Buell 2007 FIREBOLT User manual

2007 BUELL FIREBOLT MODELS

SERVICE MANUAL

Part Number 99493-07Y

Section 1: Maintenance

Section 2: Chassis

Section 3: Engine

Section 4: Fuel System

Section 5: Starter

Section 6: Drive/Transmission

Section 7: Electrical

Appendices

2007 Buell Firebolt: Appendix A A-1

HOME

APPENDIX A–TOOLS A.1

Part No. HD-25070 Robinair Heat Gun

(Use with HD-41183)

Part No. HD-26792 Spark Tester

Part No. HD-28431-B Black Light Fluorescent Additive

(Use with HD-)

HD-25070

HD-26792

HD-28431-6 Fluorescent Additive 6 1-oz. bottles

HD-28431-22 Fluorescent Additive 1 22-oz. container

HD-28431B

Part No. HD-33223-1 Cylinder Compression Gauges

Part No. HD-33416 Universal Driver Handle

Part No. HD-33418 Universal Puller Forcing Screw

h33223

HD33416

h33418

A-2 2007 Buell Firebolt: Appendix A

HOME

Part No. HD-33446A Cylinder Torque Plates

and Torque Plate Bolts Part No. HD-33446-86

Part No. HD-34623C Piston Pin

Retaining Ring Installer/Remover

Part No. HD34736-B Valve Spring Compressor

Part No. HD-34751 Nylon Valve Guide Brush

h33446

b1001a3x

h34726B

h34751

Part No.HD-34902-B Mainshaft Primary Bearing Race

Remover And Installer

Part No. HD-35102 Wrist Pin Bushing Hone (20 mm)

Part No. HD-35316-C Main Drive Gear Remover/Installer

and Main Drive Gear Bearing Installer

Part No. HD-35457 Black

Light Leak Detector

h34902b

h35102

HD-35316C

h35457

2007 Buell Firebolt: Appendix A A-3

HOME

Part No. HD-35518 Internal/External

Retaining Ring Pliers

Part No. HD-35667A Cylinder Leakdown Tester

Part No. HD-35758-B Neway Valve Seat Cutter Set

Part No. HD-38125-6 Packard Terminal Crimp Tool

(Sealed)

HD-35518

CYLINDER LEAKDOWN TESTER

JHYUY

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Foihjolm oijfollkop Yuooifoihfm

knsdl hlno hslnslnnsdl hlno

bs npond bpdk kznh

odlbndpob npond bndb n

CYLINDER LEAKDOWN TESTER

Bdhgkjsbkdv ' ksjjlkn lk

knsdl hlno hslnsln nlslns finbp pffb

odlbndpob nponno[bho

knsdl hlno hslnsln nlslns finbp pffb

odlbndpob npdb ndbno[bho

knsdl hlno hslnslnnsdl hlno hso[bho

knsdl hlno hslnslp pffb

odlbndpob npond bndb ndbno[bho

Bdhgkjsbkdv ' ksjjlkn lk

knsdl hlno hslnsln nlslns finbp pffb

odlbndpob nponno[bho

knsdl hlno hslnsln nlslns finbp pklhb

odlbndpob npdb ndbno[bho

knsdl hlno hslnslnnsdl hlno hso[bho

bs npond bpdk kznh

odlbndpob npond bndb ndbno[bho

Bdhgkjsbkdv ' ksjjlkn lk

knsdl hlno hslnsln nlslns finbp pffb

odlbndpob nponno[bho

knsdl hlno hslnsln nlslns finbp pklhb

Bdhgkjsbkdv Majjlkn Nolk

knsdl hlno hslnsln

ndpob npond

Bdhgkjsbkdv hlno hslnslp

knsdl hlno hslnsln

ndpob npond

HD35567

HD-35758

HD-38125-6

Part No. HD-38125-7 Packard Terminal Crimp Tool

(Nonsealed)

Part No. HD-38125-8 Packard Terminal Crimp Tool

Part No. HD-38515-A Clutch Spring Compressor

Part No. HD-39302 Steering Head Bearing Race Installer

(Used with B-45521)

HD-38125-7

HD38125-8

h38515A

h39302

A-4 2007 Buell Firebolt: Appendix A

HOME

Part No. HD-39565 Engine Sound Probe

Part No. HD-39617 Fluke AC/DC Current Problem

Part No. HD-39782-A Cylinder Head Support Stand

Part No. HD-39786 Cylinder Head Holding Fixture

HD-39565

HD39617

h39782

h39786

Part No. HD-39964 Reamer Lubricant (Cool Tool)

Part No. HD-39965 Deutsch Terminal Crimp Tool

Part No. HD-39969 Ultra-Torch UT-100

Part No. HD-39978 Fluke 78 Multimeter (DVOM)F

HD39964

HD39965

HD-39969

HD39978

2007 Buell Firebolt: Appendix A A-5

HOME

Part No. HD-41025-A Tool Board System

Part No. HD-41137 Two-Way Hose Clamp Pliers

Part No. HD-41155 VHS Tape Storage Rack

Part No. HD-41177 Fork Tube Holder

HD-41025-A

HD-41137

HD41155-2

b41177-94

Part No. HD-41185 Hose Cutting Tool

Part No. HD-41334 RPM Inductive Pickup

Part No. HD-41354 Speedometer Tester

Part No. HD-41404 Harness Connector Test Kit

HD-41185

HD39617

h41354

HD41404

A-6 2007 Buell Firebolt: Appendix A

HOME

Part No. HD-41417 Propane Enrichment Kit

Part No. HD-41475 Deutsch Terminal Repair Kit

Part No. HD-41475-100 Deutsch Connector Pick Tool

Part No. HD-41496 Main Drive Gear Seal Installer

HD-41417

h41475

h41475-100

HD41496

Part No. HD-41609 Amp Multi-Lock Crimper

Part No. B-41623-B Oil Line Remover

Part No. HD-41675 Oil Pressure Sending Unit Wrench

Part No. HD-42310 Engine Transmission Stand

HD39965

B41623

HD41675

h42310a

2007 Buell Firebolt: Appendix A A-7

HOME

Part No. HD-42310-150 Engine Stand Drip Tray

Part No. HD-42311 Oil Filter Wrench

Part No. HD-42320-A Piston Pin Extractor

Part No. HD-42322 Piston Support Plate

h42310-150a

h42311a

h42320a

h42322

Part No. HD-42326-A Crankshaft Guide

Part No. HD-42376 Battery Load Tester

Part No. B-42887 Brake Caliper Piston Remover

Part No HD-43646-A Rolling Engine Stand

h42326

600 200

Made in USA

PP-9606- 0001

h42376a

b42887

h43646a

A-8 2007 Buell Firebolt: Appendix A

HOME

Part No. HD-43646-10 Oil Drip Tray

Part No. B-43721 Front Fork Seal Driver

Part No. B43982 Transmission Locking Tool

Part No. HD-43984 Crankshaft Locking Tool

h43682-10a

b43721

b-43982

hd43984

Part No. B-43987 Engine Cradle

Part No. B-43993 Wheel Bearing Collets

Part No. HD-44060 Wheel Bearing Remover/Installer

Part No. HD-44067-A Oil Filter Wrench

b43987a

B-43993a

hd44060

hd44067b

2007 Buell Firebolt: Appendix A A-9

HOME

Part No. HD--44358 Flywheel Support Fixture

Part No. HD-44567 7" Universal Driver Handle

Part No HD-44687 Ignition Coil Test Adapter

Part No. HD-44720 TSSM Adapter Cable

h44358bc

h44567

h44687

HD44720a

Part No. HD-44750-P29 Panasonic Toughbook

(touch screen) and HD-44750-P50 Panasonic Toughbook

(non-touch screen)

Part No.B-45520 Gear Detente Assembly Aid

Part No. B-45521 Steering Head Bearing

Remover/Installer

Part No. B-45522 Fuel Pressure Gauge Adapter

HD-44750

b45520

b45521

B-45522a

A-10 2007 Buell Firebolt: Appendix A

HOME

Part No. B-45523 Valve Guide Reamer (7mm)

Part No. B-45524 Valve Guide Installer

Part No. B-45525 Valve Guide Hone

Part No. B-45657 Fuel Pump Puller

B-45523

B-45524

B-45525

b45657

Part No. B-45676 Sprocket Shaft Seal Installer

Part No. HD-45830 Techlink Kit

Part No. HD-45835 Road Test Kit

Part No. B-45847 Cross Plate

B-45676

hd45830a

HD45835a

B43983

2007 Buell Firebolt: Appendix A A-11

HOME

Part No. HD-45907 4" Universal Driver Handle

Part No. B-45926 Clutch Shell Bearing Remover

Part No. HD-45928 Terminal Crimper

Part No. HD-45929 Terminal Remover

h45907

b45926

HD45928

HD4529

Part No. HD-45966 Front Fork Compressor

Part No. B-46279 7/8" Axle Wrench (Hex)

Part No. HD-46283 Primary Drive Locking Tool

Part No.HD-46285 Transmission Assembly Fixture

HD45996a

B-46279

HD-46283

HD-46285

A-12 2007 Buell Firebolt: Appendix A

HOME

Part No. HD-46288 Mainshaft Locknut Wrench

Part No. HD-47183 Leak Detector Penlight

Part No. HD-47184 Leak Detector Flashlight

Part No. HD-47187 Technician Pen Light

HD-46288

HD-47183

HD-47184

HD-47187

Part No. HD-47188 Technician Flex Light

Part No. HD-47248 Rocker Housing Wrench

Part No. HD-47250 Intake Manifold Wrench

Part No. HD-47258 Rocker Cover Wrench

HD-41788

HD-47248

HD-47250

HD-47258

2007 Buell Firebolt: Appendix A A-13

HOME

Part No. HD-47855 Main Drive Gear

Needle Bearing Installer

Part No. HD-48030 Fuel Injector Fitting and Canister

Cleaner Kit

Part No. HD-48053 Advanced Battery Conductance

and Electrical System Analyzer

Part No. J-5586 Transmission Shaft

Retaining Ring Pliers

HD-47855

HD-48030a

HD-48053A

J-5586A

Part No. B-59000-B Oil Level Gauge

Part No. HD-94660-37B Mainshaft Locknut Wrench

Part No. HD-94804-57 Rocker Arm Bushing Reamer

Part No. HD-95635-46 All-Purpose Claw Puller

(use with HD-95637-46A)

0

1

2

3

4

5

6

0

m

L

HD59000B

HD-94660-37B

h94804-57

HD-95635-46

A-14 2007 Buell Firebolt: Appendix A

HOME

Part No. HD-95637-46A Wedge Attachment of Claw Puller

(use with HD-95635-46)

Part No. HD-95760-69A Bushing/Bearing Puller Tool Set.

Set includes items 1-5 and 9. Items 6 (HD-95769-69), 7

(HD-95770-69) and 8 (HD-95771-69) are optional.

Part No. HD-95952-33C Connecting Rod Clamping Tool

Part No. HD-95970-32D Piston Pin Bushing Tool

h95637-46A

h95760-69B

h95952-33C

h95920-32D

Part No. HD-96333-51E Piston Ring Compressing Tool

Part No. HD-96550-36B Valve Lapping Tool

Part No. HD-96796 Valve Spring Test Fixture

Part No. HD-96921-52B

h96333-51C

h96550-36A

96796-47

h96921-52C

2007 Buell Firebolt: Appendix A A-15

HOME

Part No. HD97097-65B Hose Clamp Pliers

Part No. HD-99500-80 Wheel Truing & Balancing Stand

h97081a

HD99500-80a

A-16 2007 Buell Firebolt: Appendix A

HOME

NOTES

2007 Buell Firebolt: Appendix B B-1

HOME

AMP MULTILOCK ELECTRICAL CONNECTORS B.1

REMOVING SOCKET/PIN

TERMINALS

1. Remove connector from the retaining device, either

attachment or rosebud clip.

2. Depress the button on the socket terminal side of the

connector (plug) and pull apart the pin and socket

halves.

3. Bend back the latch slightly and free one side of second-

ary lock, then repeat the step to release the other side.

Rotate the secondary lock outward on hinge to access

terminals in chambers of connector housing.

4. Looking in the terminal side of the connector (opposite

the secondary lock), take note of the cavity next to each

terminal.

5. See Figure B-1. With the ﬂat edge against the terminal,

insert the pick tool (Snap-On TT600-3) into the cavity

until it stops. Pivot the end of the pick away from the ter-

minal (locktab is inside housing) and gently tug on wire to

pull terminal from chamber. Do not tug on the wire until

the tang is released or the terminal will be difﬁcult to

remove. A “click” is heard if the tang is engaged but then

inadvertently released. Repeat the step without releasing

the tang.

NOTES

●

If pick tool is not available, a push pin/safety pin may be

used instead.

●

An ELECTRICAL TERMINAL CRIMP TOOL (Part No.

HD-41609) is used to install Amp Multi lock pin and

socket terminals on wires. If new terminals must be

installed, see Crimping Instructions on the next page.

INSTALLING SOCKET/PIN

TERMINALS

NOTE

For wire location purposes, numbers are stamped into the

secondary locks of both the socket and pin housings. See

Figure B-2.

1. From the secondary lock side of the connector, insert the

terminal into its respective numbered chamber until it

snaps in place. For proper ﬁt, the slot in the terminal

must face the tang in the chamber.

Figure B-1. 10-Place Amp Multilock Connector

d0242x3x

Secondary lock open

Pin housing

Latch

Pin terminal

Socket housing

Secondary lock open

Socket terminal

Button

Latch

B-2 2007 Buell Firebolt: Appendix B

HOME

NOTES

●

See Figure B-3. The tang in the chamber engages the

slot to lock the terminal in position.

●

On the pin side of the connector, tangs are positioned at

the bottom of each chamber, so the slot in the pin termi-

nal (on the side opposite the crimp tails) must face down-

ward.

●

On the socket side, tangs are at the top of each chamber,

so the socket terminal slot (on the same side as the

crimp tails) must face upward.

●

Up and down can be determined by the position of the

release button (used to separate the pin and socket

halves). Consider the button to always be on top of the

connector.

2. Gently tug on wire end to verify that the terminal is

locked in place and will not back out of chamber.

3. Rotate the hinged secondary lock inward until tabs fully

engage latches on both sides of connector.

4. Insert the socket housing (plug) into the pin housing

(receptacle) until it snaps in place.

5. Install connector on retaining device, either attachment

or rosebud clip.

Figure B-2. Release Tang and Back Out Terminals

2

1

3

4

1

2

3

Pin terminal

Socket terminal

Secondary lock open

Pick tool

Pin housing

Socket housing

1. Open secondary lock.

2. Insert pick into cavity on inboard side

of connector.

3. Pivot end of pick to release tang.

4. Gently tug on wire to remove terminal

from housing.

d0243x8x

Figure B-3. Multilock Connector Cutaway View

Pin housing

Tang

Socket housing

Tang

d0244x8x

Button

2007 Buell Firebolt: Appendix B B-3

HOME

Figure B-4. 3-Place and 6-Place Amp Multilock Connectors

– AMP

123

– AMP

123456

56 78 910

43 21

Socket terminal

Secondary lock

Socket housing

Pin housing

Pin terminal

Latch

Secondary lock

Button

Latch

Socket terminal

Secondary lock

Button

Socket housing

Pin housing

Secondary lock

Pin terminal

3-place 6-place 12-place

Secondary locks open (socket housings shown)

Stamped numbers on secondary locks indicate wire color locations

d0245x2x

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Buell 2007 FIREBOLT, Firebolt Series User manual

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