Buell Xb9 Service Manual - [Unlimited EBooks]

Buell Xb9 Service Manual - [Unlimited EBooks]

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Buell Xb9 Service Manual - [Unlimited EBooks]

Most other service manuals and specs are very similar for all Buell XB series motorcycles and model years. Performance can change with the addition of Buell aftermarket parts. NOTE: The website has been slow lately, so I have deactivated the links to the PDF downloads temporarily in an attempt to identify if they are causing the forum to slow down. Even if this is the case, I will host the service manuals somewhere else and re-activate the links. Thank you for your patience. Shop performance motorcycle parts. B-41174 Rear Wheel Support Stand and Part No. B-41174-2 Replacement Pad Part No. B-42887 Brake Caliper Piston Remover Part No. B-43721 Front Fork Seal Driver Part No. HD-33418 Universal Puller Forcing Screw Part No. HD-45966 Fork Spring Compressing Tool Part No. HD-94700-52C Shock Spanner Preload Adjustment Tool Part No. HD-28700 Tire Bead Expander Part No.B-45524 Valve Guide Installer Part No. HD-39782 Cylinder Head Support Part No. B-45523 Valve Guide Reamer (7mm) Part No. HD-39786 Cylinder Head Holding Fixture Part No. B-45525 Valve Guide Hone Part No. HD-96333-51C Piston Ring Compressor Part No. HD-33446A Cylinder Torque Plates Part No. HD-95952-33B Connecting Rod and Torque Plate Bolts Part No. HD-33446-86 Clamping Tool Part No. HD-34623C Piston Pin Part No.HD-38515-A Clutch Spring Compressing Tool and Part No. Insert the socket housing (plug) into the pin housing (receptacle) until it snaps in place. Install connector on retaining device, either attachment or rosebud clip. 2004 Buell Lightning: Appendix B. Raise locking bar and remove contact.Wire seal Internal seal 11. Pin terminal Locking wedge Figure B-13. 2-Pin, 3-pin and 4-pin Deutsch Connectors 2004 Buell Lightning: Appendix B. Push on wire end of lead to remove terminal. Pivot end of pin to depress tang. Raise tang and re-install terminal. Figure B-14. Packard Connectors B-10 2004 Buell Lightning: Appendix B. If new terminals must be installed, see Crimping Instructions.

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2004 Buell Lightning: Appendix B B-11. NOTE A series of Packard Electrical Terminal Crimp Tools are avail- able to install Packard pin and socket terminals on wires. If new terminals must be installed, see Crimping Instructions. B-12 2004 Buell Lightning: Appendix B. Distortion should be minimal. Insulation Insulation crimp Core crimp Figure B-16.The following table provides a brief description of the connec- tors found on the Buell Lightning. Table B-2. Electrical Connector and Location Table CONNECTOR COMPONENT(S) DESCRIPTION LOCATION. Always clean around lines or covers before they are removed. Headlamp, passing lamp, tail lamp, brake lamp and turn Plug, tape or cap holes and openings to keep out dirt, dust signal operation. and debris. 2004 Buell Lightning: Maintenance. Part Replacement Bearings do not usually need to be removed. Only remove bearings if necessary. Always replace worn or damaged parts with new parts. 2004 Buell Lightning: Maintenance. Don’t pull on a tool cabinet; push it in front of you. Set the brakes on the locking casters after the cabinet has been rolled to your work. 2004 Buell Lightning: Maintenance. If the Buell motorcycles were designed to give the best perfor- engine is used for short runs, change the oil even more fre- mance using unleaded gasoline. Some fuel suppliers sell quently. R- Replace or change. A- Adjust. L- Lubricate with specified lubricant. T- Tighten to proper X- Perform. torque. 2004 Buell Lightning: Maintenance. Applying Harley Gloss or Har- color body panels that are standard on your Buell motorcycle.Check the voltage of the battery to verify batteries. CAUTION Overtightening fasteners can damage battery terminals. 1-10 2004 Buell Lightning: Maintenance. Tighten rear caliper bleeder valves (metric) to 36-60 in- lbs (4-7 Nm).Bottom of master cylinder Rod adjuster Locknut Clevis Clevis pin Figure 1-12. Rear Brake Pedal Pushrod Adjustment 1-18 2004 Buell Lightning: Maintenance. Check rotor surface.

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Replace if warped or badly scored. 2.5 FRONT WHEEL 2.6 REAR WHEEL for proce- dure. Figure 1-14. Front Brake Rotor 2004 Buell Lightning: Maintenance 1-19. Rear caliper mounting fasteners Retainer, Rear caliper pin plug Rear caliper hanger pin Figure 1-16. Rear Brake Caliper 6487 Figure 1-17. Rear Brake Pad Spring 2004 Buell Lightning: Maintenance 1-21. Clutch diaphragm spring Clutch adjusting screw Primary cover Correct chaincase lubricant level Figure 1-21. Fluid Level 2004 Buell Lightning: Maintenance 1-23. Adjuster Figure 1-22. Clutch Cable Adjuster Mechanism NOTE Spring installs on outboard side of hex lockplate. 8405 Diaphragm spring Lockplate Adjusting screw Figure 1-23. Clutch Adjustment 1-24 2004 Buell Lightning: Maintenance. Adjusting Clutch Free Play gasket using three fasteners and washers and tighten to 84-108 in-lbs (10-12 Nm). Check clutch cable free play. See Step 6 above. 2004 Buell Lightning: Maintenance 1-25. Clean the drive belt with a mild soap and water spray solution as required. Dry thoroughly. Do not immerse belt in solution. 1-26 2004 Buell Lightning: Maintenance. Tighten fasteners to 40-60 in-lbs ENGINE (5-7 Nm).Counterclockwise (outward) to increase free play. Tighten locknut (1) to 20-25 ft-lbs (27-34 Nm). Locknut Adjusting Fastener Figure 1-28. Chain Tension Adjusting Fastener 1-30 2004 Buell Lightning: Maintenance. Front Fork Compression Damping Adjuster clockwise until it stops. This is the maximum compression damping setting. Then turn the dial counterclockwise the recommended amount specified in Table 1-9. Table 1-10. 1-32 2004 Buell Lightning: Maintenance. This is the maximum rebound damping setting.Install seat. Figure 1-33. Rear Shock Compression Adjustment 1-34 2004 Buell Lightning: Maintenance. A plug with a white, yellow, tan or rusty brown pow- dery deposit indicates balanced combustion. Clean off spark plug deposits at regular intervals. 1-36 2004 Buell Lightning: Maintenance. Figure 1-40.

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Make sure two crankcase breather hoses (1) and intake air sensor (2) are captured in base- plate behind velocity stack (3). 1-38 2004 Buell Lightning: Maintenance. Install seat. See 2.41 SEAT. 2004 Buell Lightning: Maintenance 1-39. Recheck operation of throttle control. Recheck engine slow idle speed; adjust if required. 10. Install airbox, baseplate and intake cover assembly. See 4.30 AIRBOX. 1-40 2004 Buell Lightning: Maintenance. If you do not see the mark, verify previous cable adjust- obtain a permanent marker. ment. 2004 Buell Lightning: Maintenance 1-41. Recheck timing. Figure 1-48. Timer Cover 8391 Figure 1-49. Cam Position Sensor b0964x1x Figure 1-50. Advanced Timing b0963x1x Figure 1-51. Retard Timing 1-44 2004 Buell Lightning: Maintenance. Figure 1-53. Headlamp Switch Adjust headlamp alignment. See ADJUSTMENT section. 2004 Buell Lightning: Maintenance 1-45. Once headlights are aligned, tighten fasteners to 48-72 in-lbs (5-8 Nm). 9950 Figure 1-54. Horizontal Headlamp Adjustment 9951 Figure 1-55. Vertical Headlamp Adjustment 1-46 2004 Buell Lightning: Maintenance. Select Buell TPS zero tab. Select TP volts on screen. Figure 1-56. Back off idle adjustment until TP volts stop decreasing and then continue to back out one full turn. If motorcycle is to be covered, use a material that will breathe, such as light canvas. Plastic materials that do not breathe promote the formation of condensation. 1-48 2004 Buell Lightning: Maintenance. Poor Fuel Economy Internal engine problem. Oxygen sensor damaged or malfunctioning (bike running Wheels not balanced correctly. rich). See dealer. 1-50 2004 Buell Lightning: Maintenance. Non-standard equipment on the front end (such as heavy radio receivers, extra lighting equipment or luggage) tends to cause unstable handling. 2004 Buell Lightning: Maintenance 1-51. A good suspension is a balance between damping and track condition. Finding this balance requires exploring all possible compression settings. Lack of tire feedback.

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Increase compression damping. Tire slides. Decrease compression damping. 1-52 2004 Buell Lightning: Maintenance. At the same time, inspect tire tread for punctures, cuts, breaks and other damage. Repeat the inspection before long trips. 2004 Buell Lightning: Chassis. Speed should not exceed 50 mph (80 tire failure.Remove wheel. Figure 2-6. Front Wheel Removal 2004 Buell Lightning: Chassis. Place the bridge (1) against the wheel hub. Hold the forcing screw (2), and turn the nut (3) clockwise until the bearing is free of the hub. 2004 Buell Lightning: Chassis. Never replace just one brake pad. Fail- ure to install brake pads as a set could result in death or serious injury. Inspect brake rotor and pads. See 1.7 BRAKE SYSTEM MAINTENANCE. 2-10 2004 Buell Lightning: Chassis. INSTALLER (Part No. B-43993-9) and forcing screw. 2004 Buell Lightning: Chassis 2-11. B-43993-10) and forcing screw. 16. Install the wheel. See INSTALLATION under 2.5 FRONT Forcing screw WHEEL. Spacer Figure 2-16. Install the Spacer 10. See Figure 2-16. Install the spacer. 2-12 2004 Buell Lightning: Chassis. Failure to comply may affect braking ability and Align reference dot on front rotor with the valve stem.Front Wheel Mounting 2-14 2004 Buell Lightning: Chassis. See IDLER PULLEY REMOVAL 6.6 DRIVE BELT SYSTEM. Remove rear axle. 6.6 DRIVE BELT SYSTEM for proper handling. Slide drive belt out of the way and remove rear wheel. 2004 Buell Lightning: Chassis 2-15. Rear Wheel Assembly 2-16 2004 Buell Lightning: Chassis. INSTALLATION Center rear wheel in the swingarm at the same time slid- ing the drive belt onto the rear sprocket. With wheel centered in swingarm, lower bike to align swingarm and wheel hub. 2004 Buell Lightning: Chassis 2-17. Checking Cast Rim Radial Runout Using Wheel Truing and Balancing Stand (HD-99500-80) 2004 Buell Lightning: Chassis 2-19. Dunlop front and rear tires for Buell motorcycles are not the same. They are not interchangeable. Use Figure 2-30.

Loosening Beads from Rim Flange front tire ONLY for a front tire. It may be neces- sary to use a TIRE BEAD EXPANDER (Part No. HD- 28700) on the tire until beads seal on rim. 2004 Buell Lightning: Chassis 2-21. Checking Tire Radial Runout Table 2-10. Tire Runout RUNOUT Tire radial 0.060 1.52 Tire lateral 0.080 2.03 2-22 2004 Buell Lightning: Chassis. Install clevis pin (2). Rear master cylinder body Install new cotter pin (7). Clevis pin Pedal bushings (2) Shift brake pedal sleeve Brake pedal fastener Brake pedal Cotter pin Figure 2-36. Brake Pedal Assembly 2-24 2004 Buell Lightning: Chassis. Brake switch fastener 11. Brake switch 12. Brake switch terminal 13. Banjo bolt (metric) 14. Brake line 15. Copper washers 16. Pivot bolt Figure 2-37. Front Brake Hand Lever Assembly 2004 Buell Lightning: Chassis 2-25. Piston Assembly in Master Cylinder Figure 2-38. Depress piston assembly (1) and remove internal circlip (2) and discard. Figure 2-37. Remove piston assembly (6) from front master cylinder reservoir (4) and discard. 2-26 2004 Buell Lightning: Chassis. Assemble new piston components placing small end of spring (5) behind primary seal of piston (4). Lubricate master cylinder body and piston seals with special lubricant found in the service parts kit. 2004 Buell Lightning: Chassis 2-27. Replace the brake line if any damage is noted. P-clamp Brake line Wire form Bleeder valve Banjo bolt Figure 2-42. Front Brake Line 2004 Buell Lightning: Chassis 2-29. Slide caliper down the rotor to clear fork lower and then remove off rotor. Figure 2-46. Removing Pistons (B-42887) 2004 Buell Lightning: Chassis 2-31. Install pistons (5) in each piston bore. Install new o-rings (8) between caliper halves. Clamp caliper together with caliper fasteners (11) and tighten to 15-19 ft-lbs (20-26 Nm). 2-32 2004 Buell Lightning: Chassis. Brake pads 11. Caliper fasteners Figure 2-47. Front Caliper Assembly 2004 Buell Lightning: Chassis 2-33.

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Prevent damage to seating surfaces by carefully removing brake line components. Figure 2-49. Rear Master Cylinder On Vehicle Figure 2-49. Remove brake reservoir hose at master cylinder. Remove seat. See 2.41 SEAT. 2-34 2004 Buell Lightning: Chassis. Cotter pin (1) from frame if necessary. 11. Rear master cylinder mount screw Figure 2-51. Rear Master Cylinder Assembly 2004 Buell Lightning: Chassis 2-35. If the circlip is not properly installed, improper brake operation could result in death or serious injury. Tuck rubber boot on rod assembly (3) into master cylin- der body (1). 2-36 2004 Buell Lightning: Chassis. To prevent death or serious HEEL GUARD AND MOUNT.Tighten bleeder valve to 36-60 in-lbs (4-7 Nm). Discard copper washer. Remove brake line from motorcycle. 2-38 2004 Buell Lightning: Chassis. Remove piston (3) using BRAKE CALI- PER PISTON REMOVER (1) (Part No. B-42887) with adaptor (2). Remove two o-rings from groove in caliper bore and dis- card. 2-40 2004 Buell Lightning: Chassis. Replace both pads as a set if the friction material of either pad is worn to 0.04 in. (1.0 mm) or less. 2004 Buell Lightning: Chassis 2-41. CAUTION Turn ignition key switch to ON. Upper and Lower Fork Clamp Assembly Figure 2-62. Loosen upper and lower fork clamp pinch fasteners (1, 4). 2004 Buell Lightning: Chassis 2-43. Remove snap ring (2). Figure 2-66. Removing Fork Cap From Outer Tube Figure 2-66. Remove fork cap from outer tube. 2-44 2004 Buell Lightning: Chassis. Remove preload washer (4) and slider piston (5). Figure 2-67. Expand fork and remove from FORK SPRING COMPRESSION TOOL. 2004 Buell Lightning: Chassis 2-45. Spring joint 26. Dust seal Rebound adjuster assembly 18. Outer tube 27. Slider fork Figure 2-69. Front Fork Assembly 2-46 2004 Buell Lightning: Chassis. Holding the damper locknut (10), unscrew the rebound adjuster assembly (9) and remove from damper rod assembly (11). Remove damper locknut (10) from damper rod assembly (11). 2004 Buell Lightning: Chassis 2-47.

Replace the sealing washer (13) and center bolt (14) 30 ft-lbs (30-40 Nm). (metric). Tighten the center bolt to 22-30 ft-lbs (30- Repeat for other fork assembly. 40 Nm). 2-48 2004 Buell Lightning: Chassis. Apply fork oil or light grease to o-rings on preload adjuster and install preload adjuster (3). Figure 2-73. Measuring Fork Oil Level 23. Install snap ring (2). 2004 Buell Lightning: Chassis 2-49. Steering Stem Assembly 2004 Buell Lightning: Chassis 2-51. Tighten steering stem capnut to 38-42 ft-lbs (52-57 Nm). Install steering stem pinch bolt applying LOCTITE 272 and tightening to 17-19 ft-lbs (23-26 Nm). 2-52 2004 Buell Lightning: Chassis. HD- Figure 2-78. Steering Head Bearing Lip 2004 Buell Lightning: Chassis 2-53. Forcing screw Steering Head Bearing Installation Tool (B-45521) Lower bearing Bearing Washer Figure 2-79. Lower Bearing 2-54 2004 Buell Lightning: Chassis. Remove swingarm brace (12).Belt Guard Assembly 2004 Buell Lightning: Chassis 2-55. Figure 2-83. Remove oil drain plug (8) and drain oil from swingarm. See Draining Oil 1.6 ENGINE LUBRI- CATION SYSTEM. Remove rear wheel. See 2.6 REAR WHEEL. 2-56 2004 Buell Lightning: Chassis. The complete bearing assembly must be replaced as a unit when replacement is necessary. Do not intermix bearing components. 2004 Buell Lightning: Chassis 2-57. Right side passenger footpeg mount. Tighten to 15- 18 ft-lbs (20-24 Nm). Right side rider footpeg mount. Tighten to 108- 132 in-lbs (12-15 Nm). Heel guard. Remove rear wheel support stand. 2-58 2004 Buell Lightning: Chassis. VICE to access the rear isolator. 2004 Buell Lightning: Chassis 2-59. Install tail frame. See 2.37 LEFT TAIL SECTION AND BATTERY PAN. Install exhaust header. See 2.29 EXHAUST SYSTEM. Rotate engine. See 3.3 ENGINE ROTATION FOR SER- VICE. 2-60 2004 Buell Lightning: Chassis. Lower shock mount Washers (2) 11. Shock spring retainer kit Lower shock mount sleeve 12. Rear shock spring Figure 2-89.

Rear Shock Absorber Assembly 2004 Buell Lightning: Chassis 2-61. Tighten to 25-33 in-lbs (3-4 Nm). Adjust cables. See 1.16 THROTTLE CABLE AND IDLE SPEED ADJUSTMENT. Install airbox assembly. See 4.30 AIRBOX. 2004 Buell Lightning: Chassis 2-63. Connect clutch cable ferrule (9) to hand lever clamp (2). Install cable strap attaching wiring harness to left handle- bar. Do not over tighten cable strap. Adjust clutch cable. See CLUTCH. 2-64 2004 Buell Lightning: Chassis. Left and right front modules Figure 2-95. Headlight Assembly and Support Bracket 2004 Buell Lightning: Chassis 2-65. Boot (2) b1147x2x Bulb holder (2) Bulb (2) Headlight housing Wiring harness Position bulb socket (used for HDI only) b1150x2x Figure 2-96. Headlight Assembly 2-66 2004 Buell Lightning: Chassis. Left and right front modules Figure 2-97. Headlight Assembly and Support Bracket 2004 Buell Lightning: Chassis 2-67. Fairing Support Bracket Assembly 2004 Buell Lightning: Chassis 2-69. Tighten both front screws to 10-12 ft-lbs (14-16 Nm). Then tighten both rear screws (2) 10-12 ft-lbs (14-16 Nm). 2-70 2004 Buell Lightning: Chassis. Handlebar Assembly 2004 Buell Lightning: Chassis 2-71. NOTE Before tightening adjuster nut, position mirrors for rider. Install mirror (1) and tighten adjuster to 115-130 in-lbs (13-14.7 Nm). b1154x2x 9990 Mirror Adjuster nut Mount Bracket Figure 2-101. Mirrors and Mounting Hardware 2-72 2004 Buell Lightning: Chassis. Remove exhaust ring (4), retaining ring (5) and port gas- ket (6). 2004 Buell Lightning: Chassis 2-73. Rider Footpeg, Mount and Heel Guard Assembly 2-76 2004 Buell Lightning: Chassis. Heel guard fasteners b0933a2x Heel guard Footpeg mount Spring Ball Detent plate Clip Footpeg 10. Footpeg mount fastener 11. Jam nut Figure 2-105. Passenger Footpeg, Mount and Heel Guard Assembly 2004 Buell Lightning: Chassis 2-77. Figure 2-106. Chin Fairing Assembly, Right Rear Fasteners Install chin fairing. See 2.34 CHIN FAIRING.

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b0943a2x Long fastener and washer Cover Short fastener and washer (2) Figure 2-107. Sprocket Cover 2-78 2004 Buell Lightning: Chassis. Install rear fender (3) with fasteners and washers (4). Tighten to 12-15 in-lbs (1-1.7 Nm). Front fender Front fender fastener Rear fender Rear fender fastener Figure 2-108. Front and Rear Fender 2004 Buell Lightning: Chassis 2-79. Remove swingarm brace by removing fasteners. See 2.19 SWINGARM AND BRACE. Remove upper belt guard (1) by removing fasteners from swingarm brace. 2-80 2004 Buell Lightning: Chassis. Belt Guard Assembly 2004 Buell Lightning: Chassis 2-81. Chin Fairing Assembly teners. Align center section (1) and install with center section fasteners and washers (2). Use LOCTITE 272 (red) on all fasteners tightening to 36-48 in-lbs (4-5 Nm). 2-82 2004 Buell Lightning: Chassis. Install seat. See 2.41 SEAT. 2004 Buell Lightning: Chassis 2-83. RAM Air Scoop, Engine Shroud, Oil Cooler 2-84 2004 Buell Lightning: Chassis. Because the surface is not bare polished aluminum, it must be cleaned using only mild soap and warm water. After washing, always dry the surface using a clean, soft cloth. 2004 Buell Lightning: Chassis 2-85. Left rear and right rear tail section fasteners (4) Fuse block and relay center Figure 2-113. Main Harness and Electrical Connectors Under Seat 2-86 2004 Buell Lightning: Chassis. Trunk pan assembly 12. Rear trunk pan fastener to center tail section (2) 13. Rear shock reservoir bracket 14. Plastic lugs (for manufacturing purposes only) Figure 2-114. Tail Frame and Trunk Pan Assembly 2-88 2004 Buell Lightning: Chassis. Install seat. See 2.41 SEAT. 2004 Buell Lightning: Chassis 2-89. Install seat. See 2.41 SEAT. 2-90 2004 Buell Lightning: Chassis. Right Side Frame Section 2004 Buell Lightning: Chassis 2-91. Remove windscreen (4).Front Windscreen 2-92 2004 Buell Lightning: Chassis. Seat and Attachment 2004 Buell Lightning: Chassis 2-93. Install seat. See 2.41 SEAT. 2-94 2004 Buell Lightning: Chassis.

Latch bracket 11. Trunk pan 2004 Buell Lightning: Chassis 2-95. Remove sidestand leg (1). Retract sidestand leg. Remove sidestand spring (8) and spring extension plate (4) using SNAP-ON SPRING TOOL (Part No. HE-52B). Remove sidestand pivot bolt (5). Extend sidestand leg and remove. 2-96 2004 Buell Lightning: Chassis. Threaded Area for Loctite Application 2004 Buell Lightning: Chassis 2-97. Your panied by blue-gray exhaust smoke and low engine compres- motorcycle will run normally using this type of gas. Buell sion, it indicates the piston rings need replacing. Low recommends you use it when possible, as an aid to compression by itself, however, may indicate improperly cleaner air in our environment. Valve guide-to-valve stem clearance. The following are some general instructions that apply to Buell motorcycle engines: Gasket surface of both head and cylinder. 2004 Buell Lightning: Engine. Adjuster Boot Loosen clutch adjuster to release tension from hand lever. Remove clutch cable ferrule from hand lever. 2004 Buell Lightning: Engine 3-11. Rear tie bar assembly 11. Fasteners for center tie bar mount (2) 22. Fasteners for rear tie bar assembly (2) Figure 3-6. Engine Mounting System 3-12 2004 Buell Lightning: Engine. See Figure 3-7. Remove rear tie bar from frame only. 25. Loosen rear isolator bolt. DO NOT REMOVE. 2004 Buell Lightning: Engine 3-13. Remove scissors jack. 3-14 2004 Buell Lightning: Engine. Wipe off any excess oil.Install sprocket cover and tighten fasteners and washers and startle the rider, possibly causing loss of vehicle to 12-36 in-lbs (1-4 Nm).Fuel Line and DDFI Electrical Connections (Typical) 2004 Buell Lightning: Engine 3-19. For XB12S with interactive exhaust system, see 7.6 INTER- ACTIVE EXHAUST SYSTEM (XB12S). 2004 Buell Lightning: Engine 3-21. Sidestand Assembly (Extended) 2004 Buell Lightning: Engine 3-23. Rear tie bar assembly 11. Fasteners for rear tie bar assembly (2) Figure 3-22. Engine Mounting System 3-24 2004 Buell Lightning: Engine.

Electrical Connectors 2004 Buell Lightning: Engine 3-25. Figure 3-30. Aluminum bushings from front exhaust mount. Right Side Timer cover. Figure 3-30. Front Exhaust Mount Bushings (2 piece) 8724 8729 Figure 3-29. Removing Threaded Insert 2004 Buell Lightning: Engine 3-27. Apply LOCTITE 242 (blue) and install swingarm pivot shaft pinch bolt threaded insert. Figure 3-37. Aluminum bushings from front exhaust mount. 2004 Buell Lightning: Engine 3-29. Inspect vent line to verify space between vent line and rear exhaust. 3-30 2004 Buell Lightning: Engine. Mount, center tie bar 21. Tie bar assembly, rear 11. Fasteners for rear tie bar assembly (2) Figure 3-43. Engine Mounting System 2004 Buell Lightning: Engine 3-31. It is important to follow this procedure to ensure correct orientation of oil lines in order to establish the proper clearances needed between the oil lines and varied com- ponents on the vehicle. 2004 Buell Lightning: Engine 3-33. Oil cooler 12. Interactive exhaust cable Figure 3-47. Oil Lines and Connections 3-34 2004 Buell Lightning: Engine. Not between the crankcase and the clamp. 2004 Buell Lightning: Engine 3-37. Orientation of return line should be approximately 12 o’clock Figure 3-53. Oil Cooler Feed and Return Oil Lines Location and Orientation 2004 Buell Lightning: Engine 3-39. Positive battery cable at starter.See SPECIFICATIONS. Install upper retaining clamp. 2004 Buell Lightning: Engine 3-41. Electrical Connections and Throttle Cables (Typical) 2004 Buell Lightning: Engine 3-43. Push rod cover 22. Screw (4) 23. O-ring (push rod cover - 2) 24. Push rod 25. Washer (4) 26. Bolt (4) b0960x3x Figure 3-60. Rocker Arm and Push Rod Cover Assemblies 2004 Buell Lightning: Engine 3-45. Remove push rods. Figure 3-62. Removing Rocker Arm Shafts 3-46 2004 Buell Lightning: Engine. Repeat the above procedure for the other valves. Valve Spring Compressor (Part No. HD-34736B) 2004 Buell Lightning: Engine 3-47. Cylinder base gasket 15. Cylinder base stud 16.

Exhaust valve 17. Exhaust valve seat Figure 3-65. Cylinder Head, Cylinder and Piston Assembly 3-48 2004 Buell Lightning: Engine. HD-94804-57). Repeat for other end of rocker arm. 8733 8734 Figure 3-73. Replacing Rocker Arm Bushings 3-52 2004 Buell Lightning: Engine. HD-34751) and hot soapy water. Valve guide brush (Part No. HD-39786) Figure 3-75. Cleaning Valve Guides 2004 Buell Lightning: Engine 3-53. Valve and Seat Dimensions 2004 Buell Lightning: Engine 3-55. Cylinder base gasket 15. Exhaust valve 17. Exhaust valve seat Figure 3-78. Cylinder Head, Cylinder and Piston Assembly 3-56 2004 Buell Lightning: Engine. Other- wise, damage to push rods or rocker arms may result. 2004 Buell Lightning: Engine 3-59. Figure 3-86. Tightening Head Screws Figure 3-86.Push rod cover 22. Screw (4) 23. O-ring (push rod cover - 2) 24. Push rod 25. Washer (4) 26. Bolt (4) b0960x3x Figure 3-87. Rocker Arm and Push Rod Cover Assemblies 2004 Buell Lightning: Engine 3-61. Place a new lower gaskets on lower rocker cover. Tighten screws to 10-14 ft-lbs (13.6-19 Nm). 3-62 2004 Buell Lightning: Engine. Cylinder and Piston DO NOT re-use piston pin retaining rings. Removal may weaken retaining rings and they may break or dislodge if reinstalled resulting in engine damage. 2004 Buell Lightning: Engine 3-63. Figure 3-92. To remove piston rings spread outward Remove circlip from claw and discard.Try to insert a feeler gauge between the straight- edge and the gasket surface.See With the cylinder at room temperature, check the piston SPECIFICATIONS.See SPECIFICATIONS. 3-66 2004 Buell Lightning: Engine. Use care to prevent foreign material from falling into the crankcase. 2004 Buell Lightning: Engine 3-69. Make sure the ring groove is clean. Ring must be fully seated in the groove with the gap away from the slot at the bottom. 3-70 2004 Buell Lightning: Engine. Remove protective sleeves from cylinder studs. Install a new cylinder base gasket. Make sure the piston does not bump the studs or crankcase.

2004 Buell Lightning: Engine 3-71. Oil cooler Return oil line from oil cooler to crankcase 12. Interactive exhaust cable Figure 3-110. Oil Lines and Connections 3-74 2004 Buell Lightning: Engine. Figure 3-113. Crankcase Breathing System 3-76 2004 Buell Lightning: Engine. Reed Valve Assembly 8759 8794 Reed valve stop Reed valve Stop screw Figure 3-115. Reed Valve Stop and Reed Valve 2004 Buell Lightning: Engine 3-77. Oil is forced through the crank- pin to properly lubricate the rod bearing assembly. 2004 Buell Lightning: Engine 3-78. Oil Pump 2004 Buell Lightning: Engine 3-79. Oil Pump Hardware 3-80 2004 Buell Lightning: Engine. Keep covered until assembly. 2004 Buell Lightning: Engine 3-83. Place new o-rings on top of push rod cover. Install push rods, cylinder head, lower and upper rocker covers. See 3.6 CYLINDER HEAD. Repeat process for remaining cylinder head. 3-84 2004 Buell Lightning: Engine. Oil pump drive gear Bushing, outer, intake camshaft gear 14. Pinion gear “E” Cam gear set 15. Nut Right crankcase half 16.Cam and Pinion Gear Location and Timing Mark Indexing 3-86 2004 Buell Lightning: Engine. Worn bushings can cause excessive backlash. 2004 Buell Lightning: Engine 3-87. Figure 3-128. Crankshaft Locking Tool (Part No. HD-43984) 3-88 2004 Buell Lightning: Engine. See CAM POSITION SENSOR AND ROTOR section. Install any components removed to gain access to gear- case (i.e. exhaust system components, air cleaner, etc.). Figure 3-130. Checking Cam Gear End Play 2004 Buell Lightning: Engine 3-89. Remove two TORX screws from each piston jet assembly to free piston jets from right crank- case. Remove piston jet gaskets from right crankcase. 2004 Buell Lightning: Engine 3-91. Gear shaft bearing Crankcase half 13. Retaining ring Bearing 14. Outer bearing race Bearing retaining ring 15. Crankshaft case Inner race, left main bearing Figure 3-135. Crankcase and Flywheel Assembly 3-92 2004 Buell Lightning: Engine. Figure 3-135.

Remove left main oil seal (2) from crankcase using Snap-On Tool (Part No. CJ 114, Body Dent Puller) Remove outer thrust washer (4) next to left main bearing (6). 2004 Buell Lightning: Engine 3-93. LAPPING PINION SHAFT BEARING OUTER RACE. 2004 Buell Lightning: Engine 3-97. Service wear limit, 0.036 in. (0.8 mm) Figure 3-147. Checking Connecting Rod Side Play 2004 Buell Lightning: Engine 3-99. Left Main Bearing Assembly 3-100 2004 Buell Lightning: Engine. Bearing retaining ring Lubricate pinion shaft bearing with engine oil. Figure 3-149. Left Main Bearing Installation Slip bearing on pinion shaft. Install new retaining ring in groove of pinion shaft bearing inner race. 2004 Buell Lightning: Engine 3-101. Slide outer race in right crankcase over pinion shaft and bearing assembly. Tighten fasteners to 15-19 ft-lbs (20-26 Nm). NOTE According to manufacturing, there is no torque sequence to follow when tightening crankcase fasteners. 3-102 2004 Buell Lightning: Engine. After repairs are performed, the work must be validated.The most sophisticated mode employs using a computer based diagnostic package called DIGITAL TECHNICIAN (Part No. HD-44750). The other mode requires using the check engine lamp. 4.5 CHECK ENGINE LAMP DIAGNOSTICS more information. 2004 Buell Lightning: Fuel System. When you have recorded the same trouble code twice, it is an indication that the transmission has been restarted and that all trouble codes have been retrieved. 2004 Buell Lightning: Fuel System. To execute one run cycle: Remove diagnostic test wire and install protective cover Start the vehicle.Return data link to original posi- tion. Let it run for at least 30 seconds. Turn the engine off. 2004 Buell Lightning: Fuel System. Start motorcycle engine and run at idle. Shake or wiggle harness to detect intermittents. If inter- mittents are present, radical voltage changes will register on the DVOM. 2004 Buell Lightning: Fuel System 4-11. See Diagnostic ADJUSTMENT.