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Buell XB 2008 Series User manual

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2008 Buell XB Models Service Manual
99490-08YA
©2007 Buell Motorcycle Company
Buell motorcycles conform to all applicable U.S.A. Federal Motor Vehicle Safety Standards and U.S.A.
Environmental Protection Agency regulations effective on the date of manufacture.
To maintain the safety, dependability, and emission and noise control performance, it is essential that
the procedures, specifications and service instructions in this manual are followed.
Any substitution, alteration or adjustment of emission system and noise control components outside of
factory specifications may be prohibited by law.
IMPORTANT NOTICE
Buell Motorcycle Company
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
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READER COMMENTS
Please comment on the completeness, accuracy, organization, usability, and readability of this manual.
Please list the page, item, and part number(s) of any errors you find in this manual.
Please tell us how we can improve this manual.
Occupation:
Name: Dealership:
Street: Department:
City: State: Zip:
Please clip out and mail to:
Service Communications Department
Buell Motorcycle Company
P.O. Box 653
Milwaukee, WI USA 53201
The Buell Motorcycle Company maintains a continuous effort to improve the quality and usefulness of its
publications. To do this effectively, we need user feedback - your critical evaluation of this manual.
2008 Buell XB Models Service Manual (99490-08YA)
NOTES
ABOUT THIS MANUAL
GENERAL
This Service Manual has been prepared with two purposes in
mind. First, it will acquaint the user with the construction of the
Buell product and assist in the performance of basic mainten-
ance and repair. Secondly, it will introduce to the professional
Buell Technician the latest field-tested and factory-approved
major repair methods. We sincerely believe that this Service
Manual will make your association with Buell products more
pleasant and profitable.
HOW TO USE YOUR SERVICE MANUAL
Refer to the table below for the content layout of this manual.
CHAPTERNO.
Maintenance1
Chassis2
Engine3
Fuel System4
Electric Starter5
Drive/Transmission6
Electrical7
Appendix A Connector RepairA
Appendix B WiringB
Appendix C ConversionsC
Appendix D Hose and Wire RoutingD
Appendix E Active Intake (Japanese Models)E
Appendix F GlossaryF
Use the TABLE OF CONTENTS (which follows this FORE-
WORD) and the INDEX (at the back of this manual) to quickly
locate subjects. Sections and topics in this manual are
sequentially numbered for easy navigation.
For example, a cross-reference shown as 2.1 SPECIFICA-
TIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFIC-
ATIONS.
For quick and easy reference, all pages contain a section
number followed by a page number. For example, page 3-5
refers to page 5 in section 3.
A number of acronyms and abbreviations are used in this
document. See the F.1 GLOSSARY for a list of acronyms,
abbreviations and definitions.
PREPARATION FOR SERVICE
Stop the engine when refueling or servicing the fuel
system. Do not smoke or allow open flame or sparks near
gasoline. Gasoline is extremely flammable and highly
explosive, which could result in death or serious injury.
(00002a)
Good preparation is very important for efficient service work.
A clean work area at the start of each job will allow you to
perform the repair as easily and quickly as possible, and will
reduce the incidence of misplaced tools and parts. A motorcycle
that is excessively dirty should be cleaned before work starts.
Cleaning will occasionally uncover sources of trouble. Tools,
instruments and any parts needed for the job should be
gathered before work is started. Interrupting a job to locate
tools or parts is a distraction and causes needless delay.
NOTES
• To avoid unnecessary disassembly, carefully read all rel-
ative service information before repair work is started.
• In figure legends, the number which follows the name of
a part indicates the quantity necessary for one complete
assembly.
SERVICE BULLETINS
In addition to the information presented in this manual, Buell
Motor Company will periodically issue Service Bulletins to Buell
dealers. Service Bulletins cover interim engineering changes
and supplementary information. Consult the Service Bulletins
to keep your product knowledge current and complete.
USE GENUINE REPLACEMENT PARTS
Do not use aftermarket parts and custom made front forks
which can adversely affect performance and handling.
Removing or altering factory installed parts can adversely
affect performance and could result in death or serious
injury. (00001a)
To ensure satisfactory and lasting repairs, carefully follow the
manual instructions and use only genuine Buell replacement
parts.This is your assurance that the parts you are using will
fit right, operate properly and last longer.
WARNINGS AND CAUTIONS
Statements in this manual preceded by the following words
are of special significance.
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury. (00119a)
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury. (00139a)
CAUTION used without the safety alert symbol indicates
a potentially hazardous situation which, if not avoided,
may result in property damage. (00140a)
NOTE
Refers to important information, and is placed in italic type. It
is recommended that you take special notice of these items.
Proper service and repair is important for the safe, reliable
operation of all mechanical products.The service procedures
recommended and described in this manual are effective
methods for performing service operations.
I
FOREWORD
Always wear proper eye protection when using hammers,
arbor or hydraulic presses, gear pullers, spring com-
pressors, slide hammers and similar tools. Flying parts
could result in death or serious injury. (00496b)
Some of these service operations require the use of tools
specially designed for the purpose.These special tools should
be used when and as recommended. It is important to note
that some warnings against the use of specific service methods,
which could damage the motorcycle or render it unsafe, are
stated in this manual. However, please remember that these
warnings are not all-inclusive. Inadequate safety precautions
could result in death or serious injury.
Since Buell Motorcycle Company could not possibly know,
evaluate or advise the service trade of all possible ways in
which service might be performed, or of the possible hazardous
consequences of each method, we have not undertaken any
such broad evaluation. Accordingly, anyone who uses a service
procedure or tool which is not recommended by Buell Motor-
cycle Company must first thoroughly satisfy himself that neither
his nor the operator's safety will be jeopardized as a result.
Failure to do so could result in death or serious injury.
CONTENTS
All photographs, illustrations and procedures in this manual
may not necessarily depict the most current model or com-
ponent, but are based on the latest production information
available at the time of publication.
Since product improvement is our continual goal, Buell Motor-
cycle Company reserves the right to change specifications,
equipment or designs at any time without notice and without
incurring obligation.
PRODUCT REFERENCES
Read and follow warnings and directions on all products.
Failure to follow warnings and directions can result in
death or serious injury. (00470b)
When reference is made in this manual to a specific brand
name product, tool or instrument, an equivalent product, tool
or instrument may be substituted.
Kent-Moore Products
All tools mentioned in this manual with an "HD", "J" or "B"
preface must be ordered through SPX Kent-Moore. For ordering
information or product returns, warranty or otherwise, visit
www.spx.com.
Loctite Sealing and Threadlocking Products
Some procedures in this manual call for the use of Loctite
products. If you have any questions regarding Loctite product
usage or retailer/wholesaler locations, please contact Loctite
Corp. at www.loctite.com.
PRODUCT REGISTERED MARKS
Allen, Amp Multilock, Bluetooth, Brembo, Delphi, Deutsch,
Dunlop, Dynojet, Fluke, G.E. Versilube, Gunk, Hydroseal,
Hylomar, Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Mag-
naflux, Marson Thread-Setter Tool Kit, MAXI fuse, Molex, MPZ,
Mulitilock, Novus, Packard, Pirelli, Permatex, Philips, PJ1,
Pozidriv, Robinair, S100, Sems, Snap-on, Teflon, Threadlocker,
Torca, Torco, TORX, Tufoil, Tyco, Ultratorch, Velcro, X-Acto,
and XM Satellite Radio are among the trademarks of their
respective owners.
H-D MICHIGAN, INC.TRADEMARK
INFORMATION
Blast, Firebolt, Glaze, Gloss, Harley, Harley-Davidson,
Lightning, Sunwash, Supersmart, Tender, Triple Tail, Thunder-
storm, Ulysses, Uniplanar and ZTL are among the trademarks
of H-D Michigan, Inc.
II FOREWORD
MAINTENANCE
1.1 GENERAL
Servicing a New Motorcycle...............................................1-1
Safe Operating Maintenance..............................................1-1
Shop Practices...................................................................1-1
Repair Notes...............................................................1-1
Safety..........................................................................1-1
Removing Parts...........................................................1-1
Cleaning......................................................................1-1
Disassembly and Assembly........................................1-2
Checking Torques on Fasteners with Lock Patches.....1-2
Magnetic Parts Trays...................................................1-2
Repair and Replacement Procedures................................1-2
Hardware and Threaded Parts....................................1-2
Threadlocking Agents..................................................1-2
Wiring, Hoses and Lines.............................................1-2
Instruments and Gauges.............................................1-2
Bearings......................................................................1-2
Bushings.....................................................................1-2
Gaskets.......................................................................1-2
Lip Type Seals.............................................................1-2
O-Rings (Preformed Packings)....................................1-3
Gears..........................................................................1-3
Shafts..........................................................................1-3
Part Replacement........................................................1-3
Exhaust System Leakage............................................1-3
Cleaning.............................................................................1-3
Part Protection............................................................1-3
Cleaning Process........................................................1-3
Rust or Corrosion Removal.........................................1-3
Bearings......................................................................1-3
Tool Safety..........................................................................1-3
Air Tools.......................................................................1-3
Wrenches....................................................................1-3
Pliers/Cutters/Pry bars................................................1-3
Hammers.....................................................................1-4
Punches/Chisels..........................................................1-4
Screwdrivers................................................................1-4
Ratchets and Handles.................................................1-4
Sockets........................................................................1-4
Storage Units...............................................................1-4
1.2 FUEL AND OIL
Fuel....................................................................................1-5
Gasoline Blends: Buell Models...........................................1-5
Engine Lubrication..............................................................1-5
Winter Lubrication..............................................................1-6
1.3 MAINTENANCE SCHEDULE
General...............................................................................1-7
1.4 BATTERY MAINTENANCE
General...............................................................................1-9
Battery Disconnection and Removal................................1-10
Cleaning and Inspection...................................................1-10
Charging Battery..............................................................1-10
Safety Precautions....................................................1-10
Using a Battery Charger............................................1-10
Battery Installation and Connection..................................1-11
Storage.............................................................................1-12
1.5 ENGINE OIL AND FILTER
General.............................................................................1-13
Engine Oil Level Check....................................................1-13
Change Engine Oil and Filter...........................................1-13
Drain Oil....................................................................1-13
Change Filter.............................................................1-14
Fill Engine With Oil....................................................1-14
Clear Oil Cooler.........................................................1-14
Return to Service......................................................1-15
1.6 BRAKE SYSTEM MAINTENANCE
General.............................................................................1-16
Bleeding Brakes...............................................................1-16
Bleeding Front Brake.................................................1-17
Bleeding Rear Brake.................................................1-18
Brake Pedal Adjustment...................................................1-18
Brake Pad Thickness........................................................1-19
Brake Rotor Thickness.....................................................1-20
Brake Pad Replacement...................................................1-20
Front Pad Removal....................................................1-20
Front Pad Installation.................................................1-20
Rear Pad Removal....................................................1-21
Rear Pad Installation.................................................1-21
1.7 TIRES AND WHEELS
Tire Inflation......................................................................1-23
Tire Wear..........................................................................1-23
Wheel Bearings................................................................1-24
1.8 CLUTCH/TRANSMISSION/PRIMARY
FLUID
Inspection.........................................................................1-25
Transmission Fluid............................................................1-25
Adjustment.......................................................................1-26
1.9 DRIVE BELT MAINTENANCE
General.............................................................................1-28
Inspection.........................................................................1-28
Rear Sprocket...........................................................1-28
Drive Belt...................................................................1-28
Idler Pulley.................................................................1-28
Cleaning...........................................................................1-28
1.10 PRIMARY CHAIN
Inspection.........................................................................1-31
Adjustment.......................................................................1-31
1.11 STEERING HEAD BEARINGS
General.............................................................................1-32
Inspection.........................................................................1-32
Determining Proper Resistance.......................................1-32
1.12 SPARK PLUGS
Inspection.........................................................................1-33
1.13 AIR CLEANER AND EXHAUST SYSTEM
Removal...........................................................................1-35
Cleaning and Inspection...................................................1-36
Installation........................................................................1-36
Exhaust System Leak Check............................................1-37
1.14 THROTTLE CABLE
Throttle Cable Adjustment................................................1-38
1.15 INTERACTIVE EXHAUST CABLE
Adjustment.......................................................................1-39
III
TABLE OF CONTENTS
1.16 HEADLIGHT
Inspection.........................................................................1-41
Adjustment: Firebolt..........................................................1-42
Adjustment: Lightning.......................................................1-42
Horizontal Alignment.................................................1-42
Vertical Alignment.....................................................1-42
Adjustment: Ulysses/Lightning XB12STT.........................1-43
Horizontal Alignment.................................................1-43
Vertical Alignment.....................................................1-43
1.17 WINDSHIELD MAINTENANCE
General.............................................................................1-45
1.18 STORAGE
General.............................................................................1-46
Removal From Storage.....................................................1-46
1.19 TROUBLESHOOTING
General.............................................................................1-47
Engine..............................................................................1-47
Starter Motor Does Not Operate or Does Not Turn Engine
Over...........................................................................1-47
Engine Turns Over But Does Not Start......................1-47
Starts Hard................................................................1-47
Starts But Runs Irregularly or Misses........................1-47
Spark Plug Fouls Repeatedly....................................1-47
Pre-Ignition or Detonation (Knocks or Pings)............1-48
Overheating...............................................................1-48
Valve Train Noise.......................................................1-48
Excessive Vibration...................................................1-48
Check Engine Light Illuminates During Operation.....1-48
Lubrication System...........................................................1-48
Oil Does Not Return To Oil Tank................................1-48
Engine Uses Too Much Oil Or Smokes Excessively...1-48
Engine Leaks Oil From Cases, Push Rods, Hoses,
Etc.............................................................................1-48
Low Oil Pressure.......................................................1-48
High Oil Pressure......................................................1-48
Electrical System..............................................................1-49
Alternator Does Not Charge......................................1-49
Alternator Charge Rate Is Below Normal..................1-49
Speedometer Operates Erratically............................1-49
Transmission.....................................................................1-49
Shifts Hard................................................................1-49
Jumps Out Of Gear...................................................1-49
Clutch Slips...............................................................1-49
Clutch Drags Or Does Not Release..........................1-49
Clutch Chatters..........................................................1-49
Clutch...............................................................................1-49
Slips..........................................................................1-49
Drags or Does Not Release......................................1-49
Chatters.....................................................................1-49
Chassis.............................................................................1-49
Irregular/Inadequate Brake Action.............................1-49
Handling Irregularities...............................................1-49
Suspension.......................................................................1-50
CHASSIS
2.1 SPECIFICATIONS
Firebolt...............................................................................2-1
Lightning.............................................................................2-1
Ulysses...............................................................................2-2
2.2 VEHICLE IDENTIFICATION NUMBER
(V.I.N.)
Vehicle Identification Number (V.I.N.).................................2-4
2.3 WHEELS
General...............................................................................2-6
Troubleshooting..................................................................2-6
2.4 FRONT WHEEL
Removal.............................................................................2-8
Disassembly.......................................................................2-8
Bearing Removal.........................................................2-8
Front Rotor Removal.................................................2-10
Cleaning and Inspection...................................................2-10
Assembly..........................................................................2-11
Bearing Installation....................................................2-11
Front Rotor Installation..............................................2-14
Installation........................................................................2-14
2.5 REAR WHEEL
Removal...........................................................................2-16
Cleaning and Inspection...................................................2-16
Disassembly.....................................................................2-16
Assembly..........................................................................2-18
Installation........................................................................2-18
2.6 TIRES
General.............................................................................2-20
Specifications...................................................................2-20
Removal...........................................................................2-21
Cleaning and Inspection...................................................2-21
Installation........................................................................2-21
Checking Tire Lateral Runout....................................2-22
Checking Tire Radial Runout.....................................2-22
Adjustment.......................................................................2-23
Wheel Balancing.......................................................2-23
2.7 CHECKING CAST RIM RUNOUT
General.............................................................................2-24
Rim Lateral Runout...................................................2-24
Rim Radial Runout....................................................2-24
2.8 FRONT BRAKE MASTER CYLINDER
AND HAND LEVER
Removal...........................................................................2-25
Disassembly.....................................................................2-25
Brake Hand Lever......................................................2-25
Front Master Cylinder................................................2-26
Cleaning and Inspection...................................................2-26
Assembly..........................................................................2-26
Front Master Cylinder................................................2-26
Brake Hand Lever......................................................2-26
Installation........................................................................2-27
2.9 FRONT BRAKE LINE
Removal...........................................................................2-28
Installation........................................................................2-28
IV TABLE OF CONTENTS
TABLE OF CONTENTS
2.10 FRONT BRAKE CALIPER
Removal...........................................................................2-30
Disassembly.....................................................................2-30
Cleaning and Inspection...................................................2-30
Assembly..........................................................................2-31
Installation........................................................................2-31
2.11 BRAKE PEDAL
Removal...........................................................................2-33
Installation........................................................................2-33
2.12 REAR BRAKE MASTER CYLINDER
Removal: Firebolt/Lightning..............................................2-34
Removal: Ulysses.............................................................2-35
Disassembly.....................................................................2-37
Cleaning and Inspection...................................................2-37
Assembly..........................................................................2-37
Installation: Firebolt/Lightning...........................................2-38
Installation: Ulysses..........................................................2-38
2.13 REAR BRAKE LINE
Removal: Firebolt..............................................................2-40
Installation: Firebolt..........................................................2-40
Removal: Lightning...........................................................2-41
Installation: Lightning........................................................2-41
Removal: Ulysses.............................................................2-42
Installation: Ulysses..........................................................2-43
2.14 REAR BRAKE CALIPER
Removal...........................................................................2-44
Disassembly.....................................................................2-44
Cleaning and Inspection...................................................2-45
Assembly..........................................................................2-45
Installation........................................................................2-45
2.15 FENDERS
Front Fender: XB12R........................................................2-47
Removal....................................................................2-47
Installation.................................................................2-47
Rear Fender: XB12R........................................................2-47
Removal....................................................................2-47
Installation.................................................................2-47
Front Fender: XB9SX/XB12S/XB12Scg/XB12XT.............2-47
Removal....................................................................2-47
Installation.................................................................2-47
Rear Fender: XB9SX/XB12S/XB12Scg............................2-47
Removal....................................................................2-47
Installation.................................................................2-47
Front Fender: XB12STT...................................................2-47
Removal....................................................................2-47
Installation.................................................................2-47
Rear Fender: XB12Ss/XB12STT/XB12XT/XB12X...........2-48
Removal....................................................................2-48
Installation.................................................................2-48
Front Fender: XB12X........................................................2-48
Removal Upper Front Fender....................................2-48
Removal Lower Front Fender....................................2-48
Installing Upper Front Fender....................................2-48
Installing Lower Front Fender....................................2-48
2.16 FRONT FORK: ALL MODELS EXCEPT
XB12STT/XB12X/XB12XT
General.............................................................................2-49
Removal...........................................................................2-49
Disassembly.....................................................................2-50
Damper Rod Disassembly.........................................2-52
Cleaning and Inspection...................................................2-54
Assembly..........................................................................2-54
Damper Rod Assembly.............................................2-54
Fork Assembly...........................................................2-54
Installation........................................................................2-56
2.17 FRONT FORK:
XB12STT/XB12X/XB12XT
General.............................................................................2-57
Removal...........................................................................2-57
Disassembly.....................................................................2-57
Cleaning and Inspection...................................................2-61
Assembly..........................................................................2-61
Installation........................................................................2-63
2.18 FORK CLAMPS: UPPER AND LOWER
Removal Firebolt..............................................................2-64
Installation: Firebolt..........................................................2-64
Removal: Lightning/Ulysses.............................................2-65
Installation: Lightning/Ulysses..........................................2-65
2.19 STEERING HEAD BEARINGS
Removal...........................................................................2-67
Installation........................................................................2-67
2.20 FRONT FORK SLIDER PROTECTORS:
XB12STT
Replacement: XB12STT...................................................2-70
2.21 SWINGARM AND BRACE
General.............................................................................2-71
Brace................................................................................2-71
Removal....................................................................2-71
Installation.................................................................2-71
Removal: Swingarm..........................................................2-71
Disassembly.....................................................................2-72
Swingarm..................................................................2-72
Cleaning and Inspection...................................................2-72
Assembly..........................................................................2-73
Swingarm..................................................................2-73
Installation: Swingarm......................................................2-73
2.22 FRONT AND REAR ISOLATORS
Front Isolator....................................................................2-75
Removal....................................................................2-75
Installation.................................................................2-75
Rear Isolator.....................................................................2-75
2.23 FRAME PUCKS
Removal...........................................................................2-76
Installation........................................................................2-76
TABLE OF CONTENTS V
TABLE OF CONTENTS
2.24 FRAME
Removal...........................................................................2-77
Installation........................................................................2-77
2.25 REAR SHOCK ABSORBER
General.............................................................................2-78
Removal: Firebolt..............................................................2-80
Removal: Lightning...........................................................2-81
Removal: Ulysses.............................................................2-81
Installation: Firebolt..........................................................2-82
Installation: Lightning........................................................2-82
Installation: Ulysses..........................................................2-83
2.26 THROTTLE CONTROL
Removal and Disassembly...............................................2-84
Cleaning and Inspection...................................................2-85
Assembly and Installation.................................................2-85
Throttle Cable Replacement.............................................2-85
Removal....................................................................2-85
Installation.................................................................2-85
2.27 CLUTCH CONTROL
General.............................................................................2-87
Removal and Disassembly...............................................2-87
Clutch Cable..............................................................2-87
Assembly and Installation.................................................2-89
Clutch Cable..............................................................2-89
2.28 HEADLAMP ASSEMBLY AND
SUPPORT BRACKET
Removal: Firebolt..............................................................2-91
Disassembly: Firebolt.......................................................2-91
Assembly: Firebolt............................................................2-91
Installation: Firebolt..........................................................2-92
Removal: Lightning/Ulysses.............................................2-93
Disassembly: Lightning/Ulysses.......................................2-95
Assembly: Lightning/Ulysses............................................2-95
Installation: Lightning/Ulysses..........................................2-96
2.29 FAIRING SUPPORT BRACKET:
FIREBOLT
Removal...........................................................................2-97
Installation........................................................................2-97
2.30 DEFLECTORS:
XB9SX/XB12STT/XB12X/XB12XT
Removal and Disassembly...............................................2-99
Assembly and Installation.................................................2-99
2.31 GRILLE: XB9SX/XB12STT/XB12X
General...........................................................................2-100
Removal and Installation................................................2-100
2.32 FRONT MODULES:
LIGHTNING/ULYSSES
Removal.........................................................................2-101
Installation......................................................................2-102
2.33 HANDLEBARS: FIREBOLT
General...........................................................................2-103
Removal.........................................................................2-103
Right Clip-On...........................................................2-103
Left Clip-On.............................................................2-103
Installation......................................................................2-103
Right Clip-On...........................................................2-103
Left Clip-On.............................................................2-103
2.34 HANDLEBARS: LIGHTNING/ULYSSES
Removal.........................................................................2-104
Installation......................................................................2-104
2.35 MIRRORS
Removal.........................................................................2-106
Installation......................................................................2-106
2.36 FOOTPEG, HEEL GUARD AND MOUNT:
FIREBOLT/LIGHTNING
Rider...............................................................................2-107
Wear Peg Removal..................................................2-107
Footpeg Removal....................................................2-107
Heel Guard Removal...............................................2-107
Mount Removal.......................................................2-107
Mount Installation....................................................2-107
Heel Guard Installation............................................2-107
Footpeg Installation.................................................2-107
Wear Peg Installation..............................................2-107
Passenger......................................................................2-107
Footpeg Removal....................................................2-107
Heel Guard Removal...............................................2-107
Mount Removal.......................................................2-107
Mount Installation....................................................2-108
Heel Guard Installation............................................2-108
Footpeg Installation.................................................2-108
2.37 HEEL GUARD AND FOOTPEG
MOUNTS: ULYSSES MODELS
Rider Footpegs...............................................................2-109
Footpeg Removal....................................................2-109
Footpeg Installation.................................................2-109
Passenger Footpegs.......................................................2-109
Footpeg Removal....................................................2-109
Footpeg Installation.................................................2-109
Mount Removal..............................................................2-109
Mount Installation...........................................................2-109
Heel Guard Replacement...............................................2-110
2.38 SPROCKET COVER
Removal.........................................................................2-111
Installation......................................................................2-111
2.39 BELT GUARDS
Removal.........................................................................2-112
Installation......................................................................2-112
2.40 INTAKE COVER
Removal.........................................................................2-113
Installation......................................................................2-113
VI TABLE OF CONTENTS
TABLE OF CONTENTS
2.41 SUBFRAME TAIL ASSEMBLY AND
BODY WORK: FIREBOLT
Disassembly...................................................................2-115
Cleaning.........................................................................2-118
Assembly........................................................................2-118
2.42 LEFT TAIL SECTION AND BATTERY
PAN: LIGHTNING
Disassembly...................................................................2-120
Cleaning.........................................................................2-121
Assembly........................................................................2-122
2.43 CENTER TAIL SECTION: LIGHTNING
Disassembly...................................................................2-124
Assembly........................................................................2-124
2.44 RIGHT TAIL SECTION: LIGHTNING
Disassembly...................................................................2-125
Assembly........................................................................2-125
2.45 LEFT TAIL SECTION AND BATTERY
PAN: XB12X/XB12XT
Disassembly...................................................................2-126
Cleaning.........................................................................2-126
Assembly........................................................................2-127
2.46 CENTER TAIL LOOP: XB12X/XB12XT
Disassembly...................................................................2-129
Assembly........................................................................2-129
2.47 RIGHT TAIL SECTION: XB12X/XB12XT
Disassembly...................................................................2-131
Assembly........................................................................2-132
2.48 SIDESTAND
General...........................................................................2-133
Removal.........................................................................2-133
Disassembly...................................................................2-133
Assembly........................................................................2-134
Installation......................................................................2-134
2.49 FRONT FAIRING,WINDSHIELD, AND
MIRRORS: FIREBOLT
Removal.........................................................................2-135
Installation......................................................................2-135
2.50 WINDSHIELD AND WINDSCREEN:
LIGHTNING AND ULYSSES
Removal: Lightning.........................................................2-136
Installation: Lightning......................................................2-136
Removal: Ulysses XB12X...............................................2-137
Installation: Ulysses XB12X............................................2-137
Removal: Ulysses XB12XT.............................................2-138
Installation: Ulysses XB12XT.........................................2-139
2.51 NUMBER PLATES: XB12STT
General...........................................................................2-140
Removal.........................................................................2-140
Installation......................................................................2-141
2.52 AIR SCOOPS
Ram Air Scoop...............................................................2-142
Removal..................................................................2-142
Installation...............................................................2-142
Engine Shroud Air Scoop...............................................2-142
Removal..................................................................2-142
Installation...............................................................2-142
Oil Cooler Air Scoop.......................................................2-142
Removal..................................................................2-142
Installation...............................................................2-142
2.53 CHIN FAIRING
Removal.........................................................................2-144
Installation......................................................................2-144
2.54 SEAT
Firebolt...........................................................................2-145
Rider Seat...............................................................2-145
Pillion.......................................................................2-145
Lightning.........................................................................2-145
Removal..................................................................2-145
Installation...............................................................2-146
Ulysses...........................................................................2-147
Removal..................................................................2-147
Installation...............................................................2-147
2.55 SEAT LOCKS
Removal: Lightning.........................................................2-149
Installation: Lightning......................................................2-149
Removal: Ulysses Models..............................................2-150
Installation: Ulysses Models...........................................2-150
Pillion Lock Removal: XB12R.........................................2-151
Pillion Lock Installation: XB12R......................................2-152
2.56 TRIPLE TAIL: ULYSSES
General...........................................................................2-153
Removal.........................................................................2-153
Disassembly...................................................................2-153
Assembly........................................................................2-153
Installation......................................................................2-154
2.57 LUGGAGE: XB12XT
Removal: Side Case.......................................................2-155
Installation: Side Case....................................................2-156
Removal:Top Case.........................................................2-156
Installation: Top Case.....................................................2-157
Luggage Case Latch Mechanism...................................2-157
Removal..................................................................2-157
Installation...............................................................2-158
ENGINE
3.1 SPECIFICATIONS
General...............................................................................3-1
3.2 ENGINE
Adjustment/Testing.............................................................3-5
General........................................................................3-5
TABLE OF CONTENTS VII
TABLE OF CONTENTS
Compression Test...............................................................3-5
Cylinder Leakage Test........................................................3-5
Diagnosing Smoking Engine or High Oil Consumption......3-6
3.3 ENGINE ROTATION FOR SERVICE
General...............................................................................3-7
Disassembly.......................................................................3-7
Assembly..........................................................................3-10
3.4 ENGINE REMOVAL
Disassembly.....................................................................3-13
3.5 ENGINE INSTALLATION
Assembly..........................................................................3-23
Engine Preparation for Re-installation.......................3-23
Installing Engine in Frame.........................................3-24
3.6 CYLINDER HEAD
Removal...........................................................................3-34
Rocker Box Assemblies.............................................3-34
Cylinder Head Assemblies........................................3-35
Disassembly.....................................................................3-36
Cleaning and Inspection...................................................3-39
Cylinder Heads..........................................................3-39
Rocker Arm Assemblies............................................3-39
Valves........................................................................3-40
Valve Seats...............................................................3-40
Valve Guides.............................................................3-40
Valve Springs............................................................3-41
Spark Plug Threads...................................................3-41
Push Rods.................................................................3-41
Replacing Rocker Arm Bushings......................................3-41
Replacing Valve Guides....................................................3-42
Procedure For Using The Neway Valve Seat Cutter.........3-43
Assembly..........................................................................3-44
Push Rod Cover Installation.............................................3-45
Cylinder Head Installation.................................................3-46
3.7 CYLINDER AND PISTON
Removal/Disassembly......................................................3-49
Cleaning and Inspection...................................................3-50
Checking Gasket Surface..........................................3-51
Measuring Cylinder Bore...........................................3-51
Deglazing Cylinder....................................................3-52
Fitting Piston Rings..........................................................3-52
Connecting Rod Bushing..................................................3-54
Assembly/Installation........................................................3-55
3.8 OILING SYSTEM
General.............................................................................3-58
3.9 OIL PUMP
General.............................................................................3-59
Removal/Disassembly......................................................3-60
Cleaning and Inspection...................................................3-62
Assembly/Installation........................................................3-63
3.10 OIL RESERVOIR AND OIL HOSE
ROUTING
General.............................................................................3-65
3.11 OIL LINE FITTINGS
Removal...........................................................................3-67
Installation........................................................................3-67
3.12 OIL COOLER
General.............................................................................3-69
Removal...........................................................................3-69
Installation........................................................................3-69
3.13 OIL PRESSURE INDICATOR SWITCH
General.............................................................................3-70
Oil Pressure Signal Light..................................................3-70
Oil Pressure......................................................................3-70
3.14 CRANKCASE BREATHING SYSTEM
General.............................................................................3-72
Reed Valve Replacement.................................................3-72
3.15 HYDRAULIC LIFTERS
General.............................................................................3-74
Removal...........................................................................3-74
Cleaning and Inspection...................................................3-74
Installation........................................................................3-75
3.16 GEARCASE AND CAM GEARS
General.............................................................................3-76
Removal and Disassembly...............................................3-77
Cleaning and Inspection...................................................3-77
Cam and Pinion Gear Identification, Inspection and
Selection...................................................................3-78
Assembly and Installation.................................................3-78
3.17 CRANKCASE
General.............................................................................3-80
Disassembly.....................................................................3-80
Crankcase Halves.....................................................3-80
Oil Filter Adapter..............................................................3-81
Piston Jets........................................................................3-82
Removal....................................................................3-82
Installation.................................................................3-82
Removing Cylinder Base Studs.................................3-82
Flywheel Assembly....................................................3-82
Pinion Shaft Bearing.........................................................3-85
General......................................................................3-85
Selection...................................................................3-86
Replacement.............................................................3-86
Lapping Pinion Shaft Bearing Outer Race................3-89
Checking Connecting Rod Side Play................................3-89
Assembly..........................................................................3-90
Crankcase Halves.....................................................3-90
FUEL SYSTEM
4.1 SPECIFICATIONS
General...............................................................................4-1
4.2 AIR CLEANER ASSEMBLY
Removal.............................................................................4-2
Inspection...........................................................................4-3
Installation..........................................................................4-3
VIII TABLE OF CONTENTS
TABLE OF CONTENTS
4.3 ELECTRONIC CONTROL MODULE (ECM)
Removal: Firebolt................................................................4-5
Installation: Firebolt............................................................4-5
Removal: Lightning.............................................................4-5
Installation: Lightning..........................................................4-5
Removal: Ulysses...............................................................4-6
Installation: Ulysses............................................................4-6
4.4 THROTTLE POSITION SENSOR (TPS)
Removal.............................................................................4-8
Installation..........................................................................4-8
4.5 IGNITION COIL
Removal.............................................................................4-9
Installation..........................................................................4-9
4.6 OXYGEN SENSOR
General.............................................................................4-10
Removal...........................................................................4-10
Installation........................................................................4-10
4.7 ENGINE TEMPERATURE SENSOR (ET)
General.............................................................................4-11
Removal...........................................................................4-11
Installation........................................................................4-12
4.8 BANK ANGLE SENSOR (BAS)
General.............................................................................4-13
Removal...........................................................................4-13
Firebolt......................................................................4-13
Lightning....................................................................4-13
Ulysses......................................................................4-13
Installation........................................................................4-14
Firebolt......................................................................4-14
Lightning....................................................................4-14
Ulysses......................................................................4-15
4.9 INTAKE AIR TEMPERATURE SENSOR
(IAT)
General.............................................................................4-16
Removal...........................................................................4-16
Installation........................................................................4-16
4.10 COOLING FAN
General.............................................................................4-17
Removal...........................................................................4-17
Installation........................................................................4-17
4.11 FUEL TANK VENT VALVE
General.............................................................................4-18
Removal...........................................................................4-18
Installation........................................................................4-18
4.12 FUEL CAP RETAINING RING
Removal...........................................................................4-19
Installation........................................................................4-19
4.13 FUEL PUMP
Draining Fuel Tank............................................................4-20
Removal...........................................................................4-20
Repair...............................................................................4-21
Fuel Pressure Regulator Replacement.....................4-21
Low Fuel Level Sensor Replacement........................4-22
Fuel Filter Replacement............................................4-23
Fuel Pump Wire Harness Replacement....................4-25
Installation........................................................................4-25
4.14 THROTTLE BODY
General.............................................................................4-27
Removal...........................................................................4-27
Repair...............................................................................4-30
Throttle Position Sensor............................................4-30
Fuel Injectors.............................................................4-30
Installation........................................................................4-30
Injector Leak Testing..................................................4-31
4.15 INTAKE LEAK TEST
General.............................................................................4-32
Leak Tester.......................................................................4-32
Parts List...................................................................4-32
Tester Assembly........................................................4-32
Tester Adjustment......................................................4-32
Procedure.........................................................................4-32
4.16 EXHAUST SYSTEM
Removal and Disassembly...............................................4-34
Muffler.......................................................................4-34
Front Muffler Mount...................................................4-34
Rear Muffler Bracket.................................................4-34
Exhaust Header........................................................4-34
Assembly and Installation.................................................4-35
Exhaust Header........................................................4-35
Rear Muffler Bracket.................................................4-36
Front Muffler Mount...................................................4-36
Muffler and Straps.....................................................4-36
4.17 EVAPORATIVE EMISSIONS CONTROL
(CA MODELS)
General.............................................................................4-38
Troubleshooting................................................................4-38
Removal: Firebolt..............................................................4-38
Vent Valve..................................................................4-38
Canister.....................................................................4-38
Removal: Lightning/Ulysses.............................................4-38
Vent Valve..................................................................4-38
Canister.....................................................................4-38
Installation: Firebolt..........................................................4-38
Vent Valve..................................................................4-38
Canister.....................................................................4-38
Installation: Lightning/Ulysses..........................................4-39
Vent Valve..................................................................4-39
Canister.....................................................................4-39
Hose Routing....................................................................4-40
ELECTRIC STARTER
5.1 SPECIFICATIONS
General...............................................................................5-1
5.2 STARTER
General...............................................................................5-2
TABLE OF CONTENTS IX
TABLE OF CONTENTS
Wiring Diagrams..........................................................5-2
Removal.............................................................................5-2
Disassembly, Inspection, and Repair..................................5-2
Assembly............................................................................5-6
Installation..........................................................................5-7
5.3 STARTER SOLENOID
Replacement......................................................................5-9
Disassembly................................................................5-9
Assembly.....................................................................5-9
DRIVE/TRANSMISSION
6.1 SPECIFICATIONS
General...............................................................................6-1
6.2 PRIMARY COVER
Removal.............................................................................6-2
Primary Chain Adjuster Replacement................................6-3
Installation..........................................................................6-4
6.3 CLUTCH RELEASE MECHANISM
Disassembly.......................................................................6-6
Cleaning and Inspection.....................................................6-6
Assembly............................................................................6-7
6.4 CLUTCH
General...............................................................................6-8
Removal...........................................................................6-10
Clutch Pack Cleaning and Inspection...............................6-11
Adjusting Screw Disassembly/Assembly..........................6-11
Assembly and Installation.................................................6-12
6.5 PRIMARY CHAIN
General.............................................................................6-15
Removal...........................................................................6-15
Clutch Shell/Hub Inspection.............................................6-16
Clutch Shell Bearing Replacement...................................6-17
Installation........................................................................6-18
6.6 DRIVE BELT AND IDLER PULLEY
General.............................................................................6-21
Drive Belt Removal...........................................................6-22
Drive Belt Installation........................................................6-22
Idler Pulley Removal.........................................................6-23
Idler Pulley Installation......................................................6-23
6.7 TRANSMISSION
General.............................................................................6-25
6.8 CASE DISASSEMBLY FOR
TRANSMISSION REMOVAL
General.............................................................................6-26
Right Crankcase Removal................................................6-26
6.9 TRANSMISSION DISASSEMBLY
Transmission Removal From Left Crankcase...................6-29
Mainshaft/Countershaft....................................................6-33
Mainshaft Disassembly.....................................................6-33
Cleaning and Inspection............................................6-34
Countershaft Disassembly................................................6-34
Cleaning and Inspection............................................6-34
6.10 TRANSMISSION ASSEMBLY
Mainshaft Assembly.........................................................6-36
Countershaft Assembly....................................................6-36
6.11 MAIN DRIVE GEAR AND BEARING
General.............................................................................6-38
Removal...........................................................................6-38
Main Drive Gear Bearing...........................................6-39
Disassembly.....................................................................6-40
Assembly..........................................................................6-40
Installation........................................................................6-41
Main Drive Gear Ball Bearing....................................6-41
Main Drive Gear........................................................6-42
Main Drive Gear Seal................................................6-43
6.12 TRANSMISSION RIGHT CASE
BEARINGS
Removal...........................................................................6-45
Countershaft Needle Bearing....................................6-45
Shifter Drum Bushing................................................6-45
Installation........................................................................6-45
Countershaft Needle Bearing....................................6-45
Shifter Drum Bushing................................................6-45
6.13 TRANSMISSION LEFT CASE
BEARINGS
Removal...........................................................................6-47
Mainshaft and Countershaft Bearings.......................6-47
Shift Drum Bearing....................................................6-47
Installation........................................................................6-47
Mainshaft and Countershaft Bearings.......................6-47
Shift Drum Bushing...................................................6-47
6.14 TRANSMISSION INSTALLATION
Installation........................................................................6-48
Shifter Forks and Drum Assembly....................................6-49
Installing Right Crankcase................................................6-50
6.15 SHIFTER SHAFT
Installation........................................................................6-52
6.16 TRANSMISSION SPROCKET
Removal...........................................................................6-54
Installation........................................................................6-55
ELECTRICAL
7.1 SPECIFICATIONS
General...............................................................................7-1
7.2 IGNITION SYSTEM
General...............................................................................7-3
Troubleshooting..................................................................7-3
7.3 IGNITION/HEADLAMP KEY SWITCH
General...............................................................................7-5
X TABLE OF CONTENTS
TABLE OF CONTENTS
Removal: Firebolt................................................................7-5
Disassembly: Firebolt.........................................................7-6
Assembly: Firebolt..............................................................7-6
Installation: Firebolt............................................................7-7
Removal: Lightning.............................................................7-7
Disassembly: Lightning.......................................................7-9
Assembly: Lightning............................................................7-9
Installation: Lightning........................................................7-11
Removal: Ulysses.............................................................7-12
Disassembly: Ulysses.......................................................7-13
Assembly: Ulysses............................................................7-13
Installation: Ulysses..........................................................7-14
7.4 SPARK PLUG CABLES
General.............................................................................7-15
Removal...........................................................................7-15
Inspection.........................................................................7-15
Installation........................................................................7-15
7.5 CHARGING SYSTEM
General.............................................................................7-17
Alternator...................................................................7-17
Voltage Regulator......................................................7-17
7.6 BATTERY CABLES
Removal...........................................................................7-19
Installation........................................................................7-19
7.7 VOLTAGE REGULATOR
General.............................................................................7-22
Removal...........................................................................7-22
Installation........................................................................7-22
7.8 ALTERNATOR
Removal and Disassembly...............................................7-23
Rotor.........................................................................7-23
Stator.........................................................................7-23
Cleaning and Inspection...................................................7-24
Assembly and Installation.................................................7-24
7.9 HEATED HAND GRIPS: ULYSSES
MODELS
Heated Hand Grips...........................................................7-25
Removal....................................................................7-25
Installation.................................................................7-25
7.10 HORN
Removal...........................................................................7-28
Installation........................................................................7-28
Troubleshooting................................................................7-29
7.11 TURN SIGNAL FLASHER
Removal...........................................................................7-30
Installation........................................................................7-30
7.12 FRONT TURN SIGNALS
Bulbs................................................................................7-32
Repair........................................................................7-32
Connections and Wire Routing..................................7-32
Firebolt.............................................................................7-32
Removal....................................................................7-32
Installation.................................................................7-35
Lightning...........................................................................7-32
Removal....................................................................7-32
Installation.................................................................7-32
Ulysses.............................................................................7-33
Removal....................................................................7-33
Installation.................................................................7-36
7.13 REAR TURN SIGNALS
Bulbs................................................................................7-35
Connections and Wire Routing..................................7-35
Firebolt.............................................................................7-35
Removal....................................................................7-35
Installation.................................................................7-35
Lightning...........................................................................7-36
Removal....................................................................7-36
Installation.................................................................7-36
Ulysses.............................................................................7-37
Remove.....................................................................7-37
Installation.................................................................7-37
7.14 INTERACTIVE EXHAUST SYSTEM
General.............................................................................7-39
Removal...........................................................................7-41
Installation........................................................................7-42
7.15 HEADLIGHT
General.............................................................................7-43
Headlight Bulbs: Firebolt..................................................7-43
Removal....................................................................7-43
Installation.................................................................7-43
Headlight Bulbs: Lightning and Ulysses...........................7-44
Removal....................................................................7-44
Installation.................................................................7-45
7.16 TAIL LAMP
Firebolt/Lighting................................................................7-48
Removal....................................................................7-48
Installation.................................................................7-48
Ulysses.............................................................................7-49
Removal....................................................................7-49
Installation.................................................................7-49
7.17 LICENSE PLATE LAMP ASSEMBLY
Lightning...........................................................................7-50
Removal....................................................................7-50
Installation.................................................................7-50
Ulysses.............................................................................7-50
Removal and Disassembly........................................7-50
Assembly and Installation..........................................7-51
7.18 MAIN FUSE AND FUSES
General.............................................................................7-52
Fuses........................................................................7-52
Main Fuse.................................................................7-52
7.19 NEUTRAL INDICATOR SWITCH
General.............................................................................7-55
Testing..............................................................................7-55
Removal and Installation..................................................7-55
TABLE OF CONTENTS XI
TABLE OF CONTENTS
7.20 CRANKSHAFT POSITION SENSOR
(CKP)
General.............................................................................7-56
Removal...........................................................................7-56
Installation........................................................................7-56
7.21 VEHICLE SPEED SENSOR (VSS)
Removal...........................................................................7-58
Installation........................................................................7-58
7.22 INSTRUMENT MODULE
General.............................................................................7-59
Removal...........................................................................7-59
Bulb Replacement.....................................................7-59
Installation........................................................................7-60
7.23 MAIN WIRE HARNESS
General.............................................................................7-62
Removal...........................................................................7-62
Installation........................................................................7-69
7.24 INTERACTIVE EXHAUST HARNESS:
XB12 MODELS
Firebolt.............................................................................7-77
Removal....................................................................7-77
Installation.................................................................7-77
Lightning...........................................................................7-78
Removal....................................................................7-78
Installation.................................................................7-78
Ulysses.............................................................................7-79
Removal....................................................................7-79
Installation.................................................................7-79
7.25 SPROCKET COVER WIRING
General.............................................................................7-81
Removal...........................................................................7-81
7.26 AUXILIARY POWER OUTLETS:
ULYSSES MODELS
General.............................................................................7-82
Accessory Load Test........................................................7-82
APPENDIX A CONNECTOR REPAIR
A.1 AMP 1-PLACE CONNECTORS
AMP 1-Place Connector Repair.........................................A-1
General.......................................................................A-1
Separating Pin and Socket Housings.........................A-1
Mating Pin and Socket Housings................................A-1
Removing Socket Terminals........................................A-1
Installing Socket Terminal...........................................A-1
Removing Pin Terminal...............................................A-1
Installing Pin Terminal.................................................A-2
A.2 AMP MULTILOCK CONNECTORS
AMP Multilock Connector Repair.......................................A-3
General.......................................................................A-3
Separating Pin and Socket Housings.........................A-3
Mating Pin and Socket Housings................................A-3
Removing Terminals from Housing.............................A-3
Inserting Terminals into Housing.................................A-4
Preparing Wire Leads for Crimping.............................A-4
Crimping Terminals to Leads......................................A-5
Inspecting Crimped Terminals.....................................A-6
A.3 AUTOFUSE ELECTRICAL
CONNECTORS
Autofuse Connector Repair................................................A-7
General.......................................................................A-7
Disassembly................................................................A-7
Assembly....................................................................A-7
A.4 DELPHI CONNECTORS
Delphi Connector Repair....................................................A-8
General.......................................................................A-8
Separating Pin and Socket Housings.........................A-8
Mating Pin and Socket Housings................................A-8
Removing Socket Terminals........................................A-8
Installing Socket Terminals..........................................A-8
A.5 DEUTSCH ELECTRICAL CONNECTORS
Deutsch Connector Repair...............................................A-10
General.....................................................................A-10
Separating Pin and Socket Housings.......................A-10
Mating Pin and Socket Housings..............................A-10
Removing Socket Terminals......................................A-10
Installing Socket Terminals........................................A-10
Removing Pin Terminals...........................................A-12
Installing Pin Terminals.............................................A-12
Crimping Terminals...................................................A-13
A.6 DEUTSCH STANDARD TERMINAL
REPAIR
Deutsch Standard Terminal Crimps.................................A-14
Preparing Wire Leads for Crimping...........................A-14
Crimping Terminal to Lead........................................A-14
Inspecting Crimps.....................................................A-14
A.7 DEUTSCH SOLID BARREL MINI
TERMINAL REPAIR
Deutsch Solid Barrel Terminal Crimps.............................A-15
Preparing Wire Leads For Crimping.........................A-15
Adjusting Crimper Tool..............................................A-15
Crimping a Barrel Contact To Wire Lead...................A-15
Inspecting Crimps.....................................................A-15
A.8 DEUTSCH MINI TERMINAL REPAIR
Deutsch Mini Terminal Crimps.........................................A-17
Preparing Wire Leads for Crimping...........................A-17
Crimping a Mini Terminal to Wire Lead.....................A-17
Inspecting Crimps.....................................................A-17
A.9 MOLEX CONNECTORS
Molex Connector Repair..................................................A-18
Separating Pin and Socket Housings.......................A-18
Mating Pin and Socket Housings..............................A-18
Removing Terminals.................................................A-18
Installing Terminals...................................................A-18
Crimp Terminal to Lead....................................................A-19
XII TABLE OF CONTENTS
TABLE OF CONTENTS
Prepare Lead............................................................A-19
Prepare Tool..............................................................A-19
Position Terminal in the Punch/Die...........................A-20
Insert Stripped Lead.................................................A-20
Crimp Terminal to Lead.............................................A-20
Inspect Crimp............................................................A-21
A.10 PACKARD 150 METRI-PACK
CONNECTORS
150 Metri-Pack Connector Repair....................................A-22
General.....................................................................A-22
Separating Pin and Socket Housings.......................A-22
Mating Pin and Socket Housings..............................A-22
Removing Socket Terminal.......................................A-22
Inserting Socket Terminal..........................................A-22
A.11 PACKARD 280 METRI-PACK RELAY
AND FUSE BLOCK CONNECTORS
Fuse Block Repair............................................................A-24
Removing Socket Terminals......................................A-24
Installing Socket Terminals........................................A-24
Crimping Terminals...................................................A-24
A.12 PACKARD 480 METRI-PACK
CONNECTORS
480 Metri-Pack Connector Repair....................................A-25
General.....................................................................A-25
Separating Pin and Socket Housings.......................A-25
Mating Pin and Socket Housings..............................A-25
Removing Socket Terminals......................................A-25
Installing Socket Terminals........................................A-25
A.13 PACKARD 630 METRI-PACK
CONNECTORS
630 Metri-Pack Connector Repair....................................A-26
General.....................................................................A-26
Separating Pin and Socket Housings.......................A-26
Mating Pin and Socket Housings..............................A-26
Removing Socket Terminal.......................................A-26
Installing Socket Terminal.........................................A-26
A.14 PACKARD METRI-PACK TERMINALS
Metri-Pack Terminal Crimps.............................................A-27
Matching Terminal To Crimper..................................A-27
Preparing Wire Lead.................................................A-27
Crimping Wire Core..................................................A-27
Crimping Insulation/Seal...........................................A-27
Inspecting Crimps.....................................................A-28
A.15 PACKARD ECM CONNECTOR
Packard 100W Connector Repair.....................................A-29
General.....................................................................A-29
Separating Socket Housing From ECM....................A-29
Mating Socket Housing To ECM...............................A-29
Removing Socket Terminal.......................................A-29
Installing Socket Terminal.........................................A-29
Crimping Terminals...................................................A-29
A.16 PACKARD MICRO-64 CONNECTORS
Packard Micro-64 Connector Repair................................A-31
General.....................................................................A-31
Separating Pin and Socket Housings.......................A-31
Mating Pin and Socket Housings..............................A-31
Removing Terminal...................................................A-31
Installing Terminal.....................................................A-31
Preparing Wire Leads for Crimping...........................A-32
Crimping Terminals...................................................A-32
Inspecting Crimps.....................................................A-32
A.17 SEALED SPLICE CONNECTORS
Sealed Splice Connector Repair......................................A-34
General.....................................................................A-34
Preparing Wire Leads...............................................A-34
Splicing Wire Leads..................................................A-34
Inspecting Seals.......................................................A-34
APPENDIX B WIRING
B.1 WIRING DIAGRAMS
Connector Locations..........................................................B-1
Function/Location.......................................................B-1
Place and Color..........................................................B-1
Connector Number......................................................B-1
Repair Instructions......................................................B-1
Wiring Diagram Information...............................................B-3
Wire Color Codes........................................................B-3
Wiring Diagram Symbols............................................B-3
2008 Buell Wiring Diagrams...............................................B-4
APPENDIX C CONVERSIONS
C.1 LENGTH CONVERSION
Conversion Table................................................................C-1
C.2 FLUID CONVERSION
United States System........................................................C-2
Metric System....................................................................C-2
British Imperial System......................................................C-2
C.3 TORQUE CONVERSION
United States System........................................................C-3
Metric System....................................................................C-3
APPENDIX D HOSE AND WIRE
ROUTING
D.1 APPENDIX D: HOSE AND WIRE
ROUTING
Firebolt...............................................................................D-1
Lightning..........................................................................D-13
Ulysses............................................................................D-25
APPENDIX E ACTIVE INTAKE
(JAPANESE MODELS)
E.1 ACTIVE INTAKE SYSTEM (JAPANESE
MODELS ONLY)
General..............................................................................E-1
TABLE OF CONTENTS XIII
TABLE OF CONTENTS
Active Intake System..................................................E-1
Diagnostic Notes.........................................................E-1
Verify Settings....................................................................E-1
WOT Check........................................................................E-1
Cable..................................................................................E-1
Adjustment..................................................................E-1
Throttle Stop Screw....................................................E-3
Removal.............................................................................E-4
Installation..........................................................................E-5
APPENDIX F GLOSSARY
F.1 GLOSSARY
Acronyms and Abbreviations..............................................F-1
REFERENCE MATERIAL
TOOLS...........................................................I
TORQUE VALUES......................................VII
INDEX....................................................XXVII
XIV TABLE OF CONTENTS
TABLE OF CONTENTS
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