 2 19 SWINGARM AND BRACE Installation Swingarm 1 4 4 Nm 12 36 in lbs Rear fender fasteners 2 39 SUBFRAME TAIL ASSEMBLY AND BODY WORK FIREBOLT Assembly 13 6 16 3 Nm 120 144 in lbs Rear shock reservoir clamp Firebolt 2 23 REAR SHOCK ABSO...

Page 88: ...SCOOPS Ram Air Scoop and Fan Shroud Ulysses 4 1 6 8 Nm 36 60 in lbs Shock preload adjuster fastener 2 23 REAR SHOCK ABSORBER Installation Lightning 4 6 8 Nm 36 60 in lbs Shock reservoir clamp rear Lightning except XB12Ss 2 23 REAR SHOCK ABSORBER Installation Lightning 9 10 Nm 80 88 in lbs Shock reservoir clamp rear XB12Ss 2 49 AIR SCOOPS Ram Air Scoop and Fan Shroud Ulysses 9 10 Nm 80 88 in lbs Sh...

Page 89: ... Triple tail plastic collar screw 2 45 TRUNK AND BATTERY PAN ULYSSES MODELS Assembly Trunk Pan and Battery Pan 8 10 8 Nm 72 96 in lbs Trunk pan fastener side Ulysses 2 45 TRUNK AND BATTERY PAN ULYSSES MODELS Assembly Trunk Pan and Battery Pan 5 4 8 1 Nm 48 72 in lbs Trunk pan fastener side Ulysses 2 40 LEFT TAIL SECTION AND BATTERY PAN LIGHTNING MODELS Assembly 5 4 8 Nm 48 72 in lbs Trunk pan to c...

Page 90: ...indshield mounting screw 2 44 CENTER TAIL LOOP ULYSSES MODELS Assembly 4 5 4 Nm 36 48 in lbs Wire cover screws Ulysses 2 52 SEAT LOCKS Installation Ulysses Models 4 5 4 Nm 36 48 in lbs Wire cover screws Ulysses 2 53 TRIPLE TAIL ULYSSES MODELS Installa tion 4 5 4 Nm 36 48 in lbs Wire cover screws Ulysses HOME 2 10 2010 XB Service Chassis ...

Page 91: ...315 143 315 147 325 143 315 143 315 GAWR front 243 535 243 535 238 525 243 535 243 535 GAWR rear 169 373 175 386 172 379 173 382 177 391 Load capacity All measurements include a full tank of gasoline Table 2 2 Dimensions 2010 Firebolt MM IN ITEM 1320 52 0 Wheel base without rider 775 30 5 Seat height with rider 110 4 35 Ground clearance without rider 83 3 3 Trail 21 degree Rake Table 2 3 Capacitie...

Page 92: ...B12SX and XB12Scg Models LITERS U S ITEM 14 5 3 82 gallons Fuel tank total including reserve 2 8 0 75 gallons Reserve low fuel lamp illuminates at 2 4 2 50 quarts Oil tank 0 9 1 00 quart Transmission NOTE Gross Vehicle Weight GVWR maximum allowable loaded vehicle weight and corresponding Gross Axle Weight Ratings GAWR are given on an information decal located on the steering head Table 2 6 Weights...

Page 93: ... 8 degrees 23 5 degrees Rake steering angle 22 0 degrees 22 3 degrees 22 3 degrees 22 0 degrees Rake fork angle Specifications for vehicle with luggage Specifications for vehicle without luggage and brackets Table 2 9 Weights 2010 Ulysses Models XB12XP XB12XT XB12XT XB12X ITEM kg lb kg lb kg lb kg lb 242 533 226 498 243 536 225 495 Weight 431 950 431 950 431 950 431 950 GVWR 156 345 156 345 156 34...

Page 94: ...e 3 1 0 83 gallons Reserve low fuel lamp illuminates at 2 4 2 5 quarts Engine oil with filter 0 9 1 0 quart Transmission Do not inflate tire beyond maximum pressure as specified on sidewall Over inflated tires can blow out which could result in death or serious injury 00027a HOME 2 14 2010 XB Service Chassis ...

Page 95: ...M MAX IMUM COMPRES SION TURNS OUT FROM MAXIMUM PRELOAD TURNS IN FROM MIN IMUM kg lb 1 3 4 2 1 2 1 1 5 8 2 3 Less than 63 Less than 140 1 1 2 1 3 4 2 1 5 8 1 3 4 5 63 73 140 160 1 1 4 1 1 2 3 1 1 2 1 1 2 6 73 82 160 180 1 1 4 1 1 4 4 1 1 2 1 1 2 7 82 91 180 200 1 1 1 4 5 1 1 4 1 1 4 8 91 100 200 220 3 4 1 6 1 1 4 1 1 4 9 100 109 220 240 3 4 1 7 1 1 10 109 to GVWR 240 to GVWR Front preload is set by...

Page 96: ...1 1 3 4 1 3 4 5 Less than 68 Less than 150 1 1 4 2 1 2 2 1 1 2 1 3 4 6 68 77 150 170 1 1 4 2 1 4 3 1 1 2 1 1 2 7 77 86 170 190 1 2 4 1 1 4 1 1 2 8 86 95 190 210 1 1 3 4 5 1 1 4 1 1 4 9 95 104 210 230 3 4 1 1 2 6 1 1 1 4 10 104 113 230 250 3 4 1 1 4 7 1 1 11 113 GVWR 250 GVWR Front preload is set by loosening adjuster counterclockwise until it stops at minimum and then counting the number of turns ...

Page 97: ... 2 1 3 4 9 1 1 4 2 3 91 104 200 230 1 1 4 1 1 2 13 1 1 8 2 3 1 2 104 118 230 260 1 1 1 8 16 1 1 7 8 3 1 2 118 132 260 290 3 4 7 8 18 1 1 7 8 4 132 145 290 320 5 8 1 2 max 7 8 1 3 4 4 145 GVWR 320 GVWR Both front and rear spring preload is set by loosening adjuster counterclockwise until it stops at minimum and then counting the number of turns in to get to the desired setting The rear preload knob...

Page 98: ...e attached refer to settings in ONE LOWER weight category Both Front and Rear Spring Preload is set by loosening adjuster counterclockwise until it stops at minimum and then counting the number of turns in to get to the desired setting The rear preload knob clicks every 1 2 turn All damping adjuster settings are done by tightening adjuster clockwise until it stops at maximum setting and then count...

Page 99: ...TION 4MZ Buell vehicles originally manufactured for sale within the United States Market designation WMI code 1 5MZ Buell vehicles originally manufactured for sale outside the United States 95Z Buell vehicles originally manufactured for sale in Brazil at Manaus CKD plant KP Blast Motorcycle type code 2 AX Firebolt JX Lightning Long KX Lightning City X WX Lightning Scg DB Ulysses Police XB12XP DX U...

Page 100: ...VALUES DESCRIPTION POSITION 0 Blast Model 8 2 XB9SX 3 XB12R 5 XB12Scg 6 XB12Ss 7 XB12X 9 XB12XP A XB12XT B 1125R C 1125CR D 1125R 105 HP France E 1125CR 105 HP France F XB12SX Varies Sequential number 9 last five digits HOME 2 20 2010 XB Service Chassis ...

Page 101: ... bearings Excessive side play or radial up and down play in wheel hubs Repair swingarm See 2 19 SWINGARM AND BRACE Alignment of rear wheel in frame or with front wheel Replace rims See 2 7 TIRES and 2 8 CHECKING CAST RIM RUNOUT Rims and tires out of true sideways should not be more than 0 080 in 2 03 mm Replace rims See 2 7 TIRES and 2 8 CHECKING CAST RIM RUNOUT Rims and tires out of round or ecce...

Page 102: ...ry 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 equip...

Page 103: ...moval 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 43993...

Page 104: ...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 105: ... Brake Caliper Cleaning and Inspection 3 Remove drive bushings 8 and discard 4 Remove washers 9 and discard 5 Remove front brake springs 4 and discard CLEANING AND INSPECTION Using compressed air to spin dry bearings can cause bearing to fly apart which could result in death or serious injury 00505b 1 Inspect all parts for damage or excessive wear NOTE The wheel bearings are designed as sealed bea...

Page 106: ...1 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 procedure describes the bearing installation for the front wh...

Page 107: ...ing 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 Install the backi...

Page 108: ...quarely into the hub with the lettered side facing out away from the wheel 12 Slide the FRONT BEARING INSTALLER Part No B 43993 9 2 onto the forcing screw 3 with the smaller diameter toward the bearing bore 13 Install a washer 4 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 the nut...

Page 109: ...screws Re using these screws can result in torque loss and damage to brake components 00319c 5 Install new rotor mounting fasteners 7 in a crisscross pattern around the wheel to verify proper fitting between rotor fastener and bushing Tighten to 25 27 ft lbs 33 9 36 6 Nm Rotor mounting fasteners must be seated into drive bushings and drive bushings must be fitted into rotor properly Failure to com...

Page 110: ...de 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 52 9 55 6 Nm 4 See Figure 2 18 Tighten the front axle pinch fasteners 1 to 20 22 ft lbs 27 1 29 8 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 ...

Page 111: ... 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 14 BRAKE SYSTEM MAINTEN ANCE and 2 14 REAR BRAKE CALIPER REPAIR Inspection Using compressed air to spin dry bearings can cause bearing to fl...

Page 112: ...procket fastener 2 Washer 3 Sprocket 4 Brake rotor 5 Rotor mounting fastener Figure 2 20 Drive Sprocket and Brake Rotor DISASSEMBLY 1 See Figure 2 21 Remove sprocket a Remove sprocket fasteners 7 and washers Discard fasteners b Remove sprocket 6 from wheel 2 Remove rear rotor a Remove and discard rotor mounting fasteners 1 b Remove and inspect brake rotor 2 for wear and warping See 1 14 BRAKE SYST...

Page 113: ...525a 6 1 Wheel spacer Rotor mounting fastener 6 2 7 Brake rotor Wheel 8 3 Sprocket Wheel spacer right side 4 9 Wheel seal 2 Sprocket fastener 10 5 Axle Wheel bearing 3 Figure 2 21 Rear Wheel Assembly HOME 2010 XB Service Chassis 2 33 ...

Page 114: ...ING Part No B 43993 7 into the wheel bearing until it fully seats against the bearing b RearWheels Insert the REMOVER COLLET REAR BEARING Part No B 43993 8 into the wheel bearing until it seats against the bearing 4 Insert the ball bearing 2 into the collet 1 5 See Figure 2 24 Thread the puller assembly 1 into the collet 2 6 Hold the collet 2 and turn the forcing screw 3 to expand the collet 7 See...

Page 115: ...er Installation Rotor Side Bearing Using compressed air to spin dry bearings can cause bearing to fly apart which could result in death or serious injury 00505b NOTES First press the rotor side bearing against the shoulder in the hub Then press the opposite side bearing until it contacts the spacer Always install the rotor side bearing first with the lettering engraved in the race facing out 1 See...

Page 116: ...3993 9 onto the forcing screw with the smaller diameter toward the bearing bore 6 Install a washer 4 bearing 5 and nut 6 onto the forcing screw 1 7 While 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 8 Remove the nut bearing washer front bearing installer and forcing screw 1 2 sm00518 1 Backing plate 2...

Page 117: ... screw 3 7 While holding the forcing screw 3 tighten the nut 6 until the bearing contacts the spacer 2 1 sm00521 1 Forcing screw 2 Spacer Figure 2 31 Install the Spacer 1 3 6 5 4 2 sm00522 1 Wheel bearing 2 Front wheel bearing installer 3 Forcing screw 4 Washer 5 Bearing 6 Nut Figure 2 32 Install the Bearing WHEEL BEARINGS THREE BEARING WHEELS TOOL NAME PART NUMBER NICE BEARING 217801 BUELL WHEEL ...

Page 118: ...RCING SCREW Part No HD 44060 4 1 the nut 2 and the washer 3 from the WHEEL BEARING INSTALLER AND REMOVER Part No HD 44060 C the NICE BEARING Part No 217801 4 and the BRIDGE Part No HD 44060 5 6 3 Lightly apply EXTREME PRESSURE LUBRICANT Part No J 23444 A to the threads of the forcing screw 4 Fit the BEARING REMOVER Part No B 50019 5 from t h e B U E L L W H E E L B E A R I N G INSTALLER REMOVER Pa...

Page 119: ...r bearing out of the wheel hub 8 Fit the bearing remover to the inner bearing 9 Set the large diameter spacer over the wheel hub 10 Insert a ball bearing and thread the forcing screw into the bearing remover 11 Hold the bearing remover and turn the forcing screw to expand the bearing remover and to seat the bridge on the wheel hub 12 Hold the forcing screw and turn the nut clockwise to pull the in...

Page 120: ...Remove the nut washer bearing and the large bearing installer cup 9 Fit the sprocket side outer bearing with the engraved let tering facing out over the guide 10 Slide on the large bearing installer cup the bearing and the washer Thread on the nut 11 Tighten the nut to press in the outer wheel bearing 12 Figure 2 39 Install the sprocket side bearing seal 1 the rotor side bearing seal 6 and the axl...

Page 121: ... 41 Tighten rear axle 1 to 23 27 ft lbs 31 2 36 6 Nm loosen two full turns and then retighten to 48 52 ft lbs 65 1 70 5 Nm 8 Tighten pinch fastener 2 on right side of swingarm to 40 45 ft lbs 54 2 61 Nm 9 Install lower belt guard See 2 37 BELT GUARDS sm00524 Figure 2 42 Rear Brake Caliper Carrier Fasteners 10 See Figure 2 42 Install caliper carrier and tighten fastener to 24 26 ft lbs 32 5 35 3 Nm...

Page 122: ...dling 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 only Buell approved replacement tires 00497d SPECI...

Page 123: ...im flange 4 See Figure 2 45 Push the lower bead into the rim well on one side and insert tire tool underneath the bead from the opposite side 5 Pry the bead over the rim edge Remove the tire from the rim sm00113 Figure 2 44 Loosening Beads from Rim Flange sm00114 Figure 2 45 Pry Bead Over Rim Edge CLEANING AND INSPECTION TOOL NAME PART NUMBER TIRE SPREADER HD 21000 1 Mount tire on TIRE SPREADER Pa...

Page 124: ...e rim Mark location of paint dot on the outside of the rim using a grease pencil or a piece of masking tape 2 Clamp the wheel in the tire machine 3 Lubricate both rim flanges and both beads of tire with tire lubricant 4 See Figure 2 47 Identify the direction of rotation arrow and set the tire against the rim with the arrow pointing in the forward direction of rotation with the tire balance dots up...

Page 125: ...sm05618 Figure 2 48 Tire Bead at Bottom of Rim Well sm05355 Figure 2 49 Tire and Wheel Balance Dots HOME 2010 XB Service Chassis 2 45 ...

Page 126: ...ES Adjustment RUNOUT Lateral 1 See Figure 2 51 Mount the wheel and tire in a wheel stand or in the swingarm and fix a gauge 1 to measure runout 2 Spin the wheel and measure tire lateral runout 2 Refer to Table 2 22 3 If the tire lateral runout is greater than specification remove the tire from the rim and measure the wheel rim lateral runout Replace the rim if out of specification See 2 8 CHECKING...

Page 127: ...ply WHEEL WEIGHTS to the flat surface of the wheel rim Refer to Table 2 23 for maximum weight permissible to accomplish balance 1 Make sure that area of application is completely clean dry and free of oil and grease 2 Remove paper backing from weight For additional adhesive strength apply three drops of LOCTITE SUPERBONDER 420 to adhesive side of weight 3 On the front wheel locate a flat surface o...

Page 128: ...ecification Refer to Table 2 24 Rim Radial Runout 1 See Figure 2 55 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 24 Table 2 24 Wheel Rim Runout MM IN MAXIMUM RUNOUT 0 76 0 030 Lateral 0 7...

Page 129: ...n tion Use in well ventilated area KEEP OUT OF REACH OF CHILDREN 00240a D O T 4 brake fluid will damage painted and body panel surfaces it comes in contact with Always use caution and protect surfaces from spills whenever brake work is per formed Failure to comply can result in cosmetic damage 00239b 1 On XB12SX models remove the right deflector See 2 28 DEFLECTORS 2 Drain brake fluid into a suita...

Page 130: ...er parts even after assembly Deterioration of these components can cause brake failure which could result in death or serious injury 00291a Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury Wear safety glasses when working with compressed air Never use your hand to check for air leaks or to determine air flow rates 00061a 1 Clean all parts with...

Page 131: ... Lubricate master cylinder bore piston and piston seals with DOT 4 brake fluid 2 Push the rubber seal onto the piston of a master cylinder piston set 3 Fit the rubber cap to the small end of the spring Be sure circlip snaps in place An unsecured circlip can cause brake failure which could result in death or serious injury 00513b 4 See Figure 2 63 Insert the spring 1 with cap 2 into master cylinder...

Page 132: ...ll damage painted and body panel surfaces it comes in contact with Always use caution and protect surfaces from spills whenever brake work is per formed Failure to comply can result in cosmetic damage 00239b 5 Protect the body work from the brake fluid 6 With the master cylinder in a level position add D O T 4 brake fluid until the level is above the LOWER line on the sight gauge A plugged or cove...

Page 133: ...copper washers to disconnect brake line from master cyl inder reservoir Discard copper washers NOTE On 12Ss XB12Scg XB12SX models it will be necessary to use a J clamp instead of the P clamp 4 Remove P clamp attaching brake line to right side of lower fork clamp 5 Carefully inspect the brake fluid line for dents cuts chaffing or other defects Replace damaged brake lines 1 2 sm04612 1 Bleeder valve...

Page 134: ...h speeds can cause loss of control which could result in death or serious injury 00289a 9 Fill the master cylinder reservoir and bleed the brakes See 1 14 BRAKE SYSTEM MAINTENANCE 10 See Figure 2 67 and Figure 2 68 Install and tighten the P clamp on the front fork clamp Tighten to 36 60 in lbs 4 6 8 Nm Be sure that all lights and switches operate properly before operating motorcycle Low visibility...

Page 135: ...ront brake caliper 3 Caliper mounting fastener 2 Figure 2 69 Front Brake Caliper Mounts Installation 1 If removed install pad spring and brake pads 2 Tighten pin hanger set to 132 180 in lbs 14 9 20 3 Nm 3 Fit pads to rotor and slide the caliper over the rotor up to the mount 4 Apply LOCTITE 271 red to fasteners and install caliper 5 Tighten caliper mounting fasteners to 35 37 ft lbs 47 5 50 2 Nm ...

Page 136: ...ounts of D O T 4 brake fluid can cause digestive discomfort If swallowed obtain medical atten tion Use in well ventilated area KEEP OUT OF REACH OF CHILDREN 00240a D O T 4 brake fluid will damage painted and body panel surfaces it comes in contact with Always use caution and protect surfaces from spills whenever brake work is per formed Failure to comply can result in cosmetic damage 00239b NOTE D...

Page 137: ... bore 4 Install new O rings 10 between caliper halves 5 Clamp caliper together with caliper fasteners 2 and tighten to 18 22 ft lbs 24 7 29 8 Nm 6 Install two new stopper O rings on the pin hangers 1 1 2 3 2 2 3 2 5 5 7 9 11 10 7 6 6 8 8 4 sm05523 1 Caliper mounting fasteners 2 2 Caliper fasteners 4 3 Pin hanger set 4 Bleeder valve 5 Caliper 6 Piston O rings 7 Pistons 8 Brake pads 4 9 Pad spring 2...

Page 138: ... 2 turn c Pump brake hand lever to drain brake fluid d Tighten bleeder valve to 36 60 in lbs 4 6 8 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 73 Remove the banjo bolt 14 metric and two copper washers 16 to disconnect brake line 15 from master cylinder 4 Discard copper washers ...

Page 139: ...s can cause brake failure which could result in death or serious injury 00291a 1 Clean all parts with denatured alcohol or D O T 4 BRAKE FLUID Do not contaminate with mineral oil or other solvents Wipe dry with a clean lint free cloth Blow out drilled passages and bore with a clean air supply Do not use a wire or similar instrument to clean drilled passages in bottom of reservoir 2 Inspect piston ...

Page 140: ...r gasket D O T 4 brake fluid will damage painted and body panel surfaces it comes in contact with Always use caution and protect surfaces from spills whenever brake work is per formed Failure to comply can result in cosmetic damage 00239b 6 Protect body work from brake fluid 7 With the master cylinder in a level position add D O T 4 BRAKE FLUID Bring fluid level to within 1 8 in 3 2 mm of molded b...

Page 141: ...NING AND ULYSSES MODELS 3 Remove p clamp 2 attaching brake line 3 to right side of lower fork clamp 4 On Ulysses models remove fasteners 4 on right lower fender NOTE Damaged banjo bolt seating surfaces will leak when reas sembled Prevent damage to seating surfaces by carefully removing brake line components 5 See Figure 2 73 Remove master cylinder banjo bolt metric 14 and two copper washers 16 to ...

Page 142: ...a See Figure 2 78 Install new copper washer 3 brake line and new copper washer 3 onto banjo bolt 2 b See Figure 2 79 Finger tighten banjo bolt onto front caliper and position brake line as shown in the figure 6 See Figure 2 79 Install and tighten p clamp 1 with fastener on lower triple clamp to 36 60 in lbs 4 6 8 Nm 7 See Figure 2 73 Tighten master cylinder banjo bolt 14 metric to 16 20 ft lbs 21 ...

Page 143: ... BRAKE CAL IPER PISTON REMOVER Part No B 42887 5 See Figure 2 83 Remove and discard piston O rings 6 1 4 3 2 sm00535 1 Pin hanger set 2 Caliper pad spring 3 Caliper fasteners 4 4 Bleeder valve Figure 2 81 Pad Spring Typical sm00536 Figure 2 82 Removing Pistons B 42887 BRAKE CALIPER CLEANING AND INSPECTION Use denatured alcohol to clean brake system components Do not use mineral based solvents such...

Page 144: ... ft lbs 20 3 25 8 Nm INSTALLATION 1 See Figure 2 83 Install pad spring 7 and brake pads 10 2 Install pin hanger set 1 and tighten to 132 168 in lbs 14 9 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 5 50 2 Nm Avoid leakage Be sure gaskets banjo bolt s brake line and master ...

Page 145: ...aliper mounting fasteners 2 Piston Pin hanger set 2 6 Brake bleeder Piston O rings 10 7 3 Brake pads Pad spring Bleeder cap 4 11 8 Caliper Caliper fasteners 4 Small O ring Figure 2 83 Front Caliper Assembly HOME 2010 XB Service Chassis 2 65 ...

Page 146: ...84 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 29 8 32 5 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 84 Brake Pedal Asse...

Page 147: ...a 4 See Figure 2 86 Remove brake reservoir hose 6 at master cylinder 5 Remove seat sm00488 Figure 2 85 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 86 Rear Master Cylinder Firebolt 6 See Figure 2 87 or Figure 2 88 Disconnect brake light connector locat...

Page 148: ... Reservoir Lightning REMOVAL ULYSSES 1 See Figure 2 91 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 6 8 Nm 2 Remove right sid...

Page 149: ...and two copper 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 94 Detach remote reservoir a Remove top clamp 2 on hose connected to master cylinder b Remove fastener and washer 3 to detach reservoir 1 from frame if necessary sm00863b Figure 2 93 Rear Brake Light Swit...

Page 150: ...rate rubber parts even after assembly Deterioration of these components can cause brake failure which could result in death or serious injury 00291a 1 Thoroughly clean master cylinder and all brake system components Stand master cylinder on wooden block or towel to protect seating surfaces a Examine walls of master cylinder reservoir for scratches and grooves Replace if damaged b Verify that vent ...

Page 151: ...properly before operating motorcycle 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 r...

Page 152: ...cle pump brakes to build brake system pressure Insufficient pressure can adversely affect brake performance which could result in death or serious injury 00279a After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 8 Install seat HOME 2 72 2010 XB Service Chassis...

Page 153: ...rding 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 6 8 Nm 7 See Figure 2 98 Remove p clamp 2 securing brake line 1 to the left side of swingarm Remove brake line components carefully Damage to seati...

Page 154: ...njury 00316a 10 Turn ignition key ON press rear brake pedal and check for proper brake light operation 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 pr...

Page 155: ...rate properly before operating motorcycle Low visibility of rider can result in death or serious injury 00316a 10 Turn ignition key ON press rear brake pedal and check for proper brake light operation 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 inju...

Page 156: ...fasteners to 48 72 in lbs 5 4 8 Nm 4 Install the rider passenger peg mount to the motorcycle See 2 35 HEEL GUARD AND FOOTPEG MOUNTS ULYSSES MODELS 5 See Figure 2 101 Connect brake light switch connector beneath seat 6 Install brake light switch banjo bolt and new copper washers to rear caliper Tighten to 16 20 ft lbs 21 7 27 1 Nm 7 Bleed brakes See 1 14 BRAKE SYSTEM MAINTEN ANCE Bleeding Brakes 8 ...

Page 157: ...ent pressure can adversely affect brake performance which could result in death or serious injury 00279a After repairing the brake system test brakes at low speed If brakes are not operating properly testing at high speeds can cause loss of control which could result in death or serious injury 00289a 11 Test ride motorcycle and check for proper brake operation HOME 2010 XB Service Chassis 2 77 ...

Page 158: ...njo 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 2 104 Rear Brake Caliper DISASSEMBLY TOOL NAME PART NUMBER BRAKE CALIPER PISTON REMOVER B 42887 1 See Figure ...

Page 159: ...ult 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 26 Rear Rotor Runout MM IN RUNOUT 0 45 0 0177 Rotor radial 0 39 0 0154 Rotor lateral ASSEMBLY 1 See Figure 2 105 Place clip 1 inside caliper body as shown NOTE To verify proper brake pad to brake rotor cl...

Page 160: ...oper 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 resul...

Page 161: ...Figure 2 109 Align rear fender to the swingarm 2 Install rear fender 3 with fasteners 4 and tighten to 12 36 in lbs 1 4 4 Nm 1 2 3 4 sm04238 1 Front fender All models except XB12X XB12Ss 2 Front fender fasteners and washers 4 3 Rear fender XB9SX XB12SX XB12Scg XB12R 4 Rear fender fastener 2 Figure 2 109 Front and Rear Fender All Models except XB12X XB12Ss FRONT FENDER XB12XP Removal 1 See Figure 2...

Page 162: ...he 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 2 110 Align upper front fender 2 to fender mounts on lower triple clamp and install upper front fender fasteners and washers 1 and tighten to 12 36 in lbs 1 4 4 Nm 2 Install headlamp fastener and washer 3 and tighten to 36 48 in lbs 4 0 5 4 N...

Page 163: ...opper ring up and over the top of the fork 6 See Figure 2 112 Remove fork from lower fork clamp 4 7 Repeat steps 4 through 6 on opposite side sm00560 Figure 2 111 Stopper Ring 2 3 1 4 5 5 sm00559 1 Screw pinch fastener 2 Steering stem pinch fastener 3 Triple clamp upper 4 Triple clamp assembly lower 5 Screw pinch fastener Figure 2 112 Upper and Lower Fork Clamp Assembly Typical DISASSEMBLY TOOL NA...

Page 164: ...no resistance felt in order to remove the fork fluid NOTES FRONT FORK COMPRESSOR Part No HD 45966 comes with a cup and screw that are for Harley Davidson Touring models only and are not to be used on Buell models When using the FRONT FORK COMPRESSOR Part No HD 45966 be sure not to bind the outer fork tube on the tool 6 See Figure 2 115 Install the fork assembly in the FRONT FORK COMPRESSOR Part No...

Page 165: ...ng 16 from slider fork by prying the slide bushing at the split NOTE Be careful not to over expand slide bushing 5 Remove guide bushing 17 seal spacer 18 oil seal 19 oil seal stopper ring 20 and dust seal 21 6 See Figure 2 119 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 7 Remove damper rod assembly NOTE S...

Page 166: ...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 2 119 Front Fork Assembly XB All Models HOME 2 86 2010 XB Service Chassis ...

Page 167: ... used to install the fork seal and dust boot depending on the size of your slider fork You will either use FORK SEAL DRIVER AND DUST BOOT INSTALLER Part No B 43721 41mm or FORK SEAL DRIVER AND DUST BOOT INSTALLER Part No B 42571 43mm or FORK SEAL DRIVER AND DUST BOOT INSTALLER Part No B 48867 47mm 2 See Figure 2 119 Place the seal driver over the end of the slider fork 22 and the slide bushing cha...

Page 168: ... 28 NOTE When installing the fork spring verify that the tighter wound portion of the spring is installed down 7 See Figure 2 119 Install the fork spring 12 fork spring joint 11 and fork spring collar 10 over the damper rod retrieval tool NOTE Be sure to never over compress the fork assembly 8 Remove the fork slider from the vise and install the fork assembly in the front fork compressor 9 See Fig...

Page 169: ...t in death or ser ious injury 00124c 4 Repeat previous steps on second front fork 5 Temporarily install front axle to the fork assemblies to verify correct alignment 6 Use LOCTITE 271 red on upper fork clamp fasteners Tighten to 23 25 ft lbs 31 2 33 9 Nm 7 Use LOCTITE 271 red on lower fork clamp fasteners Tighten to 20 22 ft lbs 27 1 29 8 Nm 8 Repeat torque sequence in previous two steps 9 Install...

Page 170: ...25 Hold or brace the lower fork clamp and remove steering stem capnut 1 8 Remove the upper fork clamp 4 9 Remove the stem 6 and lower fork clamp 8 as an assembly 10 Remove ignition switch 11 If steering head bearings need replacing see 2 18 STEERING HEAD BEARINGS 1 3 2 3 4 5 6 7 8 7 sm00573 1 Stem capnut 2 Stem pinch fastener 3 Upper fork clamp pinch fastener 4 Upper fork clamp 5 Head bearing 6 St...

Page 171: ...ll handlebars See 2 31 HANDLEBARS FIREBOLT 15 Install cable straps a Install cable strap to the right of ignition switch securing right hand switch and brake line wires to upper fork clamp b Install cable strap to the left of ignition switch securing left hand switch and clutch cable wires to upper fork clamp c Connect ignition switch and install cable strap REMOVAL LIGHTNING ULYSSES 1 Place a sci...

Page 172: ...ust both forks equally Improper fork adjustment can lead to loss of control which could result in death or ser ious injury 00124c NOTE For additional information see 2 16 FRONT FORKS 9 See Figure 2 124 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 2...

Page 173: ...ng Notches Upper Bearing Removed For Clarity INSTALLATION TOOL NAME PART NUMBER BACKING PLATE B 43993 12 STEERING HEAD BEARING INSTALLATION TOOL B 45521 STEERING HEAD BEARING RACE INSTALLER HD 39302 NOTES Steering head bearings should be installed one at a time in order to verify proper alignment of bearing in bore Use the backing plate for wheel bearing installation B 43993 12 on the opposite sid...

Page 174: ...ATION TOOL Part No B 45521 3 Place the WHEEL BEARING BACKING PLATE with the large diameter facing the frame over the forcing screw 4 Install the bearing 4 washer 5 and nut 6 from the steering head bearing race installer onto the forcing screw 1 5 Tighten the nut 6 by hand until the bearing is started into the bore in the steering head 6 See Figure 2 131 Hold the forcing screw while tightening the ...

Page 175: ...m 14 On Lightning and Ulysses models install front modules See 2 30 FRONT MODULES LIGHTNING AND ULYSSES MODELS 15 On Firebolt models install headlight assembly and support bracket See 2 26 HEADLAMP ASSEMBLY AND SUP PORT BRACKET 16 Install front brake lever housing See 2 10 FRONT BRAKE SIX PISTON CALIPER 2 1 sm00579 1 Forcing screw 2 Nut Figure 2 131 Install Bearings HOME 2010 XB Service Chassis 2 ...

Page 176: ...Tighten rear axle pinch bolt 12 to 40 45 ft lbs 54 2 61 Nm 5 For Firebolt Lightning Install right side rider footpeg mount See 2 34 FOOTPEG HEEL GUARD AND MOUNT FIREBOLT AND LIGHTNING MODELS For Ulysses Install right side rider passenger footpeg heel guard and mount with the rider and passenger foot pegs See 2 35 HEEL GUARD AND FOOTPEG MOUNTS ULYSSES MODELS 2 1 sm00302 1 Axle 2 Pinch bolt Figure 2...

Page 177: ...ced as a unit when replacement is necessary Do not intermix bearing components 2 See Figure 2 133 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 sleeve 4 Remove stone guard See 2 37 BELT GUARDS CLEANING AND INSPECTION Compressed air can pierce the skin and flying debris from compressed ai...

Page 178: ...Nm sm00585 Figure 2 134 Jiffy Tite Quick Disconnect Oil Line Fittings INSTALLATION SWINGARM 1 See Figure 2 133 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 7 62 4 Nm 3 Apply LOCTITE 271 red to pivot shaft pinch fastener 7 Install and tighten fastener to 17 19 ft lbs 23 25 8...

Page 179: ...rst If positive cable should contact ground with negative cable connected the resulting sparks can cause a battery explosion which could result in death or serious injury 00068a 14 Connect battery cables to battery positive cable red first Tighten to 60 70 in lbs 6 8 7 9 Nm See 1 16 BATTERY MAINTENANCE After installing seat pull upward on seat to be sure it is locked in position While riding a loo...

Page 180: ...pper snubber 1 tightening snubber fastener 2 to 12 36 in lbs 1 4 4 Nm 2 Loosely install front isolator bracket 4 with front isolator bolt 6 3 Install front isolator bracket fasteners 5 and tighten to 49 51 ft lbs 66 4 69 1 Nm NOTE Avoid cross threading front isolator bolt or insert Keep weight of motorcycle off front isolator by alternately tightening front isolator bolt and raising scissor jack t...

Page 181: ...g the horizontal crease and V shaped edge 4 See Figure 2 138 With a pencil trace the outline of the entire puck onto the frame 5 Obtain one primer applicator from the kit Observe warnings on label of Surface Primer Failure to follow warnings could result in death or serious injury 00454b Surface Primer contains ethyl benzene and toluene chemicals known to the State of California to cause cancer an...

Page 182: ...78 1 Directional point 2 Horizontal crease 3 V shaped edge Figure 2 137 Puck Orientation is00880 Figure 2 138 Outline the Entire Puck is00881 Figure 2 139 Pressing Puck to Frame HOME 2 102 2010 XB Service Chassis ...

Page 183: ... fastener See 3 4 ENGINE ROTA TION FOR SERVICE 10 See Figure 2 140 Lift and remove frame from the motor cycle sm00914 Figure 2 140 Lift Frame Off Motorcycle INSTALLATION 1 Place frame over the motorcycle 2 Install rear isolator fastener See 3 6 ENGINE INSTALLA TION 3 Install main wire harness See 6 26 MAIN WIRE HAR NESS 4 Install upper and lower fork clamps See 2 17 FORK CLAMPS 5 Install rear shoc...

Page 184: ...m00588 7 1 Lower shock mount Shock remote reservoir clamp fastener 2 8 Shock remote reservoir clamp Lower shock mount sleeve 9 3 Lower shock mount fastener Shock remote reservoir 4 10 Shock reservoir body Shock spring retainer kit 11 5 Rear shock spring Upper shock mount fastener 6 12 Lower shock mount nut and washer Washers Figure 2 141 Rear Shock Absorber Assembly Firebolt HOME 2 104 2010 XB Ser...

Page 185: ...rvoir 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 2 142 Rear Shock Absorber Assembly Lightning HOME 2010 XB Service Chassis 2 105 ...

Page 186: ...fastener 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 2 143 Rear Shock Absorber Assembly Ulysses REMOVAL FIREBOLT 1 Remove seat Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can ...

Page 187: ...e 2 145 Cut the cable tie 2 securing vent hose to shock housing 5 See Figure 2 142 Remove the nut 4 and washer 5 from the lower shock bolt and raise scissor jack until the lower bolt can be removed by hand 6 After removing both shock fasteners 7 9 and reservoir clamp fastener 1 remove rear shock assembly and reservoir For XB9SX XB12SX XB12S and XB12Scg The remote reservoir can be slid out of the c...

Page 188: ...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 6 16 3 Nm 4 Install cable strap NOTE See Figure 2 141 Verify compression adjuster screw is facing up 5 Install upper body work See 2 39 SUBFRAME TAIL ASSEMBLY AND BODY WORK FIREBOLT Connect positive battery cable first If positive cable should contact g...

Page 189: ... 20 3 23 Nm 3 Install upper shock bolt and tighten to 48 52 ft lbs 65 1 70 5 Nm 4 Install the two fasteners holding the preload adjuster in place and tighten to 36 60in lbs 4 1 6 8 Nm 5 Install rear shock reservoir clamp 7 and fastener 6 and tighten clamp fastener to 80 88 in lbs 9 0 9 9 Nm 6 Install ECM See 4 4 ELECTRONIC CONTROL MODULE ECM 7 Install fan shroud See 2 49 AIR SCOOPS 8 Lower scissor...

Page 190: ...nt housing 5 Screw long bottom 6 Ferrules 7 Cable wheel 8 Rear housing 9 Locating pin Figure 2 150 Cable Connections CLEANING AND INSPECTION Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury Wear safety glasses when working with compressed air Never use your hand to check for air leaks or to determine air flow rates 00061a Clean all parts excep...

Page 191: ...ontrol cable barrel in the throttle cam wheel of the throttle body and then slip the elbow into the slotted hole in the throttle cable mounting bracket Position the throttle control cable in the same manner so both elbows are inserted into the bracket 5 Tighten the cable adjustment nuts that were removed for installation purposes onto the threaded end of the elbows and thread them on until there i...

Page 192: ...sm03924 Figure 2 151 Throttle Cable Retention Clip sm03923 Figure 2 152 Throttle Cable Retention Clip Inside View sm04534 Figure 2 153 Throttle cable elbow alignment HOME 2 112 2010 XB Service Chassis ...

Page 193: ...sen clutch adjuster 2 to release tension from hand lever and clutch release mechanism 8 See Figure 2 156 Remove clutch cable ferrule 7 from hand lever 4 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 2 154 Clutch Cable Adjuster sm04195 Figure...

Page 194: ...Remove clutch cable and fitting 15 Remove and discard O ring on the clutch cable fitting 1 7 3 7 11 2 9 4 5 8 6 10 sm00602 1 Primary cover 2 Clutch inspection cover 3 Engine shift lever 4 Shift pedal assembly 5 Shift linkage assembly 6 Flange head bolt 7 Bearings shift lever 8 Sleeve shift lever 9 Shifter bracket Ulysses only 10 Oil seal rubber washer 11 Drain plug Figure 2 157 Shifter Linkage HOM...

Page 195: ...48 60 in lbs 5 4 6 8 Nm 8 See Figure 2 160 If the shift linkage assembly 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 for correct clutch cable 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 cove...

Page 196: ...36 6 Nm 17 Adjust clutch cable See 1 9 CLUTCH TRANSMIS SION PRIMARY FLUID 18 Install chin fairing See 2 50 CHIN FAIRING 19 Connect negative battery cable to battery terminal Tighten fastener to 60 70 in lbs 6 8 7 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 injur...

Page 197: ... 1 3 2 sm00604 1 Flasher 2 Bank angle sensor 3 Electronic control module Figure 2 161 Electrical Comonents Beneath Front Fairing Firebolt sm00605 Figure 2 162 Headlamp Connector Firebolt DISASSEMBLY FIREBOLT 1 See Figure 2 161 Remove bank angle sensor 2 2 Remove flasher 1 3 See Figure 2 163 Remove black rubber cover 4 from rear of headlights 4 Disconnect black connector from headlights 5 Disconnec...

Page 198: ...acket up 2 and tighten pivot fasteners 1 to 72 96 in lbs 8 10 8 Nm 7 See Figure 2 161 Install electronic control module 3 8 See Figure 2 163 Align electronic control module and headlight support bracket with fairing support bracket 9 Tighten electronic control module fasteners to 72 96 in lbs 8 10 8 Nm 10 Connect flasher 1 and bank angle sensor 2 11 Install front fairing See 2 47 FRONT FAIRING WIN...

Page 199: ...gure 2 165 b For Ulysses See Figure 2 166 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 th...

Page 200: ...n connectors 122 Headlight assembly 8 3 Fasteners 2 headlight support bracket Horn bracket 4 9 Horn fastener Headlight support bracket 10 5 Left and right front modules Headlight connector 38 Figure 2 165 Electrical Connectors Behind Windscreen Lightning HOME 2 120 2010 XB Service Chassis ...

Page 201: ...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 2 167 Align and install headlight bulbs 3 into back of headlight housing 4 NOTE The tab on the base of the headlight bulb should rest between the two tabs located at the top of the hole on the back of the h...

Page 202: ...ach 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 8 Nm 7 Connect horn connectors 122 2 8 Adjust headlights See 1 19 HEADLAMP 9 Install windshield and windscreen See 2 48 WINDSHIELD AND WINDSCREEN LIGHTNING AND ULYSSES MODELS Connect positive battery cable first If positive cable should contact ground ...

Page 203: ...s and washers 4 8 and p clamp 7 Tighten to 16 18 ft lbs 22 26 Nm 3 Connect instrument cluster connector and install instru ment cluster Tightening to 12 36 in lbs 1 4 4 Nm See 6 25 INSTRUMENT MODULE 4 Install horn and tighten fasteners to 72 96 in lbs 8 10 8 Nm See 6 12 HORN 5 Install fuse block relay and p clamp tightening fasteners to 72 96 in lbs 8 10 8 Nm See 6 20 MAIN FUSE AND FUSES 6 Install...

Page 204: ...t bracket Jam nut 2 6 Washer Instrument cluster 7 3 P clamp Rubber grommet 4 8 Fairing support bracket fasteners and washers P clamp fastener and washers Figure 2 168 Fairing Support Bracket Assembly Firebolt HOME 2 124 2010 XB Service Chassis ...

Page 205: ...s 3 6 See 2 25 CLUTCH CONTROL and 2 10 FRONT BRAKE SIX PISTON CALIPER 2 Install jam nuts 5 and tighten to 39 48 in lbs 4 4 5 4 Nm 3 Install pivot shaft risers 4 and tighten to 43 49 in lbs 4 8 5 5 Nm 4 Spread deflectors 1 and place over the pivot shaft and riser ends 5 Snap deflectors onto handlebar end caps 7 6 Install new deflector fasteners 2 and tighten to 24 36 in lbs 2 7 4 Nm 2 2 7 6 5 4 2 1...

Page 206: ...dels to provide additional protection for the headlight assemblies REMOVAL AND INSTALLATION 1 See Figure 2 170 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 2 170 Headlamp Grille Typical HOME 2 126 2010 XB Service Chassis ...

Page 207: ... HEADLAMP KEY SWITCH NOTE See Figure 2 172 Once the ignition switch has been removed there will be two remaining fasteners 9 Disconnect front turn signals See 6 14 FRONT TURN SIGNALS 10 See Figure 2 172 Remove fastener attaching p clamp to rear side of right front module NOTE See Figure 2 171 Lightning or Figure 2 173 Ulysses Once the clamp load has been released on the final fastener securing the...

Page 208: ...en fasteners to 36 60 in lbs 4 6 8 Nm 8 Connect speedometer 9 On Ulysses model connect auxiliary outlet 10 Install headlamp assembly and support bracket See 2 26 HEADLAMP ASSEMBLY AND SUPPORT BRACKET 11 Install windshield and windscreen See 2 48 WINDSHIELD AND WINDSCREEN LIGHTNING AND ULYSSES MODELS Connect positive battery cable first If positive cable should contact ground with negative cable co...

Page 209: ...rom 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 32 5 35 3 Nm 3 Install front brake master cylinder Tighten but do not torque 4 Install throttle and grip onto right clip on See 2 24 THROTTLE CONTROL 5 Install end cap onto right clip on 6 Position brake hand lev...

Page 210: ...ews in place after applying LOC TITE 271 red c Tighten both front screws to 120 144 ft lbs 13 6 16 3 Nm d Then tighten both rear screws 120 144 ft lbs 13 6 16 3 Nm 3 Install clutch hand control Tighten but do not torque See 2 25 CLUTCH CONTROL 4 Install left switch housing 5 Check control wire routings See D 1 APPENDIX D HOSE AND WIRE ROUTING a Route right hand control wires between the lower clam...

Page 211: ...ndlebar clamp 5 Left hand grip XB12X models are OEM equipped with heated handgrips 6 Handlebar Ulysses models 7 Handlebar XB9SX XB12SX 8 Handlebar XB12Scg XB12Ss 9 Clutch cable hook Ulysses models Figure 2 176 Handlebar Assembly Lightning Ulysses HOME 2010 XB Service Chassis 2 131 ...

Page 212: ...han they actually are Adjust mirrors to see a small portion of the riders shoulder in each mirror This helps the rider establish the relative distance of vehicles to the rear of the motorcycle Before tightening adjuster nut position mirrors for rider 2 Install mirror 1 and while holding in position for rider vision tighten adjuster nut to 115 130 in lbs 13 14 7 Nm 2 3 1 1 2 3 4 4 sm00634 1 Mirror ...

Page 213: ... the non California vent clamp 2 Install heel guard 3 with fasteners 4 Tighten to 72 96 in lbs 8 10 8 Nm 3 Position spring 6 in footpeg 8 4 Position footpeg 8 and spring in footpeg mount 1 5 Install footpeg pin 9 6 Install clip 5 7 Apply LOCTITE 271 red and tighten to 36 48 in lbs 4 5 Nm 3 2 7 5 8 9 1 6 4 sm03637 1 Footpeg mount 2 Footpeg mount fasteners 3 Heel guard 4 Heel guard fasteners 5 Clip ...

Page 214: ... in lbs 8 10 8 Nm 6 Position footpeg 8 detent plate 6 ball 5 and spring 4 on to footpeg mount 3 7 Install footpeg pin 9 8 Install clip 7 9 Check that footpeg clicks in the up and down position 2 4 3 9 10 8 1 6 7 5 11 sm03837 1 Heel guard fasteners 2 Heel guard 3 Footpeg mount 4 Spring 5 Ball 6 Detent plate 7 Clip 8 Footpeg 9 Pin 10 Footpeg mount fastener 11 Jamnut Lightning only Figure 2 179 Passe...

Page 215: ...licks in the up and down position 1 8 10 8 9 2 3 6 4 7 5 3 sm03636 1 Footpeg mount 2 Footpeg mount fasteners 3 3 Clip footpeg 4 Passenger footpeg 5 Detent plate 6 Ball 7 Spring 8 Pin 9 Spring 10 Rider footpeg Figure 2 180 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 2 178 Remove footpeg ...

Page 216: ...rake Master Cylinder Location Ulysses HEEL GUARD REPLACEMENT 1 See Figure 2 183 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 2 183 Heel Guard Ulysses HOME 2 136...

Page 217: ...er 1 only 1 See Figure 2 185 Install sprocket cover 2 using sprocket cover fasteners 1 3 and tighten all fasteners and washers 1 to 12 36 in lbs 1 4 4 Nm 2 Install chin fairing See 2 50 CHIN FAIRING sm00122 Figure 2 184 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 2 185 Sprocket Cover HOME 2010 XB Service ...

Page 218: ... Install upper belt guard 1 to swingarm brace tightening fasteners 2 to 12 36 in lbs 1 4 4 0 Nm 2 Install stone guard 6 and tighten fasteners to 12 36 in lbs 1 4 4 0 Nm 3 Install lower belt guard 3 and tighten fasteners 4 to 12 36 in lbs 1 4 4 0 Nm 4 Tighten rear axle See 5 7 DRIVE BELT AND IDLER PULLEY 5 Tighten rear axle pinch fastener to 40 45 ft lbs 54 2 61 0 Nm 6 Install right side rider foot...

Page 219: ...ylon washers 4 4 Remove intake cover assembly 2 INSTALLATION 1 See Figure 2 187 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 translucid 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...

Page 220: ...over fasteners with nylon washers 2 4 Front intake cover fasteners with nylon washers 2 models without translucid covers 5 Front intake cover fasteners with top hat bushings 2 and isolating washers 4 translucid covers only Figure 2 187 Intake Cover Assembly HOME 2 140 2010 XB Service Chassis ...

Page 221: ...a 2 Disconnect battery by unthreading fastener removing negative cable black from battery first See 1 16 BAT TERY MAINTENANCE 3 See Figure 2 188 Remove upper body work 1 from subframe tail assembly 7 a Remove body work fasteners 2 b Disconnect passenger seat lock cable 6 by removing cable from seat lock plate 4 and ferrule from keylock 3 c Lift upper tail body work 1 off subframe tail assembly 7 4...

Page 222: ...k 10 3 Lower tail body work fasteners Passenger seat lock 4 11 Passenger seat lock plate Trunk 12 5 Fastener Passenger seat lock retainer 6 13 Passenger seat lock cable License plate bracket 14 7 Passenger seat latch and fastener Subframe tail assembly Figure 2 188 Subframe Tail Assembly and Body Work Assembly Firebolt HOME 2 142 2010 XB Service Chassis ...

Page 223: ... body work 9 underneath subframe tail assembly by removing fasteners 10 b Remove trunk 11 12 See Figure 2 190 Disconnect main battery ground 1 and ground to wire harness 2 13 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 14 Cut cable strap 4 holding rear brake reservoir hose 5 and rear ...

Page 224: ...se to subframe tail assembly 11 See Figure 2 191 Feed rear brake reservoir hose under neath subframe tail assembly and install rear brake reservoir tightening fastener to 48 72 in lbs 5 4 8 Nm 12 See Figure 2 190 Install cable strap holding rear brake lamp wire and connector 6 and rear brake reservoir hose 5 13 See Figure 2 188 Install lower body work 9 and trunk 11 onto subframe tail assembly 7 a...

Page 225: ...us injury 00068a 21 Connect battery cables to battery positive cable red first Tighten to 60 70 in lbs 6 8 7 9 Nm See 1 16 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 22 Install seat and pillion HOME 2010 XB Service Chassis 2 145 ...

Page 226: ... fuse block and relay center from support bracket 8 Move rear main harness and shock absorber reservoir to right side of vehicle 9 Remove left side passenger footrest support assembly See 2 34 FOOTPEG HEEL GUARD AND MOUNT FIREBOLT AND LIGHTNING MODELS 10 See Figure 2 192 Remove the following fasteners a Left front trunk pan to left side tail section 14 b Left rear tail section to center tail secti...

Page 227: ...1 6 ECM connectors 10 and 11 Figure 2 192 Main Harness Electrical Connectors and Grounds 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 finish The cast aluminum tail section has a powder coat Because the surface is not bare polished aluminum it...

Page 228: ...r footrest support assembly See 2 34 FOOTPEG HEEL GUARD AND MOUNT FIREBOLT AND LIGHTNING MODELS 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 2 192 Connect a Wire harness ground 2 GRD 2 b Rear brake ...

Page 229: ...nd terminal fastener 2 7 Passenger footrest support fastener with jam nut 2 8 Front trunk pan fastener to side tail section 2 9 Passenger footrest support fastener no jam nut 2 10 Seat latch assembly 11 Trunk pan assembly 12 Rear trunk pan fastener to center tail section 2 13 Rear shock reservoir bracket 14 Plastic lugs for manufacturing purposes only Figure 2 193 Tail Frame and Trunk Pan Assembly...

Page 230: ...t and right tail sections to center tail section but do not tighten 3 Install two fasteners 12 securing trunk pan to center tail section but do not tighten 4 Apply LOCTITE 271 red to threads of left and right rear tail sections fasteners 4 and tighten to 102 114 in lbs 11 5 12 8 Nm 5 Tighten fasteners 12 securing trunk pan to center tail section to 48 72 in lbs 5 4 8 Nm Be sure that all lights and...

Page 231: ...12 36 in lbs 1 4 4 Nm b On XB12Ss models apply LOCTITE 271 red and install battery tray fasteners and tighten to 48 72 in lbs 5 4 8 Nm c Apply LOCTITE 271 red and install center tail sec tion fastener to rear tail section 15 Tighten to 102 114 in lbs 11 5 12 8 Nm d Apply LOCTITE 271 red and install fasteners attaching left and right tail sections to main frame fuel tank assembly and tighten to 21 ...

Page 232: ...tery negative cable 7 black first 12 3 11 10 13 8 5 4 6 9 9 7 1 2 14 15 15 sm04798a 9 1 Left rear and right rear tail section fasteners 4 Main harness 2 10 Electronic control module Seat lock cable 11 3 Bank angle sensor BAS connector 134 ECM connectors 10 and 11 4 12 Fuse block and relay center Auxiliary power outlet 13 5 Trunk pan Main harness ground wires GRD2 6 14 Main harness with plastic gro...

Page 233: ... be necessary to remove the rear brake fluid reservoir When removing the left side tail section it will be neces sary to remove all of the grounds attached to the left tail section 1 2 3 4 sm00547a 1 Reservoir 2 Clamp 3 Remote reservoir hose 4 Fastener and washer Figure 2 196 Remote Reservoir Ulysses 10 Remove fasteners securing front trunk pan to left and right side tail section 11 Remove fastene...

Page 234: ... 4 8 1 Nm 2 Install shock reservoir retainer and fastener Tighten fastener to 80 88 in lbs 9 0 9 9 Nm 3 Install two fasteners securing the preload adjuster to the trunk pan and tighten to 36 60 in lbs 4 6 8 Nm 4 Install battery pan a Install fasteners securing battery tray to left and right tail sections and tighten to 72 96 in lbs 8 10 8 Nm b See Figure 2 194 Install fuse block and relay center 4...

Page 235: ...ont trunk pan fastener to side tail section 2 6 Ground terminal fastener 2 7 Trunk pan assembly 8 Rear trunk pan fastener to center tail loop 2 9 Seat latch assembly 10 Bank angle sensor bracket 11 Center tail loop 12 Center tail loop fastener to rear tail section 4 Figure 2 199 Tail Frame and Trunk Pan Assembly Ulysses HOME 2010 XB Service Chassis 2 155 ...

Page 236: ...ANK 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 237: ...1 2 3 sm00664 1 Tail loop 2 License plate bracket 3 Wire cover Figure 2 200 Wire Cover Tail Loop and License Plate Bracket Ulysses HOME 2010 XB Service Chassis 2 157 ...

Page 238: ...4 Remove the trunk pan 15 Remove the fan shroud ASSEMBLY TRUNK PAN AND BATTERY PAN 1 Install the fan shroud 2 Install the trunk pan 3 Install fastener securing right front trunk pan to left and right side tail sections and tighten to 72 96 in lbs 8 10 8 Nm 4 Install fasteners securing rear of trunk pan 48 72 in lbs 5 4 8 1 Nm 5 Install shock reservoir retainer and fastener Tighten fastener to 80 8...

Page 239: ...assembly does not have to be removed from motorcycle in order to remove sidestand leg 1 Remove two fasteners from the left side of chin fairing See 2 50 CHIN FAIRING 2 See Figure 2 202 or Figure 2 203 Remove sidestand leg 3 Retract sidestand leg 9 4 Remove sidestand spring 1 and spring extension plate 3 using SNAP ON SPRING TOOL Part No HE 52B 5 Remove sidestand pivot pin circlip 7 and remove side...

Page 240: ...nsion plate should curve away from primary chain adjustment screw to allow for clearance around adjustment screw INSTALLATION 1 See Figure 2 203 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 241: ...5 onto fairing support bracket and install turn signals 6 7 See 6 14 FRONT TURN SIGNALS 2 Install mirrors 2 with fasteners and tighten to 72 96 in lbs 8 10 8 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 windsh...

Page 242: ...ve four windscreen fasteners and washers 3 2 Remove windscreen 4 Installation 1 See Figure 2 206 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 2 206 Front Windscreen Lightning...

Page 243: ...1 See Figure 2 207 Position windscreen 6 onto left and right front modules 2 8 and the center fairing support 7 2 Install six fasteners and tighten to 10 12 in lbs 1 1 1 4 Nm 3 Install windshield 4 by pushing into place Pull on wind shield when installed to verify attachment 4 1 3 2 7 8 5 6 sm00684 5 1 Windscreen fasteners 6 Headlight mounting bracket 2 6 Left front module Windscreen 7 3 Fairing s...

Page 244: ...windscreen and pull windshield from windscreen 9 10 12 11 13 1 2 15 14 4 3 7 5 8 6 sm05264a 9 1 Headlight mounting bracket Windshield 2 10 Windshield mounting pin upper 2 Left front module 11 3 Right front module Screw 2 4 12 Finish washer 2 Fairing support center 13 5 Windscreen Spacer 2 6 14 Bodywork mount grommet 2 Mounting grommet 2 15 7 Windscreen screws 6 Washer 2 8 Lock nut 2 Figure 2 208 W...

Page 245: ... push in place to install Pull on windshield to verify attachment 3 Align lower windscreen and windshield holes For left and right side lower holes insert finish washer 4 and spacer 5 onto screw 3 and place through windshield grommet and windscreen holes 4 See Figure 2 208 From inside of windscreen place washer 7 onto screw 3 and thread lock nut 8 onto screw Tighten screw to 25 30 in lbs 2 8 3 4 N...

Page 246: ...bs 1 4 4 Nm 3 Secure the voltage regulator and alternator wiring har nesses to the bottom of the left air scoop with three cable straps ENGINE SHROUD AIR SCOOP Removal 1 See Figure 2 209 On right side of motorcycle locate engine shroud air scoop 6 2 Remove three engine shroud air scoop fasteners 5 3 Remove engine shroud air scoop 6 Installation 1 See Figure 2 209 Position engine shroud air scoop 6...

Page 247: ...inless button head 3 Ulysses 8 3 Ram air scoop inner Ulysses Ram air scoop fastener and washer 4 9 Engine shroud air scoop Ram air scoop outer Ulysses 10 5 Fan shroud Ulysses Engine shroud air scoop fastener and washer 3 Figure 2 209 Ram Air Scoop Engine Shroud Air Scoop and Oil Cooler Air Scoop HOME 2010 XB Service Chassis 2 167 ...

Page 248: ...ir fastener and retainer Push the reservoir aside to access the fastener c Remove remaining fasteners securing front trunk pan to side tail sections d Remove remaining components on trunk pan as needed 10 Remove fan shroud Installation 1 Install fan shroud See Figure 2 210 sm06807 Figure 2 210 Preload Adjuster with Reservoir Hose Routing 2 Install the trunk pan a See 6 26 MAIN WIRE HARNESS Install...

Page 249: ...use a battery explosion which could result in death or serious injury 00068a 6 Install battery After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 7 Install seat HOME 2010 XB Service Chassis 2 169 ...

Page 250: ...SETTER TOOL KIT Part No MAR39200HD 1 Apply LOCTITE 271 red on all fasteners 2 See Figure 2 211 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 fast...

Page 251: ...213 Center Tab and Frame Slot Firebolt Pillion NOTE The trunk is located under the pillion 1 See Figure 2 214 Insert ignition key into the pillion lock located on the left side of motorcycle Turn key clockwise to disengage rear pillion latch NOTE Do not place keys in the trunk If pillion is installed keys will not be accessible 2 Lift and remove pillion 3 Install pillion by sliding metal locating ...

Page 252: ...sts in tail section After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 3 See Figure 2 220 Press down rapidly and firmly on rear of seat to engage seat latch Pull up on rear of seat to make sure latch is engaged 3 1 1 2 pd00242 1 Seat hooks 2 2 Seat latch 3 Tab...

Page 253: ...cycle to remove om00576 Figure 2 221 Seat Lock Ulysses Models om00574 Figure 2 222 Seat Removal Ulysses Models Installation 1 See Figure 2 223 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 sh...

Page 254: ...2 1 3 om00573 1 Seat hook 2 Seat lock latch 3 Front tab Figure 2 223 Seat Tab Hooks Ulysses Models HOME 2 174 2010 XB Service Chassis ...

Page 255: ...he hole in the trunk pan and plate now is the time to connect the cable end to the seat lock Seat lock plate must be aligned to tab on seat lock for proper installation 3 Install seat lock retainer 3 by aligning retainer to retainer grooves on back side of seat lock 1 4 Connect seat lock cable to latch a Install cable end 8 and cable 5 onto latch b Slide retainer 7 over pin on latch to lock cable ...

Page 256: ...ble 5 a Remove latch 8 from latch bracket 9 by removing two fasteners 7 b Remove cable end 6 and cable 5 from latch 8 4 Remove seat lock a Remove wire cover from bottom side of license plate bracket to access seat lock b Remove seat lock retainer 3 from seat lock 1 c Remove seat lock 1 from plate 2 and license plate bracket NOTE When removing seat lock 1 cable end 4 should release from seat lock 5...

Page 257: ... 36 48 in lbs 4 5 4 Nm 7 Install license plate light fasteners and tighten to 12 36 in lbs 1 4 4 Nm After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 8 Install cable strap around seat lock cable in original loca tion 9 Install seat 8 9 3 6 5 4 7 10 1 2 11 sm0...

Page 258: ...ing the lever to the square groove that is cast into the seat lock 7 8 Fasten the lock lever 4 to the seat lock 7 with the washer 3 and fastener 2 9 Install the ferrule 8 of the seat lock cable 9 into the seat lock lever 4 10 Open and close the seat lock with ignition key to verify that cable is working properly 11 Install the seat lock cable 9 into the seat lock plate 6 12 Install upper body work...

Page 259: ... Remove 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 f...

Page 260: ... 7 Tighten front and rear fasteners to the following specifica tions a Tighten rear fasteners 3 11 to 23 25 ft lbs 31 2 33 9 Nm b Tighten front fasteners 1 12 to 108 120 in lbs 12 2 13 6 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 5 4 Nm and tighten the nuts to 12 36 in lbs 1 4 4 Nm 4 5 4 6 8 9 2 1 1...

Page 261: ...ection castings This operation should be performed for one side case bracket at a time It does not matter which side case bracket is removed first 9 1 2 4 3 12 11 6 8 7 5 10 sm05172 1 X brace bracket 2 Rear mount side case bracket 3 Side case 4 Forward mount side case bracket 5 Fastener with locknut X brace mount 2 6 X brace mount 7 Fastener with Belleville washer rear mount side case bracket 2 8 ...

Page 262: ...final step 1 See Figure 2 229 Install rear fastener 7 securing side case support bracket 2 to trunk pan attaching bracket to vehicle snug only 2 Install forward fastener 8 attaching side case bracket 4 to trunk pan snug only 3 Install fastener with locknut 5 attaching the X brace bracket 1 to the side case bracket 6 snug only 4 Install bolt 10 attaching side case bracket 11 to the back of the pass...

Page 263: ... 2 by attaching trunk pan mounts 5 to the grab handles by installing two fasteners with Belleville washers 6 into the lower grab handle Thread the fasteners in but do not tighten at this time 2 Install fasteners with nuts 7 securing the top case bracket lower mounts 4 to the cross bar mount 3 Do not tighten at this time 3 Tighten the two fasteners 6 attaching the top case mounting bracket 2 to the...

Page 264: ...h Mechanism and Lock 4 See Figure 2 234 Loosen large hex nut and remove lock from latch mechanism Installation 1 See Figure 2 234 Install lock into new latch mechanism and secure with large hex nut 2 Slide latch mechanism into luggage case 3 See Figure 2 232 or Figure 2 233 Install two new Phillips head screws into latch mechanism and tighten NOTE See Figure 2 233 On the top case it will be necess...

Page 265: ...se locking latch 2 with key 2 Remove side case by pulling away from vehicle 3 Remove fastener 9 securing the side case bracket 10 to the back of the passenger footrest support bracket 4 Remove fastener and locknut 11 securing the X brace bracket 5 to the side case bracket 6 5 Remove forward fastener 8 securing side case bracket 3 to trunk pan 6 Remove rear fastener 7 securing side case bracket 4 t...

Page 266: ...he remaining side LUGGAGE CASE LATCH MECHANISM Removal sm06004 Figure 2 236 Side Case Latch Mechanism NOTES The lock assembly is non replaceable If it is determined that a new lock is needed the entire side case latch mechanism must now be replaced See Figure 2 236 In order to access the two rivets securing the latch to the side case it will be necessary to unlock the latch to expose the rivet hea...

Page 267: ...NE INSTALLATION 3 24 3 7 CYLINDER HEAD 3 35 3 8 CYLINDER AND PISTON 3 51 3 9 OILING SYSTEM 3 60 3 10 OIL PUMP 3 61 3 11 OIL RESERVOIR AND OIL HOSE ROUTING 3 67 3 12 OIL LINE FITTINGS 3 69 3 13 OIL COOLER 3 71 3 14 OIL PRESSURE INDICATOR SWITCH 3 72 3 15 CRANKCASE BREATHING SYSTEM 3 74 3 16 HYDRAULIC LIFTERS 3 76 3 17 GEARCASE AND CAM GEARS 3 78 3 18 CRANKCASE 3 82 ENGINE ...

Page 268: ...NOTES ...

Page 269: ... 1 Nm 10 20 ft lbs Cylinder studs 3 4 ENGINE ROTATION FOR SERVICE Assembly 8 1 10 8 Nm 72 96 in lbs Exhaust header nuts 3 6 ENGINE INSTALLATION Assembly 8 1 10 8 Nm 72 96 in lbs Exhaust header nuts 3 4 ENGINE ROTATION FOR SERVICE Assembly 66 4 69 1 Nm 49 51 ft lbs Front isolator bolt 3 6 ENGINE INSTALLATION Assembly 66 4 69 1 Nm 49 51 ft lbs Front isolator bolt 3 4 ENGINE ROTATION FOR SERVICE Asse...

Page 270: ...71 red 43 4 48 8 Nm 32 36 ft lbs Rear muffler bracket 3 15 CRANKCASE BREATHING SYSTEM Reed Valve Replacement LOCTITE 222 purple 2 8 4 0 Nm 25 35 in lbs Reed valve block fasteners 3 15 CRANKCASE BREATHING SYSTEM Reed Valve Replacement LOCTITE 222 purple 0 6 0 8 Nm 5 7 in lbs Reed valve stop fastener 3 13 OIL COOLER Installation 7 5 8 8 Nm 66 78 in lbs Stabilizer bracket fastener 3 6 ENGINE INSTALLA...

Page 271: ...ICATION ITEM Sequential non waste spark Type 1050 1150 RPM Regular idle 12 mm Spark plug size Harley Davidson No 10R12X Spark plug type 0 8890 mm 0 035 in Spark plug gap 16 24 Nm 12 18 ft lbs Spark plug torque Table 3 3 Valve and Valve Seat Specifications SERVICE WEAR LIMITS NEW COMPONENTS VALVE 0 965 mm 0 0038 in 0 0254 0 0762 mm 0 001 0 003 in Fit in guide exhaust 0 965 mm 0 0038 in 0 0254 0 076...

Page 272: ... gap 0 1651 mm 0 0065 in 0 0508 0 1143 mm 0 0020 0 0045 in Compression ring side clearance top 0 1651 mm 0 0065 in 0 0406 0 1041 mm 0 0016 0 0041 in Compression ring side clearance 2nd 0 2388 mm 0 0094 in 0 0406 0 1930 mm 0 0016 0 0076 in Oil control ring side clearance 0 02540 mm 0 00100 in 0 00127 0 01143 mm 0 00005 0 00045 in Pin fit loose at room temperature Table 3 7 Cylinder Head Specificati...

Page 273: ...076 mm 0 003 in Feed scavenge inner outer gerotor clearance Table 3 12 Gearcase Specifications SERVICE WEAR LIMITS NEW COMPONENTS GEARCASE 0 076 mm 0 003 in 0 018 0 056 mm 0 0007 0 0022 in Cam gear shaft in bore loose 0 635 mm 0 025 in 0 127 0 356 mm 0 005 0 014 in Cam gear shaft end play min 0 838 mm 0 033 in 0 127 0 559 mm 0 005 0 022 in Front intake cam gear shaft end play min Table 3 13 Flywhe...

Page 274: ...0012 0 00086 in Bearing running clearance 0 127 mm 0 0050 in 0 058 0 109 mm 0 0023 0 0043 in Fit in oil pump body bore Table 3 15 Sprocket Shaft Bearing Specifications SPECIFICATION INTERFERENCE FIT ITEM 0 152 mm 0 006 in Outer race fit in crankcase tight 0 152 mm 0 006 in Inner race fit on shaft tight HOME 3 6 2010 XB Service Engine ...

Page 275: ...ession test s make sure that the throttle plate is in the closed position before starting engine Engine will start at an extremely high RPM if throttle plate is left open 1 Disconnect spark plug wire Clean around plug base and remove spark plug 2 Connect compression tester to cylinder 3 With throttle body throttle plate in wide open position crank engine continuously through 5 7 full compression s...

Page 276: ...rottle plate is left open Table 3 17 Air Leakage Test POSSIBLE CAUSES AIR LEAK LOCATION Intake valve leaking Throttle body intake Exhaust valve leaking Exhaust pipe Leaking gasket Head gasket DIAGNOSING SMOKING ENGINE OR HIGH OIL CONSUMPTION Perform the Compression Test See 3 3 ENGINE Compression Test If further testing is needed remove the suspect cylinder heads and inspect the following Oil leve...

Page 277: ...s injury disconnect negative battery cable before proceeding 00048a 2 Remove seat and disconnect battery cables from battery negative cable black first 3 Remove intake cover See 2 38 INTAKE COVER 4 Remove air filter base plate See 4 3 AIR CLEANER ASSEMBLY NOTE When removing the left air scoop the alternator and voltage regulator harnesses and connections are secured to the bottom of the air scoop ...

Page 278: ...5 Disconnect the following sensors a Temperature sensor 11 90 b Rear oxygen sensor 12 137 c Front oxygen sensor not shown 138 16 Remove idler pulley See 5 7 DRIVE BELT AND IDLER PULLEY NOTE See 6 16 INTERACTIVE EXHAUST SYSTEM for specific details on removal of interactive components 17 Remove muffler See 4 19 EXHAUST SYSTEM NOTE Secure right side rider footrest mount to the side to prevent cosmeti...

Page 279: ...nd strap Fasteners 2 6 17 Bolt Rear isolator assembly 18 7 Fasteners for rear isolator assembly 4 Front tie bar assembly 8 19 Fasteners for front tie bar assembly 2 Washers for rear isolator assembly 4 20 9 Rear isolator bolt Nut for one fastener for front tie bar assembly 10 21 Center tie bar mount Rear tie bar assembly 22 11 Fasteners for rear tie bar assembly 2 Fasteners for center tie bar moun...

Page 280: ...rt front isolator bolt 6 through front isolator 4 and loosely thread into frame Do not tighten at this point 3 Install isolator mounting fasteners 5 and tighten to 49 51 ft lbs 66 4 69 1 Nm 4 Tighten front isolator bolt to 49 51 ft lbs 66 4 69 1 Nm 5 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 Install cent...

Page 281: ...OTPEG HEEL GUARD AND MOUNT FIREBOLT AND LIGHTNING MODELS or 2 35 HEEL GUARD AND FOOTPEG MOUNTS ULYSSES MODELS 22 Install sprocket cover See 2 36 SPROCKET COVER NOTE When installing the left side air scoop it is necessary to verify that the voltage regulator and alternator wiring harnesses are not trapped between the air scoop and cylinder head 23 Connect front oxygen sensor connector and secure in...

Page 282: ...eaner assembly See 2 35 HEEL GUARD AND FOOTPEG MOUNTS ULYSSES MODELS 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 When removing the right air scoop shroud it will be necessary to remove the front oxygen sensor connector from the scoop shroud 5 Remove left and right side air sc...

Page 283: ...e main frame above the rear cylinder head 15 Disconnect the following sensors a Temperature sensor 90 10 b Oxygen sensor 137 11 16 Disconnect throttle cables from induction module throttle body NOTE In order to remove the drive belt it will be necessary to remove all existing belt guards 17 Remove drive belt and idler pulley See 5 7 DRIVE BELT AND IDLER PULLEY 18 Remove transmission sprocket See 5...

Page 284: ...l cooler e Remove front tie bar 7 from V bracket f Remove front tie bar 7 from engine g Unbolt V bracket from main frame and remove V bracket 24 Remove center tie bar 13 from engine 25 Remove rear tie bar 21 from frame 26 Remove the cable strap securing the oil pressure wire neutral safety wire and muffler actuator cable in a bundle on the right side of the motorcycle just behind the oil pump body...

Page 285: ...ne 6 a Remove two p clamps 8 from feed oil line one on crankcase and one on swingarm oil reservoir b Remove feed oil line 6 at oil pump 1 c Disconnect feed oil line at swingarm oil reservoir and remove See 3 12 OIL LINE FITTINGS 32 Remove return oil line 7 a Remove p clamp 8 at swingarm oil reservoir 10 b Disconnect oil return line 7 at swingarm oil reservoir 10 See 3 12 OIL LINE FITTINGS c Discon...

Page 286: ...o crankcase Rear muffler bracket 10 3 Swingarm Oil reservoir Oil cooler feed line from oil pump 4 11 Oil filter Vent oil line 12 5 Oil line clamp Front muffler mount 6 13 Feed oil line Cable interactive exhaust 14 7 Drain plug Return oil line Figure 3 8 Oil Lines and Connections HOME 3 18 2010 XB Service Engine ...

Page 287: ... assembly 2 16 5 Ground strap Fasteners 2 6 17 Bolt Rear isolator assembly 18 7 Fasteners for rear isolator assembly 4 Front tie bar assembly 8 19 Fasteners for front tie bar assembly 2 Washers for rear isolator assembly 4 20 9 Rear isolator bolt Nut for one fastener for front tie bar assembly 10 21 Center tie bar mount Rear tie bar assembly 22 11 Fasteners for rear tie bar assembly 2 Fasteners fo...

Page 288: ...idestand assembly NOTE On Ulysses models it will be necessary to remove three fasteners in order to remove the sidestand assembly 35 Support engine with wide scissors jack 1 2 sm03933 1 Sidestand assembly 2 Bracket fasteners 2 Figure 3 11 Sidestand Assembly Extended NOTE See Figure 3 12 At this point it is necessary to support main frame with overhead hoist in order to remove rear isolator bolt Fa...

Page 289: ...igure 3 14 On Firebolt models the transmission vent line runs up the left side of the frame and exits beneath the rear brake reservoir and hose See Figure 3 15 and Figure 3 16 On Lightning and Ulysses models the transmission vent line runs up the left side of the frame and exits underneath the left rear side of the intake cover assembly sm00730 Figure 3 14 Transmission Vent Line Firebolt sm00737 F...

Page 290: ...r mount c See Figure 3 18 Swingarm pivot shaft pinch bolt threaded insert d See Figure 3 19 Aluminum bushings from front exhaust mount e See Figure 3 20 Wire guard located under the sprocket cover sm00740 Figure 3 18 Threaded Insert 1 2 sm03745 1 Left side 2 Right side Figure 3 19 Front Exhaust Mount Bushings 2 piece sm02996 Figure 3 20 Wire Guard sm02979 Figure 3 21 Rear Isolator Assembly HOME 3 ...

Page 291: ...me and swingarm oil tank 45 Route a ratcheting tie down through the swingarm bear ings up over the main frame through the top stabilizer area back down to the ratchet mechanism and secure swingarm to main frame NOTE See Figure 3 23 This allows the vehicle to remain together as a rolling chassis to be removed from the lift and stored if necessary 46 Remove overhead support sm03740 Figure 3 22 Secur...

Page 292: ...g items on the engine assembly as required a Shifter assembly See 5 3 PRIMARY COVER b See Figure 3 25 Install center tie bar mount with fasteners and tighten to 30 33 ft lbs 40 7 44 7 Nm NOTE Hand thread pivot shaft into crankcase prior to installing the threaded insert Remove pivot shaft after installing the threaded insert c See Figure 3 26 Apply LOCTITE 242 blue to swingarm pivot shaft pinch bo...

Page 293: ...wingarm pivot shaft to 44 46 ft lbs 59 7 62 4 Nm 4 Apply LOCTITE 271 red and tighten swingarm pivot shaft pinch bolt to 17 19 ft lbs 23 25 8 Nm 5 Install transmission vent line a See Figure 3 30 On Firebolt models route transmis sion vent line up through left side of frame exiting under the rear master cylinder under the rider s seat Install two tie wraps to secure transmission vent line in place ...

Page 294: ...nsmission Vent Hose 6 See Figure 3 33 Using the overhead hoist to align the frame to the rear isolator install rear isolator bolt and leave loose at this time sm02952b Figure 3 33 Rear Isolator Bolt HOME 3 26 2010 XB Service Engine ...

Page 295: ...Rear isolator assembly 18 7 Fasteners for rear isolator assembly 4 Front tie bar assembly 8 19 Fasteners for front tie bar assembly 2 Washers for rear isolator assembly 4 20 9 Rear isolator bolt Nut for one fastener for front tie bar assembly 10 21 Center tie bar mount Rear tie bar assembly 22 11 Fasteners for rear tie bar assembly 2 Fasteners for center tie bar mount 2 Figure 3 34 Engine Mounting...

Page 296: ...t isolator 1 and loosely thread into frame Do not tighten at this point 10 Install isolator mounting fasteners 2 and tighten to 49 51 ft lbs 66 4 69 1 Nm 11 Tighten front isolator bolt to 49 51 ft lbs 66 4 69 1 Nm NOTE When installing the tie bar first mount to engine and then to V bracket in order to prevent damage to threaded area of crankcase 12 Install front tie bar and clutch cable lower reta...

Page 297: ...ng point on muffler located on both sides of muffler 7 Front muffler mount 14 Torca clamp Figure 3 36 Muffler and Mounting System 18 See Figure 3 36 Apply LOCTITE 271 red to rear muffler bracket fasteners install and tighten to 32 36 ft lbs 43 4 48 8 Nm 19 Install front muffler mount and leave loose at this time NOTES DO NOT install muffler at this time It is necessary to install muffler mounts fi...

Page 298: ...fler mount 6 13 Feed oil line Cable interactive exhaust 14 7 Drain plug Return oil line Figure 3 37 Oil Lines and Connections 20 Install the feed oil line 6 starting at the engine working towards the rear of the vehicle See 5 3 PRIMARY COVER 21 Install p clamps 8 on feed oil line 6 at crankcase and swingarm oil reservoir and tighten fastener to 40 50 in lbs 4 5 5 6 Nm 22 Install the return oil lin...

Page 299: ...ap as shown 1 2 3 4 6 5 sm03858 4 1 Neutral switch 131 connection Speedometer sensor 65 2 5 Positive battery cable at starter Interactive exhaust cable 6 3 Oil pressure switch 120 Starter solenoid 128 Figure 3 38 Electrical Connections on Right Side of Motorcycle NOTE The connections for the alternator and voltage regulator are routed on the left side of the vehicle under the air scoop The harness...

Page 300: ...l drive belt and idler pulley See 5 7 DRIVE BELT AND IDLER PULLEY 33 Install left and right side rider footrests and support plates See 2 34 FOOTPEG HEEL GUARD AND MOUNT FIREBOLT AND LIGHTNING MODELS or 2 35 HEEL GUARD AND FOOTPEG MOUNTS ULYSSES MODELS 34 Install sprocket cover See 2 36 SPROCKET COVER 35 See Figure 3 41 Connect throttle cables 4 to induction module throttle body See 1 12 THROTTLE ...

Page 301: ...models always check to verify interactive cable is adjusted and routed properly before installing air box cover See 1 13 INTERACTIVE EXHAUST CABLE 44 Install air cleaner cover assembly See 4 3 AIR CLEANER ASSEMBLY 45 Install intake cover assembly Tighten fasteners to 12 36 in lbs 1 4 4 Nm See 2 38 INTAKE COVER 46 Install oil filter and fill oil tank See 1 6 ENGINE OIL AND FILTER NOTE The connectio...

Page 302: ...on which could result in death or serious injury 00068a 50 Install and connect battery See 1 16 BATTERY MAINTEN ANCE After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 51 Install seat HOME 3 34 2010 XB Service Engine ...

Page 303: ...a Remove two screws and washers 3 b Remove three bolts and washers 2 c Loosen the four rocker arm fasteners 1 in 1 4 1 2 turn increments using a cross pattern in order to relieve valve spring pressure on the lower rocker box 7 See Figure 3 44 Remove lower rocker cover 14 NOTES Remove lower rocker box as an assembly and then disas semble as required Mark rocker arm shafts for reassembly in their or...

Page 304: ...ts 12 3 21 Screw 2 Screw 4 Push rod cover 22 13 4 Screw 4 Washer 2 Washer 4 5 23 14 Fiber seal 4 O ring push rod cover 2 Rocker cover lower 15 6 24 Rocker arm 2 Rocker cover top Push rod 25 16 7 Washer 4 Bushing rocker arm 4 Bolt 3 8 26 17 Washer 3 Bolt 4 Gasket lower rocker cover 18 9 Hydraulic lifter Gasket inner Figure 3 44 Rocker Arm and Pushrod Cover Assemblies HOME 3 36 2010 XB Service Engin...

Page 305: ...B in vise 2 Compress valve spring with VALVE SPRING COM PRESSOR 3 See Figure 3 47 Remove valve retainers 3 upper collar 4 and valve spring 5 Mark valve retainers for reas sembly in their original locations 4 Use a fine tooth file to remove any burrs on the valve stem at the keeper groove 5 Mark valve to verify that it will be reassembled in the same head Remove valve 15 valve stem seal and lower c...

Page 306: ...sm00134 Figure 3 46 Valve Spring Compressor HOME 3 38 2010 XB Service Engine ...

Page 307: ...Cylinder head 3 Exhaust valve Valve collar retainer 4 16 9 Upper valve spring collar Exhaust valve seat Exhaust port stud 10 5 Cylinder head gasket Valve spring 6 11 Valve seal and lower valve spring collar assembly Cylinder insert 12 Cylinder with piston and rings Figure 3 47 Cylinder Head Cylinder and Piston Assembly HOME 2010 XB Service Engine 3 39 ...

Page 308: ...e a file or other hardened tool which could scratch or nick valve Polish valve stem with very fine emery cloth or steel wool 4 See Figure 3 48 Check head gasket surface on head for flatness Machine or replace any head which exceeds SERVICE WEAR LIMIT of 0 006 in 0 152 mm sm00137 Figure 3 48 Checking Gasket Surface Rocker Arm Assemblies 1 Check each rocker arm at pad end and push rod end for uneven...

Page 309: ...hed 1 Inspect seats for cracking chipping or burning Replace seats if any evidence of these conditions are found 2 See Figure 3 53 Check seats for recession by measuring valve stem protrusion 3 Wipe valve seats and valve faces clean 4 Measure valve stem protrusion 5 If valve stem protrudes more than 2 08 in 52 88 mm replace valve seat or cylinder head NOTE Replacing a valve seat is a complex opera...

Page 310: ... 12 mm spark plug repair kit Push Rods Examine push rods particularly the ball ends Replace any rods that are bent worn discolored or broken REPLACING ROCKER ARM BUSHINGS TOOL NAME PART NUMBER ROCKER ARM BUSHING REAMER HD 94804 57 1 See Figure 3 55 To replace worn bushings press or drive them from the rocker arm NOTE If bushing is difficult to remove thread a 9 16 18 tap into bushing From opposite...

Page 311: ...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 312: ...fy the inside of the valve guide is clean by using VALVE GUIDE CLEANING BRUSH Part No HD 34751 6 Install the valve seat cutter pilot 7 02 MM VALVE SEAT CUTTER PILOT Part No B 35758 52A into the valve guide hole and securely seat the pilot by pushing down and turning using the installation tool supplied in the tool set 7 Choose the proper 46 cutter intake or exhaust and gently slide the cutter onto...

Page 313: ...ebris from compressed air could cause serious eye injury Wear safety glasses when working with compressed air Never use your hand to check for air leaks or to determine air flow rates 00061a 3 Blow dry with compressed air 4 Apply a liberal amount of engine oil to the valve stem 5 See Figure 3 47 Insert valve into valve guide and bottom valve on valve seat 6 See Figure 3 60 Place a protective sleev...

Page 314: ... pushrod cover be sure to apply a small amount of clean engine oil to each O ring b Install new push rod cover gasket 5 onto bottom of each push rod cover c Install each push rod cover assembly and start the fasteners 4 securing the bottom of each cover to the crankcase d Tighten fasteners to 30 40 in lbs 3 4 4 5 Nm NOTE If installing original parts be sure to install them in their original locati...

Page 315: ...ds and covers must be installed prior to installing cylinder heads Short head screws will be installed in the 1 and 2 positions and long head screws in the 3 and 4 positions Thoroughly clean and lubricate the threads of the cylinder head screws before installation Friction caused by dirt and grime will result in a false torque indication 1 Thoroughly clean and dry the gasket surfaces of cylinders ...

Page 316: ...ube push rod sockets of rocker arms with clean engine oil NOTE Turn engine over so that both lifters from the rocker box to be installed are on the base circle of the cam the lowest position 10 See Figure 3 68 Install new gaskets Place lower rocker box assembly with rocker arms and shafts into position Place push rods in rocker arm sockets 11 See Figure 3 68 Install hardware attaching lower rocker...

Page 317: ...m00154 Figure 3 67 Tightening Head Screws 2 3 1 2 3 1 1 1 2 sm00131 1 Screws and washers 2 Bolts and washers 3 Rocker arm fasteners Figure 3 68 Lower Rocker Box Fasteners HOME 2010 XB Service Engine 3 49 ...

Page 318: ...ts 12 3 21 Screw 2 Screw 4 Push rod cover 22 13 4 Screw 4 Washer 2 Washer 4 5 23 14 Fiber seal 4 O ring push rod cover 2 Rocker cover lower 15 6 24 Rocker arm 2 Rocker cover top Push rod 25 16 7 Washer 4 Bushing rocker arm 4 Bolt 3 8 26 17 Washer 3 Bolt 4 Gasket lower rocker cover 18 9 Hydraulic lifter Gasket inner Figure 3 69 Rocker Arm and Pushrod Cover Assemblies HOME 3 50 2010 XB Service Engin...

Page 319: ...OTE With cylinder removed be careful not to bend the cylinder studs The slightest bend could cause a stress riser and lead to stud failure 7 Install a 6 in 152 mm length of 1 2 in 12 7 mm ID plastic or rubber hose over each cylinder stud This will protect the studs and the piston Wear safety glasses or goggles when removing or installing piston pin retaining rings Piston pin retaining rings are co...

Page 320: ...Leave the second circlip in the pin bore Since the piston pin is a loose fit in the piston the pin will easily slide out The pin has tapered ends to help seat the round retaining rings sm00157 Figure 3 72 Piston Pin and Piston Identification NOTE See Figure 3 72 The arrows on the pistons must always point toward the front of the engine sm00158 Figure 3 73 Removing Piston Rings 9 See Figure 3 73 Us...

Page 321: ...face for flatness a Lay a straightedge across the surface b Try to insert a feeler gauge between the straightedge and the gasket surface c If cylinder head gasket surface is not flat within 0 006 in 0 152 mm replace cylinder and piston 2 Check cylinder base gasket surface for flatness a Lay a straightedge across the surface b Try to insert a feeler gauge between the straightedge and the gasket sur...

Page 322: ...horoughly wash the cylinder bore with liquid dishwashing soap and warm water to remove all abrasive particles and residual grit Continue cleaning until a clean cloth shows no evidence or dirt or debris 6 Hot rinse the cylinder and dry with moisture free com pressed air 7 Immediately apply a thin film of clean engine oil to a clean white paper towel and thoroughly wipe the inside of the cylinder NO...

Page 323: ... side clearance with thickness gauge as shown See 3 2 SPECIFICATIONS NOTE If the ring grooves are clean and the side play is still not correct replace the rings the piston or both Table 3 21 Piston Ring End Gap MM IN RING TYPE 0 18 0 51 0 007 0 020 Top compression ring 0 18 0 51 0 007 0 020 2nd compression ring 0 23 1 32 0 009 0 052 Oil control ring rails 4 1 3 2 sm00161 1 Top compression ring ins...

Page 324: ...ver cup fits on one side of the rod while the driver fits on the opposite side as shown 3 Use two box wrenches and push worn bushing from con necting rod 4 Remove piston pin bushing tool from connecting rod 5 Remove bushing from receiver cup 6 See Figure 3 84 Place new bushing between connecting rod and driver NOTE The driver must be attached facing the opposite direction as it was for removal of ...

Page 325: ...ING INSTALLER HD 34623C PISTON SUPPORT PLATE HD 42322 PISTON RING COMPRESSOR HD 96333 51E 1 See Figure 3 85 Place PISTON SUPPORT PLATE Part No HD 42322 in position as shown 2 Install piston assembly over connecting rod NOTE See Figure 3 86 Piston must be installed with the arrows pointing towards the front of the engine 3 Liberally lube piston pin with clean engine oil and install piston pin NOTE ...

Page 326: ...te 7 Lubricate cylinder wall and piston with engine oil 8 Remove protective sleeves from cylinder studs Install a new cylinder base gasket Make sure the piston does not bump the studs or crankcase 9 See Figure 3 89 Compress the piston rings using PISTON RING COMPRESSOR Part No HD 96333 51E 10 Install cylinder over piston 11 Remove the ring compressor NOTE Push rods and covers must be installed pri...

Page 327: ...nt 2 Rear 3 Piston pin 4 Position ring end gaps at arrows minimum of 90 degrees apart Figure 3 88 Ring End Gap Position 1 sm00171 1 Piston ring compressor Figure 3 89 Compressing Piston Rings HOME 2010 XB Service Engine 3 59 ...

Page 328: ...perly lubricate the rod bearing assembly 10 Oil flow then continues to the main feed galley at the top of the oil pump body Passages in the crankcase intersect the main feed galley and carry oil to all hydraulic lifters and piston jets The piston jets which receive a supply of oil from the intake lifter bores spray the underside of the pistons for cooling of the piston crown and skirt area A check...

Page 329: ... from the flywheel compartment gearcase is drawn back into the pump and is forced by the gerotor scavenge set back to the oil reservoir The oil pump seldom needs servicing Before you disassemble an oil pump suspected of not producing adequate oil pressure be sure that all possible related malfunctions have been elim inated 1 Make sure all oil line connections are tight and that lines are not pinch...

Page 330: ...p cover screws 7 7 O rings oil line fittings Figure 3 90 Oil Pump REMOVAL DISASSEMBLY NOTE Before vehicle is placed on the lift it will necessary to remove the chin fairing See 2 50 CHIN FAIRING 1 Remove seat See 2 51 SEAT To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 2 Disconnect negative battery cable 3...

Page 331: ...d left side of the oil pump body 8 Disconnect return oil line connection 2 from the bottom and left side of the oil pump body 9 Disconnect the vent oil line connection 4 from the top left side of the oil pump body 10 Disconnect the oil cooler return line from the oil pump 11 Remove oil pressure switch 8 12 Remove pressure relief valve 9 13 See Figure 3 90 Carefully remove mounting screws and washe...

Page 332: ...y Figure 3 91 Oil Pump Connections CLEANING AND INSPECTION Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury Wear safety glasses when working with compressed air Never use your hand to check for air leaks or to determine air flow rates 00061a 1 Clean all parts in cleaning solvent Blow out holes and oil passages with compressed air HOME 3 64 201...

Page 333: ... relief valve assembly and tighten plug to 108 156 in lbs 12 2 17 6 Nm 8 Install oil pressure switch and tighten to 96 120 in lbs 10 8 13 6 Nm 9 Install hydraulic lifters and push rods See 3 16 HYDRAULIC LIFTERS Installation 10 Install rocker box assemblies See 3 7 CYLINDER HEAD Cylinder Head Installation NOTE Before attaching oil lines see 3 12 OIL LINE FITTINGS Installation 11 See Figure 3 91 At...

Page 334: ...8 6 2 4 10 3 5 1 11 9 7 sm03727 Figure 3 94 Oil Pump Body and Cover Mounting Screw Torque Sequence HOME 3 66 2010 XB Service Engine ...

Page 335: ... to the rear of the oil pump body 1 Three rubberized clamps 8 and one plastic clamp 12 secure the lines in place The oil cooler feed line 3 exits the front of the oil pump and routes across the front of the engine to the oil cooler on the left front side of the crankcases The oil cooler return line 2 then exits the oil cooler and connects to the oil pump on the right front side of the crankcases F...

Page 336: ... crankcase Rear muffler bracket 10 3 Swingarm Oil reservoir Oil cooler feed line from oil pump 4 11 Oil filter Vent oil line 12 5 Oil line clamp Front muffler mount 6 13 Feed oil line Cable interactive exhaust 14 7 Drain plug Return oil line Figure 3 95 Oil Lines and Connections HOME 3 68 2010 XB Service Engine ...

Page 337: ...oil line and the tool from the fitting 5 Repeat to remove the remaining oil lines 6 Remove oil line fittings and plug the holes until they can be replaced sm00205 Figure 3 96 Oil Line Remover sm00206 Figure 3 97 Oil Line Fitting with Spring Clip INSTALLATION 1 Install oil line fittings with O ring into swingarm and tighten to 108 156 in lbs 12 2 17 6 Nm 2 See Figure 3 98 Push the correct flanged o...

Page 338: ...sm00207 Figure 3 98 Flanged Oil Line HOME 3 70 2010 XB Service Engine ...

Page 339: ...cooler feed line 1 at oil cooler 5 Remove two fasteners 8 securing the oil cooler scoop 7 and remove scoop NOTE Place protective covering over primary cover to prevent cos metic damage when removing and installing fastener for stabil izer bracket 6 Remove fastener 6 securing oil cooler to stabilizer bracket 5 7 Remove the fasteners 4 holding the oil cooler 3 to mounting bracket 8 Remove oil cooler...

Page 340: ...tch located under the oil pump next to the oil filter mount unscrew and remove oil pressure switch from crankcase 2 See Figure 3 101 Install adapter 2 from OIL PRESSURE GAUGE SET Part No HD 96925 52B in oil pressure indicator lamp switch mounting hole Tighten adapter snugly DO NOT OVERTIGHTEN sm03000 Figure 3 100 Oil Pressure Indicator Switch Table 3 22 Troubleshooting Oil Pressure Signal Lamp PRO...

Page 341: ...E 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 1 ...

Page 342: ...n the cylinder head sm00209 Figure 3 102 Reed Valve Assembly in Gearcase 4 1 3 2 5 6 sm00216 1 Base plate air box 2 Breather hose rear 3 Breather hose front 4 PCV Valves 2 5 Grommet 6 Rocker cover 2 Figure 3 103 Crankcase Breathing System REED VALVE REPLACEMENT NOTES Whenever the gearcase cover is removed inspect the reed valve for cracks chips and breakage See Figure 3 104 The reed valve 3 opens ...

Page 343: ...ary to replace the reed block apply LOC TITE 222 purple install the fasteners and tighten to 25 35 in lbs 2 8 4 0 Nm 1 2 3 sm02944 3 1 Reed valve Reed valve fastener 2 4 Reed valve stop Reed block Figure 3 104 Reed Valve Assembly 1 2 1 2 3 3 sm00210 3 2 1 Stop screw Reed valve Reed valve stop Figure 3 105 Reed Valve Stop and Reed Valve HOME 2010 XB Service Engine 3 75 ...

Page 344: ... use your hand to check for air leaks or to determine air flow rates 00061a 1 Clean all dirt from around crankcase Blow loose particles from area with compressed air 2 Remove cylinder head assemblies See 3 7 CYLINDER HEAD 3 See Figure 3 108 Remove push rod covers a Remove screws 4 b Remove push rod covers 3 c Remove gaskets and O rings 6 2 Discard parts 4 Remove valve hydraulic lifters 7 a Remove ...

Page 345: ...rs 8 in the holes in lifter block b Tighten anti rotation screws to 55 65 in lbs 6 7 Nm NOTE Before installing O rings on the top of each pushrod cover be sure to apply a small amount of clean engine oil to each O ring 5 Install push rod cover a Place new push rod cover gasket 6 over bottom of pushrod cover b Position push rod cover 3 onto crankcase c Install screws 4 through holes in push rod cov...

Page 346: ...ed and matched Changing one component can affect many others It is important to know and understand all inspection procedures and how components interact 1 2 3 4 9 8 7 6 10 5 sm02934 6 1 Key Oil pump body 2 7 Oil pump body gasket Pinion gear spacer 8 3 Pinion gear K cam gear set 4 9 Right crankcase half Nut 10 5 Screw 4 Dowel pin Figure 3 109 Oil Pump Body and Cam Assembly HOME 3 78 2010 XB Servic...

Page 347: ...e crankshaft until all timing marks 7 8 are aligned as shown NOTE DO NOT rotate camshafts or crankshaft while gears are removed 8 See Figure 3 110 Remove cam gears 1 2 3 and 4 NOTE Nut is secured by LOCTITE 271 red on the nut threads 9 See Figure 3 109 Remove pinion nut 9 Slide pinion gear 8 and pinion gear spacer 7 off pinion shaft NOTE See Figure 3 110 The timing marks are located on the front i...

Page 348: ...INSTALLATION TOOL NAME PART NUMBER CRANKSHAFT LOCKING TOOL HD 43984 1 See Figure 3 112 Install pinion gear spacer and pinion gear on pinion shaft a Install shaft key into pinion shaft slot b Slide pinion gear spacer over pinion shaft Pinion gear spacer must align with shaft key c Align keyway in ID of pinion gear with shaft key d Slide pinion gear over shaft key and against pinion gear spacer 2 Se...

Page 349: ...gear being checked is pointing toward its respective tappet guide hole b Gently pry the cam gear toward the oil pump body using a flat blade screwdriver c Measure gap between bore in crankcase half and cam gear shaft thrust face shoulder using a feeler gauge This is cam gear end play d Compare cam gear end play measurements with the SERVICE WEAR LIMITS Make repairs as required if end play does not...

Page 350: ...bber hose over cylinder studs Lifting or moving crankcase by grasping studs will cause cylinder stud damage 2 Remove cylinders and pistons See 3 8 CYLINDER AND PISTON 3 Remove oil pump See 3 10 OIL PUMP 4 Remove gearcase components See 3 17 GEARCASE AND CAM GEARS 5 Remove primary cover and primary drive clutch compon ents See 5 3 PRIMARY COVER 6 Remove starter motor See 6 7 STARTER 7 See Figure 3 ...

Page 351: ...t 1 See Figure 3 117 Remove the oil filter adapter from the oil filter mount 2 Clean and replace components as necessary 3 Apply several drops of LOCTITE 243 blue to last few threads on end of the oil filter adapter that is installed into filter mount NOTE Do not apply LOCTITE to adapter threads on filter element side 4 Thread oil filter adapter into filter mount 5 Tighten to 96 144 in lbs 10 8 16...

Page 352: ...ews 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 Tighten nuts against each other 4 Placing wrench on first lower nut installed unscrew stud from cylinder deck 5 Loose...

Page 353: ...ng ring oil seal Connecting rod and flywheel assembly 11 3 Inner race Oil seal 4 12 Thrust washer Pinion shaft bearing 13 5 Retaining ring Crankcase half 6 14 Bearing sprocket shaft Outer bearing race 15 7 Crankshaft case Bearing retaining ring 8 Inner race sprocket shaft bearing Figure 3 120 Crankcase and Flywheel Assembly HOME 2010 XB Service Engine 3 85 ...

Page 354: ...ER Part No B 45655 HD 42720 2 and HD 46663 press sprocket shaft bearing out of the left crankcase half PINION SHAFT BEARING TOOL NAME PART NUMBER END CAP HD 34902 7 BEARING RACE REMOVER INSTALLER HD 34902B CLAW PULLER HD 95635 46 WEDGE ATTACHMENT HD 95637 46B CRANKCASE MAIN BEARING LAP PING TOOL HD 96710 40D CRANKCASE MAIN BEARING LAP HD 96718 87 General See Figure 3 120 The right side pinion shaf...

Page 355: ...398 31 7449 1 2496 1 2498 B Green 1 2 3 4 sm00186 1 Inside diameter ID 2 Outer race 3 Right crankcase half 4 Stamped class number Figure 3 125 Pinion Shaft Outer Race Table 3 27 Pinion Shaft Outer Race Stamp Specifications STAMPED NO CLASS NO OUTER RACE ID MM IN 1 1 39 7408 39 7459 1 5646 1 5648 2 2 39 7459 39 7510 1 5648 1 5650 3 3 39 7510 39 7561 1 5650 1 5652 NOTE The different sizes of crankca...

Page 356: ...656 in 39 76 mm or the required lapping to remove wear marks would enlarge bore beyond 1 5656 in continue at Step 5 b If largest measurement is 1 5656 in 39 76 mm or less cover the cam bearings with masking tape to prevent debris from entering bearings Assemble crankcase halves NOTE The next step requires lapping the outer race To keep sprocket shaft and pinion shaft bearings aligned the lap must ...

Page 357: ...llation Tool 3 4 5 2 1 sm03437 1 1 50 in 38 1 mm 2 1 00 in 25 4 mm 3 5 50 in 139 7 mm 4 1 135 1 145 in 28 83 29 08 mm 5 1 262 1 272 in 32 05 32 31 mm Figure 3 129 Pinion Shaft Inner Race Installation Tool Table 3 31 New Component Specifications SPECIFICATIONS FEATURE MM IN 3 97408 39 7561 1 5646 1 5652 Outer Race ID within 0 0051 within 0 0002 Roundness within 0 0051 within 0 0002 Taper 16 RMS Sur...

Page 358: ...ly achieved tolerance range If you are unable to perform this operation Harley Dav idson Motor Company provides a flywheel refurbishing program as outlined in Tech Tip 38 Always use the smallest outer race ID measurement and the largest OD inner race measurement when selecting bearings 10 The following example illustrates how to determine the required inner race OD a Refer to Table 3 29 For exampl...

Page 359: ...fine lapping compound sm02983 Figure 3 132 Lapping Pinion Shaft Bearing Outer Race with Crankcase Main Bearing Lapping Tool CHECKING CONNECTING ROD SIDE PLAY 1 See Figure 3 133 Check connecting rod side play with a thickness gauge as shown 2 If side play measurement is greater than the service wear limit 0 036 in 0 8 mm replace the flywheel connecting rod assembly sm02984 Figure 3 133 Checking Con...

Page 360: ...earing Assembly 4 See Figure 3 136 Attach left crankcase half to engine stand 5 Install flywheel assembly using CRANKSHAFT GUIDE Part No HD 42326 B 6 See Figure 3 137 Install pinion shaft bearing a Lubricate pinion shaft bearing with engine oil b Slip bearing on pinion shaft c Install new retaining ring in groove of pinion shaft bearing inner race HOME 3 92 2010 XB Service Engine ...

Page 361: ...aring remover installer tool 3 Retaining ring Figure 3 135 Sprocket Shaft Bearing Installation sm03929 Figure 3 136 Installing Flywheel Assembly with CRANKSHAFT GUIDE sm00195 Figure 3 137 Pinion Shaft Bearing HOME 2010 XB Service Engine 3 93 ...

Page 362: ... fasteners See Figure 3 139 Kent Moore has developed additional tools to be used with SPROCKET SHAFT BEARING INSTALLER Part No HD 42579 You will need SPROCKET SHAFT ADAPTER Part No B 42579 6 and COLLAR Part No B 42579 7 The addition of these tools will update HD 42579 SPROCKET SHAFT BEARING INSTALLER to HD 42579 A In addition you will need SPROCKET SHAFT SEAL INSTALLER Part No B 45676 A to use wit...

Page 363: ...e 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 13 6 27 1 Nm 3 4 1 2 sm00197 1 Head screw with ball inside 2 Cylinder stud 3 Shoulder on cylinder stud 4 Air gun Figure 3 140 Cylin...

Page 364: ...3 96 2010 XB Service Engine NOTES ...

Page 365: ...NSORS O2 4 12 4 8 ENGINE TEMPERATURE SENSOR ET 4 15 4 9 BANK ANGLE SENSOR BAS 4 17 4 10 INTAKE AIR TEMPERATURE SENSOR IAT 4 20 4 11 COOLING FAN 4 21 4 12 FUEL TANK VENT VALVE 4 22 4 13 FUEL CAP RETAINING RING 4 23 4 14 FUEL PUMP 4 24 4 15 THROTTLE BODY 4 27 4 16 FUEL PRESSURE SENSOR 4 32 4 17 FUEL PRESSURE TEST 4 33 4 18 INTAKE LEAK TEST 4 35 4 19 EXHAUST SYSTEM 4 37 4 20 EVAPORATIVE EMISSIONS CON...

Page 366: ...NOTES ...

Page 367: ... 70 in lbs Battery terminal fastener 4 4 ELECTRONIC CONTROL MODULE ECM Firebolt 6 8 7 9 Nm 60 70 in lbs Battery terminal fasteners 4 4 ELECTRONIC CONTROL MODULE ECM Firebolt 6 8 7 9 Nm 60 70 in lbs Battery terminal fasteners 4 4 ELECTRONIC CONTROL MODULE ECM Lightning 6 8 7 9 Nm 60 70 in lbs Battery terminal fasteners 4 4 ELECTRONIC CONTROL MODULE ECM Lightning 6 8 7 9 Nm 60 70 in lbs Battery term...

Page 368: ... 13 6 Nm 108 120 in lbs Muffler strap fastener front 4 19 EXHAUST SYSTEM Assembly and Installa tion You need to alternately tighten the fasteners to torque a total of two times to make sure the straps are evenly tightened 4 1 5 4 Nm 36 48 in lbs Muffler strap fastener rear 4 19 EXHAUST SYSTEM Assembly and Installa tion 5 4 8 Nm 48 72 in lbs Oil line p clamp at swingarm 4 7 OXYGEN SENSORS O2 Instal...

Page 369: ...r at XB9SX XB12SX XB12Scg XB12R Table 4 2 Fuel System Specifications TYPE FUEL SYSTEM 45 mm downdraft manifold ram air Intake XB9 models 49 mm downdraft manifold ram air Intake XB12 models DDFI fuel injection Fuel delivery 49 51 PSI 338 352 kPa Fuel pressure 91 octane Recommended fuel Table 4 3 Idle Speed XB Models VALUE SPECIFICATION 320 F 160 C Operating temperature 1050 1150 RPM Regular engine ...

Page 370: ...ather hose from baseplate pull out from bottom c Disconnect shorter breather hose from PVC valve located on top of rear cylinder d Remove IAT sensor 6 from grommet on bottom of baseplate e Lift baseplate off of frame carefully disengaging baseplate from velocity stack sealing ring 5 on velocity stack 4 f Remove baseplate from motorcycle 3 4 2 1 sm00894 1 Cover air cleaner 2 Fuel tank vent valve 3 ...

Page 371: ...ensor tower If hoses extend past tower damage to sensor may occur 3 Insert longer breather hose into right baseplate grommet from underside 4 Attach shorter breather hose onto crankcase breather located on top of rear cylinder 5 Carefully lower baseplate into mounting position verify rubber sealing ring on velocity stack completely engages baseplate Baseplate should be sandwiched between upper and...

Page 372: ...xhaust Air cleaner seal 9 3 Shoulder screw 4 Cable bracket 4 10 Interactive exhaust cable Base plate assembly 11 5 Breather hoses front and rear Mounting fasteners actuator 6 Cover air cleaner Figure 4 5 Air Cleaner Assembly with Interactive Exhaust XB12 Models Typical HOME 4 6 2010 XB Service Fuel System ...

Page 373: ...the throttle position sensor or ECM have been replaced or if the ECM has been recalibrated See 4 5 THROTTLE POSITION SENSOR TPS The throttle body has a throttle plate stop screw that is preset at the factory and has tamper proof paint applied to the head of the screw Do NOT attempt to adjust this screw Tampering with this screw will require throttle body replacement After installing seat pull upwa...

Page 374: ...w will require throttle body replacement sm00857 Figure 4 7 Electronic Control Module ECM Lightning Typical sm00858 Figure 4 8 Electronic Control Module ECM Lightning XB12Ss ULYSSES TOOL NAME PART NUMBER DIGITAL TECHNICIAN HD 48650 Removal 1 Remove seat Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a ba...

Page 375: ... has been recalibrated See 4 5 THROTTLE POSITION SENSOR TPS The throttle body has a throttle plate stop screw that is preset at the factory and has tamper proof paint applied to the head of the screw Do NOT attempt to adjust this screw Tampering with this screw will require throttle body replacement If the ECM was replaced with a new component it will be necessary to download the correct calibrati...

Page 376: ...tle body See 4 15 THROTTLE BODY NOTE The Throttle Position Sensor Zero Procedure should be per formed if the throttle position sensor or ECM are replaced or if the ECM has been recalibrated 5 To zero the TPS a Set the Run Stop switch to the Run position b Turn the ignition key to the On position c With the engine off rotate the throttle grip from closed throttle position to wide open throttle posi...

Page 377: ...ark plug cables to ignition coil 2 See Figure 4 12 Attach coil to frame with fasteners 2 Tighten to 120 144 in lbs 13 6 16 3 Nm 3 Attach front and rear spark plug cables to ignition coil posts 4 Attach connector 83 3 5 Install air cleaner cover See 4 3 AIR CLEANER ASSEMBLY 6 Install intake cover assembly See 2 38 INTAKE COVER 7 Connect negative battery cable tightening to 60 70 in lbs 6 8 7 9 Nm 1...

Page 378: ...air cleaner assembly See 4 3 AIR CLEANER ASSEMBLY c Remove shock absorber See 2 23 REAR SHOCK ABSORBER d Remove cooling fan See 4 11 COOLING FAN e See Figure 4 17 Unplug 1 place connector 137 f Remove oxygen sensor from rear exhaust header using OXYGEN SENSOR SOCKET Part No SNAP ON YA8875 or a crows foot 4 Remove the front oxygen sensor a Remove fasteners securing the outer engine shroud air scoop...

Page 379: ...tall intake cover assembly See 2 38 INTAKE COVER 2 Apply LOCTITE ANTI SEIZE LUBRICANT to threads of front sensor a See Figure 4 16 Thread sensor into front exhaust header Tighten sensor to 40 45 ft lbs 54 2 61 Nm b See Figure 4 17 Connect 1 place connector 137 to wiring harness c Install sensor lead into retainer d Install retainer to the inside of the inner engine shroud air scoop e Install faste...

Page 380: ... 2 sm00861b 1 Rear oxygen sensor connector 2 Front oxygen sensor connector behind engine air scoop right side inner Figure 4 17 Oxygen Sensor Connectors 137 Typical HOME 4 14 2010 XB Service Fuel System ...

Page 381: ...de access to sensor NOTES Lightning Ulysses models Remove fastener securing rear wire guide to underside of frame to provide access to temperature sensor Do not pull on engine temperature sensor wiring Excess strain to sensor wiring will cause sensor damage 6 See Figure 4 19 Disconnect engine temperature sensor connector 90 above rear cylinder head NOTE See Figure 4 20 All Buell engines come equip...

Page 382: ... 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 19 Connect ET sensor connector 90 to wiring harness 5 Install rear wire harness guide Tighten fastener 6 Install right upper tie bar fastener Tighten fastener to 25 27 ft lbs 33 9 36 6 Nm 7 Install air cleaner cover See 4 3 AIR CLEANER...

Page 383: ...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 23 Remove screws and washers to detach sensor from seat latch bracket 4 Unplug bank angle sensor connector 134 and remove 4 4 2 2 1 1 3 3 sm00864 1 Bank angle sensor 2 Fuse block and electrical relays 3 S...

Page 384: ...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 24 Bank Angle Sensor Firebolt Lightning 1 See Figure 4 25 Install bank angle sensor connector 134 2 Position bank angle sensor on seat latch bracket Make sure locating post on sensor engag...

Page 385: ...2 36 in lbs 1 4 4 Nm 2 Install BAS bracket to seat latch bracket Tighten fasteners to 72 96 in lbs 8 10 8 Nm 3 Install bank angle sensor connector 134 4 Connect negative battery cable and tighten fastener to 60 70 in lbs 6 8 7 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...

Page 386: ... cable 2 See Figure 4 26 Remove air cleaner cover and filter 3 Remove fasteners securing base See 4 3 AIR CLEANER ASSEMBLY 4 Raise base and pull IAT sensor from sensor grommet 5 Disconnect connector 89 from intake air temperature sensor 6 Inspect sensor grommet for damage and replace as required INSTALLATION 1 Connect IAT sensor connector 89 to wiring harness 2 Install IAT sensor into grommet on a...

Page 387: ...97 NOTES See Figure 4 27 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 counterclockwise into posi tion 3 Install cooling fan fasteners Tighten to 12 36 in lbs 1 4 4 Nm 4 Install shock absorber Se...

Page 388: ...ove bracket 4 fuel tank vent valve 3 and O ring 2 from fuel tank frame 1 INSTALLATION 1 See Figure 4 29 Install new O ring 2 2 Install fuel tank vent valve 3 into fuel tank frame Vent valve nozzle should be at approximately the 7 o clock position 3 Install bracket over vent valve Slot in bracket should line up with notch in valve 4 Loosely install fasteners 5 5 Tighten fasteners to 39 41 in lbs 4 ...

Page 389: ...ard O ring INSTALLATION 1 Coat new O ring 2 with thin film of clean engine oil 2 Place O ring into groove in underside of fuel cap retaining ring 3 NOTE Be sure O ring remains in groove of fuel cap retaining ring during installation 3 Insert fuel cap retaining ring into fuel filler neck 4 Install fasteners 4 Tighten to 62 71 in lbs 7 8 Nm 5 Install fuel filler cap 4 1 3 2 sm00877 1 Fuel filler nec...

Page 390: ...ure Place a scissor jack under jacking point and raise until vehicle weight is removed from rear wheel 1 Remove seat See 2 51 SEAT 2 Drain fuel tank See 4 14 FUEL PUMP Draining Fuel Tank To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 3 Disconnect negative battery cable 4 Remove rider footpeg mounts See 2 3...

Page 391: ...not over tighten fuel fitting nuts Over tightening can result in fuel leakage Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00519b 5 Install new O rings on fuel supply stud 2 Larger O ring is located in groove closer to fuel pump NOTE Install fuel line onto fitting on fuel pump so that the fuel line is at approximately the one o clock position v...

Page 392: ... fastener 60 70 in lbs 6 8 7 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 13 Install seat 14 Remove scissor jack from motorcycle 4 5 3 5 1 2 sm00223b 1 Connector 86 2 Fuel supply fitting 3 Fuel supply stud 4 Drain plug 5 Fasteners Figure 4 35 Fuel P...

Page 393: ... clip attached to throttle cable bracket 5 See Figure 4 36 On California models pull EVAP hose from fitting 1 6 Remove left and right air scoops See 2 49 AIR SCOOPS 7 Remove ignition coil See 4 6 IGNITION COIL 8 See Figure 4 38 Remove fuel line from fuel rail 14 9 Disconnect a TPS connector 88 22 b Fuel injector connectors 84 85 12 c IAC connector 87 19 d Fuel pressure sensor connector 17 10 Remov...

Page 394: ...1 2 sm00885 1 Manifold to cylinder brace fastener 2 Intake flange fastener 2 Figure 4 37 Intake Manifold Primary Side HOME 4 28 2010 XB Service Fuel System ...

Page 395: ...or Nylock nut 6 18 Cable wheel O ring idle air control 19 7 Actuator idle air control Screw 4 8 20 Throttle cable retention clip Screw 2 21 9 Washer flat 2 Cable bracket 10 22 Throttle body manifold assembly 45mm 984 49mm 1203 Throttle position sensor 23 Clamp wire spring 11 24 O ring fuel injector outlet Velocity stack 12 Fuel injector 1 front 1 rear Figure 4 38 One Piece Throttle Body Intake Man...

Page 396: ...lace the actuator 19 onto the fuel rail assembly 14 11 Install fasteners 7 and tighten to 25 30 in lbs 2 8 3 4 Nm INSTALLATION NOTES The intake flanges have been extended to improve clamp load distribution Intake flanges are interchangeable 1 See Figure 4 38 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 t...

Page 397: ...ctor Leak Testing 1 Remove intake cover assembly See 2 38 INTAKE COVER 2 Remove air cleaner cover See 4 3 AIR CLEANER ASSEMBLY 3 Conduct test a Turn key ON for two seconds b Turn key OFF for two seconds c Repeat steps 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 c...

Page 398: ...CLEANER ASSEMBLY 5 See Figure 4 42 Separate the connector from the fuel pressure sensor 6 Remove the sensor from the throttle body Installation 1 Install the sensor and tighten to 14 16 ft lbs 19 0 21 6 Nm 2 Mate the connector to the sensor 3 Mate the fuel pump connector housings 4 Install the battery fuse 5 Turn the ignition switch ON and allow the fuel system to pressurize Check for leaks 6 Inst...

Page 399: ...bore when supply valve is loosened or removed Gasoline is extremely flammable and highly explosive which could result in death or serious injury Wipe up spilled fuel immediately and dispose of rags in a suitable manner 00277a 3 See Figure 4 44 Press button 2 of fuel line connector and disconnect the fuel line 3 from throttle body inlet 1 4 See Figure 4 45 Attach FUEL PRESSURE GAUGE ADAPTER Part No...

Page 400: ...pose of rags in a suitable manner 00277a 10 See Figure 4 46 Turn engine off Detach pressure gauge 4 from adapter 1 a Open the air bleed petcock 5 to relieve fuel system pressure and purge the pressure gauge of gasoline b Remove pressure gauge from adapter 11 Detach adapter from vehicle 12 Connect fuel line to throttle body inlet 1 2 3 sm06168 1 Throttle body inlet 2 Fuel pressure gauge adapter 3 F...

Page 401: ...crew valve assembly 5 onto propane bottle 1 Tester Adjustment 1 See Figure 4 47 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 47 Leak Tester P...

Page 402: ...5 When test is finished close valve knob turn knob fully clockwise sm00251 Figure 4 48 Checking for Intake Leak HOME 4 36 2010 XB Service Fuel System ...

Page 403: ... replacement without removing the exhaust header 8 Remove muffler Front Muffler Mount 1 Remove muffler 2 See Figure 4 49 Remove front muffler mount fastener 8 3 Remove front muffler strap 5 from front muffler mount 7 4 Remove front muffler mount bushings 9 by punching out with suitable tool Rear Muffler Bracket 1 Remove muffler 2 Drain oil See 1 6 ENGINE OIL AND FILTER 3 Remove feed oil line p cla...

Page 404: ...muffler strap fastener Symbol for jacking point on muffler located on both sides of muffler 7 Front muffler mount 14 Torca clamp Figure 4 49 Muffler and Mounting System ASSEMBLY AND INSTALLATION Exhaust Header 1 See Figure 4 50 Install exhaust ring 4 exhaust retaining ring 5 and new exhaust port gasket 6 NOTE Tighten header nuts gradually alternating between studs to verify that exhaust rings are ...

Page 405: ... 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 6 16 INTERACTIVE EXHAUST SYSTEM Installation 2 Install interactive exhaust cable to muffler NOTE Never re use front muffler strap Always replace front muffler strap with a new strap when removed from system 3 See Figure 4 49 Loosely in...

Page 406: ...or leaks If leaks are present a Remove the muffler b Clean all mating surfaces c Replace any damaged components d Install the muffler 2 Inspect the muffler to header pipe for leaks If leaks persist a Remove the muffler b Apply a bead of Permatex Ultra Copper or LOCTITE 5920 FLANGE SEALANT c Install the muffler d Wipe off excess sealant e Let sealant cure before starting engine HOME 4 40 2010 XB Se...

Page 407: ... necessary label fuel tank vent hose 2 at canister fitting and remove Canister 1 Remove upper tail body work See 2 39 SUBFRAME TAIL ASSEMBLY AND BODY WORK FIREBOLT 2 See Figure 4 51 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 52 Remove rear shock absorber reservoir fasteners...

Page 408: ... Mounting 1 2 sm00905 1 Adjuster screw 2 Adjuster screw alignment hole Figure 4 53 Adjuster Screw Alignment INSTALLATION LIGHTNING ULYSSES Vent Valve Keep vent and vapor valve lines away from exhaust and engine Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00263a NOTE For XB12 models See 6 16 INTERACTIVE EXHAUST SYSTEM 1 Install vent valve See 4...

Page 409: ...er Fuel Vent Tube and Fuel Vapor Valve XB12 Translucid models sm00910 Figure 4 56 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 2 5 4 3 6 sm00888a 1 EVAP hose fitting 2 Throttle control cable slot 3 Idle control cable slot 4 Idle control cable at...

Page 410: ...4 44 2010 XB Service Fuel System NOTES ...

Page 411: ...T AND IDLER PULLEY 5 23 5 8 TRANSMISSION 5 27 5 9 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL 5 28 5 10 TRANSMISSION DISASSEMBLY 5 31 5 11 TRANSMISSION ASSEMBLY 5 38 5 12 MAIN DRIVE GEAR AND BEARING 5 40 5 13 TRANSMISSION RIGHT CASE BEARINGS 5 47 5 14 TRANSMISSION LEFT CASE BEARINGS 5 49 5 15 TRANSMISSION INSTALLATION 5 51 5 16 SHIFTER SHAFT 5 55 5 17 TRANSMISSION SPROCKET 5 57 DRIVE TRANSMISSION ...

Page 412: ...NOTES ...

Page 413: ...in lbs Battery terminal fastener 5 5 CLUTCH Assembly and Installation 6 8 7 9 Nm 60 70 in lbs Battery terminal fastener 5 6 PRIMARY CHAIN Installation 6 8 7 9 Nm 60 70 in lbs Battery terminal fastener 5 7 DRIVE BELT AND IDLER PULLEY Idler Pulley Installation LOCTITE 271 red 4 5 4 Nm 36 48 in lbs Chin fairing fasteners 5 3 PRIMARY COVER Installation 9 5 12 2 Nm 84 108 in lbs Clutch inspection cover...

Page 414: ...allation LOCTITE 271 red 4 6 8 Nm 36 60 in lbs Shift linkage fasteners 5 3 PRIMARY COVER Installation LOCTITE 271 red 29 8 32 5 Nm 22 24 ft lbs Shift pedal flange head bolt 5 7 DRIVE BELT AND IDLER PULLEY Drive Belt Installation 33 9 36 6 Nm 25 27 ft lbs Swingarm brace mounting fasteners 5 17 TRANSMISSION SPROCKET Installa tion Follow special torque procedure left hand threads LOCTITE 272 red 67 8...

Page 415: ...belt 135 teeth XB12Ss XB12XT XB12X XB12XP Secondary drive belt Table 5 3 Transmission Specifications XB Models XB12 MODELS XB9SX OVERALL GEAR RATIOS 9 563 10 688 First gear low 6 831 7 635 Second gear 5 080 5 678 Third gear 4 211 4 706 Fourth gear 3 611 4 036 Fifth gear Table 5 4 Wet Clutch Multiple Disc Clutch Plate Thickness SERVICE WEAR LIMITS NEW COMPONENTS ITEM N A 0 0866 0 0031 in 2 200 0 07...

Page 416: ... inspection cover 3 11 See Figure 5 2 Remove the outer ramp and hook 1 from the cable end 3 and coupling 2 Remove cable end from slot in coupling See 5 4 CLUTCH RELEASE MECHANISM 12 See Figure 5 1 Remove screws which secure primary cover 2 Remove cover and gasket 13 Discard gasket 14 See Figure 5 3 Remove and discard shifter lever oil seal 19 15 Clean all parts in a non volatile cleaning solution ...

Page 417: ...Shifter Assembly PRIMARY CHAIN ADJUSTER REPLACEMENT 1 See Figure 5 4 Remove locknut 3 from adjuster screw 2 Turn adjuster screw out of threaded boss in primary cover 4 2 Remove chain adjuster as an assembly 3 Inspect primary chain adjuster shoe 1 If badly worn or damaged it must be replaced 4 Replace adjuster shoe as an assembly 5 Position adjuster inside primary cover 4 with closed side of shoe a...

Page 418: ...Install new shifter lever oil seal 19 2 3 1 4 5 sm00272 1 Cable end 2 Coupling 3 Outer ramp and hook 4 Lockplate 5 Spring Figure 5 6 Clutch Release Mechanism 6 See Figure 5 6 Fit coupling 2 over cable end 1 with rounded side inboard and the ramp connector button out board With retaining ring side of ramp assembly facing inward place hook of ramp 3 around coupling button and rotate assembly counter...

Page 419: ...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 29 8 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 reason a...

Page 420: ...Unscrew nut 6 from end of adjusting screw 7 Remove hook of ramp from cable end coupling 10 Remove cable end from slot in coupling 8 Remove and discard retaining ring from ramp assembly to separate inner and outer halves Remove three balls from ramp sockets 2 1 3 4 5 6 7 10 11 8 9 sm00275 9 5 1 Primary cover Lockplate TORX screw with washers 3 2 10 6 Clutch inspection cover Coupling Nut 7 3 11 Ramp...

Page 421: ...se until resistance is felt c Adjust clutch release mechanism See 1 9 CLUTCH TRANSMISSION PRIMARY FLUID d Fit nut hex into recess of outer ramp e Install clutch adjusting lockplate 5 and spring 4 Install clutch inspection cover and new gasket with three TORX screws with washers Tighten to 84 108 in lbs 9 5 12 2 Nm 5 Adjust clutch cable See 1 9 CLUTCH TRANSMIS SION PRIMARY FLUID 6 Connect negative ...

Page 422: ...ans mitted to the rear wheel When the clutch is disengaged clutch lever pulled to left handlebar grip the pressure plate is pulled outward by clutch cable action against the diaphragm spring thereby com pressing the diaphragm spring With the pressure plate retracted strong inward force no longer squeezes the clutch plates together The fiber plates are now free to rotate at a different relative spe...

Page 423: ...er Retaining ring Outer ramp 5 25 15 Coupling Clutch hub Bearing 16 6 26 Adjusting screw Ball 3 Inner thrust washer 27 17 7 Needle bearing inner race Pressure plate Inner ramp 8 28 18 Retaining ring Needle bearing Friction plate fiber 7 19 9 29 Steel plate 7 Retaining ring Clutch shell and sprocket 30 20 10 Outer thrust washer Friction plate narrow fiber Spring seat Figure 5 12 Clutch Assembly HOM...

Page 424: ... 3 and washer 2 d Thread the tool handle 1 onto end of forcing screw NOTE See Figure 5 14 Turn compressing tool handle only the amount required to release spring seat and remove snap ring 7 Excessive compression of diaphragm spring could damage clutch pressure plate 5 See Figure 5 14 Remove pressure plate assembly a Place a wrench on the clutch spring forcing screw 5 flats to prevent the forcing s...

Page 425: ...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 and ...

Page 426: ...ion plate on the clutch hub Install six remaining sets in the same manner alternating between steel plates and friction plates 1 2 sm00285 1 Narrow plate 2 Regular plate Figure 5 18 Friction Plates 6 Place pressure plate diaphragm spring adjusting screw assembly with new retaining ring and spring seat onto clutch pack a See Figure 5 20 Align square openings of pressure plate and diaphragm spring s...

Page 427: ...ing screw assembly 5 Spring seat Figure 5 20 Spring Seat Installation 7 8 6 5 4 3 2 1 9 sm00280 1 Tool handle 2 Washer 3 Bearing 4 Bridge 5 Forcing screw 6 Diaphragm spring 7 Snap ring 8 Pressure plate 9 Spring seat Figure 5 21 Pressure Plate Assembly 3 1 2 sm00288 1 Adjusting screw assembly 2 Retaining ring 3 Tab recesses Figure 5 22 Clutch Adjusting Screw Assembly and Retaining Ring 7 Install pr...

Page 428: ...RANS MISSION PRIMARY FLUID Transmission Fluid 10 Connect negative battery cable to battery terminal Tighten fastener to 60 70 in lbs 6 8 7 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 seat HOME 5 16 2010 XB Service Drive Transmission ...

Page 429: ... 3 Remove primary cover See 5 3 PRIMARY COVER 4 Loosen engine sprocket a See Figure 5 23 Install SPROCKET LOCKING LINK Part No HD 38362 for XB9 models or SPROCKET LOCKING LINK Part No HD 46283 for XB12 models b Remove the engine sprocket bolt c Loosen but do not remove engine sprocket If neces sary use the slotted portion of TWO CLAW PULLER Part No HD 97292 61 and two bolts to loosen the engine sp...

Page 430: ... clutch shell Inspect primary chain sprocket and the starter ring gear on the clutch shell 7 Inspect slots that mate with the clutch plates on both clutch shell and hub 8 See Figure 5 26 Inspect the clutch shell compensating spring set NOTE As you proceed around the back of the clutch shell the com pensating springs go from being loaded to unloaded so it is possible for the clutch springs to float...

Page 431: ...m clutch shell 3 See Figure 5 31 Remove bearing guide from end of CLUTCH SHELL BEARING REMOVER INSTALLER Part No B 45926 4 Place new needle bearing onto installer end of tool and insert the bearing guide to prevent the bearing from falling off during installation and to align bearing with clutch shell 5 See Figure 5 32 Place clutch shell on support blocks with sprocket side facing up 6 Press beari...

Page 432: ...g 2 by 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 5 5 CLUTCH General 3 Verify that outer thrust washer 4 is installed on transmis sion shaft 4 Install the engine sprocket clutch assembly and primary chain as a unit into primary chaincase ...

Page 433: ...NG LINK 8 Install the pressure plate assembly See 5 5 CLUTCH 9 Install adjusting screw assembly into pressure plate a See Figure 5 37 Align two tabs on perimeter of release plate with corresponding recesses 3 in pressure plate b Secure the adjusting screw assembly with new retaining ring 10 Install primary cover See 5 3 PRIMARY COVER 11 Adjust clutch See 1 9 CLUTCH TRANSMIS SION PRIMARY FLUID 12 A...

Page 434: ...3 1 2 sm00288 1 Adjusting screw assembly 2 Retaining ring 3 Tab recesses Figure 5 37 Clutch Adjusting Screw Assembly and Retaining Ring HOME 5 22 2010 XB Service Drive Transmission ...

Page 435: ... will result in premature failure For maximum strength integrity and longevity avoid over bending twisting crimping pinching kinking or prying the drive belt 1 3 3 2 4 5 6 sm00301 1 Forward bend must not be less than 5 in 127 mm 2 Reverse bend must not be less than 10 in 254 mm 3 Minimum diameter 4 Do not twist belt 5 Do not crimp pinch or kink belt 6 Do not pry belt Figure 5 38 Proper Drive Belt ...

Page 436: ...302 1 Axle 2 Pinch bolt Figure 5 40 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 to pre vent belt damage 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 33 9 36 6 Nm See 2 19 SWINGARM AND BRACE NOTE S...

Page 437: ...pection 8 If pulley wheel needs replacement remove fastener 6 washer and nut 2 from idler pulley bracket 4 and discard wheel Replace with new pulley wheel 1 NOTE The pulley wheel bearings can not be replaced separately 2 1 sm00302 1 Axle 2 Pinch bolt Figure 5 42 Rear Axle IDLER PULLEY INSTALLATION 1 See Figure 5 43 Install new or existing pulley wheel 1 if removed and tighten washer and nut 2 to w...

Page 438: ...2 to 40 45 ft lbs 54 2 61 Nm 3 1 2 4 5 6 sm00304 1 Wheel 2 Wheel nut 3 Stud 2 4 Idler pulley bracket 5 Idler pulley bracket nut and washer 2 6 Wheel fastener Figure 5 43 Idler Pulley Assembly HOME 5 26 2010 XB Service Drive Transmission ...

Page 439: ...t The shifter shaft actuates a pawl and a shifter fork drum The shifter fork drum moves shifter forks which slide a series of shifter dogs on the mainshaft and countershaft into and out of mesh with the other gears 2 3 4 1 5 2 3 4 1 5 2 3 4 1 5 2 3 4 1 5 2 3 4 1 5 2 3 4 1 5 7 6 8 1 2 4 3 5 9 10 11 12 sm00305 9 5 1 Sliding members dark gray Fifth gear First gear 2 10 6 Second gear Power flow light ...

Page 440: ... Disassemble gearcase See 3 17 GEARCASE AND CAM GEARS 6 Remove primary cover See 5 3 PRIMARY COVER 7 Remove clutch assembly primary chain and engine sprocket See 5 6 PRIMARY CHAIN and 5 5 CLUTCH sm00306 Figure 5 45 Hex Fastener Countershaft Retainer 8 See Figure 5 45 Place transmission in first gear Remove hex fastener sm00307 Figure 5 46 Shifter Drum Neutral Detent 9 See Figure 5 46 Place transmi...

Page 441: ...Figure 5 49 Depress ratchet arms 3 in order to clear the shifter drum and remove shifter shaft assembly from left crankcase half 13 Remove starter See 6 7 STARTER sm02979 Figure 5 50 Rear Isolator Assembly 14 See Figure 5 50 Remove rear isolator assembly by removing the forward two fasteners first and then the two rear fasteners re install with new fasteners HOME 2010 XB Service Drive Transmission...

Page 442: ... sm00312 Figure 5 52 Separating Crankcase Halves 16 See Figure 5 52 Separate crankcase halves NOTE Flywheel assembly slides out of the left main bearing by hand No tools are required for this operation sm02981 Figure 5 53 Removing Flywheels from Left Crankcase 17 See Figure 5 53 Remove the flywheel assembly from left crankcase half HOME 5 30 2010 XB Service Drive Transmission ...

Page 443: ...um right side 5 Shifter fork shaft 6 Shifter fork 2nd 3rd 7 Shifter fork 1st Figure 5 54 Shifter Forks Drum and Shafts 1 See Figure 5 55 Remove shifter fork shafts by inserting a small flat punch in the slots and tapping on the end of each shaft until it falls free NOTE Carefully tap on alternate sides of the shaft using the provided slots 2 See Figure 5 56 Remove shifter drum 1 and shifter forks ...

Page 444: ...ever assembly 2 Fork assembly shifter 2nd 3rd 6 18 Fork assembly shifter 1st Shift lever 19 7 Bolt linkage assembly Shifter cam assembly 8 20 Fork assembly shifter 4th 5th Sleeve shift brake lever 21 9 Bolt shift lever Pin shifter stop 10 22 Spring shifter return Pad rubber shift lever 23 11 Linkage assembly shifter Spring extension 12 24 Shifter lever assembly Bolt linkage assembly Figure 5 57 Sh...

Page 445: ...liers and could be propelled with enough force to cause serious eye injury 00312a 3 See Figure 5 58 Remove left crankcase half and transmis sion assembly 4 from engine stand a Place crankcase half 3 and transmission assembly 4 on arbor press 1 and support transmission assembly on parallel supports 5 b Press transmission assembly using TRANSMISSION REMOVER Part No B 43895 1 2 to remove transmission...

Page 446: ...g ring 23 7 Countershaft 4th gear Mainshaft 5th gear 8 24 Mainshaft 1st gear Countershaft 3rd gear 25 9 Dog ring Retaining ring 4 10 26 Thrust washer 4 Thrust washer 27 11 Countershaft 2nd gear Mainshaft 4th gear 12 28 Split bearing 4 Spacer 29 13 Countershaft bearing Mainshaft 14 30 Mainshaft 3rd gear integral to shaft Retaining ring 31 15 Countershaft retaining screw Mainshaft 2nd gear integral ...

Page 447: ...ssemblies can be serviced separately All thrust washers are one common part number This transmission requires no shimming Wear safety glasses or goggles when removing or installing retaining rings Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury 00312a NOTE Use correct retaining ring pliers and correct tips Verify that tips are not exces...

Page 448: ...enough force to cause serious eye injury 00312a 1 See Figure 5 62 Remove spacer 19 and 2nd gear 18 from the end of the of the countershaft 2 Remove and discard split bearing 17 2 Remove spacer 16 NOTE When removing the dog ring 15 it is important to mark the direction of the ring on the shaft as parts establish wear pat terns 3 Remove dog ring 15 4 Using RETAINING RING PLIERS Part No J 5586 A expa...

Page 449: ...ft 3rd gear 13 3 Thrust washer Split bearing 4 14 Countershaft 1st gear Retaining ring 15 5 Dog ring Thrust washer 6 16 Retaining ring Spacer 17 7 Split bearing Dog ring 8 18 Countershaft 4th gear Countershaft 2nd gear 19 9 Spacer Retaining ring 10 Thrust washer Figure 5 62 Transmission Countershaft HOME 2010 XB Service Drive Transmission 5 37 ...

Page 450: ...al to shaft 8 Mainshaft 2nd gear integral to shaft Figure 5 63 Transmission Mainshaft COUNTERSHAFT ASSEMBLY TOOL NAME PART NUMBER RETAINING RING PLIERS J 5586 A Wear safety glasses or goggles when removing or installing retaining rings Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury 00312a NOTES Use correct retaining ring pliers and cor...

Page 451: ...ready to be pressed into the left crankcase half 1 2 3 4 5 6 9 10 13 14 7 8 11 12 15 16 18 19 17 sm00321 11 1 Split bearing Countershaft 5th gear integral to shaft 2 12 Countershaft Countershaft 3rd gear 13 3 Thrust washer Split bearing 4 14 Countershaft 1st gear Retaining ring 15 5 Dog ring Thrust washer 6 16 Retaining ring Spacer 17 7 Split bearing Dog ring 8 18 Countershaft 4th gear Countershaf...

Page 452: ... 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 5 9 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL 2 Remove transmission as an assembly See 5 10 TRANSMISSION DISASSEMBLY 3 See Figure 5 66 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 453: ... correct retaining ring pliers and correct tips Verify that tips are not excessively worn or damaged 1 See Figure 5 65 At outside of case remove and discard oil seal 10 Remove and discard main drive gear bearing retaining ring 9 2 See Figure 5 68 From inside crankcase position BEARING DRIVER Part No HD 35316 9 2 over main drive gear bearing 3 Insert 8 IN BOLT Part No HD 35316 4A 1 through bearing ...

Page 454: ...his photo 3 Wedge attachment for claw puller 4 Press ram Figure 5 69 Removing Inner Bearing Race from Main Drive Gear ASSEMBLY TOOL NAME PART NUMBER INNER OUTER MAIN DRIVE GEAR NEEDLE BEARING INSTALLATION TOOL HD 47855 1 Use INNER OUTER MAIN DRIVE GEAR NEEDLE BEARING INSTALLATION TOOL Part No HD 47855 for assembly Assemble parts The installation tool will automatically bottom on the gear when the ...

Page 455: ...bore 4 2 See Figure 5 73 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 bearing 5 flat washer 6 and nut 7 over end of bolt NOTE Do not continue to tighten nut after ball bearing bottoms against lip in crankcase bearing bore Tightening nut too much can break l...

Page 456: ...e 5 65 Install new O ring 5 into groove in main drive gear 2 Lubricate O ring with GENUINE HARLEY DAVIDSON FORMULA TRANSMISSION AND PRIMARY CHAINCASE LUBRICANT NOTE See Figure 5 65 Make sure to install new O ring 5 onto main drive gear before installing main drive gear into crankcase 3 See Figure 5 75 Insert 8 IN BOLT Part No HD 35316 4A 1 through WASHER Part No HD 35316 7 2 and main drive gear 3 ...

Page 457: ... could make it difficult to remove adapter after seal has been installed 5 See Figure 5 79 Slide INSTALLER Part No HD 47856 1 over adapter until cupped end of installer is flat against seal 6 See Figure 5 80 Thread NUT Part No HD 47856 5 onto end of adapter until it tightens against installer 7 See Figure 5 81 Place CROWFOOT WRENCH Part No HD 47856 7 1 with 1 2 inch drive breaker bar 2 on large nu...

Page 458: ...337 Figure 5 79 Place Installer over Adapter Typical sm00338 Figure 5 80 Install Nut Typical 2 1 3 sm00339 1 Crowfoot wrench 2 1 2 inch breaker bar 3 Adjustable wrench Figure 5 81 Press Seal Into Crankcase HOME 5 46 2010 XB Service Drive Transmission ...

Page 459: ...LLATION TOOL NAME PART NUMBER SNAP ON BUSHING DRIVER 1 2 INCH ADAPTER A157 8 SNAP ON BUSHING DRIVER SET A157C Countershaft Needle Bearing 1 Find a suitable bearing driver 1 1 4 in 31 75 mm in dia meter 2 See Figure 5 82 From the outside of the case place the closed end needle bearing 11 open end first next to the bearing bore Hold the driver squarely against the closed end of the bearing and tap t...

Page 460: ...aring inner Ball bearing with spacer 9 3 Retaining ring Fifth gear mainshaft 4 10 Bearing outer Oil seal 11 5 Bearing closed end countershaft O ring 6 12 Oil seal Bushing shifter drum Figure 5 82 Transmission Assembly Right Crankcase Half HOME 5 48 2010 XB Service Drive Transmission ...

Page 461: ...t 4 Bearing countershaft Figure 5 83 Ball Bearing Assembly INSTALLATION Mainshaft and Countershaft Bearings 1 Place crankcase on press with inside surface of crankcase downward 2 Lay bearing squarely over bore with printed side of bearing upward Place a pressing tool slightly smaller than outside diameter of bearing against outer race Press bearing into bore until bearing bottoms against shoulder ...

Page 462: ...3 4 1 2 sm01370 1 Retaining ring 2 Retaining ring 3 Mainshaft bearing 4 Countershaft bearing Figure 5 85 Ball Bearing Assembly HOME 5 50 2010 XB Service Drive Transmission ...

Page 463: ... shaft Gear could be damaged if it strikes a hard sur face 1 See Figure 5 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 5 87 Place left case half over transmission assembly and install transmission remover installer tool INSTALLER Part ...

Page 464: ... 12 o clock position This will place shifter drum in neutral position NOTE See Figure 5 89 Install shifter fork shafts in the left case half by lightly tapping on the end of the shaft with a brass or hard plastic hammer until shaft is seated in bore 3 Place 1st gear shifter fork onto dog ring between counter shaft 1st and 4th gear gears Install shifter fork shaft through two installed shifter fork...

Page 465: ...nd the mating surfaces of the mainshaft and countershaft with HARLEY DAVIDSON SPECIAL PURPOSE GREASE Part No 99857 97 5 See Figure 5 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 5 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 ...

Page 466: ...sm00312 Figure 5 92 Crankcase Halves D 1 1 1 1 2 sm00176 1 Crankcase fasteners 2 Crankcase fastener behind shifter mechanism Figure 5 93 Crankcase Fasteners HOME 5 54 2010 XB Service Drive Transmission ...

Page 467: ...d 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 7 50 2 Nm 5 Install transmission sprocket See 5 17 TRANSMISSION SPROCKET 6 Continue assembling engine See the following 3 18 CRANKCASE Assembly 3 7 CYLINDER HEAD Assembly 3 7 CYLINDER HEAD Cylinder Head Installation 3 8 CYLINDER AND PIST...

Page 468: ...sm00309 Figure 5 97 Installing Shifter Shaft Assembly sm00306 Figure 5 98 Hex Fastener Countershaft Retainer HOME 5 56 2010 XB Service Drive Transmission ...

Page 469: ...n in first gear Remove two socket head screws 1 and lockplate 2 NOTES Transmission sprocket nut has left hand threads Turn nut clockwise to loosen and remove from main drive gear shaft Use the P3 Blast SPROCKET HOLDING TOOL Part No B 43982 with the spacer and fastener from the Fire bolt SPROCKET LOCKING TOOL Part No B 45659 to hold the sprocket 8 See Figure 5 101 Place transmission in neutral Inst...

Page 470: ... align the screw holes The lockplate has four screw holes and can be turned to either side so you should be able to find a position without having to additionally tighten the nut If you cannot align lock plate and sprocket screw holes nut may be additionally tightened to 45 as specified above Tightening too much or too little may cause the nut to come loose during vehicle operation If you cannot a...

Page 471: ...ansmission sprocket nut 2 Transmission sprocket 3 Line scribed on nut and sprocket Figure 5 102 Aligning Transmission Sprocket 2 1 sm00302 1 Axle 2 Pinch bolt Figure 5 103 Rear Axle HOME 2010 XB Service Drive Transmission 5 59 ...

Page 472: ...5 60 2010 XB Service Drive Transmission NOTES ...

Page 473: ...37 6 14 FRONT TURN SIGNALS 6 39 6 15 REAR TURN SIGNALS 6 42 6 16 INTERACTIVE EXHAUST SYSTEM 6 47 6 17 HEADLIGHT 6 51 6 18 TAIL LAMP 6 56 6 19 LICENSE PLATE LAMP ASSEMBLY 6 58 6 20 MAIN FUSE AND FUSES 6 60 6 21 NEUTRAL INDICATOR SWITCH 6 63 6 22 SIDESTAND SWITCH HDI 6 64 6 23 CRANKSHAFT POSITION SENSOR CKP 6 65 6 24 VEHICLE SPEED SENSOR VSS 6 67 6 25 INSTRUMENT MODULE 6 68 6 26 MAIN WIRE HARNESS 6 ...

Page 474: ...NOTES ...

Page 475: ...in lbs Battery terminal fastener 6 16 INTERACTIVE EXHAUST SYSTEM Installa tion 6 8 7 9 Nm 60 70 in lbs Battery terminal fastener 6 17 HEADLIGHT Headlight Bulbs Firebolt 6 8 7 9 Nm 60 70 in lbs Battery terminal fastener 6 17 HEADLIGHT Headlight Bulbs Lightning and Ulysses 6 8 7 9 Nm 60 70 in lbs Battery terminal fastener 6 23 CRANKSHAFT POSITION SENSOR CKP Installation 6 8 7 9 Nm 60 70 in lbs Batte...

Page 476: ...fastener Firebolt 6 19 LICENSE PLATE LAMP ASSEMBLY Light ning 1 4 4 Nm 12 36 in lbs License plate lamp assembly fastener Lightning 6 8 STARTER SOLENOID Solenoid Contacts 7 3 9 0 Nm 65 80 in lbs Long post jam nut 6 17 HEADLIGHT Headlight Bulbs Lightning and Ulysses 4 5 5 Nm 36 48 in lbs Lower headlight fastener 6 28 INTERACTIVE EXHAUST HARNESS XB12 MODELS Lightning 5 4 8 Nm 48 72 in lbs Main batter...

Page 477: ...GNALS Firebolt 2 8 3 2 Nm 25 28 in lbs Turn signal fasteners front 6 13 TURN SIGNAL FLASHER Installation 4 6 8 Nm 36 60 in lbs Turn signal flasher fastener 6 13 TURN SIGNAL FLASHER Installation 1 4 4 Nm 12 36 in lbs Turn signal flasher fastener 6 13 TURN SIGNAL FLASHER Installation 4 6 8 Nm 36 60 in lbs Turn signal flasher fastener 6 14 FRONT TURN SIGNALS Bulbs 0 5 0 6 Nm 4 4 4 3 in lbs Turn signa...

Page 478: ...V Type 3 498 in 88 85 mm 3 0005 in 76 20 mm Bore 3 812 in 96 82 mm 3 812 in 96 82 mm Stroke 73 2 cu in 1203 cc 53 86 cu in 883 cc Piston displacement 79 0 ft lbs 107 2 Nm 3500 RPM 51 0 ft lbs 69 2 Nm 4300 RPM Torque 9 7 1 8 9 1 Compression ratio 2 8 qt 2 65 Liters 2 8 qt 2 65 Liters Oil tank capacity with filter Table 6 5 Service Wear Specifications MM IN SERVICE WEAR LIMITS 11 0 0 433 Brush lengt...

Page 479: ...opean models only Can be activated Off Headlight high beam On Off Headlight low beam On Off Instrument module illumination lamps Can be activated Off Stop lamp Can be activated Front and rear turn signals Can be activated Cannot be activated Horn On Off Aux power outlets FIREBOLT TOOL NAME PART NUMBER SNAP ON TAMPER RESISTANT T45 TORX DRIVER FTXR45E Removal 1 Remove seat To prevent accidental vehi...

Page 480: ...e ignition switch body fasteners 1 Separate igni tion switch body 2 from ignition switch 4 Assembly NOTE See Figure 6 5 In next step be sure wide slot in ignition switch housing 5 is installed over wide boss on ignition switch 4 1 Push ignition switch housing 5 on to ignition switch 4 NOTE In next step do not force ignition switch 4 into ignition switch body 2 If ignition switch does not easily sl...

Page 481: ...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 60 70 in lbs 6 8 7 9 Nm The automatic on headlamp feature provides increased visibility of the rider to other motorists Be sure headlamp is on at all ti...

Page 482: ...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 f...

Page 483: ...ition switch 4 by prying tabs on side of housing 2 Remove ignition switch body fasteners 1 Separate igni tion switch body 2 from ignition switch 4 Assembly NOTE See Figure 6 8 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 igni...

Page 484: ...ar ness connectors c Turn signal connectors 31 5 d Turn signal flasher connector 30 1 9 Loosely install cable strap around the main wiring harness and the ignition switch 10 Install negative battery cable to battery terminal Tighten fastener to 60 70 in lbs 6 8 7 9 Nm The automatic on headlamp feature provides increased visibility of the rider to other motorists Be sure headlamp is on at all times...

Page 485: ... harness 9 3 Horn fastener Right handlebar connector 22 4 10 Left handlebar connector 24 Horn mount 11 5 Horn connector 122 Turn signal connectors 31 6 12 Ignition switch Horn Figure 6 9 Electrical Connectors Behind Windscreen Ulysses Disassembly 1 See Figure 6 10 Remove housing 4 from ignition switch 5 by prying tabs on side of housing 2 Remove body fasteners 1 Separate body 2 from igni tion swit...

Page 486: ...and insert the fork stop pin into the upper triple clamp 3 See Figure 6 10 After applying LOCTITE 271 red attach ignition switch assembly to upper triple clamp using ignition switch fasteners 7 6 install spacer 3 onto fastener 6 and tighten to 18 20 ft lbs 24 4 27 1 Nm 4 Connect ignition switch connector 33 to wiring harness 5 Loosely install cable strap around the main wiring harness and the igni...

Page 487: ...r loose fit on ignition coil and spark plugs 2 Check cable boots caps for cracks or tears Replace boots caps that are worn or damaged NOTE Both cables are the same length 3 See Figure 6 12 Check spark plug cable resistance with an ohmmeter 4 Replace cables not meeting resistance specifications Table 6 11 Spark Plug Cable Resistance RESISTANCE OHMS CABLE LENGTH POSITION 1 350 3 465 5 7 in 145 mm Fr...

Page 488: ...sm00366 Figure 6 13 Boot Gap HOME 6 14 2010 XB Service Electrical ...

Page 489: ...r battery post fasteners Install wiring between battery cable and fastener Alternator The alternator consists of two main components The rotor which mounts to the engine sprocket shaft The stator which bolts to the engine crankcase Voltage Regulator NOTE For troubleshooting and diagnostic see Electrical Diagnostic Manual See 6 9 VOLTAGE REGULATOR The voltage regulator is a series regulator with sh...

Page 490: ...1 1 J Fuse 30 Amp To fuse and relay block BK BK BK BK BK BK BK R Y R 46A BK 6 5 3 2 1 4 sm04729 5 3 1 Voltage regulator J fuse 30A Battery 2 6 4 Battery cable Stator H D 1 phase To voltage regulator Figure 6 14 Charging System Circuit Firebolt HOME 6 16 2010 XB Service Electrical ...

Page 491: ...ck Battery Fuse 30 Amp To fuse and relay block BK BK BK BK BK BK BK R Y R R 46A BK sm04730 4 1 To voltage regulator Battery 2 5 Battery cable Voltage regulator 6 3 Stator H D 1 phase 30A battery fuse Figure 6 15 Charging System Circuit Ulysses Lightning HOME 2010 XB Service Electrical 6 17 ...

Page 492: ...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 Conne...

Page 493: ...Negative battery cable 9 To frame 10 To starter Figure 6 16 Battery Firebolt 1 8 4 3 7 6 2 5 sm00445 1 Battery 2 Battery boot 3 Positive battery cable 4 Negative battery cable 5 To frame 6 To starter 7 Red yellow wires 14 gauge to be spliced 8 Battery strap Figure 6 17 Battery Lightning Ulysses sm00394 Figure 6 18 Negative Battery Cable Typical HOME 2010 XB Service Electrical 6 19 ...

Page 494: ...1 2 sm00258 1 Positive battery cable 2 Solenoid wire Figure 6 19 Starter Wires Protective Boot Not Shown HOME 6 20 2010 XB Service Electrical ...

Page 495: ...eath or serious injury 00049a 2 Disconnect battery See 1 16 BATTERY MAINTENANCE 3 Drain transmission lubricant and remove primary cover See 2 36 SPROCKET COVER 4 Remove sprocket cover See 2 36 SPROCKET COVER NOTE A ball hex driver may be required to gain access to the starter mounting bolts 5 See Figure 6 20 Remove two starter mounting bolts and washers 1 6 See Figure 6 21 Lift rubber boot remove ...

Page 496: ... use an undercutting machine to undercut the mica to 1 32 in 0 79 mm deep The slots should then be cleaned to remove any dirt or copper dust NOTES See Figure 6 22 If an undercutting machine is not avail able undercutting can be done satisfactorily using a thin hacksaw blade After undercutting lightly sand the arma ture with crocus cloth to remove any burrs Do not use sandpaper or emery cloth on co...

Page 497: ...hex nut with captive lockwasher Tighten hex nut to 70 90 in lbs 7 9 10 2 Nm Cover field wire ring terminal with rubber boot 10 Install end cover bracket onto threaded end of thru bolts if equipped For proper orientation be sure that the longest end of the bracket before the bend is on the field wire side Install two Keps nuts and alternately tighten until snug 11 Install allen head screw to fasten...

Page 498: ...tall return spring on solenoid plunger shaft 9 Mate the solenoid and drive housings and install two hex screws using a 9 mm socket Alternately tighten hex screws until snug 10 Lubricate armature bearing with LUBRIPLATE 110 Seating armature bearing in counterbore mate field coil and solenoid housings For proper assembly a nub on the field coil housing flange must engage the slot on solenoid housing...

Page 499: ...TER Field Coil Assembly SOLENOID PLUNGER Disassembly 1 Remove three hex screws to release solenoid cover 2 Remove rubber gasket from solenoid cover flange 3 Remove plunger and return spring Assembly 1 Apply a light film of LUBRIPLATE 110 to plunger shaft and install return spring Install plunger in solenoid 2 Install new rubber gasket on solenoid cover flange 3 Install three hex screws to secure s...

Page 500: ...lenoid housing d At outside of solenoid housing install round bushing O ring and wave washer onto end of post Install jam nut but do not tighten 2 Assemble long post battery a On inside of solenoid housing align hole in paper insulator washer with hole in solenoid housing Insert sleeve on square bushing into holes b With the foot inboard against solenoid winding align hole in contact plate with ho...

Page 501: ...s 7 3 9 0 Nm Verify that contact plates have not rotated out of alignment with plunger 5 Install new rubber gasket on solenoid cover flange 6 Install three hex screws to secure solenoid cover Altern ately tighten hex screws until snug HOME 2010 XB Service Electrical 6 27 ...

Page 502: ... Remove fasteners 5 and voltage regulator 4 from bracket 3 INSTALLATION 1 See Figure 6 26 Attach new voltage regulator 4 to bracket 3 Tighten fasteners 5 to 36 60 in lbs 4 6 8 Nm NOTE When installing the left side air scoop it is necessary to verify that the voltage regulator and alternator wiring harnesses are not trapped between the air scoop and cylinder head 2 Connect stator connector 46 1 and...

Page 503: ...5 2 1 4 sm00392 1 Voltage regulator connector 77 2 Stator connector 46 3 Voltage regulator mount bracket 4 Voltage regulator 5 Fastener 3 Figure 6 26 Voltage Regulator HOME 2010 XB Service Electrical 6 29 ...

Page 504: ...he alternator and voltage regulator are routed on the left side of the vehicle under the air scoop The harnesses are secured to the air scoop with 3 cable straps 1 See Figure 6 29 Disconnect stator wiring 4 from voltage regulator wiring at connector 5 46 under the left ram air scoop See 6 29 SPROCKET COVER WIRING 2 Remove cable straps holding stator wire to the left ram air scoop NOTE Stator faste...

Page 505: ... half Secure stator using four new stator fasteners 1 Tighten to 30 40 in lbs 3 4 4 5 Nm 4 Install retainer plate with new fasteners and tighten to 56 in lbs 6 3 Nm NOTE When installing the left side air scoop it is necessary to verify that the voltage regulator and alternator wiring harnesses are not trapped between the air scoop and cylinder head 5 See Figure 6 29 Route stator wiring 4 behind re...

Page 506: ...move right side heated hand grip See 2 24 THROTTLE CONTROL Installation 1 Install the left heated grip and tighten fasteners to 14 16 in lbs 1 6 1 8 Nm 2 Install the right side heated hand grip to the handlebar See 2 24 THROTTLE CONTROL NOTES See Figure 6 31 The paint mark needs to be lined up visually with the inside edge of the right and left hand control See Figure 6 32 The hanging loop is crit...

Page 507: ...n of Cable Strap Securing the Right Side Hand Grip Wire Below the Instrument Cluster 7 See Figure 6 36 On the left side install a cable strap securing the hand grip wire to the instrument module connector under the left hand side of the instrument cluster 8 Connect the two black 3 way connectors for the heated grip leads 2 1 1 sm04637 1 Black 3 way connector for heated hand grips 2 2 Cable strap s...

Page 508: ...re 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 60 70 in lbs 6 8 7 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 seat HOME 6 3...

Page 509: ...96 in lbs 8 1 10 8 Nm 3 Install negative battery cable to battery terminal Tighten fastener to 60 70 in lbs 6 8 7 9 Nm 4 Check horn operation If horn does not sound or fails to function satisfactorily see 6 12 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 fair...

Page 510: ...Verify horn is not making contact with wiring or other components 2 If battery has a satisfactory charge and wiring appears to be in good condition test horn ground and switch using voltmeter a See Figure 6 41 RemoveY BK power and BK ground wires from terminal clips b Connect voltmeter positive lead to Y BK wire c Connect voltmeter negative lead to ground d Turn ignition key switch ON 3 See Figure...

Page 511: ...ule Lightning Tighten fastener to 12 36 in lbs 1 4 4 Nm 4 Install turn signal flasher to front headlight module Ulysses Tighten fastener to 36 60 in lbs 4 6 8 Nm 5 Install front fairing or windshield windscreen See 2 47 FRONT FAIRING WINDSHIELD AND MIRRORS FIREBOLT Firebolt or 2 48 WINDSHIELD AND WIND SCREEN LIGHTNING AND ULYSSES MODELS Light ning and Ulysses Be sure that all lights and switches o...

Page 512: ...sm00459 Figure 6 45 Turn Signal Flasher Ulysses 1 2 sm00407 1 Left turn signal 2 Right turn signal Figure 6 46 Turn Signal Controls HOME 6 38 2010 XB Service Electrical ...

Page 513: ...nal 1 using lockwasher 2 and fastener 3 Tighten fastener to 25 28 in lbs 2 8 3 2 Nm 3 Attach bullet connectors on turn signal wires as shown in Figure 6 47 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 signals...

Page 514: ... wiring through hole in front module 3 and remove turn signal 1 Installation 1 See Figure 6 50 Insert bullet connectors and wiring through hole in front module 2 Install turn signal using lockwasher and jam nut Tighten fastener to 25 28 in lbs 2 8 3 2 Nm 3 Attach bullet connectors on turn signal wires as shown in Figure 6 47 Be sure that all lights and switches operate properly before operating mo...

Page 515: ...1 5 3 4 1 3 2 sm03811a 1 Turn signal 2 Jam nut and lockwasher 3 Front module left and right 4 Windshield 5 Windscreen Figure 6 50 Front Turn Signals Ulysses HOME 2010 XB Service Electrical 6 41 ...

Page 516: ...sm00458 1 Left turn signal 2 Tail lamp 3 Right turn signal Figure 6 52 Rear Turn Signal Connections Ulysses FIREBOLT Removal 1 Remove seat See 2 51 SEAT 2 Remove tail frame upper body work See 2 39 SUBFRAME TAIL ASSEMBLY AND BODY WORK FIREBOLT 3 See Figure 6 51 Disconnect bullet connectors on turn signal wires 4 See Figure 6 53 Remove fastener 6 and lockwasher 5 5 Remove turn signal from tail sect...

Page 517: ...signals using switch on left handlebar Front and rear right turn signals must flash d Turn ignition key switch to OFF 6 Install tail frame upper bodywork See 2 39 SUBFRAME TAIL ASSEMBLY AND BODY WORK FIREBOLT 7 Install seat See 2 51 SEAT 1 6 2 3 4 7 5 sm00404a 7 4 1 Tail section License plate bracket Turn signal 2 5 Turn signal bulb Lockwasher 2 6 3 Fastener 2 Reflector bracket Figure 6 53 Rear Tu...

Page 518: ... right turn signals must flash d Turn ignition key switch to OFF 6 Install seat See 2 51 SEAT 1 2 4 3 3 5 1 6 6 sm00455a 5 3 1 Center tail section Reflector bracket Turn signal 2 2 6 4 Turn signal bulb Bungee hooks Jam nut and lockwasher 2 Figure 6 54 Rear Turn Signals Lightning ULYSSES Remove 1 Remove seat See 2 51 SEAT 2 See 6 19 LICENSE PLATE LAMP ASSEMBLY Ulysses Remove rear wire cover 3 See F...

Page 519: ...emergency light connector wires from wire cover 6 5 Disconnect emergency light connectors at the rear of the lighting siren control module and pull connectors through hole in rear wire cover 6 one connector at a time 6 Remove license plate lamp 8 7 Remove rear wire cover 6 8 Unplug turn signals and remove with bracket 1 Installation 1 See Figure 6 56 Install wire cover 6 and secure in place with l...

Page 520: ...loop 3 Turn signal left rear 4 Bracket license plate illuminationn center tail section 5 Turn signal right rear 6 Cover rear wires 7 Rear reflector bracket 8 License plate lamp Figure 6 56 Rear Turn Signal Relocation Bracket XB12XP HOME 6 46 2010 XB Service Electrical ...

Page 521: ... engine can gain RPM quickly The exhaust enters 2 the muffler and flows 3 through the open valve 1 into chamber C 7 and then exits 8 2 In the mid range the valve is closed to increase accelera tion torque The exhaust flows 4 through chamber A around to chamber B and then through chamber C and exits 3 At high RPM the valve opens again to maximize horsepower The exhaust enters 2 the muffler and flow...

Page 522: ...ess with connector 161B Actuator cover Lightning XB12 models with translucid cover only 3 Interactive exhaust cable bracket 7 4 Screws Lightning XB12 models with translucid cover only Actuator Figure 6 58 Interactive Control System XB12 Models HOME 6 48 2010 XB Service Electrical ...

Page 523: ...d support muffler until interactive exhaust cable is removed 11 Remove cable strap above starter securing actuator cable vent line main harness and positive battery cable 1 3 2 sm03744 1 Neutral switch connection 131 2 Oil pressure indicator switch wire 3 Interactive exhaust cable Figure 6 59 Electrical Connectors and Interactive Exhaust Cable Under Sprocket Cover 12 Remove cable strap securing in...

Page 524: ...0 in lbs 4 4 5 Nm 4 Attach interactive exhaust cable to cable wheel on actu ator 5 Connect interactive exhaust harness to actuator 161B 6 Attach interactive exhaust cable to bracket and cable wheel on actuator and adjust See 1 13 INTERACTIVE EXHAUST CABLE 7 Install cable strap above starter securing actuator cable vent line main harness and positive battery cable 8 Install cable strap securing act...

Page 525: ... con tains gas under pressure which if not handled carefully could cause serious eye injury 00062b Never touch the quartz bulb Fingerprints will etch the glass and decrease bulb life Handle the bulb with paper or a clean dry cloth Failure to do so could result in bulb damage 00210b 2 See Figure 6 63 Disconnect headlight connection 1 3 Remove rubber boot from headlight housing 4 Release wire retain...

Page 526: ...se death or serious injury disconnect negative battery cable before proceeding 00048a 2 Disconnect negative battery cable Handle bulb carefully and wear eye protection Bulb con tains gas under pressure which if not handled carefully could cause serious eye injury 00062b Never touch the quartz bulb Fingerprints will etch the glass and decrease bulb life Handle the bulb with paper or a clean dry clo...

Page 527: ...ps 3 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 6 64 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 ...

Page 528: ... 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 in...

Page 529: ...sm00447 Figure 6 65 Headlight Housing 20 Degree Alignment Marks for Rubber Boot Wiring Harness Guides or Spigots HOME 2010 XB Service Electrical 6 55 ...

Page 530: ...0 8 Nm 4 Attach the tail lamp harness connector 93 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 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 fron...

Page 531: ...1 5 5 3 2 sm03532a 1 Center tail section 2 Screws 2 3 Tail lamp 4 License plate lamp Firebolt 5 Screws license plate lamp 2 Figure 6 67 Tail Lamp Assembly Firebolt Lightning HOME 2010 XB Service Electrical 6 57 ...

Page 532: ...he lamp assembly away from center tail section pulling the harness out between the tail screen and the center tail section NOTE See Figure 6 69 If replacing bulb only remove both lamp lens screws 3 remove lamp lens 4 and remove bulb Replace bulb and install lens and tighten screws Installation 1 See Figure 6 68 Install license plate lamp assembly a Insert license plate lamp wiring harness and conn...

Page 533: ... 45 from license plate lamp to main harness c Attach lamp 3 and wire cover 5 to tail section using washers and jam nuts 1 and tighten to 12 36 in lbs 1 4 4 Nm d See Figure 6 70 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 ...

Page 534: ... the seat immediately behind the rear brake fluid reservoir To disable the motorcycle s ignition system pull the main fuse Lightning and Ulysses The 30 amp main fuse is located under the seat in the fuse block To disable the motorcycle s ignition system pull the main fuse sm00423 Figure 6 71 Fuse Block Firebolt 19 20 21 22 23 24 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 ...

Page 535: ... 24 25 26 27 28 29 30 31 32 1 2 3 4 5 6 7 8 9 10 11 12 sm00467 1 Fuel pump 10 amp 2 Auxiliary 10 amp 3 Main 30 amp 4 ECM 10 amp 5 Lamps 15 amp 6 Key switch 15 amp 7 Ignition 15 amp 8 Accessories 10 amp 9 Brake horn interactive exhaust 10 amp 10 Cooling fan 10 amp 11 Battery tender 10 amp 12 Spare 10 amp Figure 6 74 Fuse Block Lightning HOME 2010 XB Service Electrical 6 61 ...

Page 536: ...ary 10amp 3 Battery 30 amp 4 ECM 10 amp 5 Lamps 15 amp 6 Key switch 15 amp 7 Ignition 15 amp 8 Accessory 10 amp 9 Brake horn interactive exhaust 10 amp 10 Fan 10 amp 11 Battery tender 10 amp 12 Spare 10 amp Figure 6 76 Fuse Block Ulysses 1 3 2 sm00424 1 Negative battery cable 2 Main fuse holder 3 Rear brake fluid reservoir Figure 6 77 30A Main Fuse Location Firebolt HOME 6 62 2010 XB Service Elect...

Page 537: ...testing and repair connect wire lead to indicator switch 4 Install sprocket cover See 2 36 SPROCKET COVER REMOVAL AND INSTALLATION 1 Verify that the ignition key switch is turned to OFF 2 Remove sprocket cover See 2 36 SPROCKET COVER NOTE If replacing neutral indicator switch wiring see 6 29 SPROCKET COVER WIRING for correct wire routing 3 See Figure 6 79 Remove neutral indicator switch wire lead ...

Page 538: ...acket and remove sidestand switch and har ness Installation 1 Install fastener through the sidestand switch into the sidestand bracket and tighten to 96 120 in lbs 10 8 13 6 Nm 2 Route the switch wire harness through the re closeable tree fastener clip on the muffler in order to secure the switch harness from damage 3 Continue routing the sidestand switch harness along the front contour of the pri...

Page 539: ... Figure 6 80 Remove screw 2 securing the CKP wire bracket 3 and sensor 1 to the left crankcase Carefully remove CKP sensor 1 and O ring along with the harness bracket 3 from engine crankcase 6 Remove the plastic clip securing the CKP wire to the har ness bracket 1 2 3 sm02442 1 Crank position CKP sensor 2 Screw 3 CKP harness bracket Figure 6 80 Crank Position CKP Sensor INSTALLATION NOTE The CKP s...

Page 540: ...7 Connect negative battery cable tightening to 60 70 in lbs 6 8 7 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 8 Install seat HOME 6 66 2010 XB Service Electrical ...

Page 541: ...or 2 from crankcase INSTALLATION 1 See Figure 6 81 Lubricate O ring with engine oil and install fastener 1 to attach vehicle speed sensor 2 to crankcase and tighten to 90 110 in lbs 10 0 12 4 Nm 2 Connect vehicle speed sensor connector 65 to wiring harness 3 Install sprocket cover See 2 36 SPROCKET COVER 3 2 1 sm00410 1 Fastener 2 Vehicle speed sensor 3 Rear isolator assembly Figure 6 81 Speedomet...

Page 542: ...washers 6 See Figure 6 88 Firebolt Figure 6 89 Lightning or Figure 6 90 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 wi...

Page 543: ...LAMP ASSEMBLY AND SUPPORT BRACKET 5 For Lightning install windscreen and for Ulysses install windscreen windshield See 2 26 HEADLAMP ASSEMBLY AND SUPPORT BRACKET 6 Install negative battery cable After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 7 Install seat...

Page 544: ...ort module left and right 2 Instrument module 3 Grommet 3 4 Washer 3 5 Fastener 3 6 Instrument module connector 39 Figure 6 89 Instrument Module Assembly Lightning 5 7 3 4 2 1 6 sm00464 1 Fairing support center 2 Instrument module 3 Grommet 3 4 Washer 3 5 Fastener 3 6 Instrument module connector 39 7 Front support module left and right Figure 6 90 Instrument Module Assembly Ulysses HOME 6 70 2010 ...

Page 545: ...sitive battery cable 1 and starter solenoid connection 128 3 from starter 6 Disconnect vehicle speed sensor 65 2 NOTES On Firebolt models the rear brake switch connector is located under the seat in front of the rear break reservoir hose On Firebolt models the fuse block and relay block are attached to the fairing support bracket 7 On Firebolt models remove the main fuse case located to the right ...

Page 546: ... BAS connector 134 9 3 Main harness grounds 2 not shown Battery negative cable 4 10 Battery positive cable Left and right trunk pan fasteners 11 5 Right tail section Rear brake light switch connector 121 6 ECM connectors 10 and 11 Figure 6 92 Main Harness Electrical Connectors and Grounds Under Seat Lightning HOME 6 72 2010 XB Service Electrical ...

Page 547: ...1 1 2 2 4 3 3 sm06805 1 Left rear turn signal 2 Right rear turn signal 3 License plate lamp 4 Tail lamp connector 93 Figure 6 93 Rear Lamps Lightning HOME 2010 XB Service Electrical 6 73 ...

Page 548: ...ent cluster connector 39 Main harness 9 3 Horn fastener Right handlebar connector 22 4 10 Left handlebar connector 24 Horn mount 11 5 Horn connector 122 Turn signal connectors 31 6 12 Ignition switch Horn Figure 6 94 Electrical Connectors Behind Windscreen Ulysses HOME 6 74 2010 XB Service Electrical ...

Page 549: ...orn connector 122 11 5 Horn Turn signal connectors 31 6 Ignition switch 33 Figure 6 95 Electrical Connectors Behind Windscreen Lightning 12 Remove fairing and windscreen a For Firebolt see 2 47 FRONT FAIRING WIND SHIELD AND MIRRORS FIREBOLT b For Lightning Ulysses see 2 48 WINDSHIELD AND WINDSCREEN LIGHTNING AND ULYSSES MODELS 13 See Lightning Figure 6 99 Ulysses Figure 6 94 HOME 2010 XB Service E...

Page 550: ...erature sensor 89 b Throttle position sensor 88 c Rear O2 sensor 137 d Temperature sensor 90 e Fuel injectors 84 85 f Fuel pump connector 86 g Idle air control 87 h Fuel pressure sensor 22 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 When re...

Page 551: ...l connectors Cable strap 9 3 Right switch housing connector 22 Data link 91 4 10 Left switch housing connector 24 Ignition switch connector 33 11 5 Cable strap Cable strap 6 Headlight connector 38 Figure 6 96 Fairing Wiring Viewed From Beneath Fairing Firebolt HOME 2010 XB Service Electrical 6 77 ...

Page 552: ...they are installed the harness will not be twisted For more information on wire harness and hose routing see D 1 APPENDIX D HOSE AND WIRE ROUTING 1 On Lightning and Ulysses models install the new harness from the rear of the vehicle working towards the front 2 Feed front and center portion of harness between the trunk pan and tire through opening at rear of frame fuel tank assembly 3 On Firebolt m...

Page 553: ...itch 121 from right switch housing b Clutch switch 95 from left switch housing c Horn connector 122 11 d Headlight connector 38 e Turn signal connectors 31 5 f Left handlebar connector 24 4 and right handlebar connector 22 3 g Instrument module connector 39 2 h Turn signal flasher connector 30 1 i Install electronic control module 2 3 4 5 1 sm00428 1 Mounting strap and guide 2 Transmission vent ho...

Page 554: ... 22 4 10 Left handlebar connector 24 Horn connector 122 11 5 Horn Turn signal connectors 31 6 Ignition switch 33 Figure 6 99 Electrical Connectors Behind Windscreen Lightning 9 Install cable strap loosely around main harness 7 and ignition switch 6 10 Install ground terminal on front of steering head and tighten to 48 72 in lbs 5 4 8 Nm HOME 6 80 2010 XB Service Electrical ...

Page 555: ...ight turn signal connector 18 10 e Bank angle sensor BAS connector 134 9 f ECM connectors 10 and 11 7 164 on XB12 models g Rear brake light switch connector 121 h Main harness ground GRD 2 2 i Front auxiliary power outlet 160 25 Install starter side of positive battery cable and starter solenoid connector 128 to starter 26 Connect vehicle speed sensor 65 27 On Lightning and Ulysses models install ...

Page 556: ...le riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 40 Install seat 1 3 4 5 2 8 7 10 10 11 6 9 sm00661a 7 1 Fuse block and relay center Main harness 2 8 Electronic Control Module Grounds 2 Bat grd Bank angle sensor BAS connector 134 9 3 Main harness grounds 2 not shown Battery negative cable 4 10 Battery positive cable Left and right trunk ...

Page 557: ...ltage ground wire ECM connectors 10 and 11 8 3 Fuse block and relay center Battery negative cable 4 9 Battery positive cable Bank angle sensor BAS connector 134 5 Rear brake light switch connector 121 Figure 6 101 Main Harness and Electrical Connectors Under Seat Lightning XB12Ss HOME 2010 XB Service Electrical 6 83 ...

Page 558: ...ctor 134 ECM connectors 10 and 11 4 12 Fuse block and relay center Auxiliary power outlet 13 5 Trunk pan Main harness ground wires GRD2 6 14 Main harness with plastic grommet Left tail section 15 7 Battey tender connector Battery ground cable 8 16 Battery positive cable Right tail section Figure 6 102 Main Harness and Electrical Components Under Seat Ulysses HOME 6 84 2010 XB Service Electrical ...

Page 559: ...l connectors Cable strap 9 3 Right switch housing connector 22 Data link 91 4 10 Left switch housing connector 24 Ignition switch connector 33 11 5 Cable strap Cable strap 6 Headlight connector 38 Figure 6 103 Fairing Wiring Viewed From Beneath Fairing Firebolt HOME 2010 XB Service Electrical 6 85 ...

Page 560: ...l back terminal cover boot on battery positive cable red 5 Disconnect battery positive cable from battery positive terminal 6 Remove battery 7 Remove electronic control module See 4 4 ELECTRONIC CONTROL MODULE ECM 8 Remove windscreen and windshield See 2 48 WIND SHIELD AND WINDSCREEN LIGHTNING AND ULYSSES MODELS 9 Remove left side air scoop See 2 49 AIR SCOOPS sm06002 Figure 6 104 V Bracket with S...

Page 561: ...eft side of vehicle to the rear of the coil 4 Near fuel rail and idle air control actuator 5 Rear of fuel tank next to fan Figure 6 105 Auxiliary Harness Cable Strap Locations 16 See Figure 6 105 Remove five cable straps securing auxiliary harness and main harness to frame HOME 2010 XB Service Electrical 6 87 ...

Page 562: ... to lighting siren control module Figure 6 108 Lighting Siren Control Module and Connectors Installation NOTE Make sure to properly install the bundle components in the auxiliary harness in order to maintain component clearances 1 Install auxiliary harness starting at the seat area and guiding and pulling it towards the front of vehicle NOTE When routing the harness through the shock tower the sir...

Page 563: ...ernator wiring harnesses are not trapped between the air scoop and cylinder head 14 Install left side air scoop See 2 49 AIR SCOOPS 15 Install windscreen and windshield See 2 48 WINDSHIELD AND WINDSCREEN LIGHTNING AND ULYSSES MODELS 16 Install electronic control module See 4 4 ELECTRONIC CONTROL MODULE ECM 17 Install battery a Connect battery positive cable from battery positive terminal b Install...

Page 564: ...e Hose and Wire Routing Firebolt 1 2 3 sm00433 1 Main battery ground 2 Wire harness ground 3 Main fuse case Figure 6 110 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 will cause the muffler valve...

Page 565: ...rate exhaust actuator harness connector 161B 2 at main harness 5 Pull actuator harness through frame 6 See Figure 6 113 Disconnect connector 161B 2 from actuator NOTE For actuator or actuator cable replacement see 6 16 INTER ACTIVE EXHAUST SYSTEM 1 2 3 4 sm00911 1 ECM connector 10 2 ECM connector 11 3 Negative battery cable 4 Battery ground Figure 6 112 Harness and Cable Routing Lightning XB12 Mod...

Page 566: ...hicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 3 See Figure 6 115 Remove negative battery cable 3 from battery See 1 16 BATTERY MAINTENANCE 4 Remove the fuse block from the battery tray to access the actuator harness ground 5 5 See Figure 6 115 Separate exhaust actuator harness connector 165 beneath the main harness 6 under the s...

Page 567: ...ck on the battery tray 7 Connect negative battery cable to battery terminal Tighten fastener to 60 70 in lbs 6 8 7 9 Nm 8 Install intake cover Tighten fasteners to 12 36 in lbs 1 4 4 Nm After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 9 Install seat 1 2 3 sm...

Page 568: ...nnector and the oil pres sure switch wire is located under the sprocket cover 3 Route oil pressure switch wiring from main harness to oil pressure switch located on the bottom front of the oil pump body and connect to the oil pressure switch 4 Connect the neutral safety switch single bullet 5 See Figure 6 117 Route the interactive exhaust cable behind the oil pump body beside the neutral switch co...

Page 569: ...ion with the engine OFF RUN switch in the RUN position The 12 volt auxiliary power outlet circuit contains a 10 amp fuse to protect overloading of the circuit Verify that the com bined accessory load of both power outlets does not exceed the amperage rating of the circuit Remove the windscreen to access the forward power outlet electrical connector See 2 48 WINDSHIELD AND WIND SCREEN LIGHTNING AND...

Page 570: ...6 96 2010 XB Service Electrical NOTES ...

Page 571: ... ELECTRICAL CONNECTORS A 8 A 5 DEUTSCH STANDARD TERMINAL REPAIR A 12 A 6 DEUTSCH SOLID BARREL MINI TERMINAL REPAIR A 13 A 7 DEUTSCH MINI TERMINAL REPAIR A 15 A 8 PACKARD 150 METRI PACK CONNECTORS A 16 A 9 PACKARD 630 METRI PACK CONNECTORS A 18 A 10 PACKARD METRI PACK TERMINALS A 19 A 11 SEALED SPLICE CONNECTORS A 21 APPENDIX A CONNECTOR REPAIR ...

Page 572: ...NOTES ...

Page 573: ...et Housings 1 Hold the housings to match wire color to wire color 2 Insert the socket housing into the pin housing until it snaps in place 3 If OE location is a T stud fit large opening end of attach ment clip over T stud and slide connector to engage T stud to small end of opening 2 3 1 4 sm00002 1 Attachment clip 2 Release button 3 Socket housing 4 Pin housing Figure A 1 AMP Multilock Connector ...

Page 574: ... of the connector On the pin side of the connector tangs are positioned at the bottom of each cavity so the slot in the pin terminal on the side opposite the crimp tails must face downward On the socket side tangs are at the top of each cavity so the socket terminal slot on the same side as the crimp tails must face upward 2 Gently tug on wire end to verify that the terminal is locked in place 3 R...

Page 575: ...on 1 2 Raise locking bar by pushing up on bottom flange 2 NOTE See Figure A 4 and Figure A 5 Hold the terminal with the insulation crimp tail 1 facing up The tool will hold the terminal by the locking bar groove 3 and crimp the wire crimp tail 2 around the bare wire of the stripped lead and the insulation crimp tail around the insulation 3 See Figure A 6 With the insulation crimp tail facing upwar...

Page 576: ...rimped terminal Figure A 6 AMP Multilock Connector Terminal Crimping Procedure Inspecting Crimped Terminals See Figure A 7 Inspect the wire core crimp 2 and insulation crimp 1 Distortion should be minimal 1 2 sm00008 1 Insulation crimp 2 Wire core crimp Figure A 7 AMP Multilock Connector Terminal Crimp HOME A 4 2010 XB Service Appendix A Connector Repair ...

Page 577: ... side of terminal simultaneously 3 Gently pull on wire to remove terminal from wire end of socket housing 4 If necessary crimp new terminals on wires Assembly 1 Using a thin flat blade like that on a hobby knife carefully bend tang on each side of terminal outward away from terminal body 2 With the open side of the terminal facing rib on wire end of socket housing insert terminal into chamber unti...

Page 578: ...e unsharpened edge of a hobby knife gently pry tang 3 outward away from ter minal and then tug on wire to back terminal out wire end of chamber Do not pull on wire until tang is released or terminal will be difficult to remove Installing Socket Terminals NOTE For wire location purposes alpha or numeric characters are stamped into the wire end of each socket housing 1 Gently push tang on socket hou...

Page 579: ...2 3 1 sm00015 1 Remove wire lock 2 Remove terminal lock 3 Pry tang outward Figure A 11 Delphi Connector Removing Socket Terminals HOME 2010 XB Service Appendix A Connector Repair A 7 ...

Page 580: ...or together the latch on the socket side must be aligned with the latch cover on the pin side b For Two External Latches 8 place and 12 place Align the tabs on the socket housing with the grooves on the pin housing 2 Insert socket housing into pin housing until it snaps or clicks into place For Two External Latches 8 place and 12 place If latches do not click latch press on one side of the con nec...

Page 581: ... not require a special orientation the conical secondary locking wedge of the 3 place connector must be installed with the arrow 1 pointing toward the external latch If the secondary locking wedge does not slide into the installed position easily verify that all terminals are fully installed in the socket housing The lock indicates when terminals are not properly installed by not entering its full...

Page 582: ... may be mated with the gray since the alignment tabs are absent and the orientation of the external latch is the same sm00019 Figure A 16 Deutsch Connector Depress Terminal Latch and Back Out Pin Installing Pin Terminals 1 See Figure A 17 Fit wire seal 1 into back of pin housing 2 2 Grasp wire lead approximately 1 0 in 25 4 mm behind the pin terminal 3 Gently push pin through holes in wire seal in...

Page 583: ... the connector and follow the corresponding crimping instruc tions Refer to Table A 2 Table A 2 Deutsch Connector Terminal Crimping Instructions CRIMPING INSTRUCTIONS TYPE A 5 DEUTSCH STANDARD TERMINAL REPAIR Standard with crimp tails A 6 DEUTSCH SOLID BARREL MINI TERMINAL REPAIR Mini Terminal solid barrel A 7 DEUTSCH MINI TERMINAL REPAIR Mini Terminal with crimp tails HOME 2010 XB Service Appendi...

Page 584: ...hat the tails face straight upward When positioned the locking bar fits snugly in the space between the contact band and the core crimp tails 4 Insert stripped wire core between crimp tails until ends make contact with locking bar Verify that wire is positioned so that short pair of crimp tails squeeze bare wire strands while long pair folds over the insulation 5 Squeeze handle of crimp tool until...

Page 585: ...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 crimpin...

Page 586: ...TS DIVISIO N HDT 48 00 JDG360 1 HEMET RYAN AIRPORT P O BOX 878 HEMET CA 92343 0161 714 929 1200 IN DUSTRIAL PRODUCTS DIVISIO N 2 1 3 4 3 sm00024 1 Contact barrel 2 Indentor cover 3 Indentor point 4 Stripped wire lead Figure A 20 Deutsch Solid Barrel HOME A 14 2010 XB Service Appendix A Connector Repair ...

Page 587: ... stripped wire core stands between crimp tails Pos ition wire so that short pair of crimp tails squeeze bare wire strands while long pair squeeze over the insulation 5 Squeeze handle of crimper until tightly closed Tool auto matically opens when the crimping sequence is complete NOTE If the crimper does not open it can be opened by squeezing the ratchet trigger 2 6 Position the insulation crimp on...

Page 588: ...E The click is the sound of the tang returning to the locked posi tion as it slips from the point of the pin 5 Pick at the tang until the clicking stops and the pin seems to slide in deeper than it had previously This is an indica tion that the tang has been depressed NOTE On those terminals that have been extracted on multiple occasions the click may not be heard but pivot the pin as if the click...

Page 589: ...ve 4 Raise tang to install Figure A 22 150 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 23 150 Metri Pack Connector Push to Seat HOME 2010 XB Service Appendix A Connector Repair A 17 ...

Page 590: ...nal in place 3 Moving to the mating end of the connector take note of the small opening on the chamber wall side of each ter minal 4 Insert SNAP ON PICK Part No SNAP ON TT600 3 into opening until it stops Pivot the end of the pick toward the terminal to depress the locking tang 5 Remove the pick and gently tug on the wire to pull the terminal from the wire end of the connector Repeat steps if the ...

Page 591: ...wire striper to strip off the insulation and expose 5 32 in 4 0 mm of wire core Crimping Wire Core NOTE Metri Pack terminal crimps require two steps Always perform Crimping Wire Core before Crimping Insulation Seal 1 Squeeze and release handles until ratchet automatically opens 2 Identify the corresponding sized nest for the core crimp 3 Position the core crimp in the die Be Sure the core crimp ta...

Page 592: ...s complete Inspecting Crimps 1 See Figure A 25 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 25 Metri Pack Connector Inspe...

Page 593: ...s and insert one end of the sealed connector 3 Gently squeeze the handles until the connector is held in the jaws 4 See Figure A 27 Feed the stripped end of a wire into the connector until the wire stops inside the metal insert 1 5 Squeeze the handles tightly closed to crimp the lead in the insert 2 The tool automatically opens when the crimping is complete 6 Slide the connector to the other half ...

Page 594: ...ellow connector die Figure A 26 Packard Crimping Tool HD 38125 8 1 1 4 2 2 4 3 sm00051 1 Wire lead in metal insert 2 Crimp metal insert 3 Center of crimp 4 Melted sealant Figure A 27 Sealed Splice Connector HOME A 22 2010 XB Service Appendix A Connector Repair ...

Page 595: ...TABLE OF CONTENTS SUBJECT PAGE NO B 1 CONNECTORS B 1 B 2 WIRING DIAGRAMS B 4 APPENDIX B WIRING ...

Page 596: ...NOTES ...

Page 597: ...ight rear turn signal 18 Under seat Lightning Under tail section Firebolt Under rear wire cover Ulysses 2 1 place bullet Left rear turn signal 19 Under seat Lightning Under tail section Firebolt Behind windscreen Ulysses Lightning Gray 4 place Amp Multilock Right hand controls 22 Beneath fairing Firebolt Behind windscreen Ulysses Lightning Gray 8 place Amp Multilock Left hand controls 24 Beneath f...

Page 598: ...Gray 2 place Amp IAT sensor 89 Beneath aircleaner baseplate Gray 1 place Delphi Metri pack ET sensor 90 Beneath left airflow guide Ulysses Black 4 place Deutsch DLC 91A Under seat Lightning Under fairing Firebolt Back of tail light under seat 3 place JST Tail lamp 93 Underside of clutch lever assembly Gray 2 place Sumitomo Clutch switch 95 Behind rear cylinder under seat Gray 2 place Amp Multilock...

Page 599: ... AIS 178 Under seat Ulysses only Gray 2 place Sumitomo Rear auxiliary power outlet 180 Behind windscreen Ulysses only Black 3 place Deutsch Left heated grip 189L Behind windscreen Ulysses only Black 3 place Deutsch Right heated grip 189R Behind windscreen Ulysses only Gray 3 place Sumitomo Heated grip subharness connector 206 Throttle body Gray 3 place Delphi Fuel pressure sensor 227 HOME 2010 XB ...

Page 600: ...ction a symbol verifying that no connection between two wire traces exists symbols for actual and virtual splices and a symbol identifying two wires that are twisted together Actual splices are splices where two wires are connected together at a specific location along a wire Virtual splices are splices shown connected anywhere along a wire usually used in a wiring or schematic diagram for clarity...

Page 601: ...y Figure B 3 Relay Block Firebolt 20 18 12 3 16 17 10 8 2 2 6 7 19 13 11 4 14 15 9 3 1 4 3 1 39 33 12 27 21 6 40 34 13 28 22 7 41 35 14 29 23 8 42 36 15 30 24 9 43 37 16 31 25 10 44 38 17 32 26 11 18 ed03134 1 Ignition relay 2 Start relay 3 Key switch relay 4 Auxiliary relay 5 Relay block 6 Ignition fuse 7 Accessory fuse 8 Brake horn EVA fuse 9 Cooling fan fuse 10 Battery tender fuse 11 Empty 12 F...

Page 602: ...ke Horn EVA fuse 7 Cooling fan fuse 8 Battery tender fuse 9 Empty 10 Key switch fuse 11 Lights fuse 12 ECM fuse 13 Battery fuse 14 Auxiliary fuse 15 Fuel pump fuse 16 Key switch relay 17 Auxiliary relay 18 Relay block Figure B 5 Fuse Relay Block Ulysses Table B 2 Wire Color Codes WIRE COLOR ALPHA CODE Blue BE Black BK Brown BN Green GN Gray GY Light Green LGN Orange O Pink PK Red R Tan TN Violet V...

Page 603: ...er 2010 XB Models Firebolt Figure B 10 Chassis Grounds 2010 XB Models Ulysses Lightning Figure B 11 Chassis Grounds 2010 XB Models Firebolt Figure B 12 Main Harness 2010 XB Models Ulysses and Lightning Figure B 13 Main Harness 2010 XB Models Firebolt Figure B 14 Engine Management Circuit 2010 XB Models Ulysses and Lightning Figure B 15 Component Wiring Diagrams 2010 XB Models Figure B 16 Police Ha...

Page 604: ... 30 86 85 5 3 2 1 4 5 9 1 40 34 Battery 30A 41 35 Fuel Pump 10A 39 33 ECM 10A 42 36 Ignition 15A 21 27 Key Switch 15A 38 44 Cooling Fan 10A 30 24 4 1 4 1 On Park Lock Off Ignition Switch R R R R R On Park Lock Off 33B 33A 128A O GY O GY GY O Y BN Y BN GY O R Y R Y R Y R Y R R R R R R R R R Y Y R R BK BK BK Battery Cable Starter Solenoid Starter Motor em00366 Figure B 6 Battery Power 2010 XB Models...

Page 605: ... 15 87 30 86 85 5 3 2 1 4 5 9 1 1 2 Auxiliary 10A 21 15 Fuel Pump 10A 7 1 ECM 10A 22 16 Ignition 15A 5 11 Key Switch 15A 18 24 Cooling Fan 10A 10 4 4 1 4 1 On Park Lock Off Ignition Switch R R R R R On Park Lock Off 33B 33A O GY O GY GY O Y BN Y BN GY O R Y R Y R Y R Y R R R R R R R R R Y Y R R BK BK 128A BK Battery Cable Starter Solenoid Starter Motor em00429 Figure B 7 Battery Power 2010 XB Mode...

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

Page 607: ... sory 10A Battery Power In Wiring Diagrams 2 2 8 4 2 4 3 3 2 8 165B 165A License Plate Lamp 1 1 1 1 3 3 45A 45B Tail Light Headlight 1 1 93A 93B Flasher 2 2 38B 38A 22B 22A 170B 170A 91A 30B 30A 121A 121B Front Brake Switch 1 1 Rear Brake Switch 1 1 84B 84A Front Injector Rear Injector 1 1 85B 85A 1 1 10B 10A ECM 9 9 83B 83A Ignition Coil 2 2 24A 24B 39A 39B Engine Stop Switch Start Switch 87 86 1...

Page 608: ... Rear Turn Signal Battery Tender 1 1 1 39A 39B Instrument Cluster 13 13 95A 95B 31A 31B Clutch Switch Left Front Turn Signal 2 2 2 2 4 4 1 1 31A 31B Right Front Turn Signal Rear 12V Auxiliary Power Outlet Ulysses Only Front 12V Auxiliary Power Outlet 2 2 2 2 85 2 9 85 2 19 BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK 4 4 1 1 Flasher Horn Marker Lamp Low Beam Headlamp High Beam Headlamp BK...

Page 609: ... 30A 30B Flasher 4 4 95A 95B 31A 31B Clutch Switch Left Front Turn Signal 2 2 2 2 2 2 1 2 2 1 1 1 1 1 1 1 1 31A 31B Right Front Turn Signal Front 12V Auxiliary Power Outlet Horn 2 2 85 2 9 85 2 19 BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK 13 13 Instrument Cluster BK BK BK BK BK BK BK BK BK BK BK BK BK BK BK Left Marker Lamp 1 1 BK Low Beam Headlamp 1 1 BK High Beam Headlamp 1 1 BK Right Mark...

Page 610: ......

Page 611: ... 1 2 3 4 1 2 3 4 4 91A BATT NEUT TRNL TRNR HIB ENG Oil IGN GND TACH Fuel SPD 1 2 Clutch Switch 2 19 26 CKP Sensor 18 CKP Sensor 24 27 28 32 34 Sensor GND 3 IAC Motor 20 21 22 23 1 4 3 2 1 2 79A 79B 5v Sensor Power 25 19 11 9 10 Fuel Pressure Sensor 10 13 14 22 21 17 16 10 11 System GND 5 11 12 System GND 6 12 14 System GND 7 14 9 8 3 2 1 23 24 15 16 17 34 33 32 31 30 29 28 27 25 8 7 4 2 19 26 18 2...

Page 612: ...Figure B 12 Figure B 12 Main Harness 2010 XB Models Ulysses and Lightning Main Harness 2010 XB Models Ulysses and Lightning ...

Page 613: ...Sidestand Sensor 4 20 21 22 23 IAC Motor IAC Motor IAC Motor IAC Motor 1 2 1 2 Gray 4 key J1 J2 Black 3 key 2 3 4 5 6 7 8 12 13 14 15 16 2 3 4 5 6 7 8 12 13 14 15 16 BATT NEUT TRNL TRNR HiB ENG Oil IGN GRD TACH Fuel SPD Speedometer ECM 1 2 18 CKP 26 Crank Sensor NEG 25 5V Sensor Power 2 19 2 24 27 28 32 34 11 9 13 14 15 16 17 8 4 20 21 22 23 18 26 25 19 Sensor GND 3 1 J2 10A BK J1 11A GY 1 2 3 4 1...

Page 614: ...Figure B 13 Figure B 13 Main Harness 2010 XB Models Firebolt Main Harness 2010 XB Models Firebolt ...

Page 615: ...5 System GND 6 System GND 7 System GND 3 Battery Vehicle Speed System GND 2 Fuel Pump Output Rear Coil System GND 1 Front Ignition Coil ET Input TPS Neutral Switch 5v Sensor Power O2 Sensor Rear Sensor GND 2 O2 Sensor Front Sensor GND 1 Sidestand Sensor Clutch Switch CKP Sensor CKP Sensor Sensor GND 3 IAC Motor 5v Sensor Power 20 21 22 23 20 21 22 23 1 2 J1 11A GY ECM J2 10A BK GND 2 1 2 3 4 1 3 4...

Page 616: ...Figure B 14 Figure B 14 Engine Management Circuit 2010 XB Models Ulysses and Lightning Engine Management Circuit 2010 XB Models Ulysses and Lightning ...

Page 617: ...amp To Main Harness To Main Harness Fuel Pump RH Turn Signals LH Turn Signals 1 2 Rear Auxiliary Outlet Ulysses Only Front Auxiliary Outlet 1 2 1 2 1 2 Heated Grips Sub Harness Connector 12V Auxiliary Outlet Connector Right Hand Controls Left Hand Controls R Heat Grip L Heat Grip 1 2 3 1 2 3 1 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 BK W BK O R BK BN BE G...

Page 618: ...Figure B 15 Figure B 15 Component Wiring Diagrams 2010 XB Models Component Wiring Diagrams 2010 XB Models ...

Page 619: ... Channel 2 Rear Channel 1 Rear Channel 2 Rear Channel 1 17 16 19 4 14 2 12 5 6 18 7 8 22 23 3 1 13 15 21 17 16 19 4 14 2 12 5 6 18 7 8 22 23 3 1 13 15 J9A J9B J7B J6B J4B J5B J2B J2A J3B J1B J8B BE BK GN BK BE BK GN BK BE BK BE BK BE BK GN BK GN BK GN BK BE W GN W BE W GN W BE W BE W BE W GN W GN W GN W GY BE BN BN BK BK GY BE BN GN R W R W O BN O Y Y R R BK R R Y W GN R Y W GN BK GN BK BE BK BE B...

Page 620: ...B 24 2010 XB Service Appendix B Wiring NOTES ...

Page 621: ...TABLE OF CONTENTS SUBJECT PAGE NO C 1 LENGTH CONVERSION C 1 C 2 FLUID CONVERSION C 2 C 3 TORQUE CONVERSION C 3 APPENDIX C CONVERSIONS ...

Page 622: ...NOTES ...

Page 623: ... 535 39 2362 6 100 01 3 15 16 66 04 2 6 30 48 1 2 1 270 050 4 173 106 2 874 73 1 575 40 2756 7 101 6 4 66 67 2 5 8 31 75 1 1 4 1 524 060 4 212 107 2 913 74 1 614 41 3149 8 102 19 4 1 16 68 26 2 11 16 33 02 1 3 1 588 1 16 4 252 108 2 953 75 1 653 42 3543 9 104 14 4 1 68 58 2 7 33 34 1 5 16 1 778 070 4 291 109 2 992 76 1 693 43 3937 10 104 77 4 1 8 69 85 2 3 4 34 92 1 3 8 2 032 080 4 331 110 3 031 7...

Page 624: ...easurements in this Service Manual do not include the British Imperial Imp system equivalents The fol lowing conversions exist in the British Imperial system 1 pint Imp 20 fluid ounces Imp 1 quart Imp 2 pints Imp 1 gallon Imp 4 quarts Imp Although the same unit of measure terminology as the U S system is used in the British Imperial Imp system the actual volume of each British Imperial unit of mea...

Page 625: ...s X 0 08333 foot pounds ft lbs METRIC SYSTEM All metric torque specifications are written in Newton meters Nm To convert metric to United States units and United States to metric use the following equations Newton meters Nm X 0 737563 foot pounds ft lbs Newton meters Nm X 8 85085 inch pounds in lbs foot pounds ft lbs X 1 35582 Newton meters Nm inch pounds in lbs X 0 112985 Newton meters Nm HOME 20...

Page 626: ...C 4 2010 XB Service Appendix C Conversions NOTES ...

Page 627: ...TABLE OF CONTENTS SUBJECT PAGE NO D 1 APPENDIX D HOSE AND WIRE ROUTING D 1 APPENDIX D HOSE AND WIRE ROUTING ...

Page 628: ...NOTES ...

Page 629: ...D 1 APPENDIX D HOSE AND WIRE ROUTING FIREBOLT HOME 2010 XB Service Appendix D Hose and Wire Routing D 1 ...

Page 630: ...sm04328 Figure D 1 Front and Rear Brake Systems Right Side View HOME D 2 2010 XB Service Appendix D Hose and Wire Routing ...

Page 631: ...sm04332 Figure D 2 Rear Brake Systems Top View HOME 2010 XB Service Appendix D Hose and Wire Routing D 3 ...

Page 632: ...sm04334 Figure D 3 Rear Brake Systems Left Side View HOME D 4 2010 XB Service Appendix D Hose and Wire Routing ...

Page 633: ...1 sm04337 1 Carbon canister Figure D 4 Evaporative Emissions Control California Models Top View HOME 2010 XB Service Appendix D Hose and Wire Routing D 5 ...

Page 634: ...om induction module California 3 From fuel tank California 4 From fuel tank to atmosphere 49 state Figure D 5 Evaporative Emissions Control California and 49 State Models Left Side View HOME D 6 2010 XB Service Appendix D Hose and Wire Routing ...

Page 635: ...5 sm04344 1 Active intake solenoid Japan only 2 Ignition coil 3 Fuel pump 4 Crank position sensor CKP 5 To ECM Figure D 6 Wiring Harness Left Side View HOME 2010 XB Service Appendix D Hose and Wire Routing D 7 ...

Page 636: ...or 2 2 Idle air control IAC 3 Throttle position sensor TPS 4 Intake air temperature sensor IAT 5 Oxygen sensor O2 6 Engine temperature sensor Figure D 7 Wiring Harness Top View HOME D 8 2010 XB Service Appendix D Hose and Wire Routing ...

Page 637: ...ed sensor VSS 2 Cable starter to battery positive 3 Solenoid 4 Voltage regulator 5 Oil pressure switch 6 Neutral switch 7 Relay terminal Figure D 8 Wiring Harness Right Side View HOME 2010 XB Service Appendix D Hose and Wire Routing D 9 ...

Page 638: ... 3 2 1 sm04322 1 Feed oil line 2 Return oil line 3 Vent line 4 Oil cooler return line 5 Oil cooler feed line Figure D 9 Oil Lines Right Side View HOME D 10 2010 XB Service Appendix D Hose and Wire Routing ...

Page 639: ...1 2 sm04367 1 Exhaust valve actuator 2 Muffler valve Figure D 10 Clutch Cable and Exhaust Valve Actuator Right Side View HOME 2010 XB Service Appendix D Hose and Wire Routing D 11 ...

Page 640: ...4371 1 Muffler valve 2 Exhaust valve actuator 3 Cable seat lock Figure D 11 Clutch Throttle Seat Release Cable and Exhaust Valve Actuator Left Side View HOME D 12 2010 XB Service Appendix D Hose and Wire Routing ...

Page 641: ...ck 2 Exhaust valve actuator mounted to top of functional air cleaner cover Figure D 12 Clutch Throttle Seat Release Cable and Exhaust Valve Actuator XB12 Models Top View HOME 2010 XB Service Appendix D Hose and Wire Routing D 13 ...

Page 642: ...LIGHTNING sm04329 Figure D 13 Front and Rear Brake Systems Right Side View HOME D 14 2010 XB Service Appendix D Hose and Wire Routing ...

Page 643: ...sm04331 Figure D 14 Rear Brake Systems Top View HOME 2010 XB Service Appendix D Hose and Wire Routing D 15 ...

Page 644: ...sm04335 Figure D 15 Rear Brake Systems Left Side View HOME D 16 2010 XB Service Appendix D Hose and Wire Routing ...

Page 645: ...1 sm04338 1 Carbon canister Figure D 16 Evaporative Emissions Control California Models Top View HOME 2010 XB Service Appendix D Hose and Wire Routing D 17 ...

Page 646: ...m induction module California 3 From fuel tank California 4 From fuel tank to atmosphere 49 state Figure D 17 Evaporative Emissions Control California and 49 State Models Left Side View HOME D 18 2010 XB Service Appendix D Hose and Wire Routing ...

Page 647: ... 2 1 sm04327 1 Active Intake Solenoid Japan only 2 Ignition coil 3 Fuel pump 4 Crank position sensor CKP Figure D 18 Wiring Harness Left Side View HOME 2010 XB Service Appendix D Hose and Wire Routing D 19 ...

Page 648: ... Fuel injector 2 2 Idle air control IAC 3 Throttle position sensor TPS 4 Intake air temperature sensor IAT 5 Oxygen sensor 02 Figure D 19 Wiring Harness Top View HOME D 20 2010 XB Service Appendix D Hose and Wire Routing ...

Page 649: ...d sensor VSS 2 Cable starter to battery positive 3 Solenoid 4 Voltage regulator 5 Oil pressure switch 6 Neutral switch 7 Relay terminal Figure D 20 Wiring Harness Right Side View HOME 2010 XB Service Appendix D Hose and Wire Routing D 21 ...

Page 650: ... 1 2 3 sm04325 1 Feed oil line 2 Return oil line 3 Vent line 4 Oil cooler return line 5 Oil cooler feed line Figure D 21 Oil Lines Right Side View HOME D 22 2010 XB Service Appendix D Hose and Wire Routing ...

Page 651: ...1 2 sm04369 1 Exhaust valve actuator 2 Muffler valve Figure D 22 Clutch Cable and Exhaust Valve Actuator XB12 Models Right Side View HOME 2010 XB Service Appendix D Hose and Wire Routing D 23 ...

Page 652: ... Muffler valve 2 Exhaust valve actuator 3 Cable seat lock Figure D 23 Clutch Throttle Seat Release Cable and Exhaust Valve Actuator XB12 Models Left Side View HOME D 24 2010 XB Service Appendix D Hose and Wire Routing ...

Page 653: ...ck 2 Exhaust valve actuator mounted to top of functional air cleaner cover Figure D 24 Clutch Throttle Seat Release Cable and Exhaust Valve Actuator XB12 Models Top View HOME 2010 XB Service Appendix D Hose and Wire Routing D 25 ...

Page 654: ...ULYSSES sm04330 Figure D 25 Front and Rear Brake Systems Right Side View HOME D 26 2010 XB Service Appendix D Hose and Wire Routing ...

Page 655: ...sm04333 Figure D 26 Rear Brake Systems Top View HOME 2010 XB Service Appendix D Hose and Wire Routing D 27 ...

Page 656: ...sm04336 Figure D 27 Rear Brake Systems Left Side View HOME D 28 2010 XB Service Appendix D Hose and Wire Routing ...

Page 657: ...1 sm04339 Figure D 28 Evaporative Emissions Control California Models Top View HOME 2010 XB Service Appendix D Hose and Wire Routing D 29 ...

Page 658: ...m induction module California 3 From fuel tank California 4 From fuel tank to atmosphere 49 state Figure D 29 Evaporative Emissions Control California and 49 State Models Left Side View HOME D 30 2010 XB Service Appendix D Hose and Wire Routing ...

Page 659: ... 2 4 sm04326 1 Active intake solenoid Japan only 2 Ignition coil 3 Fuel pump 4 Crank position sensor CKP Figure D 30 Wiring Harness Left Side View HOME 2010 XB Service Appendix D Hose and Wire Routing D 31 ...

Page 660: ... Fuel injector 2 2 Idle air control IAC 3 Throttle position sensor TPS 4 Intake air temperature sensor IAT 5 Oxygen sensor O2 Figure D 31 Wiring Harness Top View HOME D 32 2010 XB Service Appendix D Hose and Wire Routing ...

Page 661: ...icle speed sensor VSS 2 Cable starter to battery positive 3 Solenoid 4 Oil pressure switch 5 Neutral switch 6 Relay terminal Figure D 32 Wiring Harness Right Side View HOME 2010 XB Service Appendix D Hose and Wire Routing D 33 ...

Page 662: ...oil line 3 Return oil line 4 Feed oil line from the oil pump to the oil cooler 5 Return oil line from the oil cooler to the oil filter housing Figure D 33 Oil Lines Right Side View HOME D 34 2010 XB Service Appendix D Hose and Wire Routing ...

Page 663: ...2 1 sm04370 1 Exhaust valve actuator 2 Muffler valve Figure D 34 Clutch Cable and Exhaust Valve Actuator Right Side View HOME 2010 XB Service Appendix D Hose and Wire Routing D 35 ...

Page 664: ...4373 1 Muffler valve 2 Exhaust valve actuator 3 Cable seat lock Figure D 35 Clutch Throttle Seat Release Cable and Exhaust Valve Actuator Left Side View HOME D 36 2010 XB Service Appendix D Hose and Wire Routing ...

Page 665: ...ck 2 Exhaust valve actuator mounted to top of functional air cleaner cover Figure D 36 Clutch Throttle Seat Release Cable and Exhaust Valve Actuator XB12 Models Top View HOME 2010 XB Service Appendix D Hose and Wire Routing D 37 ...

Page 666: ...D 38 2010 XB Service Appendix D Hose and Wire Routing NOTES ...

Page 667: ...TABLE OF CONTENTS SUBJECT PAGE NO E 1 ACTIVE INTAKE SYSTEM JAPANESE MODELS ONLY E 1 APPENDIX E ACTIVE INTAKE JAPANESE MODELS ...

Page 668: ...NOTES ...

Page 669: ...heck 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 clean...

Page 670: ... the shaft loosen jam nuts 2 and adjust cable housing 4 towards the solenoid bracket 3 until freeplay is achieved NOTE You should be able to move the solenoid shaft slightly outward until the shaft is fully extended This slight travel will be the freeplay which should be 1 32 in 0 79 mm or greater 4 See E 1 ACTIVE INTAKE SYSTEM JAPANESE MODELS ONLY Verify Settings Once freeplay has been set it wil...

Page 671: ... set screw 3 Activate Active Intake System using DIGITAL TECHNI CIAN 4 Adjust stop screw while reading the TPS on Digital Technician until setting is between the range of 10 4 to 10 9 a If the reading is below 10 4 adjust screw clockwise b If the reading is above 10 9 adjust screw counterclock wise 5 Confirm the TPS setting Repeat process if needed 6 Adjust active intake cable assembly See E 1 ACT...

Page 672: ...the baseplate 1 See Figure E 4 Disconnect electrical connector 178 1 2 Hold solenoid shaft by flat spot provided and break cable connector 6 loose 3 Unthread cable connector and disconnect cable from solenoid 8 4 Loosen jam nut 5 and disconnect active cable 2 from cable bracket 4 NOTE Follow next step only is solenoid is to be replaced 5 Loosen pinch fastener on solenoid bracket 9 HOME E 4 2010 XB...

Page 673: ...e to feed the electrical connector 1 through hole in baseplate first and then insert active cable and then grommet Follow next step only if solenoid was removed 2 Install solenoid 8 into bracket 9 and tighten pinch fastener to 48 60 in lbs 5 4 6 8 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 ...

Page 674: ...E 6 2010 XB Service Appendix E Active Intake Japanese Models NOTES ...

Page 675: ...TABLE OF CONTENTS SUBJECT PAGE NO F 1 GLOSSARY F 1 APPENDIX F GLOSSARY ...

Page 676: ...NOTES ...

Page 677: ...libration CAL Controller area network CAN Cubic centimeters cc Centimeters cm Cubic centimeters cm3 Cold cranking amps CCA Crankshaft position CKP Centimeter cm Counterclockwise CCW Clockwise CW Direct current DC Data link connector DLC Domestic DOM Diagnostic trouble code DTC Department of Transportation DOT Digital volt ohm meter DVOM Electronic control module ECM Engine coolant temperature ECT ...

Page 678: ...e HFSM Mercury Hg Heated oxygen sensor H02S Horsepower hp Hour hr Idle air control IAC Intake air temperature IAT Instrument cluster IC Inside diameter ID Ignition light key switch position IGN Inch in Cubic inch in3 Injector pulse width INJ PW Inch pounds in lbs Jiffy stand sensor JSS Kilogram kg Kilometer km Kilopascal kPa Kilometers per hour km h Kilowatt kW Liter L Pounds lb Liquid crystal dis...

Page 679: ...WM signal Quart qt Reverse control module RCM Reserve mark on fuel supply valve RES Revolutions per minute RPM seconds s Cubic feet per hour at standard conditions SCFH Throttle control actuator TCA Top dead center TDC Twist grip sensor TGS Intake air temperature manifold absolute pressure TMAP Throttle position sensor TPS Turn signal module TSM Turn signal security module TSSM Volt V Volts of alt...

Page 680: ...F 4 2010 XB Service Appendix F Glossary NOTES ...

Page 681: ...ET Installation SPROCKET HOLDING TOOL B 43982 5 15 TRANSMISSION INSTALLATION Installation INSTALLER B 43985 3 5 15 TRANSMISSION INSTALLATION Installation GUIDE B 43985 4 5 15 TRANSMISSION INSTALLATION Installation GUIDE B 43985 4 2 5 FRONT WHEEL Assembly FRONT WHEEL BEARING INSTALLER B 43993 10 2 6 REAR WHEEL Wheel Bearings Two Bearing Wheels BEARING INSTALLER FRONT BEARING B 43993 10 2 6 REAR WHE...

Page 682: ...AIN DRIVE GEAR AND BEARING Removal CROSS PLATE B 45847 5 12 MAIN DRIVE GEAR AND BEARING Installation CROSS PLATE B 45847 5 6 PRIMARY CHAIN Clutch Shell Bearing Replacement CLUTCH SHELL BEARING REMOVER INSTALLER B 45926 5 15 TRANSMISSION INSTALLATION Installation TRANSMISSION FIXTURE B 46285 4 2 16 FRONT FORKS Assembly FORK SEAL DRIVER AND DUST BOOT INSTALLER B 48867 47MM 2 6 REAR WHEEL Wheel Beari...

Page 683: ... GEAR AND BEARING Removal RECEIVER CUP HD 35316 11 5 12 MAIN DRIVE GEAR AND BEARING Installation INSTALLER CUP HD 35316 12 5 12 MAIN DRIVE GEAR AND BEARING Removal 8 IN BOLT HD 35316 4A 5 12 MAIN DRIVE GEAR AND BEARING Installation 8 IN BOLT HD 35316 4A 5 12 MAIN DRIVE GEAR AND BEARING Installation 8 IN BOLT HD 35316 4A 5 12 MAIN DRIVE GEAR AND BEARING Removal WASHER HD 35316 7 5 12 MAIN DRIVE GEA...

Page 684: ...AMP Multilock Connector Repair AMP MULTILOCK CRIMPER HD 41609 5 9 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL Right Crankcase Removal ENGINE SUPPORT STAND HD 42310 HD 43646 OR HD 43682 3 8 CYLINDER AND PISTON Assembly Installation PISTON SUPPORT PLATE HD 42322 3 18 CRANKCASE Assembly CRANKSHAFT GUIDE HD 42326 B 5 15 TRANSMISSION INSTALLATION Installing Right Crankcase CRANKSHAFT GUIDE HD 42326 B 3 1...

Page 685: ... CRANKCASE Pinion Shaft Bearing CLAW PULLER HD 95635 46 5 12 MAIN DRIVE GEAR AND BEARING Disassembly CLAW PULLER HD 95635 46 3 18 CRANKCASE Pinion Shaft Bearing WEDGE ATTACHMENT HD 95637 46B 5 12 MAIN DRIVE GEAR AND BEARING Disassembly WEDGE ATTACHMENT HD 95637 46B 5 13 TRANSMISSION RIGHT CASE BEAR INGS Removal BUSHING AND BEARING PULLER HD 95760 69A 5 13 TRANSMISSION RIGHT CASE BEAR INGS Removal ...

Page 686: ...MMER 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 8 ENGINE TEMPERATURE SENSOR ET Removal ENGINE TEMPERATURE SENSOR SOCKET SNAP ON M3503B 5 14TRANSMISSION LEFT CASE BEARINGS Removal SNAP RING PLIERS SNAP ON PR 36 A 1 AMP MULTILOCK CONNECTORS AMP Multilock Connector Repair SNAP ...

Page 687: ...allation Follow special instructions ANTI SEIZE 65 1 70 5 Nm 48 52 ft lbs Axle rear final torque 2 6 REAR WHEEL Installation Follow special instructions ANTI SEIZE 31 2 36 6 Nm 23 27 ft lbs Axle rear initial torque 2 37 BELT GUARDS Installation 54 2 61 0 Nm 40 45 ft lbs Axle pinch fastener rear 5 7 DRIVE BELT AND IDLER PULLEY Drive Belt Installation 54 2 61 Nm 40 45 ft lbs Axle pinch fastener rear...

Page 688: ...lbs Battery terminal fastener 5 6 PRIMARY CHAIN Installation 6 8 7 9 Nm 60 70 in lbs Battery terminal fastener 6 3 IGNITION HEADLAMP KEY SWITCH Firebolt 6 8 7 9 Nm 60 70 in lbs Battery terminal fastener 6 3 IGNITION HEADLAMP KEY SWITCH Lightning 6 8 7 9 Nm 60 70 in lbs Battery terminal fastener 6 3 IGNITION HEADLAMP KEY SWITCH Ulysses 6 8 7 9 Nm 60 70 in lbs Battery terminal fastener 6 6 BATTERY C...

Page 689: ...attery terminal fasteners 2 44 CENTER TAIL LOOP ULYSSES MODELS Assembly 6 8 7 9 Nm 60 70 in lbs Battery terminal fasteners 3 4 ENGINE ROTATION FOR SERVICE Assembly 6 8 7 9 Nm 60 70 in lbs Battery terminal fasteners 4 4 ELECTRONIC CONTROL MODULE ECM Firebolt 6 8 7 9 Nm 60 70 in lbs Battery terminal fasteners 4 4 ELECTRONIC CONTROL MODULE ECM Firebolt 6 8 7 9 Nm 60 70 in lbs Battery terminal fastene...

Page 690: ...lt rear 2 9 FRONT BRAKE EIGHT PISTON CAL IPER Master Cylinder Reservoir Installation 0 8 1 Nm 7 10 in lbs Brake light switch fastener front 2 9 FRONT BRAKE EIGHT PISTON CAL IPER Front Brake Fluid Line 4 6 8 Nm 36 60 in lbs Brake line P clamp front 2 10 FRONT BRAKE SIX PISTON CAL IPER Brake Line Installation 4 6 8 Nm 36 60 in lbs Brake line p clamp fastener front 2 13 REAR BRAKE LINE Installation F...

Page 691: ... Caliper bleeder valves 2 10 FRONT BRAKE SIX PISTON CAL IPER Brake Line Removal 4 6 8 Nm 36 60 in lbs Caliper bleeder valves 2 10 FRONT BRAKE SIX PISTON CAL IPER Brake Caliper Removal 4 6 8 Nm 36 60 in lbs Caliper bleeder valves 2 12 REAR BRAKE MASTER CYL INDER Removal Firebolt Lightning 4 6 8 Nm 36 60 in lbs Caliper bleeder valves 2 12 REAR BRAKE MASTER CYL INDER Removal Ulysses 4 6 8 Nm 36 60 in...

Page 692: ... 5 3 PRIMARY COVER Installation 9 5 12 2 Nm 84 108 in lbs Clutch inspection cover fasteners 5 4 CLUTCH RELEASE MECHANISM Assembly 9 5 12 2 Nm 84 108 in lbs Clutch inspection cover fasteners 5 6 PRIMARY CHAIN Installation LOCTITE 271 red if using original mainshaft nut 67 8 81 3 Nm 50 60 ft lbs Clutch mainshaft nut 4 11 COOLING FAN Installation 1 4 4 Nm 12 36 in lbs Cooling fan fasteners 6 26 MAIN ...

Page 693: ... 4 ENGINE ROTATION FOR SERVICE Assembly 8 1 10 8 Nm 72 96 in lbs Exhaust header nuts 3 6 ENGINE INSTALLATION Assembly 8 1 10 8 Nm 72 96 in lbs Exhaust header nuts 2 27 FAIRING SUPPORT BRACKET FIRE BOLT Installation 22 26 Nm 16 18 ft lbs Fairing support bracket fasteners Fire bolt 2 43 LEFT AND RIGHT TAIL SECTION ULYSSES MODELS Assembly LOCTITE 271 red 28 5 31 2 Nm 21 23 ft lbs Fasteners for tail s...

Page 694: ...LOCTITE 271 red 4 0 5 4 Nm 36 48 in lbs Front fender fasteners 2 15 FENDERS Front Fender XB12X LOCTITE 271 red 4 0 5 4 Nm 36 48 in lbs Front fender fasteners 2 15 FENDERS Front Fender XB12XP 1 4 4 Nm 12 36 in lbs Front fender fasteners and washers 2 15 FENDERS Front Fender XB12XP 4 0 5 4 Nm 36 48 in lbs Front fender fasteners and washers 2 20 FRONT AND REAR ISOLATORS Front Isol ator 66 4 69 1 Nm 4...

Page 695: ...ing and Ulysses 2 32 HANDLEBARS LIGHTNING AND ULYSSES MODELS Installation LOCTITE 271 red Tighten front screws first 13 6 16 3 Nm 120 144 ft lbs Handlebar clamp screws Lightning and Ulysses 2 31 HANDLEBARS FIREBOLT Installation 32 5 35 3 Nm 24 26 ft lbs Handlebar clip on fastener Firebolt 2 31 HANDLEBARS FIREBOLT Installation 32 5 35 3 Nm 24 26 ft lbs Handlebar clip on fastener Firebolt 2 10 FRONT...

Page 696: ...tion 13 6 16 3 Nm 120 144 in lbs Ignition coil mounting screws 6 3 IGNITION HEADLAMP KEY SWITCH Firebolt 1 4 4 Nm 12 36 in lbs Ignition switch body fastener 6 3 IGNITION HEADLAMP KEY SWITCH Lightning 1 4 4 Nm 12 36 in lbs Ignition switch body fastener 6 3 IGNITION HEADLAMP KEY SWITCH Ulysses 1 4 4 Nm 12 36 in lbs Ignition switch body fastener 6 3 IGNITION HEADLAMP KEY SWITCH Fire bolt LOCTITE 271 ...

Page 697: ... in lbs Lower rocker box bolts 1 4 20 x 1 1 4 3 7 CYLINDER HEAD Cylinder Head Installation 24 7 29 8 Nm 18 22 ft lbs Lower rocker box bolts 5 16 18 x 2 1 2 3 7 CYLINDER HEAD Cylinder Head Installation 15 3 17 5 Nm 135 155 in lbs Lower rocker box screws with hex socket head 1 4 20 x 1 1 2 2 23 REAR SHOCK ABSORBER Installation Ulysses 20 3 23 Nm 15 17 ft lbs Lower shock bolt nut 1 17 STEERING HEAD B...

Page 698: ... Nm 48 72 in lbs Oil cooler air scoop fasteners 3 13 OIL COOLER Installation LOCTITE 271 10 8 12 2 Nm 96 108 in lbs Oil cooler mounting screws 2 19 SWINGARM AND BRACE Assembly 35 3 39 3 Nm 26 29 ft lbs Oil drain plug 3 18 CRANKCASE Oil Filter Adapter 10 8 16 Nm 96 144 in lbs Oil filter adapter 3 6 ENGINE INSTALLATION Assembly 5 5 5 Nm 40 50 in lbs Oil line clamp at starter motor 3 12 OIL LINE FITT...

Page 699: ...RUNK AND BATTERY PAN ULYSSES MODELS Assembly Trunk Pan and Battery Pan 4 6 8 Nm 36 60 in lbs Preload adjuster to trunk pan 1 10 PRIMARY CHAIN Inspection 9 5 12 2 Nm 84 108 in lbs Primary chain inspection cover fasteners 1 10 PRIMARY CHAIN Adjustment 27 1 33 9 Nm 20 25 ft lbs Primary chain tension locknut 5 3 PRIMARY COVER Installation 11 3 13 6 Nm 100 120 in lbs Primary cover fasteners 1 9 CLUTCH ...

Page 700: ... bracket 6 15 REAR TURN SIGNALS Turn Signal Reloca tion Bracket XB12XP 5 4 8 Nm 48 72 in lbs Rear reflector bracket 4 20 EVAPORATIVE EMISSIONS CONTROL CA MODELS Installation Firebolt 13 6 16 3 Nm 120 144 in lbs Rear shock absorber reservoir clamp rear 2 39 SUBFRAME TAIL ASSEMBLY AND BODY WORK FIREBOLT Assembly 13 6 16 3 Nm 120 144 in lbs Rear shock reservoir clamp Firebolt 2 23 REAR SHOCK ABSORBER...

Page 701: ...g 5 3 PRIMARY COVER Installation LOCTITE 271 red 29 8 32 5 Nm 22 24 ft lbs Shifter bracket fasteners 5 3 PRIMARY COVER Installation LOCTITE 271 red 5 4 6 8 Nm 48 60 in lbs Shift lever pinch screw 2 25 CLUTCH CONTROL Assembly and Installa tion 4 6 8 Nm 36 60 in lbs Shift linkage fasteners 5 3 PRIMARY COVER Installation LOCTITE 271 red 4 6 8 Nm 36 60 in lbs Shift linkage fasteners 2 25 CLUTCH CONTRO...

Page 702: ...ft lbs Steering head clamp fastener 6 26 MAIN WIRE HARNESS Installation 21 7 24 7 Nm 16 18 ft lbs Steering head wiring clamp 6 3 IGNITION HEADLAMP KEY SWITCH Firebolt 51 5 56 9 Nm 38 42 ft lbs Steering stem cap 1 17 STEERING HEAD BEARINGS Determining Proper Resistance 51 5 56 9 Nm 38 42 ft lbs Steering stem capnut 2 18 STEERING HEAD BEARINGS Installation 51 5 56 9 Nm 38 42 ft lbs Steering stem cap...

Page 703: ... SECTION LIGHTNING MODELS Assembly LOCTITE 271 red 28 5 31 2 Nm 21 23 ft lbs Tail section to main frame fuel tank assembly Lightning 3 4 ENGINE ROTATION FOR SERVICE Assembly 4 4 5 Nm 36 40 in lbs Throttle cable retention device fasteners 4 5 THROTTLE POSITION SENSOR TPS Installation LOCTITE 222 purple 1 4 1 7 Nm 12 15 in lbs Throttle position sensor 3 4 ENGINE ROTATION FOR SERVICE Assembly 33 9 36...

Page 704: ...FRONT FORKS Installation 31 2 33 9 Nm 23 25 ft lbs Upper fork clamp fasteners 2 15 FENDERS Front Fender XB12X LOCTITE 271 red 1 4 4 Nm 12 36 in lbs Upper front fender fasteners XB12X 2 30 FRONT MODULES LIGHTNING AND ULYSSES MODELS Installation 4 6 8 Nm 36 60 in lbs Upper module fasteners Ulysses 3 7 CYLINDER HEAD Cylinder Head Installation 13 6 19 Nm 120 168 in lbs Upper rocker cover screws 2 23 R...

Page 705: ...ont fasteners 6 19 LICENSE PLATE LAMP ASSEMBLY Ulysses 1 4 4 Nm 12 36 in lbs Wire cover rear fasteners 2 44 CENTER TAIL LOOP ULYSSES MODELS Assembly 4 5 4 Nm 36 48 in lbs Wire cover screws Ulysses 2 52 SEAT LOCKS Installation Ulysses Models 4 5 4 Nm 36 48 in lbs Wire cover screws Ulysses 2 53 TRIPLE TAIL ULYSSES MODELS Installa tion 4 5 4 Nm 36 48 in lbs Wire cover screws Ulysses 6 26 MAIN WIRE HA...

Page 706: ...XXVI TORQUE VALUES NOTES ...

Page 707: ...harging Battery 1 40 Cleaning and Inspection 1 40 Tender 1 42 Voltmeter Test 1 40 Battery Pan Assembly Lightning 2 148 Cleaning Lightning 2 147 Cleaning Ulysses 2 154 Disassembly Lightning 2 146 Bearings Steering Head 1 44 Belt Gaurds Installation Firebolt Lightning 2 138 Belt Guards Removal Firebolt Lightning 2 138 Bottom End Overhaul Disassembly Removing Cylinder Base Studs 3 84 Brake Pedal Inst...

Page 708: ... Cylinder and Piston 3 51 Cleaning and Inspection 3 53 Removal Disassembly 3 51 Cylinder Base Studs Removing 3 84 Cylinder Head 3 35 Assembly 3 45 Cleaning and Inspection 3 40 Disassembly 3 37 Installation 3 47 Removal 3 35 Cylinder Leakage Test 3 7 D Deflectors Handlebars Assembly and Installation 2 125 Removal and Disassembly 2 125 Deglazing Cylinder 3 54 Delphi Connector Repair A 6 Deutsch Conn...

Page 709: ...irebolt 2 90 Removal Firebolt 2 90 Fork Clamps Lightning Ulysses Installation 2 91 Removal 2 91 Fork Oil Change 1 45 Frame Installation 2 103 Removal 2 103 Frame Pucks Installation 2 101 Removal 2 101 Front Brake Caliper Removal and Installation 2 55 Caliper Repair 2 56 Fluid Line Removal and Installation 2 53 Hand Lever 2 49 Master Cylinder Reservoir Installation 2 52 Master Cylinder Reservoir Re...

Page 710: ...ng 2 134 Removal Firebolt Lightning 2 133 Removal Firebolt Lightning 2 133 Replacement Ulysses 2 136 Horn Installation 6 35 Removal 6 35 Troubleshooting 6 36 Hose and Wire Routing Firebolt D 1 Lightning D 14 Ulysses D 26 Hydraulic Lifters 3 76 Cleaning and Inspection 3 76 Installation 3 77 Removal 3 76 I Idler Pulley Inspection 1 24 Replacement 5 25 Ignition Headlamp Key Switch Installation Lightn...

Page 711: ... 1 37 Steering Head Bearings 1 44 Storage 1 50 Main Wire Harness General Lightning 6 71 Installation Lightning 6 78 Removal Lightning 6 71 Metric System C 2 Metri Pack Terminals Crimping A 19 Mirrors Installation 2 132 Installation Firebolt 2 161 Removal 2 132 Removal Firebolt 2 161 N Neutral Indicator Switch General 6 63 Removal and Installation 6 63 Testing 6 63 Neway Valve Seat Cutter How To Us...

Page 712: ...nt 3 74 Repair and Replacement Procedures Bearings 1 4 Bushings 1 4 Exhaust System Leakage 1 5 Gaskets 1 4 Gears 1 5 Hardware and Threaded Parts 1 4 Lip Type Seals 1 4 O Rings Preformed Packings 1 4 Part Replacement 1 5 Shafts 1 5 Threadlocking Agents 1 4 Wiring Hoses and Lines 1 4 Right Tail Section Assembly Lightning 2 151 Disassembly Lightning 2 151 Rim Runout 2 48 Rocker Arm Cleaning and Inspe...

Page 713: ...arings All models Removal 2 93 Storage Maintenance 1 50 Removal from Storage 1 50 Subframe Tail Assembly Assembly Firebolt 2 144 Cleaning Firebolt 2 144 Disassembly Firebolt 2 141 Suspension Settings 2 15 Swingarm and Brace Assembly 2 98 Cleaning and Inspection 2 97 General 2 96 Installation 2 98 Removal 2 96 T Tail Lamp Installation Ulysses Firebolt Lightning 6 56 Removal Ulysses Firebolt Lightni...

Page 714: ...ions 6 39 V Valve Guides 3 43 Cleaning and Inspection 3 41 Valves Cleaning and Inspection 3 41 Valve Seats Cleaning and Inspection 3 41 Valve Springs Cleaning and Inspection 3 42 Valve Stem 2 44 Valve Stems Valve Stem Clearances and Service Wear Limits table 3 43 Vehicle Identification Number 2 19 Vehicle Speed Sensor Installation 6 67 Removal 6 67 Voltage Regulator General 6 28 Installation 6 28 ...

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