2008 Xb12r

2008 Xb12r

• Contents
• Table of Contents
• Troubleshooting
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• 9

  99490-08Ya - Buell Xb Models Service Manual -- 01/30/08Sa

  • 23

    General

  • 27

    Fuel and Oil

  • 29

    Maintenance Schedule

  • 31

    Battery Maintenance

  • 35

    Engine Oil and Filter

  • 38

    Brake System Maintenance

  • 45

    Tires and Wheels

  • 47

    Clutch/Transmission/Primary Fluid

  • 50

    Drive Belt Maintenance

  • 53

    Primary Chain

  • 54

    Steering Head Bearings

  • 55

    Spark Plugs

  • 57

    Air Cleaner and Exhaust System

  • 60

    Throttle Cable

  • 61

    Interactive Exhaust Cable

• 75

  Lightning

  • 101

    Grille: Xb9Sx/Xb12Stt/Xb12X

  • 101

    Xb9Sx/Xb12Stt/Xb12X/Xb12Xt

  • 101

    2.30 Deflectors

  • 104

    Lightning/Ulysses

  • 104

    2.32 Front Modules

  • 183

    Footpeg, Heel Guard and Mount: Firebolt/Lightning

  • 185

    Heel Guard and Footpeg Mounts: Ulysses Models

  • 187

    Sprocket Cover

  • 188

    Belt Guards

  • 189

    Intake Cover

  • 191

    Subframe Tail Assembly and Body Work: Firebolt

  • 196

    Left Tail Section and Battery Pan: Lightning

  • 200

    Center Tail Section: Lightning

  • 205

    Center Tail Loop: Xb12X/Xb12Xt

  • 209

    Sidestand

  • 211

    Front Fairing, Windshield, and Mirrors: Firebolt

  • 212

    Windshield and Windscreen: Lightning and Ulysses

  • 216

    Number Plates: Xb12Stt

  • 218

    Air Scoops

  • 220

    Chin Fairing

  • 221

    Seat

  • 225

    Seat Locks

  • 229

    Triple Tail: Ulysses

  • 231

    Luggage: Xb12Xt

2008 Buell XB Models Service Manual

99490-08YA

©2007 Buell Motorcycle Company

Chapters

• 9

  99490-08Ya - Buell Xb Models Service Manual -- 01/30/08Sa

  • 23

    General

  • 27

    Fuel and Oil

  • 29

    Maintenance Schedule

  • 31

    Battery Maintenance

  • 35

    Engine Oil and Filter

  • 38

    Brake System Maintenance

  • 45

    Tires and Wheels

  • 47

    Clutch/Transmission/Primary Fluid

  • 50

    Drive Belt Maintenance

  • 53

    Primary Chain

  • 54

    Steering Head Bearings

  • 55

    Spark Plugs

  • 57

    Air Cleaner and Exhaust System

  • 60

    Throttle Cable

  • 61

    Interactive Exhaust Cable

• 75

  Lightning

  • 101

    Grille: Xb9Sx/Xb12Stt/Xb12X

  • 101

    Xb9Sx/Xb12Stt/Xb12X/Xb12Xt

  • 101

    2.30 Deflectors

  • 104

    Lightning/Ulysses

  • 104

    2.32 Front Modules

  • 183

    Footpeg, Heel Guard and Mount: Firebolt/Lightning

  • 185

    Heel Guard and Footpeg Mounts: Ulysses Models

  • 187

    Sprocket Cover

  • 188

    Belt Guards

  • 189

    Intake Cover

  • 191

    Subframe Tail Assembly and Body Work: Firebolt

  • 196

    Left Tail Section and Battery Pan: Lightning

  • 200

    Center Tail Section: Lightning

  • 205

    Center Tail Loop: Xb12X/Xb12Xt

  • 209

    Sidestand

  • 211

    Front Fairing, Windshield, and Mirrors: Firebolt

  • 212

    Windshield and Windscreen: Lightning and Ulysses

  • 216

    Number Plates: Xb12Stt

  • 218

    Air Scoops

  • 220

    Chin Fairing

  • 221

    Seat

  • 225

    Seat Locks

  • 229

    Triple Tail: Ulysses

  • 231

    Luggage: Xb12Xt

Troubleshooting

  Related Manuals for Buell XB 2008 Series

  Summary of Contents for Buell XB 2008 Series

• Page 1 2008 Buell XB Models Service Manual 99490-08YA ©2007 Buell Motorcycle Company...

• Page 2: Important Notice

  IMPORTANT NOTICE 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.
• Page 3 2008 Buell XB Models Service Manual ©2007 Buell Motorcycle Company ALL RIGHTS RESERVED 99490-08YA Printed in the U.S.A. VISIT THE BUELL WEB SITE http://www.buell.com...
• Page 4 Blank Text Here...
• Page 5 READER COMMENTS Blank Text Here 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. Please comment on the completeness, accuracy, organization, usability, and readability of this manual.
• Page 6 NOTES...

• Page 7: About This Manual

  First, it will acquaint the user with the construction of the NOTES Buell product and assist in the performance of basic mainten- ance and repair. Secondly, it will introduce to the professional To avoid unnecessary disassembly, carefully read all rel- ative service information before repair work is started.
• Page 8 Accordingly, anyone who uses a service products. If you have any questions regarding Loctite product procedure or tool which is not recommended by Buell Motor- usage or retailer/wholesaler locations, please contact Loctite cycle Company must first thoroughly satisfy himself that neither Corp.

• Page 9: Table Of Contents

  99490-08YA - Buell XB Models Service Manual -- 01/30/08sa Change Engine Oil and Filter...........1-13 MAINTENANCE Drain Oil..............1-13 Change Filter.............1-14 1.1 GENERAL Fill Engine With Oil............1-14 Clear Oil Cooler............1-14 Servicing a New Motorcycle..........1-1 Return to Service............1-15 Safe Operating Maintenance..........1-1 Shop Practices..............1-1 1.6 BRAKE SYSTEM MAINTENANCE...
• Page 10 TABLE OF CONTENTS 1.16 HEADLIGHT Lightning................2-1 Ulysses................2-2 Inspection.................1-41 Adjustment: Firebolt............1-42 2.2 VEHICLE IDENTIFICATION NUMBER Adjustment: Lightning............1-42 (V.I.N.) Horizontal Alignment..........1-42 Vehicle Identification Number (V.I.N.).........2-4 Vertical Alignment.............1-42 Adjustment: Ulysses/Lightning XB12STT......1-43 2.3 WHEELS Horizontal Alignment..........1-43 Vertical Alignment.............1-43 General................2-6 Troubleshooting..............2-6 1.17 WINDSHIELD MAINTENANCE 2.4 FRONT WHEEL General................1-45 Removal................2-8 1.18 STORAGE...
• Page 11 TABLE OF CONTENTS 2.10 FRONT BRAKE CALIPER 2.16 FRONT FORK: ALL MODELS EXCEPT XB12STT/XB12X/XB12XT Removal................2-30 Disassembly..............2-30 General................2-49 Cleaning and Inspection...........2-30 Removal................2-49 Assembly................2-31 Disassembly..............2-50 Installation................2-31 Damper Rod Disassembly.........2-52 Cleaning and Inspection...........2-54 2.11 BRAKE PEDAL Assembly................2-54 Removal................2-33 Damper Rod Assembly..........2-54 Installation................2-33 Fork Assembly............2-54 Installation................2-56 2.12 REAR BRAKE MASTER CYLINDER 2.17 FRONT FORK:...
• Page 12 TABLE OF CONTENTS 2.24 FRAME 2.33 HANDLEBARS: FIREBOLT Removal................2-77 General................2-103 Installation................2-77 Removal.................2-103 Right Clip-On............2-103 2.25 REAR SHOCK ABSORBER Left Clip-On.............2-103 Installation..............2-103 General................2-78 Right Clip-On............2-103 Removal: Firebolt..............2-80 Left Clip-On.............2-103 Removal: Lightning............2-81 Removal: Ulysses.............2-81 2.34 HANDLEBARS: LIGHTNING/ULYSSES Installation: Firebolt............2-82 Installation: Lightning............2-82 Removal.................2-104 Installation: Ulysses............2-83 Installation..............2-104 2.26 THROTTLE CONTROL...
• Page 13 TABLE OF CONTENTS 2.41 SUBFRAME TAIL ASSEMBLY AND Installation..............2-141 BODY WORK: FIREBOLT 2.52 AIR SCOOPS Disassembly..............2-115 Ram Air Scoop...............2-142 Cleaning.................2-118 Removal..............2-142 Assembly................2-118 Installation...............2-142 Engine Shroud Air Scoop..........2-142 2.42 LEFT TAIL SECTION AND BATTERY Removal..............2-142 PAN: LIGHTNING Installation...............2-142 Oil Cooler Air Scoop............2-142 Disassembly..............2-120 Removal..............2-142 Cleaning.................2-121...
• Page 14 TABLE OF CONTENTS Compression Test...............3-5 3.11 OIL LINE FITTINGS Cylinder Leakage Test............3-5 Removal................3-67 Diagnosing Smoking Engine or High Oil Consumption..3-6 Installation................3-67 3.3 ENGINE ROTATION FOR SERVICE 3.12 OIL COOLER General................3-7 General................3-69 Disassembly...............3-7 Removal................3-69 Assembly................3-10 Installation................3-69 3.4 ENGINE REMOVAL 3.13 OIL PRESSURE INDICATOR SWITCH Disassembly..............3-13 General................3-70 Oil Pressure Signal Light..........3-70...
• Page 15 TABLE OF CONTENTS 4.3 ELECTRONIC CONTROL MODULE (ECM) Repair................4-21 Fuel Pressure Regulator Replacement.....4-21 Removal: Firebolt..............4-5 Low Fuel Level Sensor Replacement......4-22 Installation: Firebolt............4-5 Fuel Filter Replacement..........4-23 Removal: Lightning.............4-5 Fuel Pump Wire Harness Replacement....4-25 Installation: Lightning............4-5 Installation................4-25 Removal: Ulysses...............4-6 Installation: Ulysses............4-6 4.14 THROTTLE BODY 4.4 THROTTLE POSITION SENSOR (TPS) General................4-27 Removal................4-27...
• Page 16 TABLE OF CONTENTS Wiring Diagrams............5-2 Countershaft Disassembly..........6-34 Removal................5-2 Cleaning and Inspection..........6-34 Disassembly, Inspection, and Repair........5-2 6.10 TRANSMISSION ASSEMBLY Assembly................5-6 Installation................5-7 Mainshaft Assembly............6-36 Countershaft Assembly............6-36 5.3 STARTER SOLENOID 6.11 MAIN DRIVE GEAR AND BEARING Replacement..............5-9 Disassembly..............5-9 General................6-38 Assembly..............5-9 Removal................6-38 Main Drive Gear Bearing...........6-39 DRIVE/TRANSMISSION Disassembly..............6-40 Assembly................6-40...
• Page 17 TABLE OF CONTENTS Removal: Firebolt..............7-5 Removal..............7-32 Disassembly: Firebolt............7-6 Installation..............7-35 Assembly: Firebolt..............7-6 Lightning................7-32 Installation: Firebolt............7-7 Removal..............7-32 Removal: Lightning.............7-7 Installation..............7-32 Disassembly: Lightning............7-9 Ulysses................7-33 Assembly: Lightning............7-9 Removal..............7-33 Installation: Lightning............7-11 Installation..............7-36 Removal: Ulysses.............7-12 7.13 REAR TURN SIGNALS Disassembly: Ulysses............7-13 Assembly: Ulysses............7-13 Bulbs................7-35 Installation: Ulysses............7-14 Connections and Wire Routing........7-35 Firebolt................7-35 7.4 SPARK PLUG CABLES...
• Page 18 TABLE OF CONTENTS 7.20 CRANKSHAFT POSITION SENSOR Removing Terminals from Housing......A-3 Inserting Terminals into Housing.........A-4 (CKP) Preparing Wire Leads for Crimping......A-4 General................7-56 Crimping Terminals to Leads........A-5 Removal................7-56 Inspecting Crimped Terminals........A-6 Installation................7-56 A.3 AUTOFUSE ELECTRICAL 7.21 VEHICLE SPEED SENSOR (VSS) CONNECTORS Removal................7-58 Autofuse Connector Repair..........A-7 Installation................7-58...
• Page 19 Wiring Diagram Information..........B-3 CONNECTORS Wire Color Codes............B-3 480 Metri-Pack Connector Repair........A-25 Wiring Diagram Symbols..........B-3 General..............A-25 2008 Buell Wiring Diagrams..........B-4 Separating Pin and Socket Housings.......A-25 APPENDIX C CONVERSIONS Mating Pin and Socket Housings......A-25 Removing Socket Terminals........A-25 Installing Socket Terminals........A-25 C.1 LENGTH CONVERSION A.13 PACKARD 630 METRI-PACK...
• Page 20 TABLE OF CONTENTS Active Intake System..........E-1 APPENDIX F GLOSSARY Diagnostic Notes............E-1 Verify Settings..............E-1 F.1 GLOSSARY WOT Check................E-1 Cable..................E-1 Acronyms and Abbreviations..........F-1 Adjustment..............E-1 REFERENCE MATERIAL Throttle Stop Screw............E-3 Removal................E-4 Installation................E-5 TOOLS............I TORQUE VALUES........VII INDEX............XXVII XIV TABLE OF CONTENTS...
• Page 21 SUBJECT..........................PAGE NO. 1.1 GENERAL..........................1-1 1.2 FUEL AND OIL..........................1-5 1.3 MAINTENANCE SCHEDULE....................1-7 1.4 BATTERY MAINTENANCE.......................1-9 1.5 ENGINE OIL AND FILTER......................1-13 1.6 BRAKE SYSTEM MAINTENANCE..................1-16 1.7 TIRES AND WHEELS......................1-23 1.8 CLUTCH/TRANSMISSION/PRIMARY FLUID.................1-25 1.9 DRIVE BELT MAINTENANCE....................1-28 1.10 PRIMARY CHAIN........................1-31 1.11 STEERING HEAD BEARINGS....................1-32 1.12 SPARK PLUGS........................1-33 1.13 AIR CLEANER AND EXHAUST SYSTEM................1-35 1.14 THROTTLE CABLE.......................1-38...
• Page 22 NOTES...

• Page 23: General

  GENERAL SERVICING A NEW MOTORCYCLE Safety Safety is always the most important consideration when per- forming any job. Be sure you have a complete understanding of the task to be performed. Use common sense. Use the Perform the service and maintenance operations as proper tools.

• Page 24: Disassembly And Assembly

  Disassembly and Assembly Wiring, Hoses and Lines Always assemble or disassemble one part at a time. Do not Hoses, clamps, electrical wiring, electrical switches or fuel lines work on two assemblies simultaneously. Be sure to make all if they do not meet specifications. necessary adjustments.

• Page 25: O-Rings (Preformed Packings)

  Always discard seals after removal. Do not use the same seal Bearings twice. Remove shields and seals from bearings before cleaning. O-Rings (Preformed Packings) Clean bearings with permanent shields and seals in solution. Always discard o-rings after removal. Replace with new o-rings. To prevent leaks, lubricate the o-rings before installation.

• Page 26: Hammers

  Hammers Ratchets and Handles Never strike a hammer against a hardened object, such Periodically clean and lubricate ratchet mechanisms with as another hammer. a light grade oil. Do not replace parts individually; ratchets should be rebuilt with the entire contents of service kit. Always grasp a hammer handle firmly, close to the end.

• Page 27: Fuel And Oil

  Pump Octane (R+M)/2 91 (95 RON) some lubricants interact chemically when mixed. Use of GASOLINE BLENDS: BUELL MODELS inferior lubricants can damage the engine. (00184a) Engine oil is a major factor in the performance and service life Your motorcycle was designed to get the best performance of the engine.

• Page 28: Winter Lubrication

  WINTER LUBRICATION Water vapor is a normal by-product of combustion in any engine. During cold weather operation, some of the water vapor In colder climates, the engine oil should be changed often. If condenses to liquid form on the cool metal surfaces inside the motorcycle is used frequently for short trips, less than 15 engine.

• Page 29: Maintenance Schedule

  Verify component and system func- tions NOTES: 1. Should be performed by an authorized Buell dealer, unless you have the proper tools, service data and are mechanically qualified. 2. Change brake fluid every two (2) years. Table 1-4. Quick Reference Maintenance Chart: XB Models...
• Page 30 Table 1-4. Quick Reference Maintenance Chart: XB Models ITEM SERVICED SPECIFICATION DATA Primary chain/transmission Lubricant level GENUINE HARLEY-DAVIDSON FORMULA+ TRANSMISSION lubricant AND PRIMARY CHAINCASE LUBRICANT (Part No. 99851-05) as required until fluid level is even with bottom of clutch dia- phragm spring Primary chaincase drain plug Apply LOCTITE 565 THREAD SEALANT and reinstall plug and...

• Page 31: Battery Maintenance

  BATTERY MAINTENANCE GENERAL NOTE For charging information, see 1.4 BATTERY MAINTENANCE, Charging Battery. For testing information, see ELECTRICAL DIAGNOSTIC MANUAL. Batteries contain sulfuric acid, which could cause severe burns to eyes and skin. Wear a protective face shield, sm04816 rubberized gloves and protective clothing when working with batteries.

• Page 32: Battery Disconnection And Removal

  CHARGING BATTERY Table 1-5. Antidotes for Battery Acid Safety Precautions CONTACT TREATMENT Never charge a battery without first reviewing the instructions External Flush with water. for the charger being used. In addition to the manufacturer's Internal Drink large quantities of milk or water, followed instructions, follow these general safety precautions: by milk of magnesia, vegetable oil or beaten Always wear eye, face and hand protection.

• Page 33: Battery Installation And Connection

  Table 1-6. 12 Amp-Hour Battery Charging Rates and Times READING PERCENT 3 AMP 6 AMP 10 AMP 20 AMP (VOLTS) CHARGE CHARGER CHARGER CHARGER CHARGER 12.7 12.6 1 hour 10 minutes 34 minutes 20 minutes 10 minutes 12.3 2 hours 20 minutes 1 hour 10 minutes 40 minutes 20 minutes...

• Page 34: Storage

  Insert fastener through battery positive cable (red) into Figure 1-3. Self-discharge is a normal condition and occurs threaded hole of battery positive (+) terminal and tighten continuously at a rate that depends on the ambient temperature fastener to 72-96 in-lbs (8-11 Nm). and the battery's state of charge.

• Page 35: Engine Oil And Filter

  ENGINE OIL AND FILTER If the level is below the lower registration mark, add only GENERAL enough oil to bring oil level between lower and upper The engine oil level can be checked with the oil and engine at registration marks. ambient temperatures (cold check).

• Page 36: Change Filter

  Change Filter 3. Oil line fittings Remove chin fairing. See 2.53 CHIN FAIRING. Figure 1-7. Oil Filter: Buell Models except Blast Figure 1-7. Remove oil filter using pliers or belt type oil filter wrench. Fill Engine With Oil Clean filter gasket contact surface on crankcase. Surface must be smooth and free of debris or old gasket material.

• Page 37: Return To Service

  Install oil cooler scoop. See 2.52 AIR SCOOPS. Check for oil leaks at oil filter, drain plug, hoses and oil cooler. Return to Service Install chin fairing. See 2.53 CHIN FAIRING. Wipe up any spilled oil on muffler. Check (hot) oil level. See 1.5 ENGINE OIL AND FILTER, Start engine.

• Page 38: Brake System Maintenance

  BRAKE SYSTEM MAINTENANCE Inspect front and rear brake lines and replace as required: GENERAL Every 4 years. Check brake fluid level and condition: Inspect caliper and master cylinder seals and replace as When storing or removing the motorcycle for the season. required: Replace D.O.T.

• Page 39: Bleeding Front Brake

  braking ability and lead to brake failure which could result in sm00485 death or serious injury. Bleeding Front Brake NOTE Hydraulic brake fluid bladder-type pressure equipment can be used to fill the brake master cylinder through the bleeder valve if master cylinder reservoir cover is removed to prevent pres- surization.

• Page 40: Bleeding Rear Brake

  Bleeding Rear Brake sm00488 NOTE Hydraulic brake fluid bladder-type pressure equipment can be used to fill the brake master cylinder through the bleeder valve if master cylinder reservoir cover is removed to prevent pres- surization. Figure 1-11. Remove rubber cap and install end of plastic tubing over rear caliper bleeder valve.

• Page 41: Brake Pad Thickness

  engagement with the clevis (3), the flat sides must extend sm00490 below the extruded nut (1) in the clevis by at least one full thread. This is the rod minimum engagement (4). Also, there should be a minimum of 0.030 in. (0.8 mm) between brake rod end and brake pedal.

• Page 42: Brake Rotor Thickness

  BRAKE ROTOR THICKNESS sm00493 Be sure that no lubricants or fluids get on tires, wheels or brakes when changing fluid. Traction can be adversely affected, which could result in loss of control of the motorcycle and death or serious injury. (00047d) Figure 1-16 Figure 1-17.

• Page 43: Rear Pad Removal

  Figure 1-18. Install pin hanger (2) making sure it Rear Pad Installation engages hole on both pads and spring clip. Remove rear master cylinder reservoir cover. Rotate caliper clockwise to align mounting fastener hole. NOTE Install lower caliper mounting fastener (4). As the pistons are pushed back into the caliper, fluid level may rise more than 1/8 in.
• Page 44 sm00495 sm00496 Figure 1-20. Rear Brake Pad Spring Installed 1. Rear caliper mounting fasteners 2. Brake pad retainer 3. Rear caliper pin plug 4. Rear caliper pin hanger Figure 1-19. Rear Brake Caliper 1-22 2008 XB Service: Maintenance...

• Page 45: Tires And Wheels

  TIRES AND WHEELS TIRE INFLATION om00962 Use only Buell approved tires. See a Buell dealer. Using non-approved tires can adversely affect stability, which could result in death or serious injury. (00133a) Do not inflate tire beyond maximum pressure as specified on sidewall.

• Page 46: Wheel Bearings

  WHEEL BEARINGS Check front and rear wheel bearings for wear: Every time a wheel is removed. When storing or removing the motorcycle for the season. Using compressed air to "spin dry" bearings can cause Check wheel bearings for wear and corrosion. Excessive play bearing to fly apart, which could result in death or serious or roughness indicates worn bearings.

• Page 47: Clutch/Transmission/Primary Fluid

  CLUTCH/TRANSMISSION/PRIMARY FLUID INSPECTION sm01388 Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect negative battery cable from battery. Figure 1-23. Remove three TORX screws with washers (1) from clutch inspection cover (2). Remove clutch inspection cover from primary cover.

• Page 48: Adjustment

  sm05323 Do not overfill the primary chaincase with lubricant. Overfilling can cause rough clutch engagement, incom- plete disengagement, clutch drag and/or difficulty in finding neutral at engine idle. (00199b) Make certain primary chaincase is filled with proper amount of lubricant with motorcycle upright. If under filled, transmission can be damaged during vehicle operation.
• Page 49 provide 1/16-1/8 in. (1.6-3.2 mm) free play at clutch hand sm00091 lever. Adjust as follows: Figure 1-29. Pull ferrule (end of cable housing) away from bracket. Gap between ferrule and bracket should be 1/16-1/8 in. (1.6-3.2 mm). Figure 1-27. Set free play by turning adjuster (4). Tighten jam nut (3) against adjuster (4).

• Page 50: Drive Belt Maintenance

  DRIVE BELT MAINTENANCE result in belt failure and indicates worn transmission GENERAL sprocket teeth. Replace belt and transmission sprocket. The drive belt tension on a new belt will loosen after approxim- Signs of puncture or cracking at the base of the belt teeth. ately 1000 miles (1600 km).
• Page 51 Table 1-10. Potential Limits to Belt Drive Service Life CONDITION ROOT CAUSE REQUIRED ACTION Excessive edge wear Misalignment or bent drive structure Check structure (bad bearing, bent members, etc.) (mistracking) Bent or rough flange Repair flange/replace sprocket Damage due to handling (pry on, etc.) Follow proper handling/installation procedure Debris damage to edge of belt Inspect/replace belt...
• Page 52 Table 1-10. Potential Limits to Belt Drive Service Life CONDITION ROOT CAUSE REQUIRED ACTION Belt breakage Excessive load/shock load Inspect/replace belt Riding practice/operator choice Damage due to handling (pry-on, etc.) Follow proper handling/installation procedure Debris in sprocket or belt Inspect/replace sprocket Clean and protect drive Inspect/replace belt Excessive drive noise...

• Page 53: Primary Chain

  PRIMARY CHAIN 1.10 INSPECTION sm00095 Figure 1-31. Measure primary chain tension through the inspection cover opening. Adjust primary chains not meeting vertical free play specifications. Figure 1-31. Remove two fasteners with captive washers and primary chain inspection cover with gasket from primary cover.

• Page 54: Steering Head Bearings

  Loosen steering stem capnut and back off several turns. Do not operate motorcycle with loose, worn or damaged steering or suspension systems. Contact a Buell dealer Remove lower triple clamp pinch fasteners, two per side. for repairs. Loose, worn or damaged steering or suspen- Tighten steering stem capnut to 38-42 ft-lbs (52-57 Nm).

• Page 55: Spark Plugs

  SPARK PLUGS 1.12 INSPECTION sm00099 Check spark plugs: Replace every 10,000 mile (16,000 km) service interval. Use only Harley-Davidson 10R12X spark plugs. Remove left side air scoop to access front cylinder spark plug. See 2.52 AIR SCOOPS. Disconnect cable from front spark plug. Using a 5/8 in.
• Page 56 NOTE 16. Install seat. An extension may be needed to push on rear spark plug boot to ensure it is seated properly. sm00100 13. Connect spark plug cables. Verify that cables are securely connected to coil and spark plugs. See 7.4 SPARK PLUG CABLES.

• Page 57: Air Cleaner And Exhaust System

  AIR CLEANER AND EXHAUST SYSTEM 1.13 REMOVAL sm00376 Install air filter before running engine. Failure to do so can draw debris into the engine and could result in engine damage. (00207a) Check air filter element: Inspect at the 1000 mile (1600 km) service interval and at every 5000 mile (8000 km) service interval thereafter.

• Page 58: Cleaning And Inspection

  sm00501 sm00503 Figure 1-40. Air Cleaner Cover Latches 1. Breather hoses (2) 2. Intake air sensor 3. Velocity stack sm00502 Figure 1-42. Air Cleaner Baseplate Assembly INSTALLATION Figure 1-43. Place filter element (1) on baseplate (2). Position air cleaner cover over baseplate. Make sure air filter remains correctly positioned.

• Page 59: Exhaust System Leak Check

  EXHAUST SYSTEM LEAK CHECK sm00502 Check the exhaust system for leaks at every scheduled service interval as follows: Check entire exhaust system for loose or missing fasteners, broken pipe clamps or brackets, and obvious signs of leakage (carbon tracks at pipe joints, etc.). Check for loose or broken heat shields.

• Page 60: Throttle Cable

  THROTTLE CABLE 1.14 released. If this is not the case, turn adjuster on idle control THROTTLE CABLE ADJUSTMENT cable (shortening cable housing) until throttle control functions properly. Tighten cable adjuster lock on idle control cable. Recheck Be sure that steering is smooth and free without interfer- operation of throttle control.

• Page 61: Interactive Exhaust Cable

  INTERACTIVE EXHAUST CABLE 1.15 10. Cycle the actuator to verify cable and valve operation: ADJUSTMENT Hold the throttle wide open. Remove intake cover assembly. See 2.40 INTAKE COVER. Turn the engine cut-off switch to RUN. NOTES Turn the ignition/light key switch ON. The actuator cover used on models with Translucid body Watch the actuator cycle close/open/close.
• Page 62 sm00506 sm00505 Figure 1-46. Checking For 1/8 in. (3.2 mm) Maximum Free Play In Either Direction For Proper Adjustment 1. Interactive exhaust cable 2. Frame lug Figure 1-47. Correct Cable Routing Behind Frame Lug (Typical) 1-40 2008 XB Service: Maintenance...

• Page 63: Headlight

  HEADLIGHT 1.16 NOTE INSPECTION On Lightning and Ulysses models, the low beam lamp will not stay illuminated when high beam is activated. Check that the correct pattern of light is a circular The automatic-on headlamp feature provides increased pattern and is centered on the horizontal line as visibility of the rider to other motorists.

• Page 64: Adjustment: Firebolt

  Vertical Alignment pd00195 Figure 1-53. Loosen fastener on the bottom of headlamp housing to adjust the vertical alignment. NOTE Only loosen headlamp alignment fasteners enough to adjust headlamp. Once headlights are aligned, tighten fasteners to 48-72 in-lbs (5-8 Nm). pd00197 1.

• Page 65: Adjustment: Ulysses/Lightning Xb12Stt

  pd00199 pd00200 Figure 1-54. Horizontal Headlamp Adjustment Fastener Locations: Ulysses pd00201 Figure 1-53. Vertical Headlamp Adjustment Fastener: Lightning Models except XB12STT ADJUSTMENT: ULYSSES/LIGHTNING XB12STT Horizontal Alignment Figure 1-54 Figure 1-55. Loosen fasteners on right and left side of headlamp housing to adjust the horizontal alignment.
• Page 66 sm05318 Figure 1-57. Vertical Headlamp Adjustment Fastener: XB12XT 1-44 2008 XB Service: Maintenance...

• Page 67: Windshield Maintenance

  Failure to maintain polycarbonate properly can result in damage to the wind- screen/windshield. (00483d) Buell recommends using Harley Softcloths with the following products to clean your windscreen. To minimize swirl marks, cleaning should be done when motorcycle is cool and parked in the shade.

• Page 68: Storage

  STORAGE 1.18 Wash and polish molded-in-color, painted and chrome- GENERAL plated surfaces. If motorcycle is to be covered, use a material that will breathe, such as light canvas. Plastic materials that do Do not store motorcycle with gasoline in tank within the not breathe promote the formation of condensation.

• Page 69: Troubleshooting

  TROUBLESHOOTING 1.19 13. Plugged fuel injectors. GENERAL 14. Fuse blown. NOTE The troubleshooting section of this manual is a guide to dia- Starts Hard gnose problems. Read the appropriate sections of this manual Spark plugs in bad condition or have improper gap or are before performing any work.

• Page 70: Pre-Ignition Or Detonation (Knocks Or Pings)

  Piston rings badly worn or broken. LUBRICATION SYSTEM Valve guides or seals badly worn or damaged. PART NUMBER TOOL NAME Pre-Ignition or Detonation (Knocks or Pings) HD-35457 BLACK LIGHT LEAK DETECTOR Fuel octane rating too low. Oil Does Not Return To Oil Tank Faulty spark plugs.

• Page 71: Electrical System

  Bypass valve stuck in closed position. Clutch Drags Or Does Not Release Restricted oil tank return hose. Lubricant level too high in primary chaincase. ELECTRICAL SYSTEM Clutch controls improperly adjusted. Primary chain badly misaligned. NOTE For diagnostic information, see the Electrical Diagnostic Manual Insufficient clutch spring tension.

• Page 72: Suspension

  Steering head bearings improperly tightened or worn. See SUSPENSION 1.11 STEERING HEAD BEARINGS. Check for proper When making adjustments, remember there are two mediums torque and replace worn bearings. See 2.18 FORK in setting up a bike, geometry and suspension. Both compon- CLAMPS: UPPER AND LOWER.
• Page 73 Table 1-15. Front Suspension Problems TROUBLESHOOTING CONDITION ADJUSTMENT SOLUTION Not absorbing bumps. A good suspension is a balance between damping and track condition. Finding this balance requires exploring all possible compression settings. Lack of tire feedback. Increase compression damping. Tire slides. Decrease compression damping.
• Page 74 NOTES 1-52 2008 XB Service: Maintenance...

• Page 75: Lightning

  SUBJECT..........................PAGE NO. 2.1 SPECIFICATIONS........................2-1 2.2 VEHICLE IDENTIFICATION NUMBER (V.I.N.)................2-4 2.3 WHEELS............................2-6 2.4 FRONT WHEEL.........................2-8 2.5 REAR WHEEL.........................2-16 2.6 TIRES............................2-20 2.7 CHECKING CAST RIM RUNOUT...................2-24 2.8 FRONT BRAKE MASTER CYLINDER AND HAND LEVER...........2-25 2.9 FRONT BRAKE LINE......................2-28 2.10 FRONT BRAKE CALIPER.....................2-30 2.11 BRAKE PEDAL........................2-33 2.12 REAR BRAKE MASTER CYLINDER..................2-34 2.13 REAR BRAKE LINE......................2-40...
• Page 76 NOTES...

• Page 77: Firebolt

  SPECIFICATIONS FIREBOLT NOTE Gross Vehicle Weight (GVWR) (maximum allowable loaded Table 2-1. Dimensions: 2008 Firebolt Models vehicle weight) and corresponding Gross Axle Weight Ratings (GAWR) are given on an information decal located on the ITEM steering head Wheel base 52.0 1320 (without rider) Table 2-3.

• Page 78: Ulysses

  Table 2-6. Weights: 2008 Lightning Models ITEM XB9SX XB12S XB12Scg XB12Ss XB12STT Weight GVWR GAWR front GAWR rear Load capacity All measurements include a full tank of gasoline. ULYSSES Table 2-7. Capacities: 2008 XB12Ss, XB12STT ITEM U.S. LITERS Fuel tank total 4.40 gallons 16.7 (including reserve)
• Page 79 Table 2-9. Weights: 2008 Ulysses Models ITEM XB12X XB12XT (WITH LUGGAGE) XB12XT (WITHOUT LUGGAGE/ BRACKETS) Load capacity All measurements include a full tank of gasoline. NOTE Table 2-10. Capacities: 2008 Ulysses Models Gross Vehicle Weight (GVWR) (maximum allowable loaded ITEM U.S.

• Page 80: Vehicle Identification Number (V.i.n.)

  Table 2-11. Buell V.I.N. Breakdown: 2008 Models POSITION DESCRIPTION POSSIBLE VALUES Market designation (WMI code) 4MZ = Buell vehicles originally manufactured for sale within the United States 5MZ = Buell vehicles originally manufactured for sale outside the United States ® Motorcycle type code AX=Firebolt ™...
• Page 81 Table 2-11. Buell V.I.N. Breakdown: 2008 Models POSITION DESCRIPTION POSSIBLE VALUES Model 0=Blast 2=XB9SX 3=XB12R 4=XB12S 5=XB12Scg 6=XB12Ss 7=XB12X 8=XB12STT A=XB12XT B=1125R D=1125R, 105 HP France Sequential number (last five Varies digits) 2008 XB Service: Chassis 2-5...

• Page 82: General

  WHEELS GENERAL sm00110 Good handling and maximum tire mileage are directly related to the care of wheels and tires. Regularly inspect wheels and tires for damage and wear. If handling problems occur, see 1.19 TROUBLESHOOTING Table 2-12. 1.7 TIRES AND WHEELS for tire pressures.
• Page 83 Tires and wheels are critical items. Since the servicing of Buell tires are equipped with wear bars that run horizont- these components requires special tools and skills, Buell ally across the tread. When wear bars become visible and recommends that you see your dealer for these services.

• Page 84: Removal

  FRONT WHEEL REMOVAL sm00511 Place a scissor jack under jacking point and raise front wheel off ground. For location of jacking point see 4.16 EXHAUST SYSTEM. NOTE Do not operate front brake lever with front wheel removed or caliper pistons may be forced out. Reseating pistons requires caliper disassembly.
• Page 85 50A) and WHEEL BEARING REMOVER/INSTALLER (Part sm00513 No. HD-44060A). Sparingly apply EXTREME PRESSURE LUB- RICANT (Part No. J-23444-A) to the threads of the short forcing screw (1) to prolong service life and ensure smooth operation. Assemble the short forcing screw (1), nut (2), Nice bearing (3), washer (4) and bridge (5).

• Page 86: Front Rotor Removal

  sm00515 sm00517 1. Bridge 2. Nut 3. Forcing screw Figure 2-10. Remove the Spacer Figure 2-8. Remove the Bearing Front Rotor Removal Figure 2-16. Remove and discard rotor mounting fasteners (7). sm00516 Remove and inspect brake rotor (6) for wear and warping. 2.10 FRONT BRAKE CALIPER.

• Page 87: Assembly

  ASSEMBLY sm00518 PART NUMBER TOOL NAME B-43993-10 FRONT WHEEL BEARING INSTALLER B-43993-11 FRONT BACKING PLATE WHEEL B-43993-50A WHEEL BEARING REMOVER/INSTALLER KIT B-43993-7 FRONT WHEEL BEARING REMOVER COLLET B-43993-9 FRONT BEARING INSTALLER B-43993-9, FROM FRONT BEARING INSTALLER KIT PART NO. B- 43993-50A HD-44060A WHEEL BEARING...
• Page 88 sm00519 sm00520 1. Forcing screw 2. Backing plate Figure 2-13. Insert Forcing Screw and Backing Plate Figure 2-13. Remove the backing plate (2) from the long forcing screw (1). Reinstall the Backing Plate onto 1. Long forcing screw the forcing screw, with the smaller diameter toward the 2.
• Page 89 NOTE sm00522 Figure 2-14. Center the spacer (2) while installing the wheel bearing. Failure to center the spacer could cause the bearing not to pull in straight. 11. See Figure 2-15. Insert a new wheel bearing (1) squarely into the hub, with the lettered side facing out (away from the wheel).

• Page 90: Front Rotor Installation

  sm00523 Front axle Front brake springs (6) Rotor mount fastener (6) Wheel bearing Front wheel spacer Drive bushings (6) Front wheel Front brake rotor Washer (6) Figure 2-16. Front Wheel Assembly Front Rotor Installation Figure 2-16. Install new springs (4). Rotor mounting fasteners must be seated into drive Install new washers (9).
• Page 91 Figure 2-17. Install caliper. sm00511 Align wheel so that rotor mounting fasteners straddle caliper. Rotate right front fork counterclockwise to align caliper with rotor. Lower front wheel into caliper assembly. NOTE The front axle is left handed thread. Install front axle. Apply LOCTITE ANTI-SEIZE LUBRICANT to axle.

• Page 92: Removal

  REAR WHEEL REMOVAL CLEANING AND INSPECTION Place a scissor jack under jacking point and raise rear wheel off ground. For location of jacking point see 4.16 EXHAUST SYSTEM. Using compressed air to "spin dry" bearings can cause NOTE bearing to fly apart, which could result in death or serious injury.
• Page 93 sm00525 Rotor mounting fastener (6) Wheel spacer Sprocket fastener Brake rotor Wheel Axle Wheel bearing Sprocket Figure 2-20. Rear Wheel Assembly 2008 XB Service: Chassis 2-17...

• Page 94: Assembly

  ASSEMBLY BACKING PLATES (Part No. B-43993-11 front wheel and B-43993-12 rear wheel). PART NUMBER TOOL NAME The procedure for the rear wheel bearing installation is B-43993-10 FRONT WHEEL BEARING INSTALLER the same as front wheel bearing installation. See 2.4 FRONT WHEEL, Assembly.
• Page 95 Slide axle through right side of swingarm and wheel hub sm00524 and thread partially into swingarm on left side. Install idler pulley. See 6.6 DRIVE BELT AND IDLER PULLEY, Idler Pulley Installation. NOTE Never tighten rear axle with swingarm brace removed. sm00302 Figure 2-24.

• Page 96: General

  TIRES GENERAL Tires should be inspected for punctures, cuts, breaks and wear Buell tires are equipped with wear bars that run horizont- before every ride. ally across the tread. When wear bars become visible and New tires should be stored in a horizontal tire rack. Avoid only 1/32 in.

• Page 97: Removal

  Figure 2-26. Loosening Beads from Rim Flange Buell front and rear tires are not the same. Interchanging front and rear tires can cause tire failure, which could result in death or serious injury. (00512b) Damaged or leaking valve stems must be replaced.

• Page 98: Checking Tire Lateral Runout

  Install valve stem and tighten valve stem nut to 40-44 in- Table 2-14. Tire Runout lbs (4.5-4.9 Nm). TIRE RUNOUT Thoroughly lubricate rim flanges and both beads of tire with tire lubricant. Radial 0.060 1.52 Figure 2-28. Starting at the valve stem, start first bead Lateral 0.080 2.03...

• Page 99: Adjustment

  Make sure that area of application is completely clean, sm04916 dry and free of oil and grease. Remove paper backing from weight. For additional adhesive strength, apply three drops of LOCTITE SUPERBONDER 420 to adhesive side of weight. On the front wheel, locate a flat surface on the right side of the wheel rim.

• Page 100: General

  CHECKING CAST RIM RUNOUT GENERAL sm00111 PART NUMBER TOOL NAME HD-99500-80 WHEEL TRUING AND BALANCING STAND Before installing a new tire, check wheels for lateral and radial runout. Rim Lateral Runout Figure 2-32. Install truing arbor in wheel hub and place wheel in the WHEEL TRUING AND BALANCING STAND (Part No.

• Page 101: 2.30 Deflectors

  FRONT BRAKE MASTER CYLINDER AND HAND LEVER REMOVAL sm00528 On XB9SX,XB12STT, XB12XT and XB12X models, remove the right deflector. See 2.30 DEFLECTORS: XB9SX/XB12STT/XB12X/XB12XT. Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention.

• Page 102: Front Master Cylinder

  from the brake pivot shaft (17) to detach the brake hand Inspect piston bore in master cylinder housing for scoring, lever (8). pitting or corrosion. Replace housing if any of these condi- tions are found. On all other models, remove pivot bolt nut (10) (metric) and pivot bolt (17) to detach the brake hand lever.

• Page 103: Installation

  and thread nut on pivot bolt. On XB9SX,XB12STT,XB12XT and XB12X models, tighten nut to 39-48 in-lbs (4.4-5.4 Nm). On all other models, tighten nut to 80-120 in-lbs (9- After repairing the brake system, test brakes at low speed. 13.5 Nm). If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or INSTALLATION...

• Page 104: 2.32 Front Modules

  FRONT BRAKE LINE REMOVAL sm00533 Drain brake fluid into a suitable container. Discard used fluid according to local laws. Figure 2-39. Remove front caliper bleeder valve cap and install a length of plastic tubing over valve (1). Place free end in a suitable container. Open bleeder valve (metric) about 1/2-turn.
• Page 105 Figure 2-34. Tighten master cylinder banjo bolt (14) (metric) to 16-20 ft-lbs (22-27 Nm). Avoid leakage. Be sure gaskets, banjo bolt(s), brake line Figure 2-39. Tighten brake caliper banjo bolt (2) and master cylinder bore are clean and undamaged before (metric) to 16-20 ft-lbs (22-27 Nm).

• Page 106: Removal

  FRONT BRAKE CALIPER 2.10 REMOVAL sm00535 Drain brake fluid into a suitable container. Discard used fluid according to local laws. Install a length of plastic tubing over caliper bleeder valve. Place free end in a suitable container. Open bleeder valve (metric) about 1/2-turn. Pump brake hand lever to drain brake fluid.

• Page 107: Assembly

  Carefully inspect all components. Replace any parts that INSTALLATION appear damaged or worn. Do not hone caliper piston bore. Figure 2-44. Install pad spring (7) and brake pads (10). Install pin hanger set (1) and tighten to 11-14 ft-lbs (15-19 Always replace brake pads in complete sets for correct Nm).
• Page 108 sm00537 Pin hanger set Piston Caliper mounting fasteners Brake bleeder Piston o-rings Bleeder cap Pad spring Brake pads Caliper Small o-ring Caliper fasteners (4) Figure 2-44. Front Caliper Assembly 2-32 2008 XB Service: Chassis...

• Page 109: Removal

  BRAKE PEDAL 2.11 REMOVAL sm00119 Figure 2-45. Remove cotter pin (3) and discard. Remove clevis pin (2). Remove pedal fastener (4). Remove shift brake pedal sleeve (5). Remove pedal bushings (6). Remove brake pedal (7). INSTALLATION Figure 2-45. Install pedal bushings (6). Install shift brake pedal sleeve (5).

• Page 110: Removal: Firebolt/Lightning

  REAR BRAKE MASTER CYLINDER 2.12 REMOVAL: FIREBOLT/LIGHTNING sm00539 Figure 2-46. Drain brake fluid into a suitable container. Discard used fluid according to local laws. Install a length of plastic tubing over caliper bleeder valve. Place free end in a suitable container. Open bleeder valve (metric) about 1/2-turn.

• Page 111: Removal: Ulysses

  10. See Figure 2-50 Figure 2-51. Detach remote reservoir. sm00541 Remove top clamp (4) on hose connected to master cylinder. Disconnect hose. Remove fastener (2) to detach reservoir (1) from frame if necessary. sm00538 1. Reservoir 2. Fastener and washer 3.
• Page 112 Remove cotter pin from brake pedal. See 2.11 BRAKE Remove fasteners (11) to detach master cylinder (4) from PEDAL. rider footpeg mount. Remove seat. Figure 2-55. Detach remote reservoir. On Ulysses models, remove air flow guide. Figure 2-54. Disconnect brake light connector located under the seat.

• Page 113: Disassembly

  Loosen adjuster locknut on the rod assembly (3). sm00548 Remove the clevis from the rod assembly (3). NOTE Do not disassemble master cylinder unless problems are experienced. Discard all seals during the disassembly pro- cedure. Install a complete rebuild kit upon assembly. CLEANING AND INSPECTION Use denatured alcohol to clean brake system components.

• Page 114: Installation: Firebolt/Lightning

  sm00542 Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury.
• Page 115 Be sure that all lights and switches operate properly before After installing seat, pull upward on seat to be sure it is operating motorcycle. Low visibility of rider can result in locked in position. While riding, a loose seat can shift death or serious injury.

• Page 116: Removal: Firebolt

  REAR BRAKE LINE 2.13 REMOVAL: FIREBOLT sm00550 Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect battery by unthreading fastener removing negative cable (black) from battery first. See 1.4 BATTERY MAINTENANCE.

• Page 117: Removal: Lightning

  NOTE Disconnect battery by unthreading fastener removing Tighten the right side banjo bolt with FLARE NUT negative cable (black) from battery first. See 1.4 BATTERY SOCKET (Part No. SNAP-ON FRXM14) or a crowsfoot. MAINTENANCE. Install brake line, banjo bolt and new copper washers to Figure 2-61.

• Page 118: Removal: Ulysses

  NOTE Disconnect battery by unthreading fastener removing Tighten the right side banjo bolt with FLARE NUT negative cable (black) from battery first. See 1.4 BATTERY SOCKET (Part No. SNAP-ON FRXB14) or a crowsfoot. MAINTENANCE. Install brake line banjo bolt and new copper washers to Figure 2-62.

• Page 119: Installation: Ulysses

  Figure 2-64. Install brake light switch/banjo bolt with sm00552 new copper washers to the master cylinder. Tighten to 16-20 ft-lbs (22-27 Nm). Install brake line bracket and tighten fasteners to 48-72 in-lbs (5-8 Nm). Install the rider/passenger peg mount to the motorcycle. 2.37 HEEL GUARD AND FOOTPEG MOUNTS: ULYSSES MODELS.

• Page 120: Removal

  REAR BRAKE CALIPER 2.14 REMOVAL DISASSEMBLY NOTE PART NUMBER TOOL NAME Steps 1 and 2 are not required for detaching caliper from rotor. B-42887 BRAKE CALILPER PISTON REMOVER Drain fluid only when disassembling caliper. Figure 2-65. Remove pin plug (5) and pad hanger (metric) to free brake pads.

• Page 121: Cleaning And Inspection

  sm00556 Table 2-18. Rear Rotor Runout RUNOUT Rotor radial 0.0177 0.45 Rotor lateral 0.0154 0.39 ASSEMBLY Figure 2-66. Place clip (1) inside caliper body as shown. NOTE To ensure proper brake pad-to-brake rotor clearance when the caliper is installed, piston must be pressed all the way into the bore whenever new brake pads are used.
• Page 122 Figure 2-65. Install caliper assembly on caliper mount. Turn ignition key switch to ON. Apply brake pedal to test Brake pad surfaces must face rear brake rotor. brake lamp operation. Turn ignition key switch to LOCK. Install large caliper fastener (7) (metric) tightening to 18-21 ft-lbs (24-28 Nm).

• Page 123: Front Fender: Xb12R

  FENDERS 2.15 NOTE FRONT FENDER: XB12R It is necessary to align the rear brake line with the rear inner Removal fender. The rear fender captures the rear brake line to help maintain the proper alignment and location. Figure 2-70. Remove fasteners and washers (2) securing the front fender (1) to front forks.

• Page 124: Rear Fender: Xb12Ss/Xb12Stt/Xb12Xt/Xb12X

  right side of the upper front fender before installing and tight- Install the right lower front fender (9) with fasteners (6, 7). ening fastener. Tighten all fender fasteners to 36-48 in-lbs (4.0-5.4 Nm). Figure 2-71. Align front fender (2) to fender mounts on lower triple clamp, apply LOCTITE 271 (red) and Install sm00654 front fender fasteners and washers (1) and tighten to...

• Page 125: Front Fork: All Models Except Xb12Stt/Xb12X/Xb12Xt

  FRONT FORK: ALL MODELS EXCEPT XB12STT/XB12X/XB12XT 2.16 GENERAL sm00559 The front fork consists of two telescoping outer tube/inner slider assemblies. Each assembly has an internal compression spring which supports the forward weight of the vehicle and rider. The compression spring extends and retracts to cushion the ride over rough or irregular road surfaces.

• Page 126: Disassembly

  sm00560 sm00561 Figure 2-73. Stopper Ring DISASSEMBLY PART NUMBER TOOL NAME HD-41177 FORK HOLDING TOOL 1. Fork holding tool 2. Snap ring HD-41177 FORK HOLDING TOOL 3. Preload adjuster HD-45966 FORK SPRING COMPRESSOR 4. Front fork assembly NOTE Figure 2-74. Fork Holding Tool Record rider suspension settings before disassembly.
• Page 127 FORK SPRING COMPRESSOR (Part No. HD-45966) comes with a cup and screw that are for FLT models only NOTE and not to be used with Buell. After fully unthreading preload adjuster, gently pull on adjuster. When using the FORK SPRING COMPRESSOR be sure not to bind the outer fork tube on the tool.

• Page 128: Damper Rod Disassembly

  16. Release the oil seal stopper ring (25) out from the outer damper rod needs servicing refer to the Parts Catalog for tube with a small pry tool. kit information. 17. Using a slide hammer action, remove the slider fork (27) If damper locknut has been moved, proceed with the fol- lowing disassembly and assembly procedures for setting from the outer tube (18).
• Page 129 sm00566 Preload adjuster Damper locknut Stopper ring Preload adjuster o-rings Damper rod assembly Reflector assembly Fork cap Centering plate Slide bushing Fork cap o-ring Sealing washer Guide bushing Preload washer Center bolt Seal spacer Slider piston Collar Oil seal Inner slider piston o-ring Spring joint Oil seal stopper ring Snap ring...

• Page 130: Cleaning And Inspection

  CLEANING AND INSPECTION Figure 2-79. Fully thread the damper locknut (10) on to damper rod assembly (11) clockwise till it lightly bot- Thoroughly clean and inspect all parts. Replace any parts toms. that are bent, broken or damaged. NOTE Figure 2-79.
• Page 131 NOTE Table 2-20. Fork Oil Levels The outer tube can move freely up and down on the slider fork. Always hold both the slider fork and outer tube to prevent MODEL damage to bushings and seals. XB9R, XB12R 4.21 XB9SX, XB12S, XB12Ss 4.21 sm00569 XB12Scg...

• Page 132: Installation

  Figure 2-84. Position fork with alignment lines (4) sm00570 visible and reflector facing to the side and tighten the lower fork clamp. Repeat previous steps on second front fork. Temporarily install front axle to the fork assemblies to verify correct alignment. Use LOCTITE 271 (red) on upper fork clamp fasteners and tighten to 23-25 ft-lbs (31.2-33.8 Nm).

• Page 133: Front Fork: Xb12Stt/Xb12X/Xb12Xt

  FRONT FORK: XB12STT/XB12X/XB12XT 2.17 GENERAL sm00559 The front fork consists of two telescoping outer tube/inner slider assemblies. Each assembly has an internal compression spring which supports the forward weight of the vehicle and rider. The compression spring extends and retracts to cushion the ride over rough or irregular road surfaces.
• Page 134 FRONT FORK COMPRESSOR (Part No. HD-45966) assembly. comes with a cup and screw that are for FLT models only and not to be used with Buell. Figure 2-90. The bottom of the preload adjuster is round with two flat sides so a wrench (2) can be used to...
• Page 135 Hold damper rod assembly jamnut (3) and remove fork sm03822 cap (1). Figure 2-93. Inside the damper rod assembly (6) is a fork push rod (4) that is tapered on one end to control the movement of fluid in the front fork increasing and decreasing the damping properties.
• Page 136 sm03826 Fork cap Bolt, center Guide bushing Seat, rubber Spring collar Seal spacer Slider piston Spring joint Oil seal Push rod Spring Oil seal stopper ring Damper jamnut Stopper ring Dust seal Damper rod assembly Outer tube Slider fork Centering plate Reflector assembly Axle clamp bolt Washer...

• Page 137: Cleaning And Inspection

  CLEANING AND INSPECTION bushing channel to avoid damaging the oil seal lip when installing. Thoroughly clean and inspect all parts. Replace any parts Coat the sealing lips of the new oil seal (19) with fork oil that are bent, broken or damaged. or sealing grease.
• Page 138 NOTE sm03830 When installing the fork spring ensure that the tighter wound portion of the spring is installed down. 17. See Figure 2-93. Install the fork spring (12), fork spring joint (11) and fork spring collar (10) over the damper rod retrieval tool.

• Page 139: Installation

  Slide the stopper ring over top of fork assembly and into sm00570 groove. Install fork assembly into upper fork clamp. Both forks should be adjusted equally. Forks that are not properly adjusted can lead to loss of control, which could result in death or serious injury.

• Page 140: Fork Clamps: Upper And Lower

  FORK CLAMPS: UPPER AND LOWER 2.18 REMOVAL FIREBOLT sm00573 Place a scissor jack under jacking point and raise front wheel off ground. For location of jacking point see 4.16 EXHAUST SYSTEM. Remove handlebars. 2.33 HANDLEBARS: FIREBOLT. Remove cable straps securing wiring harnesses to the upper fork clamp.

• Page 141: Removal: Lightning/Ulysses

  NOTE steering head bearings need replacing, Carefully install the fork into the upper fork clamp. Forcing the 2.19 STEERING HEAD BEARINGS. fork into the upper fork clamp could move the stopper ring out of the groove which will not allow the correct clamp load. sm00574 Install one front fork assembly into lower fork clamp (8).
• Page 142 Figure 2-79. Slide the stopper ring (19) over top of NOTE fork assembly and into groove. For additional information, see 2.16 FRONT FORK: ALL MODELS EXCEPT XB12STT/XB12X/XB12XT. Install fork assembly into upper clamp. Tighten but do not Figure 2-84. Position both forks with same number torque lower fork clamp pinch fasteners.

• Page 143: Steering Head Bearings

  STEERING HEAD BEARINGS 2.19 REMOVAL INSTALLATION Place a scissor jack under jacking point and raise front PART NUMBER TOOL NAME wheel off ground. For location of jacking point see B-43993-12 BACKING PLATE 4.16 EXHAUST SYSTEM. B-45521 STEERING HEAD BEARING Remove brake lever housing. See 2.8 FRONT BRAKE INSTALLATION TOOL MASTER CYLINDER AND HAND...
• Page 144 sm00576 sm00577 Figure 2-104. Steering Head Bearing Lip sm00578 1. Steering head bearing race installer 2. Steering head bearing installer 3. Wheel bearing backing plate Figure 2-103. Steering Head Bearing Installation Tools Figure 2-103. Install new upper steering head bearing into the frame neck using STEERING HEAD BEARING 1.
• Page 145 Install the bearing (4), washer (5) and nut (6) from the 16. Install front brake lever housing. See 2.8 FRONT BRAKE steering head bearing race installer onto the forcing screw MASTER CYLINDER AND HAND LEVER. (1). Tighten the nut (6) by hand, until the bearing is started sm00579 into the bore in the steering head.

• Page 146: Front Fork Slider Protectors: Xb12Stt

  FRONT FORK SLIDER PROTECTORS: XB12STT 2.20 REPLACEMENT: XB12STT sm03835 Figure 2-107. Remove fasteners (2) from left and right front fork slider protectors (1) and remove protectors. Install left and right fork slider protectors applying LOCTITE 271 (red) to fasteners and tighten to 12-36 in-lbs (1.3-4 Nm).

• Page 147: Swingarm And Brace

  SWINGARM AND BRACE 2.21 GENERAL sm00302 The swingarm also serves as the oil tank. For information on the swingarm function as the oil tank, see 3.10 OIL RESER- VOIR AND OIL HOSE ROUTING. The swingarm features a removable brace on the right side to allow drive belt replacement.

• Page 148: Disassembly

  sm00581 Swingarm Oil drain plug Dipstick Pivot shaft Swingarm bushings Brace fastener (4) Swingarm spacer Swingarm brace Swingarm bearing (5) Rear axle pinch fastener Engine crankcase Jiffy Tite oil line fittings (3) 7. Pivot shaft pinch fastener with nut Figure 2-109. Swingarm Assembly DISASSEMBLY Figure 2-109.

• Page 149: Assembly

  Carefully inspect all bearing components for wear and/or sm00585 corrosion. Replace complete bearing assembly if any component is damaged. Check that swingarm is not bent or twisted. Replace if damaged. ASSEMBLY PART NUMBER TOOL NAME HD-44060-6 BEARING INSTALLER Swingarm Figure 2-109.
• Page 150 Install rear inner fender and tighten fasteners to 12-36 in- 14. Connect battery cables to battery: positive cable (red) first. lbs (1.4-4 Nm). Tighten to 72-96 in-lbs (8-11 Nm). See 1.4 BATTERY MAINTENANCE. Connect three oil lines to swingarm fittings and install and tighten p-clamps to 48-72 in-lbs (5.4-8 Nm).

• Page 151: Front And Rear Isolators

  FRONT AND REAR ISOLATORS 2.22 FRONT ISOLATOR sm05389 Removal NOTE Avoid cross-threading front isolator bolt or insert. Keep weight of motorcycle off front isolator by alternately loosening front isolator bolt and raising scissor jack to support engine. Place a scissor jack under jacking point for supporting engine only.

• Page 152: Installation

  FRAME PUCKS 2.23 From the tacked corners, pivot the puck onto the frame REMOVAL keeping the directional point aligned with the horizontal crease. The aluminum frame of this motorcycle is the fuel tank. is00878 Drilling, welding, cutting, grinding, sanding, polishing or other modifications to this frame can weaken it or cause a fire, which could result in death or serious injury.

• Page 153: Frame

  FRAME 2.24 Install main wire harness. See 7.23 MAIN WIRE HAR- REMOVAL NESS. Remove fuel from frame. See 4.13 FUEL PUMP, Draining Install upper and lower fork clamps. See 2.18 FORK Fuel Tank. CLAMPS: UPPER AND LOWER. Rotate engine. See 3.3 ENGINE ROTATION FOR SER- Install rear shock.

• Page 154: General

  REAR SHOCK ABSORBER 2.25 GENERAL The rear suspension is controlled by the shock absorber. The shock allows adjustment of rear compression and rebound damping and spring preload. sm00588 Shock remote reservoir clamp fastener Lower shock mount Shock remote reservoir clamp Lower shock mount sleeve Shock remote reservoir Lower shock mount fastener...
• Page 155 sm00591 XB9SX,XB12S XB12Ss XB12Scg XB12STT Remote reservoir clamp fastener Lower shock mount fastener Remote reservoir clamp Shock reservoir body Remote reservoir Upper shock mount fastener Lower shock mount nut Lower shock mount Washers (2) Shock spring retainer kit Lower shock mount sleeve Rear shock spring Figure 2-118.

• Page 156: Removal: Firebolt

  sm00594 Screw and washer, preload adjuster knob Lower shock mount nut Preload adjuster knob Lower shock mount washer, thick Preload adjust assembly Lower shock mount washer, thin Preload adjuster fasteners (2) Lower shock mount sleeve Rear shock body Lower shock mount fastener Remote reservoir clamp fastener Upper shock mount fastener Remote reservoir clamp...

• Page 157: Removal: Lightning

  Disconnect and remove battery. See 1.4 BATTERY Remove the nut (4) and washer (5) from the lower MAINTENANCE. shock bolt and raise scissor jack until the lower bolt can be removed by hand. Remove tail body work. See 2.41 SUBFRAME TAIL ASSEMBLY AND BODY WORK: FIREBOLT.

• Page 158: Installation: Firebolt

  Remove ECM. See 4.3 ELECTRONIC CONTROL MODULE (ECM). NOTE Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, When removing the ECM, the fastener closest to the shock the resulting sparks can cause a battery explosion, which assembly has a nut that is captured in the plastic shield below could result in death or serious injury.

• Page 159: Installation: Ulysses

  Install the two fasteners holding the preload adjuster in place and tighten to 36-60 in-lbs (4.0-6.7 Nm). Connect positive (+) battery cable first. If positive (+) cable Install rear shock reservoir clamp (7) and fastener (6) and should contact ground with negative (-) cable connected, tighten clamp fastener to 80-88 in-lbs (9.0-9.9 Nm).

• Page 160: Throttle Control

  THROTTLE CONTROL 2.26 REMOVAL AND DISASSEMBLY sm00596 On XB9SX, XB12STT, XB12XT and XB12X models, remove right handlebar deflector. See 2.30 DEFLECTORS: XB9SX/XB12STT/XB12X/XB12XT. NOTES Figure 2-125. The XB12STT models only require a throttle cable alignment clip. On Ulysses models, it will be necessary to disconnect and remove the heated handgrips.

• Page 161: Cleaning And Inspection

  NOTES Position the lower idle control cable barrel in the throttle On all 2008 Buell XB Models, the throttle cables have cam wheel of the throttle body and then slip the elbow into threaded adjustments on both ends of the cable.
• Page 162 becoming loose and the retaining clip will be secured to the sm03923 bracket. With the throttle cables secure at the throttle body, you will be able adjust the cables at the right hand grip. See 1.14 THROTTLE CABLE. NOTE If, after the throttle cables have been adjusted, there is not enough slack in the cables the throttle plate will not be responsive and cleanly snap back to the closed position.

• Page 163: Clutch Control

  CLUTCH CONTROL 2.27 GENERAL sm04195 For clutch adjustment, see 1.8 CLUTCH/TRANSMIS- SION/PRIMARY FLUID. For clutch replacement, see CLUTCH. REMOVAL AND DISASSEMBLY Clutch Cable Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding.
• Page 164 end from slot in coupling. See 6.3 CLUTCH RELEASE 14. See Figure 2-136. Unscrew the cable fitting from the MECHANISM. primary cover. Remove clutch cable and fitting. 15. Remove and discard o-ring on the clutch cable fitting. sm00602 1. Primary cover 2.

• Page 165: Assembly And Installation

  After applying LOCTITE 271 (red), install flange bolt (6) sm00268 and shift pedal (4) to primary cover, and tighten to 22-24 ft-lbs (30-32.5 Nm). After applying LOCTITE 271 (red), tighten engine shift lever pinch screw to 48-60 in-lbs (5.4-6.8 Nm). Figure 2-137.
• Page 166 16. Connect front tie bar to "V" bracket and tighten fastener to 25-27 ft-lbs (33.9-36.6 Nm). 17. Adjust clutch cable. See 1.8 CLUTCH/TRANSMIS- After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift SION/PRIMARY FLUID.

• Page 167: Headlamp Assembly And Support Bracket

  HEADLAMP ASSEMBLY AND SUPPORT BRACKET 2.28 REMOVAL: FIREBOLT sm00605 Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect battery cables from battery: negative cable (black) first. See 1.4 BATTERY MAINTENANCE.

• Page 168: Installation: Firebolt

  sm00606 Headlight pivot fasteners Headlight fastener Headlight support bracket High beam headlight Electronic control module fasteners Headlight bulb Black rubber cover Bank angle sensor Low beam headlight Bank angle sensor fastener with washers Figure 2-140. Headlight Support Bracket Assembly: Firebolt INSTALLATION: FIREBOLT Figure 2-141.

• Page 169: Removal: Lightning/Ulysses

  Remove windscreen and windshield. See 2.50 WIND- sm00607 SHIELD WINDSCREEN: LIGHTNING ULYSSES. Disconnect horn connectors [122] (2). For Lightning Models: See Figure 2-142. For Ulysses: See Figure 2-143. NOTE Horn (1) can remain attached to support bracket. The horn can be removed and replaced as needed.
• Page 170 sm00608 Horn Fasteners (2), upper headlight mounting Horn connectors [122] Headlight assembly Horn bracket Fasteners (2), headlight support bracket Horn fastener Headlight support bracket Headlight connector [38] Left and right front modules Figure 2-142. Electrical Connectors Behind Windscreen: Lightning 2-94 2008 XB Service: Chassis...

• Page 171: Disassembly: Lightning/Ulysses

  sm00621 Horn Screws (2), upper headlight mounting Horn connectors [122] Headlight assembly Horn bracket Screws (2), headlight support bracket Horn fastener Headlight support bracket Headlight connector [38] Left and right front modules Figure 2-143. Headlight and Support Bracket: Ulysses DISASSEMBLY: LIGHTNING/ULYSSES ASSEMBLY: LIGHTNING/ULYSSES Figure 2-144.

• Page 172: Installation: Lightning/Ulysses

  sm00622 Boot (2) Wiring harness Bulb holder (2) Position bulb socket (used for HDI only) Bulb (2) Headlight connector 4. Headlight housing Figure 2-144. Headlight Assembly INSTALLATION: LIGHTNING/ULYSSES Connect horn connectors [122] (2). Adjust headlights. See 1.16 HEADLIGHT. Install headlight support bracket (9). For Lightning Models: See Figure 2-142.

• Page 173: Removal

  FAIRING SUPPORT BRACKET: FIREBOLT 2.29 Connect instrument cluster connector and install instru- REMOVAL ment cluster. Tightening to 12-36 in-lbs (1.3-4 Nm). See Remove seat. 7.22 INSTRUMENT MODULE. Install horn and tighten fasteners to 72-96 in-lbs (8-10 Nm). See 7.10 HORN. To prevent accidental vehicle start-up, which could cause Install fuse block, relay and p-clamp tightening fasteners death or serious injury, disconnect negative (-) battery...
• Page 174 sm00625 Jam nut Fairing support bracket Washer Instrument cluster Rubber grommet P-clamp Fairing support bracket fasteners and washers P-clamp fastener and washers Figure 2-145. Fairing Support Bracket Assembly: Firebolt 2-98 2008 XB Service: Chassis...

• Page 175: Deflectors: Xb9Sx/Xb12Stt/Xb12X/Xb12Xt

  DEFLECTORS: XB9SX/XB12STT/XB12X/XB12XT 2.30 REMOVAL AND DISASSEMBLY ASSEMBLY AND INSTALLATION Figure 2-146. Remove fasteners (2) from clutch and brake Install brake and clutch levers with pivot shafts (3, 6). See pivot shafts (3, 6) and pivot shaft risers (4). 2.27 CLUTCH CONTROL 2.8 FRONT BRAKE MASTER CYLINDER AND HAND LEVER.

• Page 176: Grille: Xb9Sx/Xb12Stt/Xb12X

  GRILLE: XB9SX/XB12STT/XB12X 2.31 GENERAL sm00572 Figure 2-147. The headlamp grille is offered as a standard feature on the XB9SX, XB12STT, and XB12X models to provide additional protection for the headlight assemblies. REMOVAL AND INSTALLATION Figure 2-147. Grab headlamp grille on either side and spread to remove from headlamp assemblies.

• Page 177: Front Modules: Lightning/Ulysses

  FRONT MODULES: LIGHTNING/ULYSSES 2.32 REMOVAL sm03875 Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect battery cables from battery: negative cable (black) first. See 1.4 BATTERY MAINTENANCE.

• Page 178: Installation

  Attach front brake line p-clamp to rear of right front module sm03877 and tighten fastener to 36-60 in-lbs (4.1-6.8 Nm). Install ignition switch. See 7.3 IGNITION/HEADLAMP KEY SWITCH. Install connect instrument module. 7.22 INSTRUMENT MODULE. Connect turn signals. See 7.12 FRONT TURN SIGNALS.

• Page 179: Right Clip-On

  HANDLEBARS: FIREBOLT 2.33 GENERAL Left Clip-On Install clutch hand lever assembly onto clip-on. Tighten Firebolt handlebars are a clip-on assembly and are not but do not torque. adjustable. Install left switch gear housing. REMOVAL Figure 2-152. Install grip and end cap (1). Right Clip-On Install left clip-on into upper fork clamp (3) and tighten Remove right switch gear housing.

• Page 180: Installation

  HANDLEBARS: LIGHTNING/ULYSSES 2.34 Install clutch hand control. Tighten but do not torque. See REMOVAL 2.27 CLUTCH CONTROL. Remove seat. Install left switch housing. NOTE Check control wire routings. See D.1 APPENDIX D: HOSE On Ulysses Models, it will be necessary to disconnect and AND WIRE ROUTING.

• Page 181: Assembly

  sm03889 1. End cap 2. Harness retainers 3. Clamp fasteners 4. Handlebar clamp 5. Left hand grip (XB12X models are OEM equipped with heated handgrips) 6. Handlebar (XB12X, XB12XT) 7. Handlebar (XB9SX, XB12STT) 8. Handlebar (XB12S, XB12Scg, XB12Ss) Figure 2-153. Handlebar Assembly: Lightning/Ulysses 2008 XB Service: Chassis 2-105...

• Page 182: Installation

  MIRRORS 2.35 NOTES REMOVAL In a convex mirror, cars and other objects will look smaller Figure 2-154. Loosen adjuster nut (2) and remove and farther away than they actually are. Adjust mirrors to mirror (1) from mount (3). see a small portion of the riders shoulders in each mirror. This helps the rider establish the relative distance of Loosen mount (3) and remove from bracket (4).

• Page 183: Footpeg, Heel Guard And Mount: Firebolt/Lightning

  FOOTPEG, HEEL GUARD AND MOUNT: FIREBOLT/LIGHTNING 2.36 RIDER sm03637 Wear Peg Removal Figure 2-155. Remove wear peg (7) from end of footpeg assembly. Footpeg Removal Figure 2-155. Remove clip (5). Remove footpeg pin (9). Remove footpeg (8). Heel Guard Removal Figure 2-155.

• Page 184: Mount Installation

  Mount Installation sm03837 Figure 2-156. Position footpeg mount (3) onto sub- frame tail assembly. Install footpeg mount (3). Using LOCTITE 271 tighten, fasteners (10) to 25-28 ft-lbs (34-38 Nm). Heel Guard Installation Figure 2-156. Position heel guard (2) onto footpeg mounts (3).

• Page 185: Heel Guard And Footpeg Mounts: Ulysses Models

  HEEL GUARD AND FOOTPEG MOUNTS: ULYSSES MODELS 2.37 RIDER FOOTPEGS sm03636 Footpeg Removal Figure 2-157. Remove clip (3). Remove footpeg pin (8). Remove footpeg (10) and spring (9). Footpeg Installation Figure 2-157. Fit spring ends to footpeg mount and footpeg. Hold footpeg (10), controlling spring, to footpeg mount (1).

• Page 186: Heel Guard Replacement

  Install footpeg mount fasteners (2), and tighten to 132-144 HEEL GUARD REPLACEMENT in-lbs (15-16 Nm). Figure 2-160. If necessary, cut the rubber heel guard Install brake pedal fastener. See 2.11 BRAKE PEDAL. tabs on the inside of the footpeg mount to remove the heel guard.

• Page 187: Sprocket Cover

  SPROCKET COVER 2.38 REMOVAL sm00123 Figure 2-161. Remove rear right chin fairing fasteners. Figure 2-162. Remove sprocket cover fasteners and washers (1, 3). INSTALLATION NOTE Apply LOCTITE 222 (purple) to long fastener (1) only. Figure 2-162. Install sprocket cover (2) using sprocket cover fasteners (1, 3) and tighten all fasteners and washers (1) to 12-36 in-lbs (1-4 Nm).

• Page 188: Belt Guards

  BELT GUARDS 2.39 REMOVAL INSTALLATION Place a scissor jack under jacking point and raise rear Figure 2-163. Install upper belt guard (1) to swingarm wheel off ground. For location of jacking point see brace tightening fasteners (2) to 12-36 in-lbs (1-4 Nm). 4.16 EXHAUST SYSTEM.

• Page 189: Intake Cover

  INTAKE COVER 2.40 REMOVAL INSTALLATION Figure 2-164 Position intake cover assembly (2) over top NOTE of air cleaner cover. Figure 2-164. The X-Guard (1) on the XB9SX model is a non-replaceable part. NOTE Front fasteners are installed at a slight angle. Remove seat.
• Page 190 sm00656 1. X-Guard (XB9SX only) 2. Intake cover assembly 3. Rear intake cover fasteners with nylon washers (2) 4. Front intake cover fasteners with nylon washers (2) (models without translucent covers) 5. Front intake cover fasteners with top hat bushings (2) and isolating washers (4) (translucent covers only) Figure 2-164.

• Page 191: Subframe Tail Assembly And Body Work: Firebolt

  SUBFRAME TAIL ASSEMBLY AND BODY WORK: FIREBOLT 2.41 Figure 2-165. Remove upper body work (1) from DISASSEMBLY subframe tail assembly (7). Remove seat and pillion. Remove body work fasteners (2). Disconnect passenger seat lock cable (6) by removing cable from seat lock plate (4) and ferrule from keylock (3).
• Page 192 sm00657 Upper tail body work Subframe tail assembly fasteners Upper tail body work fasteners Lower tail body work Passenger seat lock Lower tail body work fasteners Passenger seat lock plate Trunk Passenger seat lock retainer Fastener Passenger seat lock cable License plate bracket Subframe tail assembly Passenger seat latch and fastener...
• Page 193 18. Disconnect fuel pump connection and remove connector sm00432 from subframe tail assembly. See 4.13 FUEL PUMP. 19. Remove shock reservoir fasteners and feed the reservoir out of subframe tail assembly. See 2.25 REAR SHOCK ABSORBER. 20. See Figure 2-165. Remove subframe tail assembly fasteners (8) and remove subframe tail assembly (7) from frame.

• Page 194: Cleaning

  hose. See D.1 APPENDIX D: HOSE AND WIRE ROUTING sm00660 for hose and wire routing. 10. Install cable strap (3) holding shock reservoir hose, wire harness and fuel vent hose to subframe tail assembly. 11. See Figure 2-168. Feed rear brake reservoir hose under- neath subframe tail assembly and install rear brake reservoir tightening fastener to 48-72 in-lbs (5.4-8.1 Nm).
• Page 195 Connect positive (+) battery cable first. If positive (+) cable After installing seat, pull upward on seat to be sure it is should contact ground with negative (-) cable connected, locked in position. While riding, a loose seat can shift the resulting sparks can cause a battery explosion, which causing loss of control, which could result in death or could result in death or serious injury.

• Page 196: Left Tail Section And Battery Pan: Lightning

  LEFT TAIL SECTION AND BATTERY PAN: LIGHTNING 2.42 Figure 2-169. Remove fuse block and relay center DISASSEMBLY from support bracket. Remove seat. Move rear main harness and shock absorber reservoir to right side of vehicle. Remove left side passenger footrest support assembly. Disconnect negative (-) battery cable first.

• Page 197: Cleaning

  sm00661 Main harness Bank angle sensor (BAS) connector [134] Main harness ground (high voltage ground wire) Right turn signal connector [18] Battery negative cable Left turn signal connector [19] (under remote Battery positive cable License plate lamp connector [45] Rear brake light switch connector [121] Tail light connectors [93] Ground terminals [GRD1] and [GRD3] Left and right trunk pan fasteners...

• Page 198: Assembly

  ASSEMBLY Figure 2-169. Connect: Wire harness ground (2) [GRD 2]. NOTE Rear brake light switch connector (5) [121]. Figure 2-170. There are two threaded plastic lugs (14) on the trunk pan that are used for manufacturing purposes only. ECM connectors (7) [10, 11] and [164] (on XB12 models).
• Page 199 is02466 1. Left and right tail section fastener to main frame/fuel tank assembly (4) 2. Right tail section 3. Center tail section 4. Center tail section fastener to rear tail section (4) 5. Left tail section 6. Ground terminal fastener (2) 7.

• Page 200: Center Tail Section: Lightning

  CENTER TAIL SECTION: LIGHTNING 2.43 Install two fasteners (12) securing trunk pan to center tail DISASSEMBLY section but do not tighten. Remove seat. Apply LOCTITE 271 (red) to threads of left and right rear tail sections fasteners (4) and tighten to 102-114 in- lbs (11.5-12.8 Nm).

• Page 201: Assembly

  RIGHT TAIL SECTION: LIGHTNING 2.44 DISASSEMBLY ASSEMBLY Remove seat. Figure 2-169. Install right tail section (16) onto vehicle. Install fastener (14) attaching right front trunk pan to right side tail section and tighten to 12-36 in-lbs (1.4- 4 Nm). Disconnect negative (-) battery cable first. If positive (+) On XB12Ss models, apply LOCTITE 271 (red) and cable should contact ground with negative (-) cable con- install battery tray fasteners and tighten to 48-72 in-...

• Page 202: Cleaning

  LEFT TAIL SECTION AND BATTERY PAN: XB12X/XB12XT 2.45 the fastener to retain the nut in the correct location. The DISASSEMBLY rear fastener attaches directly to the battery pan. Remove seat. Disconnect rear brake light switch connector [121]. Disconnect and remove Bank Angle Sensor (2) [134]. Remove fuse block and relay center (5).

• Page 203: Assembly

  sm04798 Main harness Battery positive cable Electronic control module Left rear and right rear tail section fasteners (4) ECM connectors [10] and [11] Seat lock cable Fuse block and relay center Bank angle sensor (BAS) connector [134] Main harness ground wire [GRD2] Auxiliary power outlet Main harness with plastic grommet Trunk pan...
• Page 204 10. Install seat. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) sm00663 1. Fastener, washer and nut to main frame/fuel tank assembly (4) 2.

• Page 205: Center Tail Loop: Xb12X/Xb12Xt

  CENTER TAIL LOOP: XB12X/XB12XT 2.46 Tighten nuts of left and right tail sections to 20-22 ft- DISASSEMBLY lbs (27-30 Nm). Repeat to verify torque. Remove seat. Connect: Right turn signal connector [18]. Left turn signal connector [19]. Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable con- License plate lamp connector [45].
• Page 206 sm00664 1. Tail loop 2. License plate bracket 3. Wire cover Figure 2-173. Wire Cover, Tail Loop and License Plate Bracket: Ulysses 2-130 2008 XB Service: Chassis...

• Page 207: Right Tail Section: Xb12X/Xb12Xt

  RIGHT TAIL SECTION: XB12X/XB12XT 2.47 DISASSEMBLY sm00665 Remove seat. NOTES Before removing right tail section, it will be necessary to remove certain components of the luggage system. See LUGGAGE: XB12XT. The center tail loop must be removed before removing the left or right tail sections.

• Page 208: Assembly

  Install master cylinder remote reservoir. See 2.12 REAR sm00667 BRAKE MASTER CYLINDER. Install shock reservoir, retainer, and fastener. Tighten to 80-88 in-lbs (9.0-9.9 Nm). Connect rear brake light switch connector [121]. Be sure that all lights and switches operate properly before operating motorcycle.

• Page 209: Sidestand

  SIDESTAND 2.48 GENERAL sm03932 This motorcycle does NOT have a locking sidestand. Park the motorcycle on a level, firm surface. An unbalanced motorcycle can fall, which could result in death or serious injury. (00122a) The sidestand is located on the left side of the motorcycle. The sidestand swings outward to support the motorcycle for parking.

• Page 210: Assembly

  Retract sidestand leg (9). sm05260 Install spring extension plate (2) and sidestand spring (1) using SNAP-ON SPRING TOOL (Part No. HE-52B). Extension plate should curve away from primary chain adjustment screw to allow for clearance around adjustment screw. INSTALLATION Figure 2-179.

• Page 211: Front Fairing, Windshield, And Mirrors: Firebolt

  FRONT FAIRING, WINDSHIELD, AND MIRRORS: FIREBOLT 2.49 REMOVAL INSTALLATION Figure 2-181. Remove two center (4) and four side Figure 2-181. Position fairing (5) onto fairing support windscreen fasteners (3) to remove windshield (1). bracket and install turn signals (6, 7). See 7.12 FRONT TURN SIGNALS.

• Page 212: Windshield And Windscreen: Lightning And Ulysses

  WINDSHIELD AND WINDSCREEN: LIGHTNING AND ULYSSES 2.50 Remove windscreen (4). REMOVAL: LIGHTNING INSTALLATION: LIGHTNING NOTE Figure 2-182.The windscreen fasteners (3) extend through Figure 2-182. Position windscreen (4) onto left and the left and right front modules (2, 5) and thread into the right front modules (2, 5).

• Page 213: Removal: Ulysses Xb12X

  REMOVAL: ULYSSES XB12X Remove windscreen (6). INSTALLATION: ULYSSES XB12X NOTES The windshield releases from the windscreen by pulling Figure 2-183. Position windscreen (6) onto left and outward and away from vehicle. right front modules (2, 8) and the center fairing support (7).

• Page 214: Removal: Ulysses Xb12Xt

  REMOVAL: ULYSSES XB12XT After removing the lower windshield mounting hardware it will be necessary to pull the windshield loose from the NOTES windscreen by pulling up sharply at the upper mounting pins. Figure 2-184. The windshield is secured to the wind- screen using two screws (4) with well nuts (6) and two Remove windshield mounting hardware (3) securing the mounting pins (2).

• Page 215: Installation: Ulysses Xb12Xt

  INSTALLATION: ULYSSES XB12XT pd00272 Figure 2-184. . Install windshield onto windscreen by aligning the mounting pins (2) on the windshield with the mounting grommets (12) on the windscreen and pushing in place to install. Pull on windshield to verify attachment. Insert well nuts (6) into the windshield and windscreen holes.

• Page 216: Number Plates: Xb12Stt

  NUMBER PLATES: XB12STT 2.51 GENERAL sm03839 The tail section number plates as well as the flyscreen number plate can be used by the rider to customize and personalize his/her motorcycle. REMOVAL Figure 2-186. Remove screw attaching the number plate to the reflector bracket (5). NOTES Figure 2-187.

• Page 217: Installation

  INSTALLATION Install screw (4) attaching the number plate (1) to the reflector bracket (5) and leave loose. Figure 2-186. Install number plates (1) to left and right Tighten the number plate screws (2) to 18-20 ft-lbs (24-27 tail sections using screws (2) and sleeves (3) and leave Nm).

• Page 218: Air Scoops

  AIR SCOOPS 2.52 RAM AIR SCOOP ENGINE SHROUD AIR SCOOP Removal Removal Figure 2-188. On right side of bike, locate engine NOTE shroud air scoop (6). When removing and installing the left air scoop, the alternator and voltage regulator harnesses and connections are secured Remove three engine shroud air scoop fasteners (5).

• Page 219: Oil Cooler Air Scoop

  sm00124 Oil cooler air scoop fastener and washer (2) Ram air scoop Oil cooler air scoop Engine shroud scoop fastener and washer (3) Ram air scoop fastener and washer Engine shroud scoop Figure 2-188. Ram Air Scoop, Engine Shroud, and Oil Cooler 2008 XB Service: Chassis 2-143...

• Page 220: Removal

  CHIN FAIRING 2.53 Align left section (3) and loosely install left side fasteners REMOVAL and washers (4). Turn wheel full right or left for easier access to center Tighten all fasteners to 36-48 in-lbs (4-5 Nm). fasteners. Figure 2-189. Remove center section fasteners and washers (2).

• Page 221: Seat

  SEAT 2.54 FIREBOLT Pillion Rider Seat NOTE The trunk is located under the pillion. Figure 2-190. Peel up rear corners of seat and remove two fasteners. Figure 2-192. Insert ignition key into the pillion lock located on the left side of motorcycle. Turn key clockwise Pull seat back over tail section and remove.

• Page 222: Installation

  Figure 2-198. Align seat hooks (1) with mounting om00339 posts in tail section. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury.

• Page 223: Installation

  Figure 2-200. Insert key into seat lock and turn pd00187 clockwise approximately 1/8 turn. Seat will unlatch at rear. Figure 2-201. Grip rear of seat and pull toward rear of motorcycle to remove. om00576 Figure 2-200. Seat Lock: Ulysses Models om00574 1.
• Page 224 pd00249 1. Seat hook 2. Seat lock latch 3. Front tab Figure 2-202. Seat Tab/Hooks: Ulysses Models 2-148 2008 XB Service: Chassis...

• Page 225: Seat Locks

  SEAT LOCKS 2.55 NOTES REMOVAL: LIGHTNING Once seat lock has been started through the hole in the Remove seat. trunk pan and plate, now is the time to connect the cable end to the seat lock. Cut cable strap loosely securing BAS wiring harness to seat lock cable.

• Page 226: Removal: Ulysses Models

  sm00689 Seat lock Retainer Plate Cable end Retainer Latch Cable end Latch bracket Cable Trunk pan 6. Latch screw Figure 2-203. Seat Lock Assembly: Lightning NOTE REMOVAL: ULYSSES MODELS When removing seat lock (1), cable end (4) should release Remove seat. from seat lock.

• Page 227: Pillion Lock Removal: Xb12R

  Install seat lock retainer (3) by aligning retainer to retainer sm03841 grooves on back side of seat lock (1). Connect seat lock cable to latch: Install cable end (6) and cable (5) onto latch (8). Install latch (8) to latch bracket (9) and tighten fasteners (7) to 60-96 in-lbs (6.7-10.8 Nm).

• Page 228: Pillion Lock Installation: Xb12R

  Remove seat lock lever (4) by removing fastener (2) and washer (3) from seat lock (7). Remove spring (5). After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift Remove seat lock clip (1) by sliding from seat lock plate causing loss of control, which could result in death or (6).

• Page 229: Triple Tail: Ulysses

  TRIPLE TAIL: ULYSSES 2.56 the upright position, it is a passenger backrest (2) with subtle GENERAL flex for passenger comfort. When in the rearward position, you Figure 2-206. The Triple Tail when folded forward acts as can carry a passenger and have a luggage rack (3) for extra a luggage rack (1) with integrated tie-down hooks.

• Page 230: Installation

  Using a Snap-on seal and bushing driver, tap in the Holding the rack, fit the RH grab handle (2) unto the front bearing. fastener and install the rear fastener. Do not tighten. Tighten front and rear fasteners to the following specifica- INSTALLATION tions: Figure...

• Page 231: Luggage: Xb12Xt

  LUGGAGE: XB12XT 2.57 REMOVAL: SIDE CASE NOTES The side cases and brackets may be removed without removing the top case and bracket. This procedure is recommended for service only. The vehicle should never Do not exceed the motorcycle's Gross Vehicle Weight be operated with just the top case in place.

• Page 232: Installation: Side Case

  Figure 2-208. Place key in side case locking latch sm05145 (12), on front surface of side case, in open position. Open latch. Remove side case by pulling away from vehicle. Remove fastener (10) securing the side case bracket (11) to the back of the passenger footrest support bracket. Remove fastener and locknut (5) securing the X-brace bracket (1) to the side case bracket (6).

• Page 233: Installation: Top Case

  Figure 2-210. Slide top case on mounting bracket to sm05230 the rear of the motorcycle until top case can be removed from bracket. Remove the fasteners with nuts securing the bracket lower mounts to the cross bar arms. Remove fasteners securing the top case bracket to the passenger grab handle and remove bracket from vehicle.

• Page 234: Installation

  Installation Figure 2-211 Figure 2-212. Install two new Phillips head screws into latch mechanism and tighten. Figure 2-213. Install lock into new latch mechanism NOTE and secure with large hex nut. Figure 2-212. On the top case it will be necessary to press Slide latch mechanism into luggage case.
• Page 235 SUBJECT..........................PAGE NO. 3.1 SPECIFICATIONS........................3-1 3.2 ENGINE.............................3-5 3.3 ENGINE ROTATION FOR SERVICE..................3-7 3.4 ENGINE REMOVAL.........................3-13 3.5 ENGINE INSTALLATION......................3-23 3.6 CYLINDER HEAD........................3-34 3.7 CYLINDER AND PISTON......................3-49 3.8 OILING SYSTEM........................3-58 3.9 OIL PUMP..........................3-59 3.10 OIL RESERVOIR AND OIL HOSE ROUTING...............3-65 3.11 OIL LINE FITTINGS......................3-67 3.12 OIL COOLER.........................3-69 3.13 OIL PRESSURE INDICATOR SWITCH.................3-70 3.14 CRANKCASE BREATHING SYSTEM...................3-72...
• Page 236 NOTES...

• Page 237: Specifications

  SPECIFICATIONS not given under SERVICE WEAR LIMITS, see NEW COMPON- GENERAL ENTS. NOTE Service wear limits are given as a guideline for measuring components that are not new. For measurement specifications Table 3-1. General Engine Specifications ITEM SPECIFICATION Type 2 cylinder, air cooled, four-stroke 45 degree V-twin Compression ratio 10:1 Bore (all models)
• Page 238 Table 3-5. Rocker Arm Specifications ROCKER ARM NEW COMPONENTS SERVICE WEAR LIMITS Shaft fit in bushing (loose) 0.0005-0.0020 in. 0.0127-0.0508 mm 0.0035 in. 0.0889 mm End clearance 0.003-0.013 in. 0.076-0.330 mm 0.025 in. 0.635 mm Bushing fit in rocker arm (tight) 0.004-0.002 in.
• Page 239 Table 3-10. Hydraulic Lifter Specifications HYDRAULIC LIFTER NEW COMPONENTS SERVICE WEAR LIMITS Fit in guide 0.008-0.0020 in. 0.0203-0.0508 mm 0.0030 in. 0.0762 mm Roller fit 0.0006-0.0010 in. 0.0152-0.0254 mm 0.0015 in. 0.0381 mm Roller end clearance 0.008-0.022 in. 0.203-0.559 mm 0.026 in.
• Page 240 Table 3-15. Pinion Shaft (Right Main) Bearing Specifications PINION SHAFT BEARINGS NEW COMPONENTS SERVICE WEAR LIMITS Bearing running clearance 0.00012-0.00086 in. 0.003-0.022 mm Fit in oil pump body bore. 0.0023-0.0043 in. 0.058-0.109 mm 0.0050 in. 0.127 mm 3-4 2008 XB Service: Engine...

• Page 241: Engine

  Use a CYLINDER LEAKDOWN TESTER (Part No. HD-35667A) to give attention to all of the cylinder head and cylinder parts. and follow the instructions supplied with the tester. COMPRESSION TEST The following are some general instructions that apply to Buell motorcycle engines: PART NUMBER TOOL NAME Run engine until it reaches normal operating temperature.

• Page 242: Diagnosing Smoking Engine Or High Oil Consumption

  NOTE DIAGNOSING SMOKING ENGINE OR HIGH If air is escaping through valves, check push rod length. OIL CONSUMPTION Repeat procedure on rear cylinder. Perform the Compression Test and/or the Cylinder Leakage NOTE Test. See 3.2 ENGINE, Compression Test 3.2 ENGINE, After completing the compression test(s), make sure that the Cylinder Leakage Test.

• Page 243: Engine Rotation For Service

  ENGINE ROTATION FOR SERVICE GENERAL The following process allows you to rotate engine down, To prevent accidental vehicle start-up, which could cause pivoting on rear isolator mount, in order to service components death or serious injury, disconnect negative (-) battery in the top end.
• Page 244 sm03746 Coil Fuel line connection Coil connection [83] Throttle position sensor connection [88] Coil wire harness retaining clip IAT sensor [89] Throttle cables Engine temperature sensor connection [90] Fuel injector connections [84 & 85] Oxygen sensor conection [137] 6. IAC sensor connection [87] Figure 3-1.
• Page 245 sm00701 Frame assembly Washers for center tie bar mount (2) "V" bracket Center tie bar assembly Fasteners for "V" bracket (3) Fasteners for center tie bar assembly (2) Front isolator assembly Washers for center tie bar assembly (2) Fasteners (2) Ground strap Bolt Rear isolator assembly...

• Page 246: Assembly

  19. Disconnect the CKP [79] on the left side of the "V" bracket. Install isolator mounting fasteners (5) and tighten to 49-51 ft-lbs (66.4-69.1 Nm). 20. See Figure 3-2. Remove "V" bracket (2) and fasteners (3) from main frame. Tighten front isolator bolt to 49-51 ft-lbs (66.4-69.1 Nm). 21.
• Page 247 13. Tighten the throttle cable jamnuts to 36-40 in-lbs (4.1-4.5 sm04534 Nm). 14. Install the ignition coil (1) and coil connection [83] (2) and tighten fasteners to 120-144 in-lbs (13.6-16.3 Nm). 15. Attach plastic clip (3) securing the coil wire to the throttle cable bracket.
• Page 248 NOTES NOTE Due to the location of the CKP it will be necessary to align The connection for fuel pump is just above the pump located the Torca clamp to ensure proper clearance between the at the rear of the fuel tank on the left side of the vehicle. chin fairing and the CKP and Torca clamp 24.

• Page 249: Engine Removal

  ENGINE REMOVAL Remove intake cover and air cleaner assembly. See DISASSEMBLY 2.52 AIR SCOOPS. NOTES NOTE Vehicle should be placed onto the lift with rear tire in the When removing the left air scoop, the alternator and voltage wheel vise in order to successfully perform this procedure. regulator harnesses and connections are secured to the bottom of the air scoop with three cable straps.
• Page 250 sm03746 Coil Fuel line connection Coil connection [83] Throttle position sensor connection [88] Coil wire harness retaining clip IAT sensor [89] Throttle cables Engine temperature sensor connection [90] Fuel injector connections [84 & 85] Oxygen sensor conection [137] 6. IAC sensor connection [87] Figure 3-6.
• Page 251 NOTE 21. See Figure 3-10. Remove front "V" bracket with oil cooler from main frame. Anytime front tie-bar is removed, it must first be removed from the "V" bracket and then the engine. When installing the tie- Disconnect alternator connector [46] (1) and voltage bar, first mount to engine and then to "V"...
• Page 252 28. See Figure 3-9. Remove vent oil line (11). 30. Remove return oil line (7). Remove clamp (12) in front of starter securing vent Remove p-clamp (8) at swingarm/oil reservoir (10). oil line to return oil line. Disconnect oil return line (7) at swingarm/oil reservoir Disconnect vent oil line from oil pump.
• Page 253 sm03729 Oil pump P-clamp Oil cooler return line to crankcase Rear muffler bracket Oil cooler feed line from oil pump Swingarm/Oil reservoir Oil filter Vent oil line Front muffler mount Oil line clamp Feed oil line Cable, interactive exhaust Return oil line Drain plug Figure 3-9.
• Page 254 sm00701 Frame assembly Washers for center tie bar mount (2) "V" bracket Center tie bar assembly Fasteners for "V" bracket (3) Fasteners for center tie bar assembly (2) Front isolator assembly Washers for center tie bar assembly (2) Fasteners (2) Ground strap Bolt Rear isolator assembly...
• Page 255 sm03744 sm03933 1. Neutral switch connection [131] 2. Oil pressure indicator switch wire 3. Interactive exhaust cable Figure 3-11. Electrical Connectors and Interactive Exhaust Cable Under Sprocket Cover 31. Remove front and rear muffler brackets. 32. See Figure 3-12. Remove two fasteners (2) and remove sidestand assembly.
• Page 256 sm03741 sm00730 Figure 3-15. Transmission Vent Line: Firebolt Figure 3-13. Supporting Vehicle for Disassembly 34. See Figure 3-10. Remove front isolator bolt (6). Remove front isolator assembly fasteners (5). sm00737 35. See Figure 3-14. Remove: Rear isolator bolt (1). Swingarm pivot shaft (2). sm02952a Figure 3-16.
• Page 257 sm03745 sm00739 1. Left side 2. Right side Figure 3-20. Front Exhaust Mount Bushings (2 piece) Figure 3-18. Center Tie Bar Mount 40. Once engine has been removed from vehicle, finish sm02996 removing the following items as required: Shifter assembly. See 6.2 PRIMARY COVER.
• Page 258 41. See Figure 3-22. If the crankcases are being separated it sm03731 will be necessary to remove rear isolator assembly by removing the forward two fasteners first and then the two rear fasteners (re-install with new fasteners). 42. See Figure 3-23.

• Page 259: Engine Installation

  ENGINE INSTALLATION NOTE ASSEMBLY Hand thread pivot shaft into crankcase prior to installing Engine Preparation for Re-installation the threaded insert. Remove pivot shaft after installing the threaded insert. NOTE Figure 3-27. Apply LOCTITE 242 (blue) to Install components that were removed from engine as were swingarm pivot shaft pinch bolt threaded insert and necessary for service prior to installing engine in frame.

• Page 260: Installing Engine In Frame

  Installing Engine in Frame Install transmission vent line. Figure 3-31. On Firebolt models, route transmis- NOTES sion vent line up through left side of frame exiting Vehicle should be placed onto the lift with rear tire in the under the rear master cylinder under the rider's seat. wheel vise in order to successfully perform this procedure.
• Page 261 sm02952b sm00736 Figure 3-33. Transmission Vent Line: Ulysses Figure 3-34. Rear Isolator Bolt Figure 3-34. Using the overhead hoist to align the frame to the rear isolator, install rear isolator bolt and leave loose at this time. 2008 XB Service: Engine 3-25...
• Page 262 sm00701 Frame assembly Washers for center tie bar mount (2) "V" bracket Center tie bar assembly Fasteners for "V" bracket (3) Fasteners for center tie bar assembly (2) Front isolator assembly Washers for center tie bar assembly (2) Fasteners (2) Ground strap Bolt Rear isolator assembly...
• Page 263 on the rear exhaust at the head with engine rotated in the Figure 3-36. Insert front isolator bolt (3) through front up position. isolator (1) and loosely thread into frame. Do not tighten at this point. It is necessary to tighten the front head pipe first. 10.
• Page 264 sm00936 Clamp, Torca Front muffler mount Muffler (XB9 models) Rear muffler bracket Muffler (XB12 models) Rear muffler straps Front muffler strap Rear muffler strap fastener 5. Front muffler strap fastener Figure 3-37. Muffler Mounting System 18. See Figure 3-37. Apply LOCTITE 271 (red) to rear muffler NOTES bracket fasteners, install and tighten to 32-36 ft-lbs (43.4- DO NOT install muffler at this time.
• Page 265 sm03729 Oil pump P-clamp Oil cooler return line to crankcase Rear muffler bracket Oil cooler feed line from oil pump Swingarm/Oil reservoir Oil filter Vent oil line Front muffler mount Oil line clamp Feed oil line Cable, interactive exhaust Return oil line Drain plug Figure 3-38.
• Page 266 25. Install oil line clamp (12) attaching vent oil line (11) to NOTE return oil line (7) in front of starter motor and tighten to Figure 3-39. Route neutral indicator switch and the oil 40-50 in-lbs (5-5.5 Nm). pressure indicator switch wiring behind the vent oil line. Route the interactive exhaust cable in front of the vent and return oil 26.
• Page 267 31. Install muffler. See 4.16 EXHAUST SYSTEM. sm05389 32. Install rear belt and idler pulley. See 6.6 DRIVE BELT AND IDLER PULLEY. 33. Install left and right side rider footrests and support plates. 2.36 FOOTPEG, HEEL GUARD AND MOUNT: FIREBOLT/LIGHTNING 2.37 HEEL GUARD AND FOOTPEG MOUNTS: ULYSSES MODELS.
• Page 268 sm03746 Coil Fuel line connection Coil connection [83] Throttle position sensor connection [88] Coil wire harness retaining clip IAT sensor [89] Throttle cables Engine temperature sensor connection [90] Fuel injector connections [84 & 85] Oxygen sensor conection [137] 6. IAC sensor connection [87] Figure 3-42.
• Page 269 48. Install battery cables to battery: positive cable (red) first. Tighten to 72-96 in-lbs (8-11 Nm). See 1.4 BATTERY MAINTENANCE. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury.

• Page 270: Cylinder Head

  CYLINDER HEAD REMOVAL sm00131 Before removing the cylinder head assembly, it is necessary to rotate engine down as described in 3.3 ENGINE ROTATION SERVICE. The rocker arm covers and internal compon- ents must be removed before removing cylinder heads. NOTE All washers and fasteners used in the engine are hardened.

• Page 271: Cylinder Head Assemblies

  sm00130 Crankcase breather Gasket (lower) Screw, tappet anti-rotation (2) Grommet Rocker arm shafts Gasket (push rod cover) Screw (4) Screw (2) Push rod cover Washer (4) Washer (2) Screw (4) Fiber seal (4) Rocker cover (lower) O-ring (push rod cover - 2) Rocker cover (top) Rocker arm (2) Push rod...

• Page 272: Disassembly

  Discard head gasket. sm00133 Figure 3-45. Remove push rod cover (21), gasket (20) and lifters (18). DISASSEMBLY PART NUMBER TOOL NAME HD-34736B VALVE SPRING COMPRESSOR Figure 3-47. Clamp VALVE SPRING COM- PRESSOR (Part No. HD-34736B) in vise. Compress valve spring with VALVE SPRING COM- PRESSOR.
• Page 273 sm00134 Figure 3-47. Valve Spring Compressor 2008 XB Service: Engine 3-37...
• Page 274 sm00135 Screw Valve guide intake and exhaust Cylinder base gasket Screw Cylinder base stud Valve collar retainer Cylinder head Exhaust valve Upper valve spring collar Exhaust port stud Exhaust valve seat Valve spring Cylinder head gasket Valve seal and lower valve Cylinder insert spring collar assembly 12.

• Page 275: Cleaning And Inspection

  CLEANING AND INSPECTION Measure and record rocker arm shaft diameter. Figure 3-50. Measure where shaft fits in lower PART NUMBER TOOL NAME rocker arm cover. B-45525 VALVE GUIDE HONE Figure 3-51. Measure where rocker arm bushings HD-34751 VALVE GUIDE CLEANING BRUSH ride.

• Page 276: Valves

  Inspect for burrs around the valve stem keeper groove. sm00140 Remove burrs with a fine tooth file if found. Valve Seats NOTE Valve seats are also subject to wear. Resurface valve seats whenever valves are refinished. Inspect seats for cracking, chipping or burning. Replace seats if any evidence of these conditions are found.

• Page 277: Valve Springs

  Valve Springs sm00144 Inspect valve springs for broken or discolored coils. NOTE A single valve spring is used for each valve. The inner and outer springs are combined into one tapered spring that is progressively wound. Figure 3-55. Check free length and compression force of each spring.

• Page 278: Replacing Valve Guides

  REPLACING VALVE GUIDES sm00145 PART NUMBER TOOL NAME B-45523 VALVE GUIDE REAMER B-45524-A VALVE GUIDE REMOVER/INSTALLER B-45525 VALVE GUIDE HONE HD-34751 VALVE GUIDE CLEANING BRUSH Valve guide replacement, if necessary, must be done before valve seat is ground. It is the valve stem hole in valve guide that determines seat grinding location.

• Page 279: Procedure For Using The Neway Valve Seat Cutter

  PROCEDURE FOR USING THE NEWAY Set your dial caliper to the lesser measurement and lock down for quick reference. This is the location of your valve VALVE SEAT CUTTER seat. PART NUMBER TOOL NAME Use a permanent magic marker to highlight the valve seat area that is going to be cut and be sure to highlight all 3 B-35758-52A 7.02 MM VALVE SEAT CUTTER PILOT...

• Page 280: Assembly

  12. Select the proper 60° cutter and gently slide the cutter Blow dry with compressed air. down the cutter pilot to the valve seat. Apply a liberal amount of engine oil to the valve stem. 13. Remove just enough material to provide an even valve Figure 3-48.

• Page 281: Push Rod Cover Installation

  PUSH ROD COVER INSTALLATION sm00150 Figure 3-66. Install push rod covers. Install new o-rings (2) on top of each push rod cover (3). NOTE Before installing o-rings on the top of each pushrod cover be sure to apply a small amount of clean engine oil to each o-ring.

• Page 282: Cylinder Head Installation

  NOTE sm00153 The procedure for tightening the head screws is critical to proper distribution of pressure over gasket area. It prevents gasket leaks, stud failure, and head and cylinder distortion. Always tighten in sequence shown. Start the cylinder head screws onto the cylinder studs, two short screws on the left side of the engine, two long bolts on the right.
• Page 283 12. See Figure 3-70. Install upper rocker covers (6). sm00154 Place a new inner gasket (9) on lower rocker box assemblies. Place a new lower gasket (10) on lower rocker cover. Install upper rocker cover using screws with washers and new fiber seals (5). Tighten screws to 120-168 in-lbs (13.6-18.9 Nm).
• Page 284 sm00130 Crankcase breather Gasket (lower) Screw, tappet anti-rotation (2) Grommet Rocker arm shafts Gasket (push rod cover) Screw (4) Screw (2) Push rod cover Washer (4) Washer (2) Screw (4) Fiber seal (4) Rocker cover (lower) O-ring (push rod cover - 2) Rocker cover (top) Rocker arm (2) Push rod...

• Page 285: Cylinder And Piston

  CYLINDER AND PISTON REMOVAL/DISASSEMBLY sm00155 PART NUMBER TOOL NAME HD-34623C PISTON PIN RETAINING RING INSTALLER Strip motorcycle as described under 3.3 ENGINE ROTA- TION FOR SERVICE. Remove cylinder head. See 3.6 CYLINDER HEAD. Clean crankcase around cylinder base to prevent dirt and debris from entering crankcase while removing cylinder.

• Page 286: Cleaning And Inspection

  sm00156 sm00157 Figure 3-73. Piston Pin and Piston Identification NOTE Figure 3-73. The arrows on the pistons must always point toward the front of the engine. sm00158 1. Piston pin retaining ring 2. Piston pin retaining ring installer Figure 3-72. Removing Piston Pin Circlip Figure 3-72.

• Page 287: Checking Gasket Surface

  Soak cylinder and piston in an aluminum-compatible Figure 3-75. Check cylinder head gasket surface for cleaner/solvent until deposits are soft, then clean with a flatness. brush. Blow off loosened carbon and dirt particles and Lay a straightedge across the surface. wash in solvent.

• Page 288: Deglazing Cylinder

  NOTE NOTES If cylinder clearance exceeds service wear limit, cylinders and Stop to examine the cylinder bore and/or take measure- pistons should be replaced with new components. See ments. A precise 60° cross hatch pattern in the piston SPECIFICATIONS. travel area is the most important. The angular cross hatch pattern ensures an even flow of Table 3-20.
• Page 289 NOTE sm00162 Install second compression ring with dot towards top. Figure 3-80. Install rings so end gaps of adjacent rings are a minimum of 90° apart. Ring gaps are not to be within 10° of the thrust face centerline. Figure 3-81.

• Page 290: Connecting Rod Bushing

  CONNECTING ROD BUSHING sm00163 PART NUMBER TOOL NAME HD-35102 WRIST PIN BUSHING HONE HD-94800-26A REAMER HD-95952-33C CONNECTING ROD CLAMPING TOOL HD-95970-32D PISTON PIN BUSHING TOOL When connecting rod bushing is worn to excessive pin clear- ance 0.002 in. (0.051 mm) or more, it must be replaced. Figure 3-82.

• Page 291: Assembly/Installation

  ASSEMBLY/INSTALLATION sm00166 PART NUMBER TOOL NAME HD-34623C PISTON PIN RETAINING RING INSTALLER HD-42322 PISTON SUPPORT PLATE HD-96333-51E PISTON RING COMPRESSOR Figure 3-86. Place PISTON SUPPORT PLATE (Part No. HD-42322) in position as shown. Install piston assembly over connecting rod. NOTE Figure 3-87.
• Page 292 sm00169 sm00156 Figure 3-86. Piston Support Plate sm00157 1. Piston pin retaining ring 2. Piston pin retaining ring installer Figure 3-88. Installing Piston Pin Circlip sm00163 Figure 3-87. Piston Pin and Piston Identification 1. Front 2. Rear 3. Piston pin 4.
• Page 293 sm00171 1. Piston ring compressor Figure 3-90. Compressing Piston Rings 2008 XB Service: Engine 3-57...

• Page 294: Oiling System

  OILING SYSTEM 10. Oil flow then continues to the main feed galley at the top GENERAL of the oil pump body. Passages in the crankcase intersect The engine has a gravity/suction type oiling system, the main feed galley and carry oil to all hydraulic lifters incorporating oil feed and return pumps in the same body and piston jets.

• Page 295: Oil Pump

  OIL PUMP The oil pump seldom needs servicing. Before you disassemble GENERAL an oil pump suspected of not producing adequate oil pressure, Figure 3-91. The oil pump consists of two gerotor gear be sure that all possible related malfunctions have been elim- sets, feed and return, housed in one pump body.

• Page 296: Removal/Disassembly

  sm02940 88 4 Oil pump cover Oil pump body Oil pump cover gasket Oil pump mounting gasket Separator plate Oil pump mounting screws (4) Scavenge gerotor gear set Oil pressure indicator switch Feed gerotor gear set Pressure relief valve Oil line fittings Oil pump cover screws (7) 7.
• Page 297 Remove and discard oil filter. Disconnect return oil line connection (2) from the bottom and left side of the oil pump body. NOTES Oil pump can be removed with engine in frame. Disconnect the vent oil line connection (4) from the top left side of the oil pump body.

• Page 298: Cleaning And Inspection

  SM03730 Feed oil line Return oil line from oil cooler Return oil line Feed oil line to oil cooler Oil pump cover Oil pressure switch Vent oil line Pressure relief valve 5. Oil pump body Figure 3-92. Oil Pump Connections Figure 3-93.

• Page 299: Assembly/Installation

  12. Attach return line connections on the bottom and right side sm00219 of the oil pump body. 13. Attach the vent line connection to the top left side of the oil pump body. 14. Attach oil cooler return line to oil pump. 15.
• Page 300 sm03727 Figure 3-95. Oil Pump Body and Cover Mounting Screw Torque Sequence 3-64 2008 XB Service: Engine...

• Page 301: Oil Reservoir And Oil Hose Routing

  OIL RESERVOIR AND OIL HOSE ROUTING 3.10 The oil cooler feed line (3) exits the front of the oil pump and GENERAL routes across the front of the engine to the oil cooler on the Figure 3-96. Engine oil runs through the swingarm which left front side of the crankcases.
• Page 302 sm03729 Oil pump P-clamp Oil cooler return line to crankcase Rear muffler bracket Oil cooler feed line from oil pump Swingarm/Oil reservoir Oil filter Vent oil line Front muffler mount Oil line clamp Feed oil line Cable, interactive exhaust Return oil line Drain plug Figure 3-96.

• Page 303: Oil Line Fittings

  OIL LINE FITTINGS 3.11 REMOVAL sm00206 PART NUMBER TOOL NAME B-41623-B OIL LINE REMOVER Figure 3-97. Close the OIL LINE REMOVER (Part No. B-41623-B) over the oil line. Match the notches in the tool flange to the U-bends in the spring clip. Figure 3-98.
• Page 304 sm00207 Figure 3-99. Flanged Oil Line 3-68 2008 XB Service: Engine...

• Page 305: Oil Cooler

  OIL COOLER 3.12 GENERAL REMOVAL For engine oil flow through the engine, See 3.8 OILING Cover the front chin fairing to protect finish. SYSTEM. NOTE Engine oil flows from the oil pump to the oil cooler through a Dispose of oil in accordance with local regulations. supply hose.

• Page 306: Oil Pressure Indicator Switch

  OIL PRESSURE INDICATOR SWITCH 3.13 GENERAL sm03000 The oil pressure indicator switch is a pressure-actuated dia- phragm-type switch. When oil is not circulating through the system or when oil pressure is low, spring tension holds the switch contacts closed, thereby completing the signal light cir- cuit and causing the indicator lamp to illuminate.
• Page 307 engine to reach operating temperature of 180° F (82° C) Start engine and test oil pressure switch for proper opera- tion. Check oil pressure switch for leaks. At 3000 RPM, oil pressure will vary from 20-28 psi (138-193 kPa). sm05397 At idle speed (1050-1150 RPM), oil pressure will vary from 10-16 psi (69-110 kPa).

• Page 308: Crankcase Breathing System

  CRANKCASE BREATHING SYSTEM 3.14 GENERAL sm00216 Figure 3-103. Pressure created in the flywheel area on piston downstroke is released through the reed valve into the gearcase. From there a mixture of crankcase air and oil mist is vented up the push rod covers to the upper rocker box. Figure 3-104.
• Page 309 With the lower part of the curve on the reed valve stop (2) If it was necessary to replace the reed block, apply facing out, apply LOCTITE 222 (purple), install and tighten LOCTITE 222 (purple), install the fasteners and tighten to fastener to 5-7 in-lbs (0.6-0.8 Nm).

• Page 310: Hydraulic Lifters

  HYDRAULIC LIFTERS 3.15 GENERAL REMOVAL Figure 3-107. The lifter assembly consists of a hydraulic lifter and roller. The lifter and roller, under compression force from valve spring, follow the surface of the revolving cam. The Compressed air can pierce the skin and flying debris from up-and-down motion produced is transmitted to the valve by compressed air could cause serious eye injury.

• Page 311: Installation

  Check lifter roller end clearance. sm00173 End clearance should be within 0.008-0.022 in. (0.203-0.559 mm). Replace lifters if clearance exceeds SERVICE WEAR LIMIT of 0.026 in. (0.660 mm). Soak lifters in clean engine oil. Keep covered until assembly. INSTALLATION Figure 3-108.

• Page 312: Gearcase And Cam Gears

  GEARCASE AND CAM GEARS 3.16 For the gearcase components to operate at their optimum, all GENERAL components must be properly fitted and matched. Changing Read the complete gearcase section carefully before you begin one component can affect many others. It is important to know any service work.

• Page 313: Removal And Disassembly

  REMOVAL AND DISASSEMBLY Check for minimum cam gear end play. Record readings. Remove oil pump. See 3.9 OIL PUMP Figure 3-111. Rotate crankshaft until all timing marks (7, 8) are aligned as shown. Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury.

• Page 314: Cam And Pinion Gear Identification, Inspection And Selection

  ASSEMBLY AND INSTALLATION PART NUMBER TOOL NAME Compressed air can pierce the skin and flying debris from HD-43984 CRANKSHAFT LOCKING TOOL compressed air could cause serious eye injury. Wear safety glasses when working with compressed air. Never Figure 3-113. Install pinion gear spacer and pinion use your hand to check for air leaks or to determine air gear on pinion shaft.
• Page 315 Install oil pump body and all gears and onto right crank- sm02987 case half, install fasteners and tighten. See 3.9 OIL PUMP. Figure 3-115. Check cam gear end play for each cam gear as follows: Turn engine over until lobe of cam gear being checked is pointing toward its respective tappet guide hole.

• Page 316: Crankcase

  CRANKCASE 3.17 Remove starter motor. See STARTER. GENERAL Figure 3-116. Remove rear isolator assembly by When rod bearings, pinion shaft bearing, or sprocket shaft removing the forward two fasteners first and then the two bearing are in need of repair, the engine must be removed rear fasteners (re-install with new fasteners).

• Page 317: Oil Filter Adapter

  sm00176 1. Crankcase fasteners 2. Crankcase fastener behind shifter mechanism Figure 3-117. Crankcase Fasteners OIL FILTER ADAPTER NOTE The oil filter adapter has identical ends. Either end may be installed into the filter mount. Figure 3-118. Remove the oil filter adapter from the oil filter mount.

• Page 318: Piston Jets

  sm03862 sm02980 Figure 3-119. Piston Oil Jet Assemblies Installation NOTES Gaskets that are missing, distorted, pinched or otherwise damaged will result in either oil leakage or low oil pressure. Gasket is part of the piston jet assembly. Gasket not sold separately.
• Page 319 sm02981 Figure 3-120. Removing Flywheels from Left Crankcase sm02942 14 13 Spacer, sprocket shaft Thrust washer Retaining ring, oil seal Connecting rod and flywheel assembly Oil seal Inner race Thrust washer Pinion shaft bearing Crankcase half Retaining ring Bearing, sprocket shaft Outer bearing race Bearing retaining ring Crankshaft case...
• Page 320 Figure 3-121. Remove sprocket shaft oil seal (3) from sm00181 crankcase using SNAP-ON BODY DENT PULLER (Part No. CJ114). Remove outer thrust washer (4) next to sprocket shaft bearing (6). sm00183 Figure 3-122. Removing Sprocket Shaft Inner Bearing Race Figure 3-124. Removing Sprocket Shaft Bearing Retaining Ring Figure 3-122.

• Page 321: Pinion Shaft Bearing

  PINION SHAFT BEARING sm02982 PART NUMBER TOOL NAME HD-34902-7 END CAP HD-34902B BEARING RACE REMOVER/INSTALLER HD-95635-46 CLAW PULLER HD-95637-46B WEDGE ATTACHMENT HD-96710-40D CRANKCASE MAIN BEARING LAP- PING TOOL HD-96718-87 CRANKCASE MAIN BEARING LAP General Figure 3-121. The right side pinion shaft bearing consists of an inner and outer race with rollers.

• Page 322: Selection

  Table 3-27. Pinion Shaft Outer Race Stamp Specifications sm00187 OUTER RACE ID CLASS STAMPED 1.5646- 39.7408-39.7459 1.5648 1.5648- 39.7459-39.7510 1.5650 1.5650- 39.7510-39.7561 1.5652 NOTE 1. Roller OD cannot be measured to required accuracy with micrometer (refer to Pinion Shaft The different sizes of crankcase sets and flywheel assemblies Bearing Selection table) will not have separate part numbers.
• Page 323 NOTE sm03436 The next step requires lapping the outer race. To keep sprocket shaft and pinion shaft bearings aligned the lap must be sup- ported by an adaptor or pilot in the left crankcase half. See LAPPING PINION SHAFT BEARING OUTER RACE. Lap race until all wear marks are removed.
• Page 324 sm00189 sm03437 1. Bearing race remover/installer 2. End cap 3. Wedge attachment for claw puller Figure 3-132. Removing Pinion Bearing Inner Race NOTES For necessary dimensions for constructing a press on tool for the pinion bearing inner race, see Figure 3-131.

• Page 325: Lapping Pinion Shaft Bearing Outer Race

  shaft bearing bushing. Sleeves, for use with tapered sm00190 bearing, are assembled to case with bearings and small spacer collar. Finger-tighten the sleeve parts. Insert lap shaft with arbor assembled through pinion bearing bushing and into guide sleeve. Tighten arbor expansion collars using a length of 0.156 in.

• Page 326: Assembly

  ASSEMBLY sm02984 PART NUMBER TOOL NAME B-42579-6 SPROCKET SHAFT ADAPTER B-42579-7 COLLAR B-45655, HD-42720- CRANKCASE BEARING 2 AND HD-46663 REMOVER/INSTALLER WITH ADAPTER B-45676-A SPROCKET SHAFT SEAL INSTALLER HD-42326-B CRANKSHAFT GUIDE HD-42579 SPROCKET SHAFT BEARING INSTALLER HD-97228-55A COLLAR Crankcase Halves NOTE Lubricate all parts with Harley-Davidson 20W50 engine oil, and proceed as follows: Figure...
• Page 327 sm02941 1. Spacer, sprocket shaft 2. Retaining ring, oil seal 3. Oil seal 4. Thrust washer 5. Crankcase half 6. Bearing 7. Bearing retaining ring Figure 3-136. Sprocket Shaft Bearing Assembly Figure 3-138. Attach left crankcase half to engine stand. Install flywheel assembly...
• Page 328 sm00194 sm03929 Figure 3-138. Installing Flywheel Assembly with CRANKSHAFT GUIDE sm00195 Figure 3-139. Pinion Shaft Bearing 1. Shoulder 2. Crankcase bearing remover/installer tool 3. Retaining ring Figure 3-137. Sprocket Shaft Bearing Installation 3-92 2008 XB Service: Engine...
• Page 329 sm00176 1. Crankcase fasteners 2. Crankcase fastener behind shifter mechanism Figure 3-140. Crankcase Fasteners Figure 3-140. Assemble crankcase halves together. Apply a thin coat of GREY HIGH-PERFORMANCE sm00196 SEALANT (Part No. 99650-02) to crankcase joint faces. Slide outer race in right crankcase over pinion shaft and bearing assembly.
• Page 330 Install sprocket shaft seal. sm00197 Center seal/spacer driver over seal, so that the sleeve (smaller OD) seats between seal wall and garter spring. Sparingly apply graphite lubricant to threads of pilot shaft to ensure smooth operation. Slide sleeve over pilot until sleeve contacts the oil seal.
• Page 331 SUBJECT..........................PAGE NO. 4.1 SPECIFICATIONS........................4-1 4.2 AIR CLEANER ASSEMBLY.......................4-2 4.3 ELECTRONIC CONTROL MODULE (ECM)................4-5 4.4 THROTTLE POSITION SENSOR (TPS)...................4-8 4.5 IGNITION COIL.........................4-9 4.6 OXYGEN SENSOR.........................4-10 4.7 ENGINE TEMPERATURE SENSOR (ET)................4-11 4.8 BANK ANGLE SENSOR (BAS)....................4-13 4.9 INTAKE AIR TEMPERATURE SENSOR (IAT).................4-16 4.10 COOLING FAN........................4-17 4.11 FUEL TANK VENT VALVE.....................4-18 4.12 FUEL CAP RETAINING RING....................4-19...
• Page 332 NOTES...

• Page 333: Fuel System

  SPECIFICATIONS GENERAL Table 4-2. Fuel System Specifications FUEL SYSTEM TYPE Table 4-1. Fuel Tank Specifications Intake (XB9 models) 45 mm downdraft manifold, FUEL TANK CAPACITY GALLONS LITERS ram air Total (including reserve) 4.40 16.7 Intake (XB12 models) 49 mm downdraft manifold, (XB12Ss, XB12STT, XB12XT, ram air XB12X)

• Page 334: Air Cleaner Assembly

  AIR CLEANER ASSEMBLY REMOVAL sm00896 Remove intake cover. See 2.40 INTAKE COVER. Figure 4-1 Figure 4-2. Remove fuel tank vent tube (4) from fuel tank vent valve (5) and groove on top of air cleaner cover (3). NOTE Figure 4-3 Figure 4-4.

• Page 335: Inspection

  Insert IAT sensor into grommet on baseplate from under- sm00897 side. NOTES A small amount of soapy water applied to the inside dia- meter of grommet will make breather hose installation easier. In next step, be sure breather hoses do not extend past Intake air temperature sensor tower.
• Page 336 sm00898 Actuator, interactive exhaust Filter element Harness, interactive exhaust Air cleaner seal Cable bracket Shoulder screw (4) Interactive exhaust cable Base plate assembly Mounting fasteners, actuator Breather hoses, front and rear 6. Cover, air cleaner Figure 4-5. Air Cleaner Assembly with Interactive Exhaust (XB12 Models, Typical) 4-4 2008 XB Service: Fuel System...

• Page 337: Removal: Firebolt

  ELECTRONIC CONTROL MODULE (ECM) REMOVAL: FIREBOLT Remove seat. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury.

• Page 338: Removal: Ulysses

  sm00858 Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a) Connect battery positive cable (red) first, tightening to 72-96 in-lbs (8-11 Nm).
• Page 339 Connect battery positive cable (red) first, tightening to Install seat. 72-96 in-lbs (8-11 Nm). See 1.4 BATTERY MAINTEN- ANCE. sm00863 Connect negative battery cable, tightening to 72-96 in- lbs (8-11 Nm). NOTES The Throttle Position Sensor Zero Procedure should be performed if the throttle position sensor or ECM have been replaced or if the ECM has been recalibrated.

• Page 340: Throttle Position Sensor (Tps)

  THROTTLE POSITION SENSOR (TPS) REMOVAL sm00244 Remove air cleaner cover. See 4.2 AIR CLEANER ASSEMBLY. Remove throttle body assembly. See 4.14 THROTTLE BODY. Figure 4-10. Disconnect throttle position sensor con- nector [88]. Figure 4-11. Remove two screws and washers to detach TP sensor.

• Page 341: Ignition Coil

  IGNITION COIL REMOVAL sm00855 To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect negative battery cable. Remove intake cover assembly. See 2.40 INTAKE COVER. Remove air cleaner cover. See 4.2 AIR CLEANER ASSEMBLY.

• Page 342: Oxygen Sensor

  OXYGEN SENSOR Figure 4-15. Connect 1-place connector [137] to wiring GENERAL harness. Figure 4-14. The oxygen sensor (O2 Sensor), located in Install sensor lead into retainer. the rear header pipe, monitors oxygen content in the exhaust gas and converts it to a voltage reading. This voltage reading Install air cleaner assembly.

• Page 343: General

  4-17. Disconnect engine temperature sensor connector [90] above rear cylinder head. NOTE Figure 4-18 For 2008 Model Year, all Buell engines will come equipped with a piece of conduit approximately 3.94 in. (100mm) long to protect the engine temperature sensor lead from chafing on the inside of the rocker box.

• Page 344: Installation

  NOTE sm04650 In next step, make sure wire is in cutout portion (slot) of socket to prevent damage. Secure sensor with ENGINE TEMPERATURE SENSOR SOCKET (Part No. SNAP-ON M3503B). Tighten ET sensor to 120-168 in-lbs (13.6-19 Nm). NOTE Orient the rubber boot so the flat on the boot is towards the left side of the motorcycle.

• Page 345: Firebolt

  BANK ANGLE SENSOR (BAS) GENERAL sm00864 The Bank Angle Sensor (BAS) provides input to the ECM on lean angle. If lean angle exceeds the predetermined limit, the BAS will shut off power to the ignition and fuel pump. REMOVAL Firebolt Remove seat.

• Page 346: Installation

  Connect negative battery cable, tightening to 72-96 in- sm00865 lbs (8-11 Nm). After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury.

• Page 347: Ulysses

  sm00864 After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) Install seat. sm00865 1. Bank angle sensor 2.

• Page 348: Intake Air Temperature Sensor (Iat)

  INTAKE AIR TEMPERATURE SENSOR (IAT) GENERAL INSTALLATION The intake air temperature sensor (IAT Sensor), located on Connect IAT sensor connector [89] to wiring harness. the air cleaner cover baseplate, measures the air temperature Install IAT sensor into grommet on air cleaner base from allowing the ECM to calculate the density of the air entering beneath.

• Page 349: Installation

  COOLING FAN 4.10 Connect negative battery cable, tightening to 72-96 in- GENERAL lbs (8-11 Nm). A computer-controlled cooling fan assists engine cooling during operation in high temperatures. Fan actuation is controlled by the ECM. Refer to Table 4-4. After installing seat, pull upward on seat to be sure it is Table 4-4.

• Page 350: Installation

  FUEL TANK VENT VALVE 4.11 Connect fuel tank vent line to vent valve. GENERAL Install air cleaner cover. See 4.2 AIR CLEANER The fuel tank vent valve opens to allow gas vapor to escape ASSEMBLY. the fuel tank and either vent to the atmosphere or to the char- coal canister on California Models (EVAP-equipped) and closes Install intake cover assembly.

• Page 351: Installation

  FUEL CAP RETAINING RING 4.12 REMOVAL sm00877 NOTE The fuel tank must be drained to perform this service. Drain fuel tank. See 4.13 FUEL PUMP, Draining Fuel Tank. Remove fuel filler cap. Figure 4-29. Remove fasteners (4) securing fuel cap retaining ring (3) to fuel filler neck (1).

• Page 352: Fuel Pump

  FUEL PUMP 4.13 DRAINING FUEL TANK REMOVAL NOTES Before vehicle is placed on the lift it will necessary to remove the chin fairing. See 2.53 CHIN FAIRING. To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is Vehicle should be placed onto the lift with the front tire extremely flammable and highly explosive, which could placed in the wheel vise in order to successfully perform...

• Page 353: Repair

  sm00867 With fuel tank drained, gasoline can spill from bore when supply valve is loosened or removed. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Wipe up spilled fuel immediately and dispose of rags in a suitable manner. (00277a) Figure 4-38.

• Page 354: Low Fuel Level Sensor Replacement

  sm00868 Plastic retaining ring Fuel pressure regulator Plastic retainers Fuel pressure regulator housing Figure 4-33. Fuel Pressure Regulator Install new sensor. Low Fuel Level Sensor Replacement Install screw (8) securing sensor and tighten to 18-22 in- Remove fuel pump assembly from tank. See 4.13 FUEL lbs (2.0-2.5 Nm).

• Page 355: Fuel Filter Replacement

  sm00869 Fuel supply stud Fuel pump connectors Fuel pump housing Low fuel level sensor O-rings Fastener Fuel filter Fuel pressure regulator Fuel pump Low fuel level sensor connector Figure 4-34. Fuel Pump Assembly Install rubber seals on new fuel filter and install filter into Fuel Filter Replacement pump housing (11).
• Page 356 sm00870 Fuel supply stud Fuel pump Fuel filter Bracket, fuel pump and fuel filter Pressure regulator housing Overflow hose Low fuel level sensor Fuel pump housing Fuel pump connectors Ground fastener Low fuel level sensor connector Protective sleeve 7. Pressure regulator E-clip (1) Figure 4-35.

• Page 357: Fuel Pump Wire Harness Replacement

  Table 4-5. Fuel Pump Specifications sm00223 SPECIFICATION DATA Pressure Setting 49 PSI (338 kPa) Operating Voltage 13.2 volts Min. Fuel Delivery 60 LPH @ 45 PSI (310 kPa) Current Draw 6.0 amps Fuel Pump Wire Harness Replacement Remove fuel pump assembly from tank. See 4.13 FUEL PUMP, Removal in this section.
• Page 358 Install new o-rings on fuel supply stud (2). Larger o-ring 2.37 HEEL GUARD AND FOOTPEG MOUNTS: ULYSSES is located in groove closer to fuel pump. MODELS. NOTE Install fuel line onto fitting on fuel pump so that the fuel line is at approximately the one o-clock position.

• Page 359: Throttle Body

  THROTTLE BODY 4.14 10. Remove assembly from motorcycle. GENERAL Figure 4-40. On primary side, loosen but do not The throttle body consists of the following components: remove the two front and rear intake flange fasteners Fuel supply fitting. (2). IAC sensor. Remove fastener (1) holding manifold to cylinder brace.
• Page 360 sm00885 1. Manifold to cylinder brace fastener 2. Intake flange fastener (2) Figure 4-40. Intake Manifold (Primary Side) 4-28 2008 XB Service: Fuel System...
• Page 361 sm04397 88 6 Seal, intake manifold (2) O-ring, fuel injector, inlet Mounting flange, intake (2) Fuel rail Bolt (2) Screw (4) Bolt (2) Gasket, idle air control Nylock nut Oring, idle air control Cable wheel Actuator, idle air control Screw (4) Screw (2) Throttle cable retention clip Washer, flat (2)

• Page 362: Repair

  REPAIR Place a new seal in each intake flange with the beveled side against the counterbore. Throttle Position Sensor Install throttle body/intake manifold assembly. 4.4 THROTTLE POSITION SENSOR (TPS) for removal, Figure 4-43. Slide the assembly toward the installation and calibration information. installed position.

• Page 363: Injector Leak Testing

  Injector Leak Testing sm00885 Remove intake cover assembly. See 2.40 INTAKE COVER. Remove air cleaner cover. See 4.2 AIR CLEANER ASSEMBLY. Conduct test. Turn key ON for two seconds. Turn key OFF for two seconds. Repeat Steps A and B five consecutive times. Open throttle and look for raw fuel in manifold.

• Page 364: Intake Leak Test

  INTAKE LEAK TEST 4.15 GENERAL sm02629 Do not allow open flame or sparks near propane. Propane is extremely flammable, which could cause death or ser- ious injury. (00521b) Read and follow warnings and directions on propane bottle. Failure to follow warnings and directions can result in death or serious injury.
• Page 365 When test is finished, close valve knob (turn knob fully sm00251 clockwise). Figure 4-46. Checking for Intake Leak 2008 XB Service: Fuel System 4-33...

• Page 366: Exhaust System

  EXHAUST SYSTEM 4.16 REMOVAL AND DISASSEMBLY Front Muffler Mount Remove muffler. NOTE For details on removal of components on XB12 models with Figure 4-47. Remove front muffler mount fastener interactive exhaust systems, see 7.14 INTERACTIVE (8). EXHAUST SYSTEM, Removal. Remove front muffler strap (5) from front muffler mount Muffler (7).

• Page 367: Assembly And Installation

  sm00636 Rear muffler strap fastener (2) Front muffler mount fastener Rear muffler strap (2) Front muffler mount bushings Interactive muffler (XB12 models) Interactive exhaust cable Muffler (XB9 models) Rear muffler bracket Front muffler strap Rear muffler bracket fasteners (2) Front muffler strap fastener Symbol for jacking point on muffler (located on 7.

• Page 368: Rear Muffler Bracket

  To ensure sealing integrity of muffler clamps and prevent the possibility of leakage, Buell recommends that muffler clamp assemblies be discarded and replaced each time they are removed. Due to the location of the CKP it will be necessary to align the Torca Clamp to ensure proper clearance between the chin fairing and the CKP and Torca clamp.
• Page 369 sm00638 1. Torca clamp 2. Header 3. Header mount fastener 4. Exhaust ring 5. Exhaust retaining ring 6. Exhaust port gasket Figure 4-48. Exhaust Header 2008 XB Service: Fuel System 4-37...

• Page 370: Evaporative Emissions Control (Ca Models)

  4.17 GENERAL sm00903 Buell motorcycles sold in the state of California are equipped with an evaporative (EVAP) emissions control system. The EVAP system prevents fuel hydrocarbon vapors from escaping into the atmosphere and is designed to meet the California Air Resource Board (CARB) regulations in effect at the time of manufacture.

• Page 371: Installation: Lightning/Ulysses

  Place rear shock reservoir assembly (3) into position. sm00905 NOTE Figure 4-51. To ensure proper reservoir mounting, tempor- arily place upper body work onto tail section and adjust reser- voir placement so adjuster screw (1) aligns with alignment hole (2). Figure 4-50.

• Page 372: Hose Routing

  sm00909 sm00910 Figure 4-54. Canister Mounting Bracket 1. Lock tab (6) HOSE ROUTING 2. Air cleaner cover 3. Fuel tank vent hose location Both fuel tank and canister vent hoses are routed through notch 4. Mounting towers for interactive exhaust actuator in fan body.
• Page 373 SUBJECT..........................PAGE NO. 5.1 SPECIFICATIONS........................5-1 5.2 STARTER..........................5-2 5.3 STARTER SOLENOID.......................5-9...
• Page 374 NOTES...

• Page 375: Specifications

  SPECIFICATIONS GENERAL Table 5-2. Service Wear Specifications SERVICE WEAR LIMITS Table 5-1. Starter Specifications Brush length (minimum) 0.433 11.0 STARTER Commutator diameter (min- 1.141 28.981 Free speed 3000 RPM (min) @ 11.5 V imum) Free current 90 amp (max) @ 11.5 V Stall current 400 amp (max) @ 2.4 V Stall torque...

• Page 376: Wiring Diagrams

  STARTER GENERAL sm00257 The starter is made up of a field coil assembly, solenoid assembly and drive assembly.The repair instructions contained in this section are divided into three major service areas accordingly. NOTE For troubleshooting and diagnostic information, see the ELECTRICAL DIAGNOSTIC MANUAL for this motorcycle.
• Page 377 Place armature in lathe or truing stand and check commut- sm00056 ator runout and diameter. Commutators with more than 0.016 in. (0.406 mm) of runout should be replaced or machined on a lathe. Replace commutators when diameter is less than 1.141 in.
• Page 378 sm00058 1. Starting groove in mica with 3-cornered file 2. Undercutting mica with piece of hacksaw blade 3. Wrong way (mica must not be left with a thin edge next to segments) 4. Right way (mica must be cut away clean between segments) 5.
• Page 379 sm00061 sm00059 Figure 5-9. Open Starter Armature Test 1. Growler 2. Thin steel strip Figure 5-7. Shorted Armature Test Using Growler 13. See Figure 5-10. Check for GROUNDED FIELD COIL with an ohmmeter or continuity tester. Touch one probe to the frame (1). Touch the other probe to each of the brushes (2) sm00060 attached to the field coil.
• Page 380 sm00062 sm00064 1. Frame 2. Brushes (2) 1. Holder plate Figure 5-10. Grounded Starter Field Test 2. Brush holders Figure 5-12. Starter Brush Holder Insulation Test sm00063 ASSEMBLY Figure 5-13. Clean, inspect and lubricate drive assembly components. Lubricate parts with high temper- ature grease, such as LUBRIPLATE 110.
• Page 381 sm00266 Through-bolt (2) Drive housing mounting screw Return spring End cover screw and o-ring Drive housing Ball Solenoid housing Gasket End cover Drive assembly/overrunning Washer (2) Brush holder clutch Mounting bolt (2) Brush spring (4) Idler gear Field wire Armature Idler gear roller (5) O-ring (2) Field frame...
• Page 382 Install sprocket cover. See 2.38 SPROCKET COVER. sm00258 Install primary cover. See CLUTCH. Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury.
• Page 383 STARTER SOLENOID REPLACEMENT sm00067 NOTE Figure 5-16. Do not tighten nut (7) without removing items (1) through (5). The contact will move and be destroyed. The starter solenoid is a switch that is designed to open and close the starting circuit electromagnetically. The switch con- sists of contacts and a winding around a hollow cylinder con- taining a movable plunger.
• Page 384 NOTES 5-10 2008 XB Service: Electric Starter...
• Page 385 SUBJECT..........................PAGE NO. 6.1 SPECIFICATIONS........................6-1 6.2 PRIMARY COVER........................6-2 6.3 CLUTCH RELEASE MECHANISM...................6-6 6.4 CLUTCH............................6-8 6.5 PRIMARY CHAIN........................6-15 6.6 DRIVE BELT AND IDLER PULLEY..................6-21 6.7 TRANSMISSION........................6-25 6.8 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL............6-26 6.9 TRANSMISSION DISASSEMBLY...................6-29 6.10 TRANSMISSION ASSEMBLY....................6-36 6.11 MAIN DRIVE GEAR AND BEARING..................6-38 6.12 TRANSMISSION RIGHT CASE BEARINGS.................6-45 6.13 TRANSMISSION LEFT CASE BEARINGS................6-47 6.14 TRANSMISSION INSTALLATION..................6-48...
• Page 386 NOTES...

• Page 387: Specifications

  SPECIFICATIONS not given under SERVICE WEAR LIMITS, see NEW COMPON- GENERAL ENTS. NOTE Service wear limits are given as a guideline for measuring components that are not new. For measurement specifications Table 6-1. Primary Drive (Engine-to-Transmission) ITEM (XB9SX) (XB12 MODELS) Engine sprocket 34 teeth 38 teeth...

• Page 388: Primary Cover

  PRIMARY COVER 16. Blow parts dry with low pressure compressed air. REMOVAL Remove seat. sm00351 To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect negative battery cable from battery. Remove chin fairing.

• Page 389: Primary Chain Adjuster Replacement

  sm00269 Gasket Screw Oil seal Shifter bushing Rubber shift lever pad Sems screws (13) Primary cover Shifter linkage assembly Adjuster assembly Gasket Bolt Chain adjustment nut Clutch inspection cover Flange bolt O-ring Sems screws (5) Sleeve Drain plug Inspection cover gasket Pedal bearing (2) Rubber washer Cover, inspection...

• Page 390: Installation

  sm00270 sm00271 Figure 6-5. Primary Cover Tightening Sequence (Typical) Figure 6-5. Tighten fasteners to 100-120 in-lbs (11.3- 13.5 Nm) in sequence shown. Figure 6-3. Install new shifter lever oil seal (19). sm00272 1. Shoe, chain adjuster 2. Chain adjuster screw 1.
• Page 391 12. See Figure 6-8. For Ulysses only, install shifter bracket sm00273 (4) on primary cover (7) by applying LOCTITE 271 (red) to fasteners and tightening to 22-24 ft-lbs (30.0-32.5 Nm). Lightning and Firebolt models do not have a shifter bracket. 13.

• Page 392: Clutch Release Mechanism

  CLUTCH RELEASE MECHANISM amount of free play at clutch hand lever. See DISASSEMBLY 1.8 CLUTCH/TRANSMISSION/PRIMARY FLUID. NOTE Figure 6-9. Remove three TORX screws with washers For clutch adjustment procedure, see 1.8 CLUTCH/TRANS- (1) and clutch inspection cover (2). MISSION/PRIMARY FLUID. Slide spring (4) with attached screw lockplate (5) from flats Remove seat.

• Page 393: Assembly

  ASSEMBLY sm00276 Figure 6-10. Assemble inner and outer ramps. Apply multi-purpose grease to balls (2) and ramps (1, Insert balls in sockets of outer ramp (1). Install inner ramp on hub of outer ramp with tang (3) rotated 180° from hook (6) of outer ramp. Install new retaining ring in groove of outer ramp hub.

• Page 394: Clutch

  CLUTCH The pressure plate then presses the clutch plates together GENERAL causing the plates to turn as a single unit. The result is that The purpose of the clutch is to smoothly disengage and engage the rotational force of the clutch shell is transmitted through the engine from the rear wheel for starting, stopping and shifting the clutch plates to the clutch hub.
• Page 395 sm00278 Spring Diaphragm spring Damper spring Lockplate Retaining ring Damper spring seat Release plate Mainshaft nut Outer ramp Retaining ring Washer Coupling Bearing Clutch hub Ball (3) Adjusting screw Inner thrust washer Inner ramp Pressure plate Needle bearing inner race Retaining ring Friction plate, fiber (7) Needle bearing...

• Page 396: Removal

  REMOVAL sm00279 PART NUMBER TOOL NAME HD-38515-91 CLUTCH SPRING FORCING SCREW HD-38515-A SPRING COMPRESSING TOOL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Remove negative battery cable from battery. Drain the transmission fluid.

• Page 397: Clutch Pack Cleaning And Inspection

  CLUTCH PACK CLEANING AND sm00283 INSPECTION Separate the pack in to the following components: Seven fiber plates. Seven steel plates. One narrow fiber plate. One damper spring. One damper spring seat. Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury.

• Page 398: Assembly And Installation

  If necessary, disassemble adjusting screw assembly. sm00282 Remove and discard small retaining ring (6). Separate the adjusting screw (8) from the bearing (7) and release plate (5). Remove bearing (7) from release plate (5). Replace components as required and reassemble adjusting screw assembly in reverse order.
• Page 399 Place pressure plate, diaphragm spring, adjusting screw sm00287 assembly with new retaining ring and spring seat onto clutch pack. Figure 6-21. Align square openings of pressure plate and diaphragm spring so that the assembly can be installed over prongs on clutch hub. Position spring seat with its larger outer diameter side toward diaphragm spring.
• Page 400 Install primary cover. See 6.2 PRIMARY COVER. sm00288 Adjust Clutch. See CLUTCH. Fill with GENUINE HARLEY-DAVIDSON FORMULA+ TRANSMISSION AND PRIMARY CHAINCASE LUB- RICANT (Part No. 99851-05). See CLUTCH. 10. Connect negative battery cable to battery terminal.Tighten fastener to 72-96 in-lbs (8.6-10.9 Nm). After installing seat, pull upward on seat to be sure it is locked in position.

• Page 401: Primary Chain

  PRIMARY CHAIN GENERAL sm00289 Since the primary chain runs in lubricant, little service will be required other than checking lubricant level and chain tension. If, through hard usage, the primary chain does become worn and cannot be adjusted to within specifications, it must be replaced.

• Page 402: Clutch Shell/Hub Inspection

  10. See Figure 6-29. Inspect clutch shell bearing inner race sm00290 on the back side of the clutch hub for pitting and wear. If the inner race shows any of these signs the complete hub assembly must be replaced. 11. Replace damaged parts as necessary. sm00249 1.

• Page 403: Clutch Shell Bearing Replacement

  sm00293 sm00294 1. Removal end of bearing tool 2. Installation end of bearing tool 3. Bearing guide, installer Figure 6-30. Clutch Shell Bearing Remover/Installer Figure 6-29. Clutch Hub Bearing Race sm00295 CLUTCH SHELL BEARING REPLACEMENT PART NUMBER TOOL NAME B-45926 CLUTCH SHELL BEARING REMOVER/INSTALLER NOTE...

• Page 404: Installation

  Submerge and soak all friction and steel plates in FOR- sm00296 MULA+ PRIMARY/TRANSMISSION LUBRICANT for at least five minutes and assemble clutch pack in sequence in the clutch hub. See 6.4 CLUTCH, General. Verify that outer thrust washer (4) is installed on transmis- sion shaft.
• Page 405 Figure 6-36. Install mainshaft washer (2) and nut (1). sm00299 If using original mainshaft nut apply two or three drops of LOCTITE 271 (red) onto threads on end of main- shaft. Place washer (2) on mainshaft with the word "out" facing away from clutch hub.
• Page 406 sm00288 1. Adjusting screw assembly 2. Retaining ring 3. Tab recesses Figure 6-38. Clutch Adjusting Screw Assembly and Retaining Ring 6-20 2008 XB Service: Drive/Transmission...

• Page 407: Drive Belt And Idler Pulley

  DRIVE BELT AND IDLER PULLEY GENERAL NOTE Figure 6-39. Mishandling drive belt will result in premature There is no drive belt adjustment required. The system utilizes failure. For maximum strength, integrity and longevity, avoid a fixed idler pulley that maintains the desired tension throughout over bending, twisting, crimping, pinching, kinking or prying suspension travel and life of the belt.

• Page 408: Drive Belt Removal

  DRIVE BELT REMOVAL sm00302 Place a scissor jack under jacking point and raise rear wheel off ground. For location of jacking point, see 4.16 EXHAUST SYSTEM. Remove right side rider footpeg support bracket. See 2.36 FOOTPEG, HEEL GUARD MOUNT: FIREBOLT/LIGHTNING 2.37 HEEL GUARD AND FOOTPEG MOUNTS: ULYSSES MODELS.

• Page 409: Idler Pulley Removal

  Remove front sprocket cover. See 2.38 SPROCKET sm00303 COVER. Figure 6-44. Remove idler pulley bracket nuts and washers (5) from studs (3). Slide idler pulley bracket (4) off studs (3). Inspect pulley by spinning wheel (1) and checking for wheel bearing wear. See 1.9 DRIVE BELT MAINTEN- ANCE, Inspection.
• Page 410 sm00304 1. Wheel 2. Wheel nut 3. Stud (2) 4. Idler pulley bracket 5. Idler pulley bracket nut and washer (2) 6. Wheel fastener Figure 6-44. Idler Pulley Assembly 6-24 2008 XB Service: Drive/Transmission...

• Page 411: Transmission

  TRANSMISSION The transmission is foot-operated by the gear shifter lever, GENERAL which transmits the force through a gear shifter shaft. The Figure 6-45. The transmission is a five-speed constant- shifter shaft actuates a pawl and a shifter fork drum. The shifter mesh type housed in an extension of the crankcase.

• Page 412: Case Disassembly For Transmission Removal

  CASE DISASSEMBLY FOR TRANSMISSION REMOVAL GENERAL sm00307 The rear compartment of the left and right crankcase halves form the transmission case. Servicing of transmission compon- ents requires removing the engine and disassembling (splitting) the crankcase. RIGHT CRANKCASE REMOVAL PART NUMBER TOOL NAME HD-42310/HD-43646 ENGINE SUPPORT STAND...
• Page 413 sm00309 sm00310 1. Shifter shaft 2. Return spring 3. Ratchet arms Figure 6-50. Shifter Shaft Assembly 12. See Figure 6-50. Depress ratchet arms (3) in order to clear the shifter drum and remove shifter shaft assembly from left crankcase half. 13.
• Page 414 sm00176 1. Crankcase fasteners 2. Crankcase fastener behind shifter mechanism Figure 6-52. Crankcase Fasteners 15. See Figure 6-52. Remove crankcase bolt set (14 fasteners). sm02981 sm00312 Figure 6-53. Separating Crankcase Halves Figure 6-54. Removing Flywheels from Left Crankcase 16. See Figure 6-53.

• Page 415: Transmission Disassembly

  TRANSMISSION DISASSEMBLY Figure 6-56. Remove shifter fork shafts by inserting TRANSMISSION REMOVAL FROM LEFT a small flat punch in the slots and tapping on the end of CRANKCASE each shaft until it falls free. PART NUMBER TOOL NAME NOTE Carefully tap on alternate sides of the shaft using the provided B-43895-1 TRANSMISSION REMOVER slots.
• Page 416 sm00316 Spring, detent Oil seal Detent spring sleeve assembly Rubber washer Screw, detent assembly Lever, engine Shaft, shifter forks (2) Bolt, engine lever Fork assembly, shifter (2nd-3rd) Bearing, shift lever assembly (2) Fork assembly, shifter (1st) Shift lever Shifter cam assembly Bolt, linkage assembly Fork assembly, shifter (4th-5th) Sleeve, shift/brake lever...
• Page 417 sm00317 Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) Figure 6-59. Remove left crankcase half and transmis- sion assembly (4) from engine stand.
• Page 418 sm00318 Oil seal Retaining ring Retaining ring Closed end bearing Ball bearing Countershaft 5th gear (integral to shaft) O-ring Countershaft Oil seal Countershaft 1st gear Needle bearing (2) Dog ring Mainshaft 5th gear Countershaft 4th gear Mainshaft 1st gear Countershaft 3rd gear Retaining ring (4) Dog ring Thrust washer (4)

• Page 419: Mainshaft/Countershaft

  MAINSHAFT/COUNTERSHAFT MAINSHAFT DISASSEMBLY NOTES PART NUMBER TOOL NAME As the transmission runs, each part develops a certain J-5586-A TRANSMISSION SHAFT RETAINING wear pattern and a kind of "set" with its mating parts. For RING PLIERS this reason, it is important that each component be rein- NOTES stalled in its original location and facing its original direc- tion.

• Page 420: Cleaning And Inspection

  Cleaning and Inspection Figure 6-63. Remove spacer (19) and 2nd gear (18) from the end of the of the countershaft (2). Remove and discard split bearing (17). Remove spacer (16). Compressed air can pierce the skin and flying debris from NOTE compressed air could cause serious eye injury.
• Page 421 sm00321 15 16 Countershaft 5th gear (integral to shaft) Split bearing Countershaft Countershaft 3rd gear Split bearing Thrust washer Countershaft 1st gear Retaining ring Thrust washer Dog ring Retaining ring Spacer Dog ring Split bearing Countershaft 4th gear Countershaft 2nd gear Retaining ring Spacer 10.

• Page 422: Transmission Assembly

  TRANSMISSION ASSEMBLY 6.10 MAINSHAFT ASSEMBLY NOTES Use correct retaining ring pliers and correct tips. Verify PART NUMBER TOOL NAME that tips are not excessively worn or damaged. J-5586-A RETAINING RING PLIERS During assembly, the split bearings and the internal bores of the gears must be lubricated with Harley-Davidson FORMULA+ TRANSMISSION AND PRIMARY CHAIN- CASE LUBRICANT prior to assembly.
• Page 423 10. Install dog ring (15). Make sure to install with dog ring 13. Install 2nd gear (18) and spacer (19). facing same direction as when it was removed. NOTE 11. Install spacer (16). At this point both mainshaft and countershaft sub-assemblies are ready to be pressed into the left crankcase half.

• Page 424: Main Drive Gear And Bearing

  MAIN DRIVE GEAR AND BEARING 6.11 with spacer (8) inner race. Without any support at the inner GENERAL race, the bearing is destroyed. Whenever the main drive gear NOTE is removed, the main drive gear bearing must be replaced. Figure 6-66 When removing the main drive gear (3), the gear is pressed out against the resistance of the ball bearing sm00322...

• Page 425: Main Drive Gear Bearing

  sm00323 sm00325 1. Main drive gear 2. Needle bearing (2) 3. Seal 4. O-ring 5. Retaining ring 1. Cross plate 2. 8 in. bolt Figure 6-67. Main Drive Gear Assembly 3. Main drive gear 4. Washer 5. Nice bearing 6. Washer sm00324 7.

• Page 426: Disassembly

  Discard main drive gear bearing. ASSEMBLY DISASSEMBLY PART NUMBER TOOL NAME HD-47855 INNER/OUTER MAIN DRIVE GEAR PART NUMBER TOOL NAME NEEDLE BEARING INSTALLATION HD-95635-46 CLAW PULLER TOOL HD-95637-46B WEDGE ATTACHMENT Use INNER/OUTER MAIN DRIVE GEAR NEEDLE Figure 6-67. Remove and discard retaining ring (5). BEARING INSTALLATION TOOL (Part No.

• Page 427: Installation

  will be at the prescribed depth from the end of the main INSTALLATION drive gear. Refer to Table 6-8. PART NUMBER TOOL NAME Table 6-8. Outer Needle Bearing Depth B-45847 CROSS PLATE HD-35316-12 INSTALLER CUP MODEL DEPTH HD-35316-4A 8 IN. BOLT All Models 0.285 in.

• Page 428: Main Drive Gear

  destroyed. Whenever the main drive gear is removed, the main sm00330 drive gear bearing must be replaced. Figure 6-75. Lubricate both main drive gear needle bearing assemblies and the mating surface of the main- shaft with HARLEY-DAVIDSON SPECIAL PURPOSE GREASE (Part No. 99857-97). Figure 6-66.

• Page 429: Main Drive Gear Seal

  sm00333 sm00334 1. 8 in. bolt 2. Washer 3. Main drive gear 4. Installer cup 5. Nice bearing 6. Flat washer 7. Nut Figure 6-76. Installing Main Drive Gear (Typical) Main Drive Gear Seal Figure 6-77. Install Pilot (Typical) Figure 6-77.
• Page 430 sm00336 sm00338 Figure 6-81. Install Nut (Typical) Figure 6-79. Install Adapter (Typical) sm00339 sm00337 1. Crowfoot wrench 2. 1/2-inch breaker bar 3. Adjustable wrench Figure 6-80. Place Installer over Adapter (Typical) Figure 6-82. Press Seal Into Crankcase 6-44 2008 XB Service: Drive/Transmission...

• Page 431: Transmission Right Case Bearings

  TRANSMISSION RIGHT CASE BEARINGS 6.12 REMOVAL INSTALLATION PART NUMBER TOOL NAME PART NUMBER TOOL NAME HD-95760-69A BUSHING AND BEARING PULLER A157-8 SNAP-ON BUSHING DRIVER 1/2-INCH ADAPTER HD-95765-69A 1/2 IN. COLLET A157C SNAP-ON BUSHING DRIVER SET Split crankcases in half. See 6.8 CASE DISASSEMBLY FOR TRANSMISSION REMOVAL.
• Page 432 sm00322 Retaining ring Right crankcase half Bearing (inner) Ball bearing with spacer Fifth gear mainshaft Retaining ring Bearing (outer) Oil seal O-ring Bearing, (closed end) countershaft Oil seal Bushing, shifter drum Figure 6-83. Transmission Assembly - Right Crankcase Half 6-46 2008 XB Service: Drive/Transmission...

• Page 433: Transmission Left Case Bearings

  TRANSMISSION LEFT CASE BEARINGS 6.13 REMOVAL INSTALLATION Mainshaft and Countershaft Bearings PART NUMBER TOOL NAME SNAP-ON PR-36 SNAP RING PLIERS Place crankcase on press with inside surface of crankcase downward. Mainshaft and Countershaft Bearings Lay bearing squarely over bore with printed side of bearing Split crankcases in half.

• Page 434: Transmission Installation

  TRANSMISSION INSTALLATION 6.14 INSTALLATION sm00342 PART NUMBER TOOL NAME B-43985-3 INSTALLER B-43985-4 GUIDE B-43985-4 GUIDE B-46285 (4) TRANSMISSION FIXTURE NOTES After re-installing the transmission assembly, verify that all parts have been properly installed. See: 6.11 MAIN DRIVE GEAR AND BEARING 6.10 TRANSMISSION ASSEMBLY 6.13 TRANSMISSION LEFT CASE BEARINGS 6.12 TRANSMISSION RIGHT CASE BEARINGS...

• Page 435: Shifter Forks And Drum Assembly

  SHIFTER FORKS AND DRUM ASSEMBLY sm00313 NOTES Figure 6-88. Shifter design allows for one common part number for both countershaft shifter forks. As the transmission runs, each shifter fork develops a certain wear pattern with its mating parts. For this reason, it is important that each shifter fork be reinstalled in its original location.

• Page 436: Installing Right Crankcase

  INSTALLING RIGHT CRANKCASE sm00344 PART NUMBER TOOL NAME B-45520 GEAR DETENT ASSEMBLY AID HD-42326-B CRANKSHAFT GUIDE Figure 6-90. Install the flywheel assembly into the left crankcase half using CRANKSHAFT GUIDE (Part No. HD- 42326-B). NOTE The Gear Detent Assembly Aid is used to move the gear detent lever clear of the shifter drum for assembly purposes.
• Page 437 sm00176 1. Crankcase fasteners 2. Crankcase fastener behind shifter mechanism Figure 6-93. Crankcase Fasteners 2008 XB Service: Drive/Transmission 6-51...

• Page 438: Shifter Shaft

  SHIFTER SHAFT 6.15 INSTALLATION sm00346 Figure 6-94. Correctly install shifter return spring onto the reverse side of the shifter shaft assembly before pla- cing shaft in left crankcase half. NOTE Figure 6-95. The shifter shaft return spring can be installed incorrectly and then assembled in the left crankcase half.
• Page 439 sm00309 sm00306 Figure 6-98. Hex Fastener Countershaft Retainer Figure 6-97. Installing Shifter Shaft Assembly 2008 XB Service: Drive/Transmission 6-53...

• Page 440: Transmission Sprocket

  TRANSMISSION SPROCKET 6.16 REMOVAL sm00304 PART NUMBER TOOL NAME B-43982 SPROCKET HOLDING TOOL B-45659 SPROCKET LOCKING TOOL HD-46288 MAINSHAFT LOCKNUT WRENCH HD-94660-37B MAINSHAFT LOCKNUT WRENCH NOTE Use spacer and fastener from B-45659 to install sprocket locking tool. Loosen rear axle pinch fastener. Unthread axle approximately 15 threads to release tension from drive belt.

• Page 441: Installation

  Tighten the transmission sprocket nut an additional 30°- sm00348 40°. NOTE Maximum allowable tightening of sprocket nut is 45° of coun- terclockwise rotation, after initially tightening to 50 ft-lbs. Do not loosen sprocket nut while attempting to align the screw holes.
• Page 442 sm00350 sm00302 45° 30° 1. Axle 2. Pinch bolt 1. Transmission sprocket nut 2. Transmission sprocket Figure 6-103. Rear Axle 3. Line scribed on nut and sprocket Figure 6-102. Aligning Transmission Sprocket 6-56 2008 XB Service: Drive/Transmission...
• Page 443 SUBJECT..........................PAGE NO. 7.1 SPECIFICATIONS........................7-1 7.2 IGNITION SYSTEM........................7-3 7.3 IGNITION/HEADLAMP KEY SWITCH..................7-5 7.4 SPARK PLUG CABLES......................7-15 7.5 CHARGING SYSTEM......................7-17 7.6 BATTERY CABLES.........................7-19 7.7 VOLTAGE REGULATOR......................7-22 7.8 ALTERNATOR.........................7-23 7.9 HEATED HAND GRIPS: ULYSSES MODELS.................7-25 7.10 HORN............................7-28 7.11 TURN SIGNAL FLASHER.....................7-30 7.12 FRONT TURN SIGNALS.......................7-32 7.13 REAR TURN SIGNALS......................7-35 7.14 INTERACTIVE EXHAUST SYSTEM..................7-39 7.15 HEADLIGHT..........................7-43...
• Page 444 NOTES...

• Page 445: Specifications

  SPECIFICATIONS GENERAL Table 7-4. Regulator Specifications REGULATOR Table 7-1. Battery Specifications Voltage output @ 3600 RPM 14.3-14.7 VDC @ 75° F (24° BATTERY Size 12 VDC/12 AH/200CCA Amperes @ 3600 RPM 32 Amps Type Sealed, AGM Table 7-5. Ignition Coil Specifications Table 7-2.
• Page 446 Table 7-8. Bulb Chart: 2008 Lightning Models BULBS BULBS WATTS AMPS PART REQUIRED NUMBER Headlamps Bulb (H7) 4.58 Y0148.1AD Position lamp 0.37 53436-97 (European models only) Marker lamps Tail/stop lamp 5/21 0.42/1.75 68169-90A Front and rear turn signal lamps 0.74 Y0042.K (1 bulb each) License plate illumination lamp...

• Page 447: Ignition System

  IGNITION SYSTEM temperature of the engine. The ECM will provide a richer fuel GENERAL mixture on start up and a higher degree of spark advance. As PART NUMBER TOOL NAME the vehicle warms up to operating temperature the fuel mixture will lean and the spark advance will decrease.
• Page 448 sm00241 Electronic control module Mounting fastener Crank position sensor (CKP) (ECM) Ignition coil O-ring Connector, interactive Front spark plug cable exhaust system 8. Cylinder brace 3. Spark plug (2) 4. Rear spark plug cable Figure 7-1. Ignition Components 7-4 2008 XB Service: Electrical...

• Page 449: Ignition/Headlamp Key Switch

  IGNITION/HEADLAMP KEY SWITCH GENERAL Table 7-12. Indicator Markers ITEM Headlight position marker lamps The automatic-on headlamp feature provides increased (European models only) visibility of the rider to other motorists. Be sure headlamp Headlight high beam Can be is on at all times. Poor visibility of rider to other motorists activated can result in death or serious injury.

• Page 450: Disassembly: Firebolt

  sm00360 sm00361 1. Upper fork clamp pinch fastener (2) Figure 7-3. Cable Straps On Upper Fork Clamp: Firebolt 2. Stem pinch fastener 3. Stem capnut 4. Upper fork clamp Figure 7-4. Upper Fork Clamp: Firebolt sm00363 1. Headlights (2) 2. Cable strap 3.

• Page 451: Installation: Firebolt

  Figure 7-3. Attach cable straps to upper fork clamp. sm00362 Install cable strap to the right of ignition switch securing right hand switch and brake line wires to upper fork clamp. Install cable strap to the left of ignition switch securing left hand switch and clutch cable wires to upper fork clamp.
• Page 452 sm00473 Turn signal flasher connector [30] Main harness Instrument cluster connector [39] Horn fastener Right handlebar connector [22] Horn mount Left handlebar connector [24] Horn connector [122] Turn signal connectors [31] Horn 6. Ignition switch [33] Figure 7-7. Electrical Connectors Behind Windscreen: Lightning Figure 7-8.

• Page 453: Disassembly: Lightning

  sm00476 1. Socket head fastener (1) with spacer behind switch 2. Tamper-resistant Torx fasteners (2) 3. Throttle cables 4. Ignition switch as positioned on vehicle 5. Fork stop pin (retracted) Figure 7-8. Ignition Switch: Lightning (Typical) Push ignition switch housing (4) on to ignition switch (5). DISASSEMBLY: LIGHTNING NOTE Figure...
• Page 454 sm00477 1. Body fastener (2) 2. Body 3. Spacer 4. Housing 5. Ignition switch 6. Socket head fastener 7. Tamper-resistant Torx fasteners (2) 8. Ignition switch connector [33] Figure 7-9. Ignition Switch Assembly 7-10 2008 XB Service: Electrical...
• Page 455 sm00473 Turn signal flasher connector [30] Main harness Instrument cluster connector [39] Horn fastener Right handlebar connector [22] Horn mount Left handlebar connector [24] Horn connector [122] Turn signal connectors [31] Horn 6. Ignition switch [33] Figure 7-10. Electrical Connectors Behind Windscreen: Lightning Install spacer (3) onto fastener (6), and attach ignition INSTALLATION: LIGHTNING switch assembly to upper triple clamp.

• Page 456: Removal: Ulysses

  Connect: REMOVAL: ULYSSES Instrument cluster connector [39] (2) PART NUMBER TOOL NAME Left [24] (4) and right [22] (3) handlebar wiring har- FTXR45E SNAP-ON TAMPER-RESISTANT T45 ness connectors TORX DRIVER Turn signal connectors [31] (5) Remove seat. Turn signal flasher connector [30] (1) Loosely install cable strap around the main wiring harness and the ignition switch.

• Page 457: Disassembly: Ulysses

  sm00475 Turn signal flasher connector [30] Cable strap Instrument cluster connector [39] Main harness Right handlebar connector [22] Horn fastener Left handlebar connector [24] Horn mount Turn signal connectors [31] Horn connector [122] Ignition switch Horn Figure 7-12. Electrical Connectors Behind Windscreen: Ulysses NOTE DISASSEMBLY: ULYSSES In next step, do not force ignition switch (5) into body (2).
• Page 458 Install the ignition switch with the fork stop pin pointing sm00477 down and, once in place, roll the assembly toward you and insert the fork stop pin into the upper triple clamp. Figure 7-13. After applying LOCTITE 271 (red), attach ignition switch assembly to upper triple clamp using ignition switch fasteners (7, 6) install spacer (3) onto fastener (6) and tighten to 18-20 ft-lbs (24.4-27.1 Nm).

• Page 459: Spark Plug Cables

  SPARK PLUG CABLES Figure 7-15. Check spark plug cable resistance with GENERAL an ohmmeter (4). Replace cables not meeting resistance Resistor-type high-tension spark plug cables have a carbon- specifications. impregnated fabric core, instead of solid wire, for radio noise suppression and improved reliability of electronic components. Table 7-13.
• Page 460 sm00366 Figure 7-16. Boot Gap 7-16 2008 XB Service: Electrical...

• Page 461: Charging System

  CHARGING SYSTEM GENERAL Alternator The alternator consists of two main components: The charging system consists of the alternator and regulator. Charging system circuits are shown in Figure 7-17 The rotor which mounts to the engine sprocket shaft. Figure 7-18. The stator which bolts to the engine crankcase. NOTE Voltage Regulator Never install accessory wiring between battery post and battery...
• Page 462 sm04730 Battery Fuse/Relay Block Battery Fuse 30 Amp GND 1 [77B] [77A] To fuse and relay block Voltage Regulator Stator [46A] [46B] Battery To voltage regulator Battery cable Voltage regulator 30A battery fuse Stator H-D 1-phase Figure 7-18. Charging System Circuit (Ulysses, Lightning) 7-18 2008 XB Service: Electrical...

• Page 463: Battery Cables

  BATTERY CABLES Connect cables to frame and starter. REMOVAL Figure 7-22. First, connect positive battery cable to starter using fastener with washer. Tighten fastener to 60-85 in-lbs (7-10 Nm). To prevent accidental vehicle start-up, which could cause Reinstall protective rubber boot. death or serious injury, disconnect negative (-) battery cable before proceeding.
• Page 464 sm00445 sm00393 1. Battery 2. Battery boot 3. Positive battery cable 4. Negative battery cable 5. To frame 6. To starter 7. Red/yellow wires (14 gauge, to be spliced) 8. Battery strap Figure 7-20. Battery: Lightning/Ulysses 1. Battery strap bracket 2.
• Page 465 sm00258 1. Positive battery cable 2. Solenoid wire Figure 7-22. Starter Wires (Protective Boot Not Shown) 2008 XB Service: Electrical 7-21...

• Page 466: Voltage Regulator

  VOLTAGE REGULATOR GENERAL sm00391 The voltage regulator is mounted to the front of the crankcase. The voltage regulator is not repairable. Replace the unit if it fails. REMOVAL Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding.

• Page 467: Alternator

  ALTERNATOR REMOVAL AND DISASSEMBLY sm00387 To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect negative battery cable. Remove primary cover. See 6.2 PRIMARY COVER. Remove clutch assembly, primary chain and engine sprocket/rotor assembly as a unit.

• Page 468: Cleaning And Inspection

  thread locking compound. Loss of torque on fasteners could sm00389 result in alternator damage. Position stator (2) on left crankcase half. Secure stator using four new stator fasteners (1). Tighten to 30-40 in- lbs (3-4 Nm). Install retainer plate with new fasteners and tighten to 56 in-lbs (6.3 Nm).

• Page 469: Heated Hand Grips: Ulysses Models

  HEATED HAND GRIPS: ULYSSES MODELS HEATED HAND GRIPS sm05236 Removal Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect battery negative cable. Remove the windscreen/windshield assembly from the vehicle.
• Page 470 sm04632 sm04640 Figure 7-33. Location of Cable Strap Securing the Right Side Hand Grip Wire Below the Instrument Cluster 1. Handlebar wire harness retainer 2. Cable strap for heated hand grip wire Figure 7-34. On the left side, install a cable strap Figure 7-31.
• Page 471 NOTE sm04640 After installation is complete, return to the right hand grip wire and rotate the throttle grip to ensure the loop has not changed and the moving wire on the heated grip does not make contact with anything when the throttle is rotated. 10.

• Page 472: Horn

  HORN 7.10 REMOVAL sm00443 Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect negative battery cable. Access horn: For Firebolt, remove headlight support bracket. See 2.28 HEADLAMP ASSEMBLY AND SUPPORT BRACKET.

• Page 473: Troubleshooting

  TROUBLESHOOTING sm00465 If the horn does not sound or fails to function satisfactorily, check for the following conditions: Discharged battery. Loose, frayed, or damaged wiring leading to horn terminal. Verify horn is not making contact with wiring or other components. If battery has a satisfactory charge and wiring appears to be in good condition, test horn ground and switch using voltmeter.

• Page 474: Turn Signal Flasher

  TURN SIGNAL FLASHER 7.11 REMOVAL sm00406 NOTE The turn signal flasher is not repairable. Replace flasher upon failure. Remove front fairing or windshield/windscreen. See 2.49 FRONT FAIRING, WINDSHIELD, AND MIRRORS: FIREBOLT (Firebolt) or 2.50 WINDSHIELD AND WIND- SCREEN: LIGHTNING AND ULYSSES (Lightning and Ulysses).
• Page 475 sm00407 1. Left turn signal 2. Right turn signal Figure 7-44. Turn Signal Controls 2008 XB Service: Electrical 7-31...

• Page 476: Front Turn Signals

  FRONT TURN SIGNALS 7.12 Check turn signals for proper operation. If operation fails, BULBS reread procedure and verify that all steps were performed. Repair Turn ignition/key switch to ON. Remove screw on back of housing to access turn signal Activate left turn signals using switch on left bulbs.

• Page 477: Ulysses

  Install turn signal using lockwasher and jam nut. Tighten Installation fastener to 25-28 in-lbs (2.8-3.2 Nm). Figure 7-48. Insert bullet connectors and wiring Attach bullet connectors on turn signal wires as shown in through hole in front module. Figure 7-45. Install turn signal using lockwasher and jam nut.
• Page 478 sm03811 1. Turn signal 2. Jam nut and lockwasher 3. Front module, left and right 4. Windshield 5. Windscreen Figure 7-48. Front Turn Signals: Ulysses 7-34 2008 XB Service: Electrical...

• Page 479: Rear Turn Signals

  REAR TURN SIGNALS 7.13 BULBS sm00458 Remove screws on back of housing to access turn signal [19A] [19B] bulbs. Rotate bulb 1/4 turn and remove. [19B] [19A] Before replacing, apply a light coat of dielectric grease on the bulb contact terminals. [93A] [93B] Install screw and tighten to 4.4-4.3 in-lbs (0.5-0.6 Nm).

• Page 480: Installation

  Check turn signals for proper operation. If operation fails, reread procedure and verify that all steps were performed. Turn ignition/key switch to ON. Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in Activate left turn signals using switch on left death or serious injury.

• Page 481: Ulysses

  NOTE Check turn signals for proper operation. If operation fails, Be sure tab on turn signal fits into hole in reflector bracket and reread procedure and verify that all steps were performed. tab on reflector bracket fits into hole in enter tail section. Turn ignition key switch to ON.
• Page 482 Check turn signals for proper operation. If operation fails, Activate right turn signals using switch on left reread procedure and verify that all steps were performed. handlebar. Front and rear right turn signals must flash. Turn ignition key switch to ON. Turn ignition key switch to OFF.

• Page 483: Interactive Exhaust System

  INTERACTIVE EXHAUST SYSTEM 7.14 At low RPM with a wide-open throttle, the valve (1) is GENERAL opened to reduce back-pressure so the engine can gain NOTE RPM quickly. The exhaust enters (2) the muffler and flows (3) through the open valve (1) into chamber C (7) and then The interactive exhaust system is standard equipment on the exits (8).
• Page 484 sm00375 Interactive exhaust cable Air cleaner cover Harness with connector [161B] Actuator cover (Lightning XB12 models with 3. Interactive exhaust cable bracket translucid cover only) Actuator Screws (Lightning XB12 models with translucid cover only) Figure 7-55. Interactive Control System (XB12 Models) 7-40 2008 XB Service: Electrical...

• Page 485: Removal

  REMOVAL sm03744 PART NUMBER TOOL NAME HS0020.02A8A HOSE ASSEMBLY Remove seat. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect negative battery cable. Remove chin fairing. See 2.53 CHIN FAIRING.

• Page 486: Installation

  Install cable strap above starter securing actuator cable, sm00376 vent line, main harness and positive battery cable. Install cable strap securing actuator cable, neutral switch and oil pressure wiring. Install front sprocket cover. See 2.38 SPROCKET COVER. 10. Install chin fairing. See 2.53 CHIN FAIRING.

• Page 487: Headlight

  HEADLIGHT 7.15 GENERAL Dual headlights are equipped with replaceable bulbs. Never touch the quartz bulb. Fingerprints will etch the High beam headlight is located on the left side of vehicle. glass and decrease bulb life. Grab the bulb with paper or and turns on and off with headlight switch.

• Page 488: Headlight Bulbs: Lightning And Ulysses

  sm00399 To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Disconnect negative battery cable. Handle bulb carefully and wear eye protection. Bulb con- tains gas under pressure, which, if not handled carefully, could cause serious eye injury.

• Page 489: Installation

  sm00446 Headlight Low beam connection [38] (right side) with ground Bulb holder (2) Headlight bulbs 3. High beam connection [38] (left side) with ground Figure 7-61. Headlight Assembly: Lightning/Ulysses (Rear View) Installation NOTE If the rubber boots are not installed correctly the wiring har- NOTE nesses can contact the edge of the forward frame mount.
• Page 490 Be sure that all lights and switches operate properly before After installing seat, pull upward on seat to be sure it is operating motorcycle. Low visibility of rider can result in locked in position. While riding, a loose seat can shift death or serious injury.
• Page 491 sm00447 Figure 7-62. Headlight Housing 20 Degree Alignment Marks for Rubber Boot Wiring Harness Guides or Spigots 2008 XB Service: Electrical 7-47...

• Page 492: Tail Lamp

  TAIL LAMP 7.16 FIREBOLT/LIGHTING Removal Be sure that all lights and switches operate properly before Lightning Models: Remove seat. operating motorcycle. Low visibility of rider can result in death or serious injury. (00316a) Figure 7-63. Remove two screws (2) to detach tail Check tail lamp for proper operation.

• Page 493: Ulysses

  ULYSSES Removal After installing seat, pull upward on seat to be sure it is Remove seat. locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or Disconnect connector [93] from tail lamp. serious injury.

• Page 494: License Plate Lamp Assembly

  LICENSE PLATE LAMP ASSEMBLY 7.17 LIGHTNING sm00452 Removal Remove seat. Figure 7-65. Disconnect the two connectors [45] from license plate lamp harness (2). Remove two jam nuts and washers (1) to detach license plate lamp from center tail section (3). Pull the lamp assembly away from center tail section pulling the harness out between the tail screen and the center tail section.

• Page 495: Assembly And Installation

  See {MISSING_XREF_C20-art-hdtopic001720-1}. Remove Install seat. the cover for the rear wiring (3). Disconnect the two connectors [45] from license plate sm00450 lamp harness. Pull the lamp assembly away from license plate bracket (1) pulling the harness out of the license plate bracket. Assembly and Installation Figure 7-67.

• Page 496: Main Fuse And Fuses

  MAIN FUSE AND FUSES 7.18 GENERAL sm00373 Buell motorcycles feature two components which protect the electrical system. Fuses Firebolt: See Figure 7-68 Figure 7-69. The covered fuse block is under the seat. Lightning: See Figure 7-70 Figure 7-71. The covered fuse block is under the seat.
• Page 497 sm00469 sm00467 1. Fuel pump (10 amp) 2. Auxiliary (10 amp) 3. Main (30 amp) 4. ECM (10 amp) 5. Lamps (15 amp) 6. Key switch (15 amp) 7. Ignition (15 amp) 8. Accessories (10 amp) 9. Brake/horn/interactive exhaust (10 amp) 1.
• Page 498 sm00467 sm00424 1. Negative battery cable 2. Main fuse holder 3. Rear brake fluid reservoir Figure 7-74. 30A Main Fuse Location: Firebolt 1. Fuel pump (10amp) 2. Auxiliary (10amp) 3. Battery (30 amp) 4. ECM (10 amp) 5. Lamps (15 amp) 6.

• Page 499: Neutral Indicator Switch

  NEUTRAL INDICATOR SWITCH 7.19 Install sprocket cover. See 2.38 SPROCKET COVER. GENERAL Figure 7-75. The neutral indicator switch (2) is threaded into the transmission portion of the right crankcase half. It is sm00421 immediately forward of the transmission sprocket (1). The sprocket cover must be removed to test the switch.

• Page 500: Crankshaft Position Sensor (Ckp)

  CRANKSHAFT POSITION SENSOR (CKP) 7.20 GENERAL sm02442 The crank position (CKP) sensor is a variable reluctance (VR) sensor that generates an AC signal by sensing the passing of the 30 teeth cast into the engine's left side flywheel. Two con- secutive teeth are missing in the flywheel to establish a refer- ence point.
• Page 501 Connect battery positive cable (red) first, tightening to 72-96 in-lbs (8-11 Nm). See 1.4 BATTERY MAINTEN- ANCE. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift Connect negative battery cable, tightening to 72-96 in- causing loss of control, which could result in death or lbs (8-11 Nm).

• Page 502: Vehicle Speed Sensor (Vss)

  VEHICLE SPEED SENSOR (VSS) 7.21 REMOVAL sm00410 Remove sprocket cover. See 2.38 SPROCKET COVER. Disconnect 3-place Deutsch connector [65] under sprocket cover. See 7.25 SPROCKET COVER WIRING. Figure 7-78. Remove fastener (1) to detach vehicle speed sensor (2) from crankcase. INSTALLATION Figure 7-78.

• Page 503: Instrument Module

  INSTRUMENT MODULE 7.22 Remove the nine fasteners securing the back of the GENERAL module housing to the display and remove back cover. Replace the instrument module if the unit is not working prop- NOTE erly. However, before replacing a component, check that the Do not turn display over.

• Page 504: Installation

  INSTALLATION sm00466a Figure 7-85 (Firebolt), Figure 7-86 (Lightning) or Figure 7-87 (Ulysses). Place instrument module (2) into position in support (1). Install washers (4) and fasteners (5). Tighten fasteners to 12-36 in-lbs (1.4-4.0 Nm). Figure 7-82 (Firebolt), Figure 7-83 (Lightning), or Figure 7-84 (Ulysses).
• Page 505 sm00415 sm00464 1. Headlight support bracket 1. Fairing support, center 2. Instrument module 2. Instrument module 3. Grommet (3) 3. Grommet (3) 4. Washer (3) 4. Washer (3) 5. Fastener (3) 5. Fastener (3) 6. Instrument module connector [39] 6. Instrument module connector [39] Figure 7-85.

• Page 506: Main Wire Harness

  MAIN WIRE HARNESS 7.23 11. See figures: GENERAL Lightning: Figure 7-97 The main wire harness runs from the front of the motorcycle XB12Ss: Figure 7-90 to the tail section. Firebolt: Figure 7-96 Always replace plastic tree fasteners when replacing main wire Ulysses: Figure 7-91Figure 7-94.
• Page 507 sm00661 Main harness Bank angle sensor (BAS) connector [134] Main harness ground (high voltage ground wire) Right turn signal connector [18] Battery negative cable Left turn signal connector [19] (under remote Battery positive cable License plate lamp connector [45] Rear brake light switch connector [121] Tail light connectors [93] Ground terminals [GRD1] and [GRD3] Left and right trunk pan fasteners...
• Page 508 sm00472 Main harness Ground terminals (low voltage ground wires) Main harness ground (high voltage ground wire) ECM connectors [10] and [11] Battery negative cable Fuse block and relay center Battery positive cable Bank angle sensor (BAS) connector [134] 5. Rear brake light switch connector [121] Figure 7-90.
• Page 509 sm00475 Turn signal flasher connector [30] Cable strap Instrument cluster connector [39] Main harness Right handlebar connector [22] Horn fastener Left handlebar connector [24] Horn mount Turn signal connectors [31] Horn connector [122] Ignition switch Horn Figure 7-91. Electrical Connectors Behind Windscreen: Ulysses 2008 XB Service: Electrical 7-65...
• Page 510 sm00473 Turn signal flasher connector [30] Main harness Instrument cluster connector [39] Horn fastener Right handlebar connector [22] Horn mount Left handlebar connector [24] Horn connector [122] Turn signal connectors [31] Horn 6. Ignition switch [33] Figure 7-92. Electrical Connectors Behind Windscreen: Lightning 15.
• Page 511 17. See Firebolt: Figure 7-100. 24. Disconnect: Disconnect: Intake air temperature sensor [89]. Flasher connector [30]. Throttle position sensor [88]. Bank angle sensor connector [134]. O2 sensor [137]. Electronic control module (ECM). See 4.3 ELEC- Temperature sensor [90]. TRONIC CONTROL MODULE (ECM).
• Page 512 sm00431 Cable strap Right turn signal connectors Left turn signal connectors Cable strap Data link [91] Right switch housing connector [22] Left switch housing connector [24] Ignition switch connector [33] Cable strap Cable strap 6. Headlight connector [38] Figure 7-93. Fairing Wiring (Viewed From Beneath Fairing): Firebolt 7-68 2008 XB Service: Electrical...

• Page 513: Installation

  sm00475 Turn signal flasher connector [30] Cable strap Instrument cluster connector [39] Main harness Right handlebar connector [22] Horn fastener Left handlebar connector [24] Horn mount Turn signal connectors [31] Horn connector [122] Ignition switch Horn Figure 7-94. Electrical Connectors Behind Windscreen: Ulysses Feed front and center portion of harness between the trunk INSTALLATION pan and tire through opening at rear of frame/fuel tank...
• Page 514 NOTE sm00428 Fuel line is installed under engine connector portion of wire harness. Route portion of main wire harness that contains the pos- itive battery cable (3), sprocket cover wiring (4) and transmission vent hose (2) through corner mounting strap and guide (1) at rear of frame.
• Page 515 sm00473 Turn signal flasher connector [30] Main harness Instrument cluster connector [39] Horn fastener Right handlebar connector [22] Horn mount Left handlebar connector [24] Horn connector [122] Turn signal connectors [31] Horn 6. Ignition switch [33] Figure 7-96. Electrical Connectors Behind Windscreen: Lightning Install cable strap loosely around main harness (7) and 11.
• Page 516 12. Install and connect ignition coil. 27. On Lightning and Ulysses models, install wire harness guide on steering neck and tighten to 36-60 in-lbs (4-6.7 13. Install connector on oil pressure switch [120]. See 3.13 OIL Nm). PRESSURE INDICATOR SWITCH. 28.
• Page 517 sm00661 Main harness Bank angle sensor (BAS) connector [134] Main harness ground (high voltage ground wire) Right turn signal connector [18] Battery negative cable Left turn signal connector [19] (under remote Battery positive cable License plate lamp connector [45] Rear brake light switch connector [121] Tail light connectors [93] Ground terminals [GRD1] and [GRD3] Left and right trunk pan fasteners...
• Page 518 sm00472 Main harness Ground terminals (low voltage ground wires) Main harness ground (high voltage ground wire) ECM connectors [10] and [11] Battery negative cable Fuse block and relay center Battery positive cable Bank angle sensor (BAS) connector [134] 5. Rear brake light switch connector [121] Figure 7-98.
• Page 519 sm04798 Main harness Battery positive cable Electronic control module Left rear and right rear tail section fasteners (4) ECM connectors [10] and [11] Seat lock cable Fuse block and relay center Bank angle sensor (BAS) connector [134] Main harness ground wire [GRD2] Auxiliary power outlet Main harness with plastic grommet Trunk pan...
• Page 520 sm00431 Cable strap Right turn signal connectors Left turn signal connectors Cable strap Data link [91] Right switch housing connector [22] Left switch housing connector [24] Ignition switch connector [33] Cable strap Cable strap 6. Headlight connector [38] Figure 7-100. Fairing Wiring (Viewed From Beneath Fairing): Firebolt 7-76 2008 XB Service: Electrical...

• Page 521: Interactive Exhaust Harness: Xb12 Models

  INTERACTIVE EXHAUST HARNESS: XB12 MODELS 7.24 FIREBOLT sm00433 Removal Remove seat and pillion. Remove intake cover assembly. See 2.40 INTAKE COVER. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) Remove negative battery cable from battery.

• Page 522: Lightning

  NOTE For actuator or actuator cable replacement see 7.14 INTER- ACTIVE EXHAUST SYSTEM. After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or sm00911 serious injury.

• Page 523: Ulysses

  Figure 7-106. Verify that the interactive exhaust cable (3) is routed behind the frame lug (1) before installing air intake cover. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery Figure 7-105. Connect exhaust actuator harness cable before proceeding.
• Page 524 Figure 7-108. Verify that the interactive exhaust cable sm00434 (3) is routed behind the frame lug (1) before installing air intake cover. Figure 7-107. Mate exhaust actuator harness con- nector [165] beneath main harness (6) under seat. Install ground bolt through main battery ground cable and actuator ground wire.Tighten to 48-72 in-lbs (5.4-8.1 Nm).

• Page 525: Sprocket Cover Wiring

  SPROCKET COVER WIRING 7.25 GENERAL REMOVAL Connectors for the neutral switch [131] and the oil pressure Remove sprocket cover. See 2.38 SPROCKET COVER. indicator switch [120] are located under the sprocket cover. Disconnect appropriate connector(s). NOTE sm03744c The actuator cable, neutral switch connector and the oil pres- sure switch wire is located under the sprocket cover.

• Page 526: Auxiliary Power Outlets: Ulysses Models

  AUXILIARY POWER OUTLETS: ULYSSES MODELS 7.26 GENERAL sm00441 The 12-volt auxiliary power outlet circuit consists of two power outlets for 12-volt electrical accessories. The forward power outlet is located in the dash to the left of the speedometer assembly. The rearward power outlet is located in the tail section under the seat.
• Page 527 SUBJECT..........................PAGE NO. A.1 AMP 1-PLACE CONNECTORS....................A-1 A.2 AMP MULTILOCK CONNECTORS..................A-3 A.3 AUTOFUSE ELECTRICAL CONNECTORS................A-7 A.4 DELPHI CONNECTORS......................A-8 A.5 DEUTSCH ELECTRICAL CONNECTORS................A-10 A.6 DEUTSCH STANDARD TERMINAL REPAIR.................A-14 A.7 DEUTSCH SOLID BARREL MINI TERMINAL REPAIR............A-15 A.8 DEUTSCH MINI TERMINAL REPAIR..................A-17 A.9 MOLEX CONNECTORS......................A-18 A.10 PACKARD 150 METRI-PACK CONNECTORS..............A-22 A.11 PACKARD 280 METRI-PACK RELAY AND FUSE BLOCK CONNECTORS......A-24 A.12 PACKARD 480 METRI-PACK CONNECTORS..............A-25...
• Page 528 NOTES...

• Page 529: Amp 1-Place Connectors

  AMP 1-PLACE CONNECTORS AMP 1-PLACE CONNECTOR REPAIR sm00011 PART NUMBER TOOL NAME HD-38125-7 PACKARD TERMINAL CRIMPER HD-39621-27 SOCKET TERMINAL TOOL HD-39621-28 PIN TERMINAL REMOVER General Obtain the necessary tools to repair the connector or terminals. For terminal crimping, use the PACKARD TERMINAL CRIMPER (Part No.

• Page 530: Installing Pin Terminal

  Figure A-2. sm00012 Fit the barrel of the PIN TERMINAL REMOVER (Part No. HD-39621-28) over the pin, and while rotating the tool slightly, push until it bottoms in the housing. Allow the plunger to "back out" of the handle. Holding the pin housing while keeping the tool firmly bottomed, depress the plunger.

• Page 531: Amp Multilock Connectors

  AMP MULTILOCK CONNECTORS AMP MULTILOCK CONNECTOR REPAIR sm00002 PART NUMBER TOOL NAME HD-41609 AMP MULTILOCK CRIMPER General AMP Multilock connectors are found between wire harnesses and component wiring and may be either floating or anchored to the frame with attachment clips. Figure A-3.

• Page 532: Inserting Terminals Into Housing

  NOTES sm00013 Up and down can be determined by the position of the release button, the button is the top of the connector. On the pin side of the connector, tangs are positioned at the bottom of each cavity, so the slot in the pin terminal (on the side opposite the crimp tails) must face downward.

• Page 533: Crimping Terminals To Leads

  Figure A-6 Figure A-7. Select the pin/socket ter- Figure A-8. Squeeze the handles to cycle the AMP minals from the parts catalog and identify the insulation MULTILOCK CRIMPER (Part No. HD-41609) to the fully crimp tails (1) and the wire crimp tails (2) and the groove open position (1).

• Page 534: Inspecting Crimped Terminals

  Inspecting Crimped Terminals sm00007 Figure A-9. Inspect the wire core crimp (2) and insulation crimp (1). Distortion should be minimal. sm00008 1. Insulation crimp 2. Wire core crimp Figure A-9. AMP Multilock Connector: Terminal Crimp 1. Open position 2. Locking bar flange 3.

• Page 535: Autofuse Electrical Connectors

  AUTOFUSE ELECTRICAL CONNECTORS AUTOFUSE CONNECTOR REPAIR sm02849 PART NUMBER TOOL NAME GA500A SNAP-ON TERMINAL PICK General Autofuse electrical connector terminals are found in ignition switches and some fuse blocks. Disassembly Obtain SNAP-ON TERMINAL PICK (Part No. GA500A). Figure A-10 Figure A-11.

• Page 536: Delphi Connectors

  DELPHI CONNECTORS DELPHI CONNECTOR REPAIR sm00014 General Delphi connectors are embossed with the brand name, Delphi, on the housing latch. Separating Pin and Socket Housings Figure A-12. Bend back the external latch(es) slightly and separate pin and socket halves of connector. Mating Pin and Socket Housings Push pin and socket halves of connector together until external latch(es) engage.
• Page 537 sm00015 1. Remove wire lock 2. Remove terminal lock 3. Pry tang outward Figure A-13. Delphi Connector: Removing Socket Terminals 2008 XB Service: Appendix A Connector Repair A-9...

• Page 538: Deutsch Electrical Connectors

  DEUTSCH ELECTRICAL CONNECTORS Place large end of slot on attachment clip over T-stud on DEUTSCH CONNECTOR REPAIR frame. Push assembly forward to engage small end of PART NUMBER TOOL NAME slot. HD-41475 DEUTSCH CONNECTOR SERVICE sm00017 HD-41475-100 FLAT BLADE L-HOOK General Deutsch connectors are colored coded for location purposes.
• Page 539 Install internal seal (4) on lip of socket housing, if removed. sm00018 Insert tapered end of secondary locking wedge (5) into socket housing and press down until it snaps in place. The wedge fits into the center groove within the socket housing and holds the terminal latches tightly closed.

• Page 540: Removing Pin Terminals

  gray connectors, plugs or receptacles must be replaced sm00010 by those of the same color. When replacing both socket and pin housings, then the black may be substituted for the gray, and vice versa. The socket and pin housings of all other connectors are inter- changeable, that is, the black may be mated with the gray, since the alignment tabs are absent and the orientation of the external latch is the same.

• Page 541: Crimping Terminals

  Crimping Terminals sm00020 Identify which of the types of Deutsch terminals are used with the connector and follow the corresponding crimping instruc- tions. Refer to Table A-2. 1. Wire seal 2. Pin housing 3. Pin terminal 4. Locking wedge Figure A-19. Deutsch Connector: 2, 3, 4 and 12-Place Pin Housings Table A-2.

• Page 542: Deutsch Standard Terminal Repair

  DEUTSCH STANDARD TERMINAL REPAIR straight upward. When positioned, the locking bar fits snugly DEUTSCH STANDARD TERMINAL CRIMPS in the space between the contact band and the core crimp tails. PART NUMBER TOOL NAME Insert stripped wire core between crimp tails until ends HD-39965-A DEUTSCH TERMINAL CRIMP TOOL make contact with locking bar.

• Page 543: Deutsch Solid Barrel Mini Terminal Repair

  DEUTSCH SOLID BARREL MINI TERMINAL REPAIR DEUTSCH SOLID BARREL TERMINAL sm00023 CRIMPS PART NUMBER TOOL NAME HD-42879 ELECTRICAL CRIMPER TOOL Preparing Wire Leads For Crimping For size 20, 16 and 12 contacts, wire ranges 26-12 AWG. Strip wire lead removing 1/4 in. (6.4 mm) of insulation. Adjusting Crimper Tool Figure A-21.
• Page 544 sm00024 1. Contact barrel 2. Indentor cover 3. Indentor point 4. Stripped wire lead Figure A-22. Deutsch Solid Barrel A-16 2008 XB Service: Appendix A Connector Repair...

• Page 545: Deutsch Mini Terminal Repair

  DEUTSCH MINI TERMINAL REPAIR DEUTSCH MINI TERMINAL CRIMPS Inspecting Crimps Inspect the core and insulation crimps. Distortion should be PART NUMBER TOOL NAME minimal. HD-38125-7 PACKARD TERMINAL CRIMPER Preparing Wire Leads for Crimping sm00022 Strip wire lead removing 5/32 in. (4.0 mm) of insulation. Crimping a Mini Terminal to Wire Lead Figure A-23.

• Page 546: Molex Connectors

  MOLEX CONNECTORS MOLEX CONNECTOR REPAIR sm00040 PART NUMBER TOOL NAME HD-48114 MOLEX ELECTRICAL CONNECTOR TERMINAL REMOVER Separating Pin and Socket Housings Figure A-24. Depress the latch while pulling the pin and socket housings apart. Mating Pin and Socket Housings Orient the latch on the pin housing to the latch pocket on the socket housing so the rails on the outside of the pin housings lines up with the tunnels on the socket housing.

• Page 547: Crimp Terminal To Lead

  Prepare Tool sm00043 Identify the punch/die in the jaws of the ELECTRICAL CRIMP TOOL (Part No. HD-48119) for the wire gauge. Refer to Table A-4. Squeeze and release the handles to open the tool. NOTE The crimp tool automatically opens when the handles are released.

• Page 548: Position Terminal In The Punch/Die

  Insert Stripped Lead sm02854 Figure A-34. Insert the stripped end (wire core) between the crimp tails at an up angle until the wire core touches the face of the socket locator bar above the square opening. NOTES The insulation must extend through the insulation crimp tails.

• Page 549: Inspect Crimp

  NOTE Inspect Crimp A stuck or jammed tool can be opened by pressing the ratchet Inspect Crimp: Inspect the core and insulation crimp. release lever found between the handles. Do not force the Figure A-35. The core tails should be creased handles open or closed.

• Page 550: Packard 150 Metri-Pack Connectors

  PACKARD 150 METRI-PACK CONNECTORS A.10 150 METRI-PACK CONNECTOR REPAIR Inserting Socket Terminal General NOTE For wire location purposes, alpha characters are stamped into Metri-Pack connectors are embossed with the initials (P.E.D.). the socket housings. There are two types of connectors in this series: Figure A-36 for pull-to-seat connector or Figure A-37...
• Page 551 sm00028 sm00027 1. Remove wire lock 1. Locate tang in chamber 2. Pivot pin to depress tang 2. Pivot pin to depress tang 3. Pull to remove 3. Push to remove 4. Raise tang to install 4. Raise tang to install Figure A-37.

• Page 552: Packard 280 Metri-Pack Relay And Fuse Block Connectors

  PACKARD 280 METRI-PACK RELAY AND FUSE BLOCK CONNECTORS A.11 FUSE BLOCK REPAIR NOTE The wiring diagram indicates when one socket terminal is be Removing Socket Terminals crimped to two wire leads. Figure A-38. To remove secondary locks, insert end of small flat blade screwdriver (1) under lip of locking sm00025 wedge (2) and gently pry up secondary lock.

• Page 553: Packard 480 Metri-Pack Connectors

  PACKARD 480 METRI-PACK CONNECTORS A.12 Rotate the hinged secondary lock inward until latches fully 480 METRI-PACK CONNECTOR REPAIR engage tabs on both sides of connector housing. General NOTE A 480 Metri-Pack (P.E.D.) connector is frequently used for the If removed, install new anchored cable strap in O.E. location. B+ (battery voltage) connector to power P&A accessories.

• Page 554: Packard 630 Metri-Pack Connectors

  PACKARD 630 METRI-PACK CONNECTORS A.13 engages a rib in the chamber wall to lock the terminal in 630 METRI-PACK CONNECTOR REPAIR place. PART NUMBER TOOL NAME Moving to the mating end of the connector, take note of SNAP-ON TT600-3 SNAP-ON PICK the small opening on the chamber wall side of each ter- minal.

• Page 555: Packard Metri-Pack Terminals

  PACKARD METRI-PACK TERMINALS A.14 METRI-PACK TERMINAL CRIMPS sm00035 PART NUMBER TOOL NAME HD-38125-6 PACKARD TERMINAL CRIMP TOOL HD-38125-7 PACKARD TERMINAL CRIMPER HD-38125-8 PACKARD CRIMPING TOOL Matching Terminal To Crimper Metri-Pack connectors embossed with the initials P.E.D. require Packard crimp tools to crimp terminals to wire leads. Terminals are crimped twice to a wire lead, once over the wire core and a second time over the insulation/seal.

• Page 556: Inspecting Crimps

  Position the insulation/seal crimp in the nest. Be sure the sm00036 insulation/seal crimp tails are facing the forming jaws. Squeeze handle of crimp tool until tightly closed. Tool automatically opens when the crimp is complete. Inspecting Crimps Figure A-42. Inspect the wire core crimp (1). The tails should be folded in on the wire core without any distortion or excess wire strands.

• Page 557: Packard Ecm Connector

  PACKARD ECM CONNECTOR A.15 PACKARD 100W CONNECTOR REPAIR sm00037 General A Packard 100W connector connects the the electronic control module (ECM) to the main harness. NOTE For vehicles with 73-pin connectors, see A.16 PACKARD MICRO-64 CONNECTORS A.14 PACKARD METRI-PACK TERMINALS. Separating Socket Housing From ECM Figure A-43.
• Page 558 sm00038 sm00039 1. Latch 2. Secondary lock 3. Cable strap 4. Strain relief collar 5. Conduit Figure A-44. Packard 100W Connector 1. Pins 2. Socket terminal Figure A-45. Packard 100W Connector: Separate Halves of Socket Housing A-30 2008 XB Service: Appendix A Connector Repair...

• Page 559: Packard Micro-64 Connectors

  PACKARD MICRO-64 CONNECTORS A.16 PACKARD MICRO-64 CONNECTOR REPAIR sm00048 PART NUMBER TOOL NAME HD-45928 PACKARD MICRO-64 TERMINAL REMOVER HD-45929 PACKARD MICRO-64 TERMINAL CRIMPER General Packard Micro-64 connectors are frequently found on speedometers, tachometers and the ECM of Touring Models. For pin 73 of these ECMs, see A.10 PACKARD 150 METRI- PACK CONNECTORS.

• Page 560: Preparing Wire Leads For Crimping

  With the center ear on the head of the secondary lockpin sm00045 facing the mating end of the connector, push secondary lock in until head is flush with the connector housing. Preparing Wire Leads for Crimping Strip lead removing 1/8 in. (3.0 mm) of insulation. Crimping Terminals Inspect new socket terminal for bent or deformed contact and crimp tails.
• Page 561 sm00049 1. Open position 2. Raising locking bar 3. Insert terminal 4. Crimp terminal Figure A-50. Packard Micro 64 Connector: Terminal in Crimper 2008 XB Service: Appendix A Connector Repair A-33...

• Page 562: Sealed Splice Connectors

  SEALED SPLICE CONNECTORS A.17 Slide the connector to the other half of the metal insert. SEALED SPLICE CONNECTOR REPAIR Insert the stripped wire lead (1) until it stops, and crimp PART NUMBER TOOL NAME the lead in the insert (2). HD-25070 ROBINAIR HEAT GUN HD-38125-8...
• Page 563 sm00051 1. Wire lead in metal insert 2. Crimp metal insert 3. Center of crimp 4. Melted sealant Figure A-52. Sealed Splice Connector 2008 XB Service: Appendix A Connector Repair A-35...
• Page 564 NOTES A-36 2008 XB Service: Appendix A Connector Repair...
• Page 565 SUBJECT..........................PAGE NO. B.1 WIRING DIAGRAMS.........................B-1...
• Page 566 NOTES...

• Page 567: Connector Locations

  WIRING DIAGRAMS CONNECTOR LOCATIONS Connector Number On wiring diagrams and in service/repair instructions, con- Function/Location nectors are identified by a number in brackets. Refer to Table B-1. On the motorcycle, a connector can be Repair Instructions identified by its function and location. The repair instructions in this Service Manual are by connector Place and Color type.
• Page 568 Table B-1. Connector Locations: XB Models NUMBER COMPONENT TYPE LOCATION FIREBOLT LIGHTNING ULYSSES [46] Stator 4-place Deutsch [61] Fuse and diode assembly Spade terminals Right side of fairing [62] Relay assembly Spade terminals Left side of fairing [65] Vehicle speed sensor (VSS) 3-place Deutsch Under sprocket cover [77]...

• Page 569: Wiring Diagram Information

  WIRING DIAGRAM INFORMATION ed01269 Wire Color Codes Wire traces on wiring diagrams are labeled with alpha codes. Refer to Table B-2. For Solid Color Wires: See Figure B-1. The alpha code identifies wire color (3). For Striped Wires: The code is written with a slash (/) between the solid color code and the stripe code (4).

• Page 570: Buell Wiring Diagrams

  2008 BUELL WIRING DIAGRAMS Wiring Diagram List DIAGRAM LOCATION Main Harness, Ulysses and Lightning Figure B-2 Main Harness, Firebolt Figure B-3 Engine Management Circuit, All Models Figure B-4 Lighting Circuit, Ulysses and Lightning Figure B-5 Lighting Circuit, Firebolt Figure B-6...
• Page 571 Exhaust [11B] [11A] et00001 Valve Crank Voltage (Japan only) Vehicle Neutral LH CONTROLS WIRING DIAGRAM Pressure Foot Brake Starter TN/LGN Clutch switch Actuator Position Cooling Active Intake Regulator Speed [11A] Throttle position sensor Battery Switch Switch Solenoid PINS Fuel Pump Sub-harness Sensor TN/Y...
• Page 572 Figure B-2. Figure B-2. Main Harness, Ulysses and Lightning Main Harness, Ulysses and Lightning...
• Page 573 Key Switch Ignition Horn Headlight Relay Right Turn Signal Fuel Pump Fuse Assembly et00008 IGNITION SW WIRING DIAGRAM Left Turn Signal [38B] Center O/GY KEY POSITION Auxiliary [122A] Brake/Horn/EVA PARK [62B] R/BK LOCK R/BK Cooling Fan 14 15 [31B] [31B] [122B] Y/BN Lights...
• Page 574 Figure B-3. Figure B-3. Main Harness, Firebolt Main Harness, Firebolt...
• Page 575 Active et00007 Japan only Ignition Intake [33A] [33B] Switch Solenoid [88B] [88A] [83B] [83A] Throttle Ignition BK/W IGNITION SWITCH WIRING DIAGRAM Y/BE Engine Temp Sensor Position [178] Coil R/GY KEY POSITION Sensor [90B] [90A] BE/O R/BK R/BK PARK PK/Y LOCK Oxygen Sensor [137B] [137A]...
• Page 576 Figure B-4. Figure B-4. Engine Management Circuit, All Models Engine Management Circuit, All Models...
• Page 577 RH Turn Signal et00002 Brake SW IGNITION SWITCH WIRING DIAGRAM KEY POSITION PARK [31B] LOCK [170B] WIRE COLOR R/BK R/GY WIRE SECT MM Ignition CONNECTING Switch BATTERY USER + BATTERY USER + Flasher [30B] [GRD2] GRD 2 GRD 4 [33A] [33B] LIC.
• Page 578 Figure B-5. Figure B-5. Lighting Circuit, Ulysses and Lightning Lighting Circuit, Ulysses and Lightning...
• Page 579 RH Turn Signal et00055 Brake SW IGNITION SWITCH WIRING DIAGRAM KEY POSITION PARK [31B] LOCK [121B] WIRE COLOR R/BK R/GY WIRE SECT MM Ignition Switch CONNECTING BATTERY USER + BATTERY USER + Flasher [30B] [121A] [121B] Foot Brake Switch GRD 2 [33A] GRD 4 [33B]...
• Page 580 Figure B-6. Figure B-6. Lighting Circuit, Firebolt Lighting Circuit, Firebolt...
• Page 581 et00003 IGNITION SWITCH WIRING DIAGRAM Ignition KEY POSITION Switch PARK [GRD2] LOCK WIRE COLOR R/BK R/GY [11A] [11B] [33A] WIRE SECT MM [33B] 5V sensor power 24 24 [11A] CONNECTING (GY) BATTERY USER + BATTERY USER + TN/W Sidestand switch 34 34 BK/W Sensor ground...
• Page 582 Figure B-7. Figure B-7. Horn and Instruments Circuit, All Models Horn and Instruments Circuit, All Models...
• Page 583 et00056 IGNITION SWITCH WIRING DIAGRAM KEY POSITION PARK [GRD2] LOCK [33A] WIRE COLOR [33B] R/BK R/GY [11A] [11B] WIRE SECT MM 5V sensor power [11A] CONNECTING BATTERY USER + (GY) BATTERY USER + Sidestand switch TN/W Sensor ground BK/W Vehicle speed sensor Battery Fuse (Ulysses;...
• Page 584 Figure B-8. Figure B-8. Horn and Instruments Circuit, Firebolt Horn and Instruments Circuit, Firebolt...
• Page 585 Ignition et00004 Switch IGNITION SWITCH WIRING DIAGRAM KEY POSITION PARK RH Controls LOCK 1 2 3 [22A] WIRE COLOR R/BK R/GY WIRE SECT MM Starter [33A] Solenoid [33B] CONNECTING GRD 2 BATTERY USER + BATTERY USER + [11A] [11B] Exhaust Valve [128A] Actuator Sub-Harness...
• Page 586 Figure B-9. Figure B-9. Starting Circuit, Ulysses and Lightning Starting Circuit, Ulysses and Lightning...
• Page 587 et00057 Ignition Switch IGNITION SWITCH WIRING DIAGRAM KEY POSITION PARK RH Controls LOCK 1 2 3 [22A] WIRE COLOR R/BK R/GY WIRE SECT MM [11A] [11B] [33A] CONNECTING [33B] BATTERY USER + BATTERY USER + [11A] Starter (GY) Solenoid GRD 2 Exhaust Valve Actuator Sub-Harness...
• Page 588 Figure B-10. Figure B-10. Starting Circuit, Firebolt Starting Circuit, Firebolt...
• Page 589 et00005 Battery Cable Starter Solenoid [128A] Battery Starter Motor [GRD2] Ulysses/Lightning Firebolt Fuse/Relay Assembly Fuse/Relay Assembly Battery, 30 Amp Battery, 30 Amp [61B] J-FUSE To Voltage Regulator [77B] [77A] Voltage Regulator Stator [46A] [46B] Figure B-11. Charging Circuits, All Models...
• Page 590 Figure B-11. Figure B-11. Charging Circuits, All Models Charging Circuits, All Models...
• Page 591 et00087 Left Side Right Side 1 2 3 Left Hand 2 3 4 5 6 7 8 [24B] [189LA] 1 2 3 [189RA] R Heat L Heat Controls Grip Grip [189LB] [189RB] 1 2 3 1 2 3 [160A] Right Hand [22B] 1 2 3 Auxiliary...
• Page 592 Figure B-12. Figure B-12. Heated Hand Grips (Ulysses) Heated Hand Grips (Ulysses)
• Page 593 SUBJECT..........................PAGE NO. C.1 LENGTH CONVERSION......................C-1 C.2 FLUID CONVERSION......................C-2 C.3 TORQUE CONVERSION......................C-3...
• Page 594 NOTES...

• Page 595: Conversion Table

  LENGTH CONVERSION CONVERSION TABLE Table C-1. Metric Conversions MILLIMETERS to INCHES INCHES to MILLIMETERS (MM x 0.03937 = IN.) (IN. x 25.40 = MM) IN.. .0039 .9842 2.283 3.582 .001 .025 15.240 1-15/16 49.21 3-5/16 84.14 .0078 1.024 2.323 3.622 .002 .051 15.875...

• Page 596: United States System

  FLUID CONVERSION UNITED STATES SYSTEM BRITISH IMPERIAL SYSTEM Unless otherwise specified, all fluid volume measurements in Fluid volume measurements in this Service Manual do not this Service Manual are expressed in United States (U.S.) include the British Imperial (Imp.) system equivalents. The fol- units-of-measure.

• Page 597: United States System

  TORQUE CONVERSION UNITED STATES SYSTEM METRIC SYSTEM The U.S. units of torque, foot pounds and inch pounds, are All metric torque specifications are written in Newton-meters used in this service manual. To convert units, use the following (Nm). To convert metric to United States units and United equations: States to metric, use the following equations: foot pounds (ft-lbs) X 12.00000 = inch pounds (in-lbs).
• Page 598 NOTES C-4 2008 XB Service: Appendix C Conversions...
• Page 599 SUBJECT..........................PAGE NO. D.1 APPENDIX D: HOSE AND WIRE ROUTING................D-1...
• Page 600 NOTES...
• Page 601 APPENDIX D: HOSE AND WIRE ROUTING FIREBOLT 2008 XB Service: Appendix D Hose and Wire Routing D-1...
• Page 602 sm04328 Figure D-1. Front and Rear Brake Systems, Right Side View D-2 2008 XB Service: Appendix D Hose and Wire Routing...
• Page 603 sm04332 Figure D-2. Rear Brake Systems, Top View 2008 XB Service: Appendix D Hose and Wire Routing D-3...
• Page 604 sm04334 Figure D-3. Rear Brake Systems, Left Side View D-4 2008 XB Service: Appendix D Hose and Wire Routing...
• Page 605 sm04337 1. Carbon canister Figure D-4. Evaporative Emissions Control, California Models, Top View 2008 XB Service: Appendix D Hose and Wire Routing D-5...
• Page 606 sm04340 1. To induction module 2. From induction module (California) 3. From fuel tank (California) 4. From fuel tank to atmosphere (49 state) Figure D-5. Evaporative Emissions Control, California and 49 State Models, Left Side View D-6 2008 XB Service: Appendix D Hose and Wire Routing...
• Page 607 sm04344 1. Active intake solenoid (Japan only) 2. Ignition coil 3. Fuel pump 4. Crank position sensor (CKP) 5. To ECM Figure D-6. Wiring Harness, Left Side View 2008 XB Service: Appendix D Hose and Wire Routing D-7...
• Page 608 sm04346 1. Fuel injector (2) 2. Idle air control (IAC) 3. Throttle position sensor (TPS) 4. Intake air temperature sensor (IAT) 5. Oxygen sensor (O2) 6. Engine temperature sensor Figure D-7. Wiring Harness, Top View D-8 2008 XB Service: Appendix D Hose and Wire Routing...
• Page 609 sm04349 1. Vehicle speed sensor (VSS) 2. Cable, starter to battery positive 3. Solenoid 4. Voltage regulator 5. Oil pressure switch 6. Neutral switch 7. Relay terminal Figure D-8. Wiring Harness, Right Side View 2008 XB Service: Appendix D Hose and Wire Routing D-9...
• Page 610 sm04322 1. Feed oil line 2. Return oil line 3. Vent line 4. Oil cooler return line 5. Oil cooler feed line Figure D-9. Oil Lines, Right Side View D-10 2008 XB Service: Appendix D Hose and Wire Routing...
• Page 611 sm04367 1. Exhaust valve actuator 2. Muffler valve Figure D-10. Clutch Cable and Exhaust Valve Actuator, Right Side View 2008 XB Service: Appendix D Hose and Wire Routing D-11...
• Page 612 sm04371 1. Muffler valve 2. Exhaust valve actuator 3. Cable, seat lock Figure D-11. Clutch, Throttle, Seat Release Cable and Exhaust Valve Actuator, Left Side View D-12 2008 XB Service: Appendix D Hose and Wire Routing...
• Page 613 sm04374 1. Cable, seat lock 2. Exhaust valve actuator (mounted to top of functional air cleaner cover) Figure D-12. Clutch, Throttle, Seat Release Cable and Exhaust Valve Actuator (XB12 Models), Top View LIGHTNING 2008 XB Service: Appendix D Hose and Wire Routing D-13...
• Page 614 sm04329 Figure D-13. Front and Rear Brake Systems, Right Side View D-14 2008 XB Service: Appendix D Hose and Wire Routing...
• Page 615 sm04331 Figure D-14. Rear Brake Systems, Top View 2008 XB Service: Appendix D Hose and Wire Routing D-15...
• Page 616 sm04335 Figure D-15. Rear Brake Systems, Left Side View D-16 2008 XB Service: Appendix D Hose and Wire Routing...
• Page 617 sm04338 1. Carbon canister Figure D-16. Evaporative Emissions Control, California Models, Top View 2008 XB Service: Appendix D Hose and Wire Routing D-17...
• Page 618 sm04342 1. To induction module 2. From induction module (California) 3. From fuel tank (California) 4. From fuel tank to atmosphere (49 state) Figure D-17. Evaporative Emissions Control, California and 49 State Models, Left Side View D-18 2008 XB Service: Appendix D Hose and Wire Routing...
• Page 619 sm04327 1. Active Intake Solenoid (Japan only) 2. Ignition coil 3. Fuel pump 4. Crank position sensor (CKP) Figure D-18. Wiring Harness, Left Side View 2008 XB Service: Appendix D Hose and Wire Routing D-19...
• Page 620 sm04347 1. Fuel injector (2) 2. Idle air control (IAC) 3. Throttle position sensor (TPS) 4. Intake air temperature sensor (IAT) 5. Oxygen sensor (02) Figure D-19. Wiring Harness, Top View D-20 2008 XB Service: Appendix D Hose and Wire Routing...
• Page 621 sm04351 1. Vehicle speed sensor (VSS) 2. Cable, starter to battery positive 3. Solenoid 4. Voltage regulator 5. Oil pressure switch 6. Neutral switch 7. Relay terminal Figure D-20. Wiring Harness, Right Side View 2008 XB Service: Appendix D Hose and Wire Routing D-21...
• Page 622 sm04325 1. Feed oil line 2. Return oil line 3. Vent line 4. Oil cooler return line 5. Oil cooler feed line Figure D-21. Oil Lines, Right Side View D-22 2008 XB Service: Appendix D Hose and Wire Routing...
• Page 623 sm04369 1. Exhaust valve actuator 2. Muffler valve Figure D-22. Clutch Cable and Exhaust Valve Actuator (XB12 Models), Right Side View 2008 XB Service: Appendix D Hose and Wire Routing D-23...
• Page 624 sm04372 1. Muffler valve 2. Exhaust valve actuator 3. Cable, seat lock Figure D-23. Clutch, Throttle, Seat Release Cable and Exhaust Valve Actuator (XB12 Models), Left Side View D-24 2008 XB Service: Appendix D Hose and Wire Routing...
• Page 625 sm04375 1. Cable, seat lock 2. Exhaust valve actuator (mounted to top of functional air cleaner cover) Figure D-24. Clutch, Throttle, Seat Release Cable and Exhaust Valve Actuator (XB12 Models), Top View ULYSSES 2008 XB Service: Appendix D Hose and Wire Routing D-25...
• Page 626 sm04330 Figure D-25. Front and Rear Brake Systems, Right Side View D-26 2008 XB Service: Appendix D Hose and Wire Routing...
• Page 627 sm04333 Figure D-26. Rear Brake Systems, Top View 2008 XB Service: Appendix D Hose and Wire Routing D-27...
• Page 628 sm04336 Figure D-27. Rear Brake Systems, Left Side View D-28 2008 XB Service: Appendix D Hose and Wire Routing...
• Page 629 sm04339 Figure D-28. Evaporative Emissions Control, California Models, Top View 2008 XB Service: Appendix D Hose and Wire Routing D-29...
• Page 630 sm04361 1. To induction module 2. From induction module (California) 3. From fuel tank (California) 4. From fuel tank to atmosphere (49 state) Figure D-29. Evaporative Emissions Control, California and 49 State Models, Left Side View D-30 2008 XB Service: Appendix D Hose and Wire Routing...
• Page 631 sm04326 1. Active intake solenoid (Japan only) 2. Ignition coil 3. Fuel pump 4. Crank position sensor (CKP) Figure D-30. Wiring Harness, Left Side View 2008 XB Service: Appendix D Hose and Wire Routing D-31...
• Page 632 sm04348 1. Fuel injector (2) 2. Idle air control (IAC) 3. Throttle position sensor (TPS) 4. Intake air temperature sensor (IAT) 5. Oxygen sensor (O2) Figure D-31. Wiring Harness, Top View D-32 2008 XB Service: Appendix D Hose and Wire Routing...
• Page 633 sm04353 1. Vehicle speed sensor (VSS) 2. Cable, starter to battery positive 3. Solenoid 4. Oil pressure switch 5. Neutral switch 6. Relay terminal Figure D-32. Wiring Harness, Right Side View 2008 XB Service: Appendix D Hose and Wire Routing D-33...
• Page 634 sm04444 1. Vent line 2. Feed oil line 3. Return oil line 4. Feed oil line from the oil pump to the oil cooler 5. Return oil line from the oil cooler to the oil filter housing Figure D-33. Oil Lines, Right Side View D-34 2008 XB Service: Appendix D Hose and Wire Routing...
• Page 635 sm04370 1. Exhaust valve actuator 2. Muffler valve Figure D-34. Clutch Cable and Exhaust Valve Actuator, Right Side View 2008 XB Service: Appendix D Hose and Wire Routing D-35...
• Page 636 sm04373 1. Muffler valve 2. Exhaust valve actuator 3. Cable, seat lock Figure D-35. Clutch, Throttle, Seat Release Cable and Exhaust Valve Actuator, Left Side View D-36 2008 XB Service: Appendix D Hose and Wire Routing...
• Page 637 sm04376 1. Cable, seat lock 2. Exhaust valve actuator (mounted to top of functional air cleaner cover) Figure D-36. Clutch, Throttle, Seat Release Cable and Exhaust Valve Actuator (XB12 Models), Top View 2008 XB Service: Appendix D Hose and Wire Routing D-37...
• Page 638 NOTES D-38 2008 XB Service: Appendix D Hose and Wire Routing...
• Page 639 SUBJECT..........................PAGE NO. E.1 ACTIVE INTAKE SYSTEM (JAPANESE MODELS ONLY)............E-1...
• Page 640 NOTES...

• Page 641: Diagnostic Notes

  ACTIVE INTAKE SYSTEM (JAPANESE MODELS ONLY) While holding the throttle wide open, activate the active GENERAL intake tab on Digital Technician. PART NUMBER TOOL NAME Verify that the TPS setting is between 10.4-10.9 degrees. HD-41404 TEST CONNECTOR KIT If settings are not correct proceed to cable adjustment Active Intake System procedure.
• Page 642 sm03607 1. Solenoid shaft 2. Cable adjusting and jam nuts 3. Solenoid bracket 4. Cable housing Figure E-1. Checking for Freeplay in the Solenoid Shaft in the Fully Retracted Position Figure E-2. Inspect for proper extension freeplay in NOTE solenoid shaft: You should be able to move the solenoid shaft slightly outward until the shaft is fully extended.
• Page 643 sm03608 1. Solenoid shaft 2. Cable adjusting and jam nuts 3. Solenoid bracket 4. Cable housing Figure E-2. Checking for Freeplay in the Solenoid Shaft in the Fully Extended Position Throttle Stop Screw Adjust stop screw, while reading the TPS on Digital Technician, until setting is between the range of 10.4 to Remove cosmetic intake cover assembly and functional 10.9.
• Page 644 sm03609 1. Cable stop screw 2. Active cable wheel Figure E-3. Active Intake Cable Stop Screw REMOVAL Unthread cable connector and disconnect cable from solenoid (8). NOTE Loosen jam nut (5) and disconnect active cable (2) from If solenoid bracket needs to be replaced, remove the baseplate cable bracket (4).
• Page 645 NOTE the throttle body. If the cable comes out the cable will not work When removing baseplate it will be necessary to feed the properly and will not be able to be adjusted. electrical connector and active cable and grommets through NOTES the baseplate.
• Page 646 NOTES E-6 2008 XB Service: Appendix E Active Intake (Japanese Models)
• Page 647 SUBJECT..........................PAGE NO. F.1 GLOSSARY..........................F-1...
• Page 648 NOTES...

• Page 649: Acronyms And Abbreviations

  GLOSSARY ACRONYMS AND ABBREVIATIONS Table F-1. Acronyms and Abbreviations ACRONYM OR ABBREVIATION DESCRIPTION Amperes Alternating Current Accessory Automatic Compression Release Absorbed Glass Mat (battery) Ampere American Wire Gauge Battery Voltage Bank Angle Sensor BTDC Before Top Dead Center Celsius (Centigrade) California Calibration Cubic Centimeters...
• Page 650 Table F-1. Acronyms and Abbreviations ACRONYM OR ABBREVIATION DESCRIPTION Intake Air Temperature Instrument Cluster Inside Diameter Ignition Light/Key Switch Inch INJ PW Injector Pulse Width in-lbs Inch-Pounds Kilogram Kilometer Kilopascal km/hr Kilometers Per Hour Liter Liquid Crystal Display Light Emitting Diode Milliampere Manifold Absolute Pressure milliliter...
• Page 651 Table F-1. Acronyms and Abbreviations ACRONYM OR ABBREVIATION DESCRIPTION Vehicle Identification Number Vehicle Speed Sensor 2008 XB Service: Appendix F Glossary F-3...
• Page 652 NOTES F-4 2008 XB Service: Appendix F Glossary...
• Page 653 Tools Used in This Manual PART NUMBER TOOL NAME NOTES 94654-98 SUPERSMART BATTERY TENDER 1.4 BATTERY MAINTENANCE, Storage A157-8 SNAP-ON BUSHING DRIVER 1/2-INCH 6.12 TRANSMISSION RIGHT CASE BEARINGS, Install- ADAPTER ation A157C SNAP-ON SEAL AND BUSHING DRIVER 2.56 TRIPLE TAIL: ULYSSES, Assembly A157C SNAP-ON BUSHING DRIVER SET 6.12 TRANSMISSION RIGHT CASE BEARINGS, Install-...
• Page 654 Tools Used in This Manual PART NUMBER TOOL NAME NOTES B-43993-9, FROM KIT FRONT BEARING INSTALLER 2.4 FRONT WHEEL, Assembly PART NO. B-43993-50A B-45520 GEAR DETENT ASSEMBLY AID 6.14 TRANSMISSION INSTALLATION, Installing Right Crankcase B-45521 STEERING HEAD BEARING INSTALLA- 2.19 STEERING HEAD BEARINGS, Installation TION TOOL B-45523 VALVE GUIDE REAMER...
• Page 655 Tools Used in This Manual PART NUMBER TOOL NAME NOTES HD-34751 VALVE GUIDE CLEANING BRUSH 3.6 CYLINDER HEAD, Assembly HD-34902-7 END CAP 3.17 CRANKCASE, Piston Jets HD-34902-7 END CAP 3.17 CRANKCASE, Pinion Shaft Bearing HD-34902B BEARING RACE REMOVER/INSTALLER 3.17 CRANKCASE, Piston Jets HD-34902B BEARING RACE REMOVER/INSTALLER 3.17 CRANKCASE, Pinion Shaft Bearing...
• Page 656 Tools Used in This Manual PART NUMBER TOOL NAME NOTES HD-39786 CYLINDER HEAD HOLDING FIXTURE 3.6 CYLINDER HEAD, Procedure For Using The Neway Valve Seat Cutter HD-39965-A DEUTSCH TERMINAL CRIMP TOOL A.6 DEUTSCH STANDARD TERMINAL REPAIR, Deutsch Standard Terminal Crimps HD-39969 ULTRA TORCH UT-100 A.17 SEALED SPLICE CONNECTORS, Sealed Splice...
• Page 657 Tools Used in This Manual PART NUMBER TOOL NAME NOTES HD-45966 FRONT FORK COMPRESSOR 2.17 FRONT FORK: XB12STT/XB12X/XB12XT, Disas- sembly HD-46283 FOR XB12 SPROCKET LOCKING LINK 6.5 PRIMARY CHAIN, Removal MODELS HD-46283 FOR XB12 SPROCKET LOCKING LINK 6.5 PRIMARY CHAIN, Installation MODELS HD-46288 MAINSHAFT LOCKNUT WRENCH...
• Page 658 Tools Used in This Manual PART NUMBER TOOL NAME NOTES HS0020.02A8A HOSE ASSEMBLY 7.14 INTERACTIVE EXHAUST SYSTEM, Removal J-23444-A EXTREME PRESSURE LUBRICANT 2.4 FRONT WHEEL, Disassembly J-23444-A EXTREME PRESSURE LUBRICANT 2.4 FRONT WHEEL, Assembly J-5586-A TRANSMISSION SHAFT RETAINING RING 3.7 CYLINDER AND PISTON, Fitting Piston Rings PLIERS J-5586-A TRANSMISSION SHAFT RETAINING RING...
• Page 659 2008 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Active cable jam nut 48-60 in-lbs 5.4-6.7 Nm E.1 ACTIVE INTAKE SYSTEM (JAPANESE MODELS ONLY), Installation Active intake cable connector 20-24 in lbs 2.3-2.7 Nm E.1 ACTIVE INTAKE SYSTEM (JAPANESE...
• Page 660 2008 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Battery terminal fastener 72-96 in-lbs 8-11 Nm 1.4 BATTERY MAINTENANCE, Battery Installation and Connection Battery terminal fastener 72-96 in-lbs 8-11 Nm 4.8 BANK ANGLE SENSOR (BAS), Installation Battery terminal fastener...
• Page 661 2008 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Battery terminal fasteners 72-96 in-lbs 8-11 Nm 3.5 ENGINE INSTALLATION, Assembly Battery terminal fasteners 72-96 in-lbs 8-11 Nm 4.3 ELECTRONIC CONTROL MODULE (ECM), Installation: Firebolt Battery terminal fasteners 72-96 in-lbs 8-11 Nm 4.3 ELECTRONIC CONTROL MODULE...
• Page 662 2008 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Battery tray fasteners, Lightning 48-72 in-lbs 5.4-8 Nm 2.42 LEFT TAIL SECTION AND BATTERY PAN: LIGHTNING, Assembly / LOCTITE 271 (red) Battery tray fasteners, Ulysses 72-96 in-lbs 8-11 Nm 2.45 LEFT TAIL SECTION AND BATTERY PAN:...
• Page 663 2008 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Caliper bleeder valves 36-60 in-lbs 4-7 Nm 2.8 FRONT BRAKE MASTER CYLINDER AND HAND LEVER, Removal Caliper bleeder valves 36-60 in-lbs 4-7 Nm 2.9 FRONT BRAKE LINE, Removal Caliper bleeder valves...
• Page 664 2008 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Cooling fan fasteners 12-36 in-lbs 1.4-4.1 Nm 4.10 COOLING FAN, Installation Cooling fan fasteners 12-36 in-lbs 1.4-4.1 Nm 7.23 MAIN WIRE HARNESS, Installation Countershaft retaining screw 33-37 ft-lbs 44.8-50 Nm 6.15 SHIFTER SHAFT, Installation / LOCTITE 271...
• Page 665 2008 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Engine sprocket bolt 155-165 ft-lbs 210-224 Nm 6.5 PRIMARY CHAIN, Installation / LOCTITE 271 (red) Engine temperature sensor 120-168 in-lbs 13.6-19 Nm 4.7 ENGINE TEMPERATURE SENSOR (ET), Installation Exhaust header mounting nut...
• Page 666 2008 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Fork clamp, upper 23-25 ft-lbs 31-34 Nm 2.18 FORK CLAMPS: UPPER AND LOWER, Installation: Lightning/Ulysses / LOCTITE 271 (red) Fork clamp, upper 23-25 ft-lbs 31.2-33.8 Nm 2.19 STEERING HEAD BEARINGS, Installation /...
• Page 667 2008 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Front tie bar to V bracket 25-27 ft-lbs 33.9-36.6 Nm 2.27 CLUTCH CONTROL, Assembly and Installa- tion Front wire guide fasteners 36-60 in-lbs 4.1-6.8 Nm 2.26 THROTTLE CONTROL, Throttle Cable...
• Page 668 2008 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Headlight support bracket pivot 72-96 in-lbs 8-11 Nm 2.28 HEADLAMP ASSEMBLY AND SUPPORT fasteners, Firebolt BRACKET, Installation: Firebolt heated grip fasteners 14-16 in-lbs 1.6-1.8 Nm 7.9 HEATED HAND GRIPS: ULYSSES...
• Page 669 2008 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Intake cover fasteners 12-36 in-lbs 1-4 Nm 3.5 ENGINE INSTALLATION, Assembly Intake cover fasteners 12-36 in-lbs 1.4-4.0 Nm 7.24 INTERACTIVE EXHAUST HARNESS: XB12 MODELS, Firebolt Intake cover fasteners 12-36 in-lbs 1.4-4.0 Nm...
• Page 670 2008 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Master cylinder mounting fasteners, rear 72-96 in-lbs 8-11 Nm 2.12 REAR BRAKE MASTER CYLINDER, Installa- tion: Ulysses Master cylinder reservoir cover screws 9-13 in-lbs 1.0-1.5 Nm 1.3 MAINTENANCE SCHEDULE, General...
• Page 671 2008 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Oil line p-clamp fastener 48-72 in-lbs 5.4-8 Nm 3.5 ENGINE INSTALLATION, Assembly Oil line p-clamp fastener 48-72 in-lbs 5.4-8 Nm 3.5 ENGINE INSTALLATION, Assembly Oil line p-clamps at swingarm 48-72 in-lbs 5.4-8 Nm...
• Page 672 2008 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Rear axle (initial torque) 23-27 ft-lbs 31.2-36.6 Nm 2.21 SWINGARM AND BRACE, Brace / After initial torque, back off two turns and tighten to final torque. Rear axle pinch bolt...
• Page 673 2008 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Reed valve block fasteners 25-35 in-lbs 2.8-4.0 Nm 3.14 CRANKCASE BREATHING SYSTEM, Reed Valve Replacement / LOCTITE 222 (purple) Reed valve stop fastener 5-7 in-lbs 0.6-0.8 Nm 3.14 CRANKCASE BREATHING SYSTEM, Reed...
• Page 674 2008 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Shock mounting fastener, upper 48-52 ft-lbs 65-70.5 Nm 2.25 REAR SHOCK ABSORBER, Installation: Lightning Shock mounting fastener, upper 48-52 ft-lbs 65-70.5 Nm 2.25 REAR SHOCK ABSORBER, Installation: Ulysses Shock reservoir clamp, rear (Lightning...
• Page 675 2008 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Swing arm pivot 44-46 ft-lbs 60-62 Nm 4.13 FUEL PUMP, Installation Swingarm pivot pinch fastener 17-19 ft-lbs 23-26 Nm 4.13 FUEL PUMP, Installation Swingarm pivot shaft 44-46 ft-lbs 59-62 Nm 2.21 SWINGARM AND BRACE, Installation:...
• Page 676 2008 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Torca clamp 45-50 ft-lbs 61-68 Nm 4.16 EXHAUST SYSTEM, Assembly and Installa- tion Transmission sprocket nut (initial torque) 50 ft-lbs 67.8 Nm 6.16 TRANSMISSION SPROCKET, Installation / Follow special torque procedure, left-hand threads, LOCTITE 272 (red).
• Page 677 2008 Buell XB Models Service Manual FASTENER TORQUE VALUE NOTES Windscreen fasteners, Firebolt 10-12 in-lbs 1-1.4 Nm 2.49 FRONT FAIRING, WINDSHIELD, AND MIR- RORS: FIREBOLT, Installation Windscreen fasteners, Lightning 10-12 in-lbs 1.1-1.4 Nm 2.50 WINDSHIELD AND WINDSCREEN: LIGHTNING AND ULYSSES, Installation: Lightning...
• Page 678 NOTES XXVI TORQUE VALUES...
• Page 679 Installation and Connection....1-11 Storage........1-12 150 Metri-Pack Connector Battery Cables Repair.
• Page 680 Transmission Fluid Replacement....1-25 Clutch Adjusting Screw......6-11 Deflectors/Handlebars Clutch Control/Cable Assembly and Installation.
• Page 681 Installation....... . 2-65 Gasoline Blends: Buell Models....1-5 Installation (Firebolt).
• Page 682 Gearcase Assembly and Installation..... 3-78 Idler Pulley Gearcase Cover Inspection....... . . 1-28 Cleaning and Inspection.
• Page 683 Left Tail Section Terminal Crimps......A-19 Assembly (Lightning)..... . . 2-122 Assembly (Ulysses).
• Page 684 Tension (table)......1-31 Threadlocking Agents......1-2 Primary Chain Adjuster Wiring, Hoses and Lines.
• Page 685 Buell........i-II...
• Page 686 Transmission Left Case Bearings Front Wheel Installation..... . 2-14 Removal........6-47 Front Wheel Removal.

2008 Xb12r

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