Buell 2009 XB Series, Руководство по обслуживанию

Страница: 178 / 712

THROTTLE CABLE REPLACEMENT
Removal
NOTE
On the Lightning and the Ulysses models it will be necessary
to remove the windscreen. See
2.48 WINDSHIELD AND
WINDSCREEN: LIGHTNING AND ULYSSES .
1. Remove the air cleaner assembly. See 4.3 AIR CLEANER
ASSEMBLY .
NOTES
• It will be necessary to loosen the bolted joints that attach
the front wire guide to the front of the frame on the Light-
ning and the Ulysses models. If these are loose the cables
can feed through the bracket without damaging the inner
wires of the throttle cables. The front wire guides upper
cavity is designed for the two throttle cables to route right
through the space. The hand control end of the throttle
cables need to be fed under the instrument cluster and
along the handlebar.
• It will be necessary to remove the plastic clip securing the
coil wire to the throttle cable bracket at the throttle body
and move the harness out of the way in order to loosen
the jamnuts on the throttle cables.
2. Disconnect the coil and remove the fasteners that hold
the coil to the coil bracket.
NOTE
The loose coil will allow room to access the throttle cable jam-
nuts and the plug wires should be left in place without disturbing
their connections if possible.
3. Remove the old throttle cables.
Installation
1. Install the new throttle cables, by connecting them to the
right hand grip first.
NOTE
This is to verify the cables can be routed correctly with no
binding and maintain proper orientation.
2. Route both cables along the handle bar, under and through
the instrument cluster area, through the front wire guide,
where applicable, and up under the frame to the throttle
body bracket.
NOTES
• Keep the throttle cables parallel all the way along their
path so they do not become twisted. If the cables are not
kept parallel it can create binding when everything is
tightened in place.
• When installing the throttle cables at the throttle body you
need to avoid allowing the elbows of the throttle cables to
rotate up when tightening the throttle cable jamnuts. This
can cause the cable elbows to contact the frame. See
Figure 2-130 for correct routing of the cables.
3. Back the throttle cable jamnuts off that are closest to the
90° portion of the metal elbow on the throttle cables at the
throttle body. Back the open end of the elbow nuts all the
way off so they can float on the inner wires.
4. Position the lower idle control cable barrel in the throttle
cam wheel of the throttle body and then slip the elbow into
the slotted hole in the throttle cable mounting bracket.
Position the throttle control cable in the same manner so
both elbows are inserted into the bracket.
5. Tighten the cable adjustment nuts, that were removed for
installation purposes, onto the threaded end of the elbows
and thread them on until there is exposed thread beyond
the nut about one sixteenth of an inch or more. Do this on
both the throttle control and idle control cables.
NOTE
You need to verify there is enough slack in the cables at the
throttle cable wheel. You want to push on the cable and have
the sag at about one quarter of an inch. If you don't have
enough slack, you need to thread the outer nuts further onto
the elbow producing more sag.
6. See Figure 2-128 . Install the throttle cable retaining clip
and place it so the outside of the retaining clip is flat
against the throttle body cable mounting bracket and
covers the two nuts that are closest to the cable wheel.
Tighten the two jamnuts closest to the 90° degree elbow
to 36-40 in-lbs (4-4.5 Nm) to secure the retaining clip in
place.
NOTE
See Figure 2-129 . When this is done correctly, the retaining
clip will cover the two inner nuts and prevent them from
becoming loose and the retaining clip will be secured to the
bracket.
7. With the throttle cables secure at the throttle body, you
will be able adjust the cables at the right hand grip. See
1.15 THROTTLE CABLE .
NOTE
If, after the throttle cables have been adjusted, there is not
enough slack in the cables the throttle plate will not be
responsive and cleanly snap back to the closed position. The
cables will feel like they are binding.
8. If there is binding, add more slack at the throttle end of
the cable.
NOTE
When the adjustment is complete it will be necessary to turn
the handlebars all the way in both directions and work the
throttle to verify there is no binding. This is critical to the oper-
ation of the throttle control.
9. Install the ignition coil and apply Loctite 272 (red) to the
ignition coil fasteners and tighten to 120-144 in-lbs (13.6-
16.3 Nm).
NOTE
Verify that the spark plug wires were not disturbed and are
tight on the coil and spark plug ends.
10. Tighten the bolted joints that attach the front wire guide
to the front of the frame on Lightning and Ulysses models
to 72-84 in-lbs (8-9.5 Nm).
11. Install the air cleaner assembly. See 4.3 AIR CLEANER
ASSEMBLY .
12. Install the windscreen. See 2.48 WINDSHIELD AND
WINDSCREEN: LIGHTNING AND ULYSSES .
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2-100 2009 XB Service: Chassis