Buell Xb 2010 User manual

2010 Buell XB Models Service Manual

99490-10Y

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

2010 Buell XB Models

Service Manual

99490-10Y

Printed in the U.S.A.

VISITTHE BUELLWEB SITE

http://www.buell.com

Blank Text Here

READER COMMENTS

Please comment on the completeness, accuracy, organization, usability, and readability of this manual.

Please list the page, item, and part number(s) of any errors you find in this manual.

Please tell us how we can improve 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.

2010 Buell XB Models Service Manual (99490-10Y)

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

reducetheincidenceof 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, Michelin, MPZ, Mulitilock, NGK, 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 trademarks 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 (Pre-Formed Packings).................................1-4

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

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 BULB REQUIREMENTS

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

1.5 MAINTENANCE SCHEDULE

Service Intervals...............................................................1-10

1.6 ENGINE OIL AND FILTER

General.............................................................................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

1.8TIRES AND WHEELS

Tire Inflation......................................................................1-17

Tire Wear..........................................................................1-17

Wheel Bearings................................................................1-18

1.9 CLUTCH/TRANSMISSION/PRIMARY

FLUID

Inspection.........................................................................1-19

Transmission Fluid............................................................1-19

Adjustment.......................................................................1-20

1.10 PRIMARY CHAIN

Inspection.........................................................................1-22

Adjustment.......................................................................1-22

1.11 DRIVE BELT MAINTENANCE

General.............................................................................1-24

Inspection.........................................................................1-24

Rear Sprocket...........................................................1-24

Drive Belt...................................................................1-24

Idler Pulley.................................................................1-24

Cleaning...........................................................................1-24

1.12THROTTLE CABLE

Throttle Cable Adjustment................................................1-27

1.13 INTERACTIVE EXHAUST CABLE

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

1.14 BRAKE SYSTEM MAINTENANCE

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

Bleeding Brakes...............................................................1-30

Bleeding Front Brake.................................................1-31

Bleeding Rear Brake.................................................1-32

Brake Pedal Adjustment...................................................1-32

Brake Pad Thickness........................................................1-33

Brake Rotor Thickness.....................................................1-34

Brake Pad Replacement...................................................1-34

Front Pad Removal....................................................1-34

Front Pad Installation.................................................1-34

Rear Pad Removal....................................................1-35

Rear Pad Installation.................................................1-35

1.15 SPARK PLUGS

Inspection.........................................................................1-37

1.16 BATTERY MAINTENANCE

General.............................................................................1-39

Battery Disconnection and Removal................................1-40

Cleaning and Inspection...................................................1-40

Voltmeter Test...................................................................1-40

Voltmeter Test............................................................1-40

Charging Battery..............................................................1-40

Safety Precautions....................................................1-40

III

TABLE OF CONTENTS

Using a Battery Charger............................................1-40

Battery Installation and Connection..................................1-41

Storage.............................................................................1-42

Maintaining Charge..........................................................1-42

1.17 STEERING HEAD BEARINGS

General.............................................................................1-44

Inspection.........................................................................1-44

Determining Proper Resistance.......................................1-44

1.18 FRONT FORK OIL REPLACEMENT

General.............................................................................1-45

Procedure.........................................................................1-45

1.19 HEADLAMP

Headlamp Alignment........................................................1-46

Headlamp Adjustment: Firebolt........................................1-46

Headlamp Adjustment: Lightning......................................1-47

Horizontal Alignment.................................................1-47

Vertical Alignment.....................................................1-47

Headlamp Adjustment: Ulysses........................................1-47

Horizontal Alignment.................................................1-47

Vertical Alignment.....................................................1-48

1.20WINDSHIELD MAINTENANCE

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

1.21 STORAGE

General.............................................................................1-50

Removal From Storage.....................................................1-50

1.22TROUBLESHOOTING

General.............................................................................1-51

Engine..............................................................................1-51

Starter Motor Does Not Operate or Does NotTurn Engine

Over...........................................................................1-51

Engine Turns Over But Does Not Start......................1-51

Starts Hard................................................................1-51

Starts But Runs Irregularly or Misses........................1-51

Spark Plug Fouls Repeatedly....................................1-51

Pre-Ignition or Detonation (Knocks or Pings)............1-52

Overheating...............................................................1-52

Valve Train Noise.......................................................1-52

Excessive Vibration...................................................1-52

Check Engine Light Illuminates During Operation.....1-52

Lubrication System...........................................................1-52

Oil Does Not Return To Oil Tank................................1-52

Engine UsesToo Much Oil Or Smokes Excessively...1-52

Engine Leaks Oil From Cases, Push Rods, Hoses,

Etc.............................................................................1-52

Low Oil Pressure.......................................................1-52

High Oil Pressure......................................................1-53

Electrical 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 Irregularities...............................................1-53

Suspension.......................................................................1-54

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

Repair...............................................................................2-31

Inspection..................................................................2-31

Drive Sprocket...........................................................2-31

Brake Rotor...............................................................2-32

Disassembly.....................................................................2-32

Wheel Bearings: Two Bearing Wheels..............................2-34

Removal....................................................................2-34

Installation: Rotor Side Bearing.................................2-35

Installation: Opposite Side Bearing...........................2-36

Wheel Bearings:Three Bearing Wheels...........................2-37

Removal: Brake Rotor Side.......................................2-37

Removal: Sprocket Side............................................2-39

Installation: Brake Rotor Side....................................2-39

Installation: Sprocket Side.........................................2-40

Installation........................................................................2-41

IV TABLE OF CONTENTS

TABLE OF CONTENTS

2.7TIRES

General.............................................................................2-42

Specifications...................................................................2-42

Tire Sizes..................................................................2-42

Rim Sizes..................................................................2-42

Dismounting.....................................................................2-43

Cleaning and Inspection...................................................2-43

Mounting...........................................................................2-44

Wheel and Valve Stems............................................2-44

Using the Tire Machine.............................................2-44

Inflate Tire.................................................................2-46

Runout..............................................................................2-46

Lateral.......................................................................2-46

Radial........................................................................2-46

Adjustment.......................................................................2-47

Wheel Balancing.......................................................2-47

2.8 CHECKING CAST RIM RUNOUT

General.............................................................................2-48

Rim Lateral Runout...................................................2-48

Rim Radial Runout....................................................2-48

2.9 FRONT BRAKE: EIGHT PISTON

CALIPER

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

Master Cylinder/Reservoir: Removal................................2-49

Master Cylinder/Reservoir: Repair...................................2-50

Disassembly..............................................................2-50

Cleaning and Inspection............................................2-50

Assembly...................................................................2-51

Master Cylinder/Reservoir: Installation.............................2-52

Front Brake Fluid Line......................................................2-53

Removal....................................................................2-53

Installation.................................................................2-53

Caliper: Removal and Installation.....................................2-55

Removal....................................................................2-55

Installation.................................................................2-55

Caliper: Repair..................................................................2-56

Disassembly..............................................................2-56

Clean and Inspect.....................................................2-56

Assembly...................................................................2-57

2.10 FRONT BRAKE: SIX PISTON CALIPER

Master Cylinder Reservoir Removal.................................2-58

Master Cylinder and Hand Lever Disassembly.................2-59

Brake Hand Lever......................................................2-59

Front Master Cylinder................................................2-59

Master Cylinder: Cleaning and Inspection........................2-59

Master Cylinder and Hand Lever Assembly.....................2-59

Front Master Cylinder................................................2-59

Brake Hand Lever......................................................2-60

Master Cylinder Installation..............................................2-60

Brake Line Removal.........................................................2-61

Brake Line Installation......................................................2-62

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..........................................................2-71

2.13 REAR BRAKE LINE

Removal: Firebolt..............................................................2-73

Installation: Firebolt..........................................................2-74

Removal: Lightning...........................................................2-74

Installation: Lightning........................................................2-75

Removal: Ulysses.............................................................2-75

Installation: Ulysses..........................................................2-76

2.14 REAR BRAKE CALIPER

Removal...........................................................................2-78

Disassembly.....................................................................2-78

Cleaning and Inspection...................................................2-79

Assembly..........................................................................2-79

Installation........................................................................2-79

2.15 FENDERS

Front Fender:

XB12R/XB9SX/XB12SX/XB12Scg/XB12XT.....................2-81

Removal....................................................................2-81

Installation.................................................................2-81

Rear Fender: XB12R/XB9SX/XB12SX/XB12Scg.............2-81

Removal....................................................................2-81

Installation.................................................................2-81

Front Fender: XB12XP.....................................................2-81

Removal....................................................................2-81

Installation.................................................................2-81

Rear Fender: XB12Ss/XB12XT/XB12X............................2-82

Removal....................................................................2-82

Installation.................................................................2-82

Front Fender: XB12X........................................................2-82

Removal: Upper Front Fender...................................2-82

Removal: Lower Front Fender...................................2-82

Installation: Upper Front Fender................................2-82

Installation: Lower Front Fender................................2-82

2.16 FRONT FORKS

Removal...........................................................................2-83

Disassembly.....................................................................2-83

Initial Disassembly.....................................................2-83

Final Disassembly.....................................................2-85

Cleaning and Inspection...................................................2-87

Assembly..........................................................................2-87

Initial Assembly.........................................................2-87

Final Assembly..........................................................2-88

Installation........................................................................2-89

2.17 FORK CLAMPS

Removal Firebolt:.............................................................2-90

TABLE OF CONTENTS V

TABLE OF CONTENTS

Installation: Firebolt..........................................................2-90

Removal: Lightning/Ulysses.............................................2-91

Installation: Lightning/Ulysses..........................................2-91

2.18 STEERING HEAD BEARINGS

Removal...........................................................................2-93

Installation........................................................................2-93

2.19 SWINGARM AND BRACE

General.............................................................................2-96

Brace................................................................................2-96

Removal....................................................................2-96

Installation.................................................................2-96

Removal: Swingarm..........................................................2-96

Disassembly.....................................................................2-97

Swingarm..................................................................2-97

Cleaning and Inspection...................................................2-97

Assembly..........................................................................2-98

Swingarm..................................................................2-98

Installation: Swingarm......................................................2-98

2.20 FRONT AND REAR ISOLATORS

Front Isolator..................................................................2-100

Removal..................................................................2-100

Installation...............................................................2-100

Rear Isolator...................................................................2-100

2.21 FRAME PUCKS

Removal.........................................................................2-101

Installation......................................................................2-101

2.22 FRAME

Removal.........................................................................2-103

Installation......................................................................2-103

2.23 REAR SHOCK ABSORBER

General...........................................................................2-104

Removal: Firebolt............................................................2-106

Removal: Lightning.........................................................2-107

Removal: Ulysses...........................................................2-107

Installation: Firebolt........................................................2-108

Installation: Lightning......................................................2-108

Installation: Ulysses........................................................2-109

2.24THROTTLE CONTROL

Removal and Disassembly.............................................2-110

Cleaning and Inspection.................................................2-110

Assembly and Installation...............................................2-110

Throttle Cable Replacement...........................................2-111

Removal..................................................................2-111

Installation...............................................................2-111

2.25 CLUTCH CONTROL

General...........................................................................2-113

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 SUPPORT BRACKET:

FIREBOLT

Removal.........................................................................2-123

Installation......................................................................2-123

2.28 DEFLECTORS

Removal and Disassembly.............................................2-125

Assembly and Installation...............................................2-125

2.29 GRILLE:

XB9SX/XB12X/XB12XP/XB12SX

General...........................................................................2-126

Removal and Installation................................................2-126

2.30 FRONT MODULES: LIGHTNING AND

ULYSSES MODELS

Removal.........................................................................2-127

Installation......................................................................2-128

2.31 HANDLEBARS: FIREBOLT

General...........................................................................2-129

Removal.........................................................................2-129

Right Clip-On...........................................................2-129

Left Clip-On.............................................................2-129

Installation......................................................................2-129

Right Clip-On...........................................................2-129

Left Clip-On.............................................................2-129

2.32 HANDLEBARS: LIGHTNING AND

ULYSSES MODELS

Removal.........................................................................2-130

Installation......................................................................2-130

2.33 MIRRORS

Removal.........................................................................2-132

Installation......................................................................2-132

2.34 FOOTPEG, HEEL GUARD AND MOUNT:

FIREBOLT AND LIGHTNING MODELS

Rider...............................................................................2-133

REMOVAL...............................................................2-133

INSTALLATION........................................................2-133

Passenger......................................................................2-133

REMOVAL...............................................................2-133

INSTALLATION........................................................2-134

VI TABLE OF CONTENTS

TABLE OF CONTENTS

2.35 HEEL GUARD AND FOOTPEG

MOUNTS: ULYSSES MODELS

Rider Footpegs...............................................................2-135

Footpeg Removal....................................................2-135

Footpeg Installation.................................................2-135

Passenger Footpegs.......................................................2-135

Footpeg Removal....................................................2-135

Footpeg Installation.................................................2-135

Mount Removal..............................................................2-135

Mount Installation...........................................................2-135

Heel Guard Replacement...............................................2-136

2.36 SPROCKET COVER

Removal.........................................................................2-137

Installation......................................................................2-137

2.37 BELT GUARDS

Removal.........................................................................2-138

Installation......................................................................2-138

2.38 INTAKE COVER

Removal.........................................................................2-139

Installation......................................................................2-139

2.39 SUBFRAMETAIL ASSEMBLY AND

BODY WORK: FIREBOLT

Disassembly...................................................................2-141

Cleaning.........................................................................2-144

Assembly........................................................................2-144

2.40 LEFTTAIL SECTION AND BATTERY

PAN: LIGHTNING MODELS

Disassembly...................................................................2-146

Cleaning.........................................................................2-147

Assembly........................................................................2-148

2.41 CENTERTAIL SECTION: LIGHTNING

MODELS

Disassembly...................................................................2-150

Assembly........................................................................2-150

2.42 RIGHTTAIL SECTION: LIGHTNING

MODELS

Disassembly...................................................................2-151

Assembly........................................................................2-151

2.43 LEFT AND RIGHTTAIL SECTION:

ULYSSES MODELS

Disassembly/Left and/or Right Side Tail Section............2-152

Cleaning.........................................................................2-154

Assembly........................................................................2-154

2.44 CENTERTAIL LOOP: ULYSSES

MODELS

Disassembly...................................................................2-156

Assembly........................................................................2-156

2.45TRUNK 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

2.48WINDSHIELD AND WINDSCREEN:

LIGHTNING AND ULYSSES MODELS

Lightning.........................................................................2-162

Removal..................................................................2-162

Installation...............................................................2-162

Ulysses XB12X...............................................................2-163

Removal..................................................................2-163

Installation...............................................................2-163

Ulysses XB12XT/XB12XP..............................................2-164

Removal..................................................................2-164

Installation...............................................................2-165

2.49 AIR SCOOPS

Ram Air Scoop...............................................................2-166

Removal..................................................................2-166

Installation...............................................................2-166

Engine Shroud Air Scoop...............................................2-166

Removal..................................................................2-166

Installation...............................................................2-166

Oil Cooler Air Scoop.......................................................2-166

Removal..................................................................2-166

Installation...............................................................2-166

Ram Air Scoop and Fan Shroud: Ulysses......................2-168

Removal..................................................................2-168

Installation...............................................................2-168

2.50 CHIN FAIRING

Removal.........................................................................2-170

Installation......................................................................2-170

2.51 SEAT

Firebolt...........................................................................2-171

Rider Seat...............................................................2-171

Pillion.......................................................................2-171

Lightning.........................................................................2-171

Removal..................................................................2-171

Installation...............................................................2-172

Ulysses...........................................................................2-173

Removal..................................................................2-173

Installation...............................................................2-173

2.52 SEAT LOCKS

Lightning.........................................................................2-175

TABLE OF CONTENTS VII

TABLE OF CONTENTS

Removal..................................................................2-175

Installation...............................................................2-175

Removal: Ulysses Models..............................................2-176

Installation: Ulysses Models...........................................2-176

Pillion Lock Removal: XB12R.........................................2-177

Pillion Lock Installation: XB12R......................................2-178

2.53TRIPLETAIL: ULYSSES MODELS

General...........................................................................2-179

Removal.........................................................................2-179

Disassembly...................................................................2-179

Assembly........................................................................2-179

Installation......................................................................2-180

2.54 LUGGAGE: XB12XT

Removal: Side Case.......................................................2-181

Installation: Side Case....................................................2-182

Removal:Top Case.........................................................2-182

Installation: Top Case.....................................................2-183

Luggage Case Latch Mechanism...................................2-183

Removal..................................................................2-183

Installation...............................................................2-184

2.55 LUGGAGE: XB12XP

Side Case.......................................................................2-185

Removal..................................................................2-185

Installation...............................................................2-186

Luggage Case Latch Mechanism...................................2-186

Removal..................................................................2-186

Installation...............................................................2-186

ENGINE

3.1 FASTENERTORQUEVALUES

Fastener Torque Values in this Chapter..............................3-1

3.2 SPECIFICATIONS

General...............................................................................3-3

3.3 ENGINE

Adjustment/Testing.............................................................3-7

General........................................................................3-7

Compression Test...............................................................3-7

Cylinder Leakage Test........................................................3-7

Diagnosing Smoking Engine or High Oil Consumption......3-8

3.4 ENGINE ROTATION FOR SERVICE

General...............................................................................3-9

Disassembly.......................................................................3-9

Assembly..........................................................................3-12

3.5 ENGINE REMOVAL

Disassembly.....................................................................3-14

3.6 ENGINE INSTALLATION

Assembly..........................................................................3-24

Engine Preparation for Re-installation.......................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 For Using The Neway Valve Seat Cutter.........3-44

Assembly..........................................................................3-45

Push Rod Cover Installation.............................................3-46

Cylinder Head Installation.................................................3-47

3.8 CYLINDER AND PISTON

Removal/Disassembly......................................................3-51

Cleaning and Inspection...................................................3-52

Checking Gasket Surface..........................................3-53

Measuring Cylinder Bore...........................................3-53

Deglazing Cylinder....................................................3-54

Fitting Piston Rings..........................................................3-54

Connecting Rod Bushing..................................................3-56

Assembly/Installation........................................................3-57

3.9 OILING SYSTEM

General.............................................................................3-60

3.10 OIL PUMP

General.............................................................................3-61

Removal/Disassembly......................................................3-62

Cleaning and Inspection...................................................3-64

Assembly/Installation........................................................3-65

3.11 OIL RESERVOIR AND OIL HOSE

ROUTING

General.............................................................................3-67

3.12 OIL LINE FITTINGS

Removal...........................................................................3-69

Installation........................................................................3-69

3.13 OIL COOLER

General.............................................................................3-71

Removal...........................................................................3-71

Installation........................................................................3-71

3.14 OIL PRESSURE INDICATOR SWITCH

General.............................................................................3-72

Oil Pressure Signal Light..................................................3-72

Oil Pressure......................................................................3-72

3.15 CRANKCASE BREATHING SYSTEM

General.............................................................................3-74

VIII TABLE OF CONTENTS

TABLE OF CONTENTS

Reed Valve Replacement.................................................3-74

3.16 HYDRAULIC LIFTERS

General.............................................................................3-76

Removal...........................................................................3-76

Cleaning and Inspection...................................................3-76

Installation........................................................................3-77

3.17 GEARCASE AND CAM GEARS

General.............................................................................3-78

Removal and Disassembly...............................................3-79

Cleaning and Inspection...................................................3-79

Cam and Pinion Gear Identification, Inspection and

Selection...................................................................3-80

Assembly and Installation.................................................3-80

3.18 CRANKCASE

General.............................................................................3-82

Disassembly.....................................................................3-82

Crankcase Halves.....................................................3-82

Oil Filter Adapter..............................................................3-83

Piston Jets........................................................................3-84

Removal....................................................................3-84

Installation.................................................................3-84

Removing Cylinder Base Studs.................................3-84

Flywheel Assembly....................................................3-84

Pinion Shaft Bearing.........................................................3-86

General......................................................................3-86

Selection...................................................................3-88

Replacement.............................................................3-88

Lapping Pinion Shaft Bearing Outer Race................3-90

Checking Connecting Rod Side Play................................3-91

Assembly..........................................................................3-91

Crankcase Halves.....................................................3-91

FUEL SYSTEM

4.1 FASTENERTORQUEVALUES

Fastener Torque Values in this Chapter..............................4-1

4.2 SPECIFICATIONS

General...............................................................................4-3

4.3 AIR CLEANER ASSEMBLY

Removal.............................................................................4-4

Inspection...........................................................................4-5

Installation..........................................................................4-5

4.4ELECTRONICCONTROLMODULE (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

4.5THROTTLE 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 ENGINETEMPERATURE SENSOR (ET)

General.............................................................................4-15

Removal...........................................................................4-15

Installation........................................................................4-16

4.9 BANK ANGLE SENSOR (BAS)

General.............................................................................4-17

Removal...........................................................................4-17

Firebolt......................................................................4-17

Lightning....................................................................4-17

Ulysses......................................................................4-17

Installation........................................................................4-18

Firebolt......................................................................4-18

Lightning....................................................................4-18

Ulysses......................................................................4-19

4.10 INTAKE AIRTEMPERATURE SENSOR

(IAT)

General.............................................................................4-20

Removal...........................................................................4-20

Installation........................................................................4-20

4.11 COOLING FAN

General.............................................................................4-21

Removal...........................................................................4-21

Installation........................................................................4-21

4.12 FUELTANK VENT VALVE

General.............................................................................4-22

Removal...........................................................................4-22

Installation........................................................................4-22

4.13 FUEL CAP RETAINING RING

Removal...........................................................................4-23

Installation........................................................................4-23

4.14 FUEL PUMP

Draining Fuel Tank............................................................4-24

Removal...........................................................................4-24

Installation........................................................................4-25

4.15THROTTLE BODY

General.............................................................................4-27

Removal...........................................................................4-27

Repair...............................................................................4-30

Throttle Position Sensor............................................4-30

Fuel Pressure Sensor................................................4-30

TABLE OF CONTENTS IX

TABLE OF CONTENTS

Fuel Injectors.............................................................4-30

Installation........................................................................4-30

Injector Leak Testing..................................................4-31

4.16 FUEL PRESSURE SENSOR

Replacement....................................................................4-32

Removal....................................................................4-32

Installation.................................................................4-32

4.17 FUEL PRESSURETEST

Inspection.........................................................................4-33

4.18 INTAKE LEAKTEST

General.............................................................................4-35

Leak Tester.......................................................................4-35

Parts List...................................................................4-35

Tester Assembly........................................................4-35

Tester Adjustment......................................................4-35

Procedure.........................................................................4-35

4.19 EXHAUST SYSTEM

Removal and Disassembly...............................................4-37

Muffler.......................................................................4-37

Front Muffler Mount...................................................4-37

Rear Muffler Bracket.................................................4-37

Exhaust Header........................................................4-37

Assembly and Installation.................................................4-38

Exhaust Header........................................................4-38

Rear Muffler Bracket.................................................4-39

Front Muffler Mount...................................................4-39

Muffler and Straps.....................................................4-39

Exhaust System Leak................................................4-40

4.20 EVAPORATIVE EMISSIONS CONTROL

(CA MODELS)

General.............................................................................4-41

Troubleshooting................................................................4-41

Removal: Firebolt..............................................................4-41

Vent Valve..................................................................4-41

Canister.....................................................................4-41

Removal: Lightning/Ulysses.............................................4-41

Vent Valve..................................................................4-41

Canister.....................................................................4-41

Installation: Firebolt..........................................................4-41

Vent Valve..................................................................4-41

Canister.....................................................................4-41

Installation: Lightning/Ulysses..........................................4-42

Vent Valve..................................................................4-42

Canister.....................................................................4-42

Hose Routing....................................................................4-43

DRIVE/TRANSMISSION

5.1 FASTENERTORQUEVALUES

Fastener Torque Values in this Chapter..............................5-1

5.2 SPECIFICATIONS

General...............................................................................5-3

5.3 PRIMARY 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

Clutch Shell Bearing Replacement...................................5-19

Installation........................................................................5-20

5.7 DRIVE BELT AND IDLER PULLEY

General.............................................................................5-23

Drive Belt Removal...........................................................5-24

Drive Belt Installation........................................................5-24

Idler Pulley Removal.........................................................5-25

Idler Pulley Installation......................................................5-25

5.8TRANSMISSION

General.............................................................................5-27

5.9 CASE DISASSEMBLY FOR

TRANSMISSION REMOVAL

General.............................................................................5-28

Right Crankcase Removal................................................5-28

5.10TRANSMISSION DISASSEMBLY

Transmission Removal From Left Crankcase...................5-31

Mainshaft/Countershaft....................................................5-35

Mainshaft Disassembly.....................................................5-35

Cleaning and Inspection............................................5-36

Countershaft Disassembly................................................5-36

Cleaning and Inspection............................................5-36

5.11TRANSMISSION ASSEMBLY

Mainshaft Assembly.........................................................5-38

Countershaft Assembly....................................................5-38

5.12 MAIN DRIVE GEAR AND BEARING

General.............................................................................5-40

Removal...........................................................................5-40

Main Drive Gear Bearing...........................................5-41

Disassembly.....................................................................5-42

Assembly..........................................................................5-42

Installation........................................................................5-43

Main Drive Gear Ball Bearing....................................5-43

Main Drive Gear........................................................5-44

X TABLE OF CONTENTS

TABLE OF CONTENTS

Main Drive Gear Seal................................................5-45

5.13TRANSMISSION RIGHT CASE

BEARINGS

Removal...........................................................................5-47

Countershaft Needle Bearing....................................5-47

Shifter Drum Bushing................................................5-47

Installation........................................................................5-47

Countershaft Needle Bearing....................................5-47

Shifter Drum Bushing................................................5-47

5.14TRANSMISSION LEFT CASE

BEARINGS

Removal...........................................................................5-49

Mainshaft and Countershaft Bearings.......................5-49

Shift Drum Bearing....................................................5-49

Installation........................................................................5-49

Mainshaft and Countershaft Bearings.......................5-49

Shift Drum Bushing...................................................5-49

5.15TRANSMISSION INSTALLATION

Installation........................................................................5-51

Shifter Forks and Drum Assembly....................................5-52

Installing Right Crankcase................................................5-53

5.16 SHIFTER SHAFT

Installation........................................................................5-55

5.17TRANSMISSION SPROCKET

Removal...........................................................................5-57

Installation........................................................................5-58

ELECTRICAL

6.1 FASTENERTORQUEVALUES

Fastener Torque Values in this Chapter..............................6-1

6.2 SPECIFICATIONS

General...............................................................................6-4

6.3 IGNITION/HEADLAMP KEY SWITCH

General...............................................................................6-5

Firebolt...............................................................................6-5

Removal......................................................................6-5

Disassembly................................................................6-6

Assembly.....................................................................6-6

Installation...................................................................6-7

Lightning.............................................................................6-7

Removal......................................................................6-7

Disassembly................................................................6-9

Assembly.....................................................................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..........................................................6-21

Disassembly..............................................................6-21

Inspection..................................................................6-22

Assembly...................................................................6-23

Drive Assembly.................................................................6-23

Disassembly..............................................................6-23

Inspection..................................................................6-23

Assembly...................................................................6-24

Installation........................................................................6-24

6.8 STARTER SOLENOID

Solenoid Assembly...........................................................6-25

Disassembly..............................................................6-25

Assembly...................................................................6-25

Solenoid Plunger..............................................................6-25

Disassembly..............................................................6-25

Assembly...................................................................6-25

Solenoid Contacts............................................................6-25

Disassembly..............................................................6-25

Assembly...................................................................6-26

6.9VOLTAGE REGULATOR

General.............................................................................6-28

Removal...........................................................................6-28

Installation........................................................................6-28

6.10 ALTERNATOR

Removal and Disassembly...............................................6-30

Rotor.........................................................................6-30

Stator.........................................................................6-30

Cleaning and Inspection...................................................6-31

Assembly and Installation.................................................6-31

6.11 HEATED HAND GRIPS: ULYSSES

MODELS

Heated Hand Grips...........................................................6-32

Removal....................................................................6-32

Installation.................................................................6-32

6.12 HORN

Removal...........................................................................6-35

Installation........................................................................6-35

Troubleshooting................................................................6-36

TABLE OF CONTENTS XI

TABLE OF CONTENTS

6.13TURN SIGNAL FLASHER

Removal...........................................................................6-37

Installation........................................................................6-37

6.14 FRONTTURN SIGNALS

Bulbs................................................................................6-39

Repair........................................................................6-39

Connections and Wire Routing..................................6-39

Firebolt.............................................................................6-39

Removal....................................................................6-39

Installation.................................................................6-39

Lightning...........................................................................6-39

Removal....................................................................6-39

Installation.................................................................6-39

Ulysses.............................................................................6-40

Removal....................................................................6-40

Installation.................................................................6-40

6.15 REARTURN SIGNALS

Bulbs................................................................................6-42

Connections and Wire Routing..................................6-42

Firebolt.............................................................................6-42

Removal....................................................................6-42

Installation.................................................................6-42

Lightning...........................................................................6-43

Removal....................................................................6-43

Installation.................................................................6-44

Ulysses.............................................................................6-44

Remove.....................................................................6-44

Installation.................................................................6-44

Turn Signal Relocation Bracket: XB12XP.........................6-45

Removal....................................................................6-45

Installation.................................................................6-45

6.16 INTERACTIVE EXHAUST SYSTEM

General.............................................................................6-47

Removal...........................................................................6-49

Installation........................................................................6-50

6.17 HEADLIGHT

General.............................................................................6-51

Headlight Bulbs: Firebolt..................................................6-51

Removal....................................................................6-51

Installation.................................................................6-51

Headlight Bulbs: Lightning and Ulysses...........................6-52

Removal....................................................................6-52

Installation.................................................................6-53

6.18TAIL LAMP

Ulysses/Firebolt/Lightning................................................6-56

Removal....................................................................6-56

Installation.................................................................6-56

6.19 LICENSE PLATE LAMP 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

Installation.................................................................6-64

6.23 CRANKSHAFT POSITION SENSOR

(CKP)

General.............................................................................6-65

Removal...........................................................................6-65

Installation........................................................................6-65

6.24VEHICLE SPEED SENSOR (VSS)

Removal...........................................................................6-67

Installation........................................................................6-67

6.25 INSTRUMENT MODULE

General.............................................................................6-68

Removal...........................................................................6-68

Bulb Replacement.....................................................6-68

Installation........................................................................6-69

6.26 MAINWIRE HARNESS

General.............................................................................6-71

Removal...........................................................................6-71

Installation........................................................................6-78

6.27 AUXILIARY HARNESS: XB12XP

XB12XP Ulysses Police Model Auxiliary Harness............6-86

Removal....................................................................6-86

Installation.................................................................6-88

6.28 INTERACTIVE EXHAUST HARNESS:

XB12 MODELS

Firebolt.............................................................................6-90

Removal....................................................................6-90

Installation.................................................................6-90

Lightning...........................................................................6-91

Removal....................................................................6-91

Installation.................................................................6-91

Ulysses.............................................................................6-92

Removal....................................................................6-92

Installation.................................................................6-92

6.29 SPROCKET COVER WIRING

General.............................................................................6-94

Removal...........................................................................6-94

XII TABLE OF CONTENTS

TABLE OF CONTENTS

6.30 AUXILIARY POWER OUTLETS:

ULYSSES MODELS

General.............................................................................6-95

Accessory Load Test........................................................6-95

APPENDIX A CONNECTOR REPAIR

A.1 AMP MULTILOCK CONNECTORS

AMP Multilock Connector Repair.......................................A-1

General.......................................................................A-1

Separating Pin and Socket Housings.........................A-1

Mating Pin and Socket Housings................................A-1

Removing Terminals from Housing.............................A-1

Inserting Terminals into Housing.................................A-2

Preparing Wire Leads for Crimping.............................A-2

Crimping Terminals to Leads......................................A-3

Inspecting Crimped Terminals.....................................A-4

A.2 AUTOFUSE ELECTRICAL

CONNECTORS

Autofuse Connector Repair................................................A-5

General.......................................................................A-5

Disassembly................................................................A-5

Assembly....................................................................A-5

A.3 DELPHI CONNECTORS

Delphi Connector Repair....................................................A-6

General.......................................................................A-6

Separating Pin and Socket Housings.........................A-6

Mating Pin and Socket Housings................................A-6

Removing Socket Terminals........................................A-6

Installing Socket Terminals..........................................A-6

A.4DEUTSCH ELECTRICAL CONNECTORS

Deutsch Connector Repair.................................................A-8

General.......................................................................A-8

Separating Pin and Socket Housings.........................A-8

Mating Pin and Socket Housings................................A-8

Removing Socket Terminals........................................A-8

Installing Socket Terminals..........................................A-8

Removing Pin Terminals...........................................A-10

Installing Pin Terminals.............................................A-10

Crimping Terminals...................................................A-11

A.5 DEUTSCH STANDARDTERMINAL

REPAIR

Deutsch Standard Terminal Crimps.................................A-12

Preparing Wire Leads for Crimping...........................A-12

Crimping Terminal to Lead........................................A-12

Inspecting Crimps.....................................................A-12

A.6 DEUTSCH SOLID BARREL MINI

TERMINAL REPAIR

Deutsch Solid Barrel Terminal Crimps.............................A-13

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 MINITERMINAL 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

Separating Pin and Socket Housings.......................A-16

Mating Pin and Socket Housings..............................A-16

Removing Socket Terminal.......................................A-16

Inserting Socket Terminal..........................................A-16

A.9 PACKARD 630 METRI-PACK

CONNECTORS

630 Metri-Pack Connector Repair....................................A-18

General.....................................................................A-18

Separating Pin and Socket Housings.......................A-18

Mating Pin and Socket Housings..............................A-18

Removing Socket Terminal.......................................A-18

Installing Socket Terminal.........................................A-18

A.10 PACKARD METRI-PACKTERMINALS

Metri-Pack Terminal Crimps.............................................A-19

Matching Terminal To Crimper..................................A-19

Preparing Wire Lead.................................................A-19

Crimping Wire Core..................................................A-19

Crimping Insulation/Seal...........................................A-19

Inspecting Crimps.....................................................A-20

A.11 SEALED SPLICE CONNECTORS

Sealed Splice Connector Repair......................................A-21

General.....................................................................A-21

Preparing Wire Leads...............................................A-21

Splicing Wire Leads..................................................A-21

Inspecting Seals.......................................................A-21

APPENDIX BWIRING

B.1 CONNECTORS

Connector Locations..........................................................B-1

Function/Location.......................................................B-1

Place and Color..........................................................B-1

Connector Number......................................................B-1

Repair Instructions......................................................B-1

B.2WIRING DIAGRAMS

Wiring Diagram Information...............................................B-4

Wire Color Codes........................................................B-4

Wiring Diagram Symbols............................................B-4

2010 XB Wiring Diagrams..................................................B-7

APPENDIX C CONVERSIONS

C.1 LENGTH CONVERSION

Conversion Table................................................................C-1

TABLE OF CONTENTS XIII

TABLE OF CONTENTS

C.2 FLUID CONVERSION

United States System........................................................C-2

Metric System....................................................................C-2

British Imperial System......................................................C-2

C.3TORQUE CONVERSION

United States System........................................................C-3

Metric System....................................................................C-3

APPENDIX D HOSE ANDWIRE

ROUTING

D.1 APPENDIX D: HOSE ANDWIRE

ROUTING

Firebolt...............................................................................D-1

Lightning..........................................................................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....................................................XXVII

XIV TABLE OF CONTENTS

TABLE OF CONTENTS

This manual suits for next models

Table of contents

Other Buell Motorcycle manuals

Popular Motorcycle manuals by other brands

KTM

KTM 250 EXC-F 2016 Setup instructions

Benelli

Benelli 249R manual

KTM

KTM 450 SMR Supplement

Daytona

Daytona DD125E-5C user manual

Raybar

Raybar Striker 150 user manual

Bajaj Auto

Bajaj Auto Pulsar 135 LS owner's manual

A.J.S.

A.J.S. 16 Instruction book

MOTO GUZZI

MOTO GUZZI V100 E5 2023 Service station manual

HYOSUNG

HYOSUNG Comet 250 R user guide

Suzuki

Suzuki FL125S Service manual

KTM

KTM 250 SX-F 2019 Setup instructions

KTM

KTM 690 Duke 2018 Setup instructions

KTM

KTM 250 SX 2020 owner's manual

Yamaha

Yamaha XV950CU owner's manual

Yamaha

Yamaha XVS650N owner's manual

MOTO GUZZI

MOTO GUZZI GRISO 1100 manual

Yamaha

Yamaha FZS600'98 Service manual

Beta

Beta Evo 80 Senior manual

Buell XB 2010 User manual

Popular Motorcycle manuals by other brands