Buell 2009 xb series User manual

2009 Buell XB Models Service Manual

99490-09Y

Buell motorcycles conform to all applicable U.S.A. Federal Motor Vehicle Safety Standards and U.S.A.

Environmental Protection Agency regulations effective on the date of manufacture.

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

2009 Buell XB Models

Service Manual

99490-09Y

Printed in the U.S.A.

VISITTHE BUELLWEB SITE

http://www.buell.com

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2009 Buell XB Models Service Manual (99490-09Y)

NOTES

ABOUTTHIS MANUAL

GENERAL

This Service Manual has been prepared with two purposes in

mind.First, it will acquaint the user with the construction of the

Buell product and assist in the performance of basic mainten-

ance and repair. Secondly, it will introduce to the professional

Buell Technician the latest field-tested and factory-approved

major repair methods. We sincerely believe that this Service

Manual will make your association with Buell products more

pleasant and profitable.

HOWTO USEYOUR SERVICE MANUAL

Refer to the table below for the content layout of this manual.

CHAPTERNO.

Maintenance1

Chassis2

Engine3

Fuel System4

Drive/Transmission5

Electrical6

Appendix A Connector RepairA

Appendix B WiringB

Appendix C ConversionsC

Appendix D Hose and Wire RoutingD

Appendix E Active Intake (Japanese Models)E

Appendix F GlossaryF

Use the TABLE OF CONTENTS (which follows this FORE-

WORD) and the INDEX (at the back of this manual) to quickly

locate subjects. Sections and topics in this manual are

sequentially numbered for easy navigation.

For example, a cross-reference shown as 2.1 SPECIFICA-

TIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFIC-

ATIONS.

For quick and easy reference, all pages contain a section

number followed by a page number. For example, page 3-5

refers to page 5 in section 3.

A number of acronyms and abbreviations are used in this

document. See the F.1 GLOSSARY for a list of acronyms,

abbreviations and definitions.

PREPARATION FOR SERVICE

Stop the engine when refueling or servicing the fuel

system. Do not smoke or allow open flame or sparks near

gasoline. Gasoline is extremely flammable and highly

explosive, which could result in death or serious injury.

(00002a)

Good preparation is very important for efficient service work.

A clean work area at the start of each job will allow you to

perform the repair as easily and quickly as possible, and will

reducetheincidence of misplaced tools and parts.Amotorcycle

that is excessively dirty should be cleaned before work starts.

Cleaning will occasionally uncover sources of trouble. Tools,

instruments and any parts needed for the job should be

gathered before work is started. Interrupting a job to locate

tools or parts is a distraction and causes needless delay.

NOTES

•To avoid unnecessary disassembly, carefully read all rel-

ative service information before repair work is started.

•In figure legends, the number which follows the name of

a part indicates the quantity necessary for one complete

assembly.

SERVICE BULLETINS

In addition to the information presented in this manual, Buell

Motor Company will periodically issue Service Bulletins to Buell

dealers. Service Bulletins cover interim engineering changes

and supplementary information. Consult the Service Bulletins

to keep your product knowledge current and complete.

USE GENUINE REPLACEMENT PARTS

Do not use aftermarket parts and custom made front forks

which can adversely affect performance and handling.

Removing or altering factory installed parts can adversely

affect performance and could result in death or serious

injury. (00001a)

To verify satisfactory and lasting repairs, carefully follow the

manual instructions and use only genuine Buell replacement

parts.This is your assurance that the parts you are using will

fit right, operate properly and last longer.

WARNINGS AND CAUTIONS

Statements in this manual preceded by the following words

are of special significance.

WARNING indicates a potentially hazardous situation

which, if not avoided, could result in death or serious

injury. (00119a)

CAUTION indicates a potentially hazardous situation

which, if not avoided, may result in minor or moderate

injury. (00139a)

CAUTION used without the safety alert symbol indicates

a potentially hazardous situation which, if not avoided,

may result in property damage. (00140a)

NOTE

Refers to important information, and is placed in italic type. It

is recommended that you take special notice of these items.

Proper service and repair is important for the safe, reliable

operation of all mechanical products.The service procedures

recommended and described in this manual are effective

methods for performing service operations.

FOREWORD

Always wear proper eye protection when using hammers,

arbor or hydraulic presses, gear pullers, spring com-

pressors, slide hammers and similar tools. Flying parts

could result in death or serious injury. (00496b)

Some of these service operations require the use of tools

specially designed for the purpose.These special tools should

be used when and as recommended. It is important to note

thatsomewarningsagainstthe use of specific servicemethods,

which could damage the motorcycle or render it unsafe, are

stated in this manual. However, please remember that these

warnings are not all-inclusive. Inadequate safety precautions

could result in death or serious injury.

Since Buell Motorcycle Company could not possibly know,

evaluate or advise the service trade of all possible ways in

which service might be performed, or of the possible hazardous

consequences of each method, we have not undertaken any

such broad evaluation.Accordingly, anyone who uses a service

procedure or tool which is not recommended by Buell Motor-

cycle Company must first thoroughly satisfy himself that neither

his nor the operator's safety will be jeopardized as a result.

Failure to do so could result in death or serious injury.

PRODUCT REFERENCES

Read and follow warnings and directions on all products.

Failure to follow warnings and directions can result in

death or serious injury. (00470b)

When reference is made in this manual to a specific brand

name product, tool or instrument, an equivalent product, tool

or instrument may be substituted.

Kent-Moore Products

All tools mentioned in this manual with an "HD", "J" or "B"

preface mustbe ordered through SPXKent-Moore.Forordering

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 product

usage or retailer/wholesaler locations, please contact Loctite

Corp. at www.loctite.com.

PRODUCT REGISTERED MARKS

Alcantara S.p.A., Allen, Amp Multilock, Bluetooth, Brembo,

Delphi, Deutsch, Dunlop, Dynojet, Fluke, G.E.Versilube, Gunk,

Hydroseal, Hylomar, Kevlar, Lexan, Loctite, Lubriplate, Keps,

K&N, Magnaflux, Marson Thread-Setter Tool Kit, MAXI fuse,

Molex, MPZ, Mulitilock, Novus, Packard, Pirelli, Permatex,

Philips, PJ1, Pozidriv, Robinair, S100, Sems, Snap-on,Teflon,

Threadlocker, Torca, Torco, TORX, Tufoil, Tyco, Ultratorch,

Velcro, X-Acto, and XM Satellite Radio are among the trade-

marks of their respective owners.

H-D MICHIGAN, INC.TRADEMARK

INFORMATION

1125CR, 1125R, Blast, Buell, Firebolt, Glaze, Gloss, Harley,

Harley-Davidson, HD, H-D, Lightning, Sunwash,Tender,Triple

Tail, Thunderstorm, Ulysses, Uniplanar, ZTL and ZTL-2 are

among the trademarks of H-D Michigan, Inc.

CONTENTS

All photographs, illustrations and procedures in this manual

may not necessarily depict the most current model or com-

ponent, but are based on the latest production information

available at the time of publication.

Since product improvement is our continual goal, Buell Motor-

cycle Company reserves the right to change specifications,

equipment or designs at any time without notice and without

incurring obligation.

II FOREWORD

MAINTENANCE

1.1 FASTENERTORQUEVALUES

Fastener Torque Values in this Chapter..............................1-1

1.2 GENERAL

Servicing a New Motorcycle...............................................1-3

Safe Operating Maintenance..............................................1-3

Shop Practices...................................................................1-3

Repair Notes...............................................................1-3

Safety..........................................................................1-3

Removing Parts...........................................................1-3

Cleaning......................................................................1-3

Disassembly and Assembly........................................1-4

CheckingTorques on Fasteners with Lock Patches.....1-4

Magnetic Parts Trays...................................................1-4

Repair and Replacement Procedures................................1-4

Hardware and Threaded Parts....................................1-4

Threadlocking Agents..................................................1-4

Wiring, Hoses and Lines.............................................1-4

Instruments and Gauges.............................................1-4

Bearings......................................................................1-4

Bushings.....................................................................1-4

Gaskets.......................................................................1-4

Lip Type Seals.............................................................1-4

O-Rings (Preformed Packings)....................................1-5

Gears..........................................................................1-5

Shafts..........................................................................1-5

Part Replacement........................................................1-5

Exhaust System Leakage............................................1-5

Cleaning.............................................................................1-5

Part Protection............................................................1-5

Cleaning Process........................................................1-5

Rust or Corrosion Removal.........................................1-5

Bearings......................................................................1-5

Tool Safety..........................................................................1-5

Air Tools.......................................................................1-5

Wrenches....................................................................1-5

Pliers/Cutters/Pry bars................................................1-5

Hammers.....................................................................1-6

Punches/Chisels..........................................................1-6

Screwdrivers................................................................1-6

Ratchets and Handles.................................................1-6

Sockets........................................................................1-6

Storage Units...............................................................1-6

1.3 FUEL AND OIL

Fuel....................................................................................1-7

Gasoline Blends: Buell Models...........................................1-7

Engine Lubrication..............................................................1-7

Winter Lubrication..............................................................1-8

1.4 MAINTENANCE SCHEDULE

General...............................................................................1-9

1.5 BATTERY MAINTENANCE

General.............................................................................1-11

Battery Disconnection and Removal................................1-12

Cleaning and Inspection...................................................1-12

Charging Battery..............................................................1-12

Safety Precautions....................................................1-12

Using a Battery Charger............................................1-12

Battery Installation and Connection..................................1-13

Storage.............................................................................1-14

1.6 ENGINE OIL AND FILTER

General.............................................................................1-15

Engine Oil Level Check....................................................1-15

Change Engine Oil and Filter...........................................1-15

Drain Oil....................................................................1-15

Change Filter.............................................................1-16

Fill Engine With Oil....................................................1-16

Clear Oil Cooler.........................................................1-16

Return to Service......................................................1-17

1.7 BRAKE SYSTEM MAINTENANCE

General.............................................................................1-18

Bleeding Brakes...............................................................1-18

Bleeding Front Brake.................................................1-19

Bleeding Rear Brake.................................................1-20

Brake Pedal Adjustment...................................................1-20

Brake Pad Thickness........................................................1-21

Brake Rotor Thickness.....................................................1-22

Brake Pad Replacement...................................................1-22

Front Pad Removal....................................................1-22

Front Pad Installation.................................................1-22

Rear Pad Removal....................................................1-23

Rear Pad Installation.................................................1-23

1.8TIRES AND WHEELS

Tire Inflation......................................................................1-25

Tire Wear..........................................................................1-25

Wheel Bearings................................................................1-26

1.9 CLUTCH/TRANSMISSION/PRIMARY

FLUID

Inspection.........................................................................1-27

Transmission Fluid............................................................1-27

Adjustment.......................................................................1-28

1.10 DRIVE BELT MAINTENANCE

General.............................................................................1-30

Inspection.........................................................................1-30

Rear Sprocket...........................................................1-30

Drive Belt...................................................................1-30

Idler Pulley.................................................................1-30

Cleaning...........................................................................1-30

1.11 PRIMARY CHAIN

Inspection.........................................................................1-33

Adjustment.......................................................................1-33

1.12 STEERING HEAD BEARINGS

General.............................................................................1-35

Inspection.........................................................................1-35

Determining Proper Resistance.......................................1-35

1.13 SPARK PLUGS

Inspection.........................................................................1-36

1.14AIR CLEANER AND EXHAUSTSYSTEM

Removal...........................................................................1-38

Cleaning and Inspection...................................................1-39

Installation........................................................................1-39

Exhaust System Leak Check............................................1-40

1.15THROTTLE CABLE

Throttle Cable Adjustment................................................1-41

III

TABLE OF CONTENTS

1.16 INTERACTIVE EXHAUST CABLE

Adjustment.......................................................................1-42

1.17 HEADLAMP

Headlamp Alignment........................................................1-44

Headlamp Adjustment: Firebolt........................................1-44

Headlamp Adjustment: Lightning......................................1-45

Horizontal Alignment.................................................1-45

Vertical Alignment.....................................................1-45

Headlamp Adjustment: Ulysses........................................1-45

Horizontal Alignment.................................................1-45

Vertical Alignment.....................................................1-46

1.18WINDSHIELD MAINTENANCE

General.............................................................................1-47

1.19 STORAGE

General.............................................................................1-48

Removal From Storage.....................................................1-48

1.20TROUBLESHOOTING

General.............................................................................1-49

Engine..............................................................................1-49

Starter Motor Does Not Operate or Does NotTurn Engine

Over...........................................................................1-49

Engine Turns Over But Does Not Start......................1-49

Starts Hard................................................................1-49

Starts But Runs Irregularly or Misses........................1-49

Spark Plug Fouls Repeatedly....................................1-49

Pre-Ignition or Detonation (Knocks or Pings)............1-50

Overheating...............................................................1-50

Valve Train Noise.......................................................1-50

Excessive Vibration...................................................1-50

Check Engine Light Illuminates During Operation.....1-50

Lubrication System...........................................................1-50

Oil Does Not Return To Oil Tank................................1-50

Engine UsesToo Much Oil Or Smokes Excessively...1-50

Engine Leaks Oil From Cases, Push Rods, Hoses,

Etc.............................................................................1-50

Low Oil Pressure.......................................................1-50

High Oil Pressure......................................................1-51

Electrical System..............................................................1-51

Alternator Does Not Charge......................................1-51

Alternator Charge Rate Is Below Normal..................1-51

Speedometer Operates Erratically............................1-51

Transmission.....................................................................1-51

Shifts Hard................................................................1-51

Jumps Out Of Gear...................................................1-51

Clutch Slips...............................................................1-51

Clutch Drags Or Does Not Release..........................1-51

Clutch Chatters..........................................................1-51

Clutch...............................................................................1-51

Slips..........................................................................1-51

Drags or Does Not Release......................................1-51

Chatters.....................................................................1-51

Chassis.............................................................................1-51

Irregular/Inadequate Brake Action.............................1-51

Handling Irregularities...............................................1-51

Suspension.......................................................................1-52

CHASSIS

2.1 FASTENERTORQUEVALUES

Fastener Torque Values in this Chapter..............................2-1

2.2 SPECIFICATIONS

Firebolt.............................................................................2-11

Lightning...........................................................................2-12

Ulysses.............................................................................2-13

Suspension Settings.........................................................2-15

2.3VEHICLE IDENTIFICATION NUMBER

(VIN)

Vehicle Identification Number (V.I.N.)...............................2-19

2.4WHEELS

General.............................................................................2-21

Troubleshooting................................................................2-21

2.5 FRONTWHEEL

Removal...........................................................................2-23

Disassembly.....................................................................2-23

Bearing Removal.......................................................2-23

Front Rotor Removal.................................................2-25

Cleaning and Inspection...................................................2-25

Assembly..........................................................................2-26

Bearing Installation....................................................2-26

Front Rotor Installation..............................................2-29

Installation........................................................................2-29

2.6 REARWHEEL

Removal...........................................................................2-31

Cleaning and Inspection...................................................2-31

Disassembly.....................................................................2-31

Assembly..........................................................................2-33

Installation........................................................................2-33

2.7TIRES

General.............................................................................2-35

Specifications...................................................................2-35

Removal...........................................................................2-36

Cleaning and Inspection...................................................2-36

Installation........................................................................2-36

Checking Tire Lateral Runout....................................2-37

Checking Tire Radial Runout.....................................2-37

Adjustment.......................................................................2-38

Wheel Balancing.......................................................2-38

2.8 CHECKING CAST RIM RUNOUT

General.............................................................................2-39

Rim Lateral Runout...................................................2-39

Rim Radial Runout....................................................2-39

2.9 FRONT BRAKE: EIGHT PISTON

CALIPER

Front Brake Hand Lever....................................................2-40

Master Cylinder/Reservoir: Removal................................2-40

Master Cylinder/Reservoir: Repair...................................2-41

Disassembly..............................................................2-41

IV TABLE OF CONTENTS

TABLE OF CONTENTS

Cleaning and Inspection............................................2-41

Assembly...................................................................2-42

Master Cylinder/Reservoir: Installation.............................2-43

Front Brake Fluid Line......................................................2-44

Removal....................................................................2-44

Installation.................................................................2-45

Caliper: Removal and Installation.....................................2-45

Removal....................................................................2-45

Installation.................................................................2-46

Caliper: Repair..................................................................2-46

Disassembly..............................................................2-46

Clean and Inspect.....................................................2-47

Assembly...................................................................2-47

2.10 FRONT BRAKE: SIX PISTON CALIPER

Master Cylinder Reservoir Removal.................................2-48

Master Cylinder and Hand Lever Disassembly.................2-49

Brake Hand Lever......................................................2-49

Front Master Cylinder................................................2-49

Cleaning and Inspection...................................................2-49

Master Cylinder and Hand Lever Assembly.....................2-49

Front Master Cylinder................................................2-49

Brake Hand Lever......................................................2-50

Master Cylinder Installation..............................................2-50

Brake Line Removal.........................................................2-51

Brake Line Installation......................................................2-52

Brake Caliper Removal.....................................................2-52

Brake Caliper Disassembly..............................................2-53

Cleaning and Inspection...................................................2-53

Brake Caliper Assembly...................................................2-54

Installation........................................................................2-54

2.11 BRAKE PEDAL

Removal...........................................................................2-56

Installation........................................................................2-56

2.12 REAR BRAKE MASTER CYLINDER

Removal: Firebolt/Lightning..............................................2-57

Removal: Ulysses.............................................................2-58

Disassembly.....................................................................2-60

Cleaning and Inspection...................................................2-60

Assembly..........................................................................2-60

Installation: Firebolt/Lightning...........................................2-61

Installation: Ulysses..........................................................2-61

2.13 REAR BRAKE LINE

Removal: Firebolt..............................................................2-63

Installation: Firebolt..........................................................2-63

Removal: Lightning...........................................................2-64

Installation: Lightning........................................................2-65

Removal: Ulysses.............................................................2-65

Installation: Ulysses..........................................................2-66

2.14 REAR BRAKE CALIPER

Removal...........................................................................2-68

Disassembly.....................................................................2-68

Cleaning and Inspection...................................................2-69

Assembly..........................................................................2-69

Installation........................................................................2-69

2.15 FENDERS

Front Fender: XB12R........................................................2-71