Buell 2009 XB Series User manual

2009 Buell XB Models Service Manual
99490-09Y
©2008 Buell Motorcycle Company

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
©2008 Buell Motorcycle Company
ALL RIGHTS RESERVED
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.
I
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