oes e ee eS — ra = ap at OFFICIAL FACTORY MANUAL - Part No. 99493-03YIMPORTANT NOTICE Buell motercyeies conform te all appllesble U.S.A. Fedaral Mator Vehicle Safoty Standards and U.S.A. Environmental Protection Agency regulations effective on the date af manutacture. ‘To maintain the safety, dependabilty, 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 nolse contral components outside of factory specifications may be prohibited by law. Buell Distribution CorporationMAINTENANCE 1 3 2003 CHASSIS 2 E ‘BUELL® XB9R FIREBOLT™ MODEL ENGINE 3 3 SERVICE FUEL SYSTEM 4 g MANUAL ELECTRIC STARTER 5 DRIVE/TRANSMISSION 6 § COPYRIGHT 2002 BUELL DISTRIBUTION COMPANY ELECTRICAL 7 z ALL RIGHTS RESERVED PART NO. 68493-087 APPENDICES z CMI - a.m -0802 Printed in U.S.A. on Recycled Paper The information in this Service Manual applies to 2003 Buell Fireboli™ XB8R model motorcycles.FOREWORD GENERAL “This Service Manual has been prepared with two purposes in mind. First, i will aequaint the user with the construction of ‘the Buell product and assist in the performance of basic maintenange and repair. Secon, t will ntraduce to the pro- ‘jessional Buell Technician the latest fiold-lested and tatary- approved major repair methods, We sincerely believe that his Service Manual will Make your association with Buel prod- ucts more pleasant and profitable HOW TO USE YOUR SERVICE MANUAL Information is arranged as follows: (© Section 1-Maintonance © Section 2-Chassis, © Section } Engine © Section 4-Fuel System © Section §-Eleette Starter © Section & Driver Transmission © Section 7-Electrical © Appendix A~Too's (© Appendix B-Electrical Connectors . © Appendic C-Metric Conversions © Appendix D-Hose and Wire Routings Use the TABLE OF CONTENTS follewing this FOREWORD (F the INDEX al the back of the book to find the desired sub- ject Note hat een manual section topic is sequentially numbered Inthe upper loft oF right nand comer of the page. The num bering system allows the user to quickly find cross referenced topics by fipping through the pages. For example, the ninth topic (CLUTCH) in section one (MAIN: TENANCE) is istod as: 19 CLUTCH ‘The 4.9 will appasr in the upper left of right hand comer of the page. PREPARATION FOR SERVICE ‘Gasoline 1a extremely flammable and highly explosive, ‘Always stop the engine when refueling er servicing the ‘uel system, De not smoke or allow opan flame or sparks near the wark site. Inadequate safety precautions may ‘esuft in personal injury. ‘Good praparation is vory Important for afficiat service work, ‘Aelean work area at the Start ot eacn oo wil stow you 10 per- {orm the repair as easly and quicky as possible, and wil reduce the incidence of misplaced tools and parts. A motorcy do thal is excussively diny should be cleaned botore wore stars. Cleaning wil opasionaly uncover sourees of trouble, “Teale, nistrumants and any parts nesded tor the job should be gathered deiowe work ia started. Interrupting a job to loosts ‘ool or paris isa dtaction and causes needioss delay. See APPENDIX A-TOOLS for equipment required for special sor- vie work, NOTE © Toavoid unnecessary disassembly. carsfully read all re! ste service information before repair work is started. © In figure Fegenas, the number which follows tho name of part indicates the quantity necessary for ane complete assembly. SERVICE BULLETINS In addsion 10 the information presented in this Servica Manual, Buell Gisiribution Corporation will periodically [Ssue Service Bulletins lo Buoll dealers. Service Bulletins cover interim engineering changas and supplementary information. USE GENUINE REPLACEMENT PARTS. When replacement parts are required, use only genuina Buoll parts er parts with equivalont characteristics (whieh include type, strongth and material). Faliure to do 50 may result in product malfunction and possible per- sonel injury. ‘ To encure salisfactory and lasting repairs, carsfully follow the Service Manual instructions and use only genuine Buell replacement parts. This fs your assurance that the paris you are using wil fit right, operate properly and last longer,SAFETY DEFINITIONS ‘Statements in this serviee manual preceded by the fol lowing words ara of special significance: WARNING indicates a potentially hazardous situation which, If not svolded, could result In desth or serlous injury. oe CAUTION Indicates potentiaity hazardous situation which, if not avoided, may result in minor or moderate Injury, ee CAUTION without the safety alert symbol indicates a potentially hazardous situation whieh, It not avoided, may result in serious property damage. eas Proper service and repair is important for the oats, reliable operation of all mechanical products. The service procedures recommandad and described in thls Service Manuel are effective methods for per- forming service operations, Some of these service operations require the use of tools specially designed for the purpose. These special tools should be used when and 2s recommended. It Is important to note that some warnings against the use of specific wervice methods, which could dam- age the motorcycle or render It unsate, are stated in this Service Manual. However, please remember that these warnings are not all-inclusive. © Sines Busi could not possibly knom, evaluate or dviae the service rade ofall possible ways in which ssrvice might bo performed, or of the possible haz- ardous consequences of each method, we have nat undertaken any such broad evaluation, Accordingly, anyone who uses a service procedure or tool which |s not recommended by Buell must first thoroughly satisfy himself that neither his nor the operator's safety will be jeopardized as a result (© Wear eye protection when using hammers, arbor or hydraulic presses, gear pullers, spring compressors, slide hammers and similar tools, Be especially lous when using pulling, pressing or compressing aquipment. The foress involved ean cause parts to fly outward with considerable force, possibly result- ing in personal injury. Buell products are manufactured under one or more of the following U. PRODUCT REFERENCES Follow the directions listed on all products. Carefully read all labels, warnings and cautions before use. Inade- ‘quate safety precautions may result In personal Injury. ‘When reterance is made in this Service Manual to & spectfic brand name product, tool ar instrument, an equivalent Product, tool or instrument may be substtuted Kent-Moore Products ‘All tools mehtioned in this manual with ani *HD®, *J" or "B* preface must be ordered through: Kent-Moare SPX Corporation ‘28695 Mound Road ‘Warren, Michigan 48092-3499 ‘Telephone: 1-200-345-2233 Direct all product returns, warranty r otherwise, to the folow= ing address: Kent-ntoore Atin: Returned Gaods 655 Eisenhower Drive ‘Owatonna, Minnesota 55080-0995 Sealing and Threadlocking Products LOCTITE PRODUCTS ’ Some procedures in this Service Manual call for the use of Loctite® products. I you have any questions regarding Loctite product usage or retalleriwmolesaier locations, please call Loctite Corp. at 1-200-222-5106. CONTENTS All photegrephs, illustrations and procedures may not neces sarily depiel the mos! current model or component, bal are asad on the latest production information available at the time of publication. Since product improvement is our eantinual goal, vall Dict. bbulion Corporation roserwas the right 1o change spocifica- tions, equipment or designs at any time without notice and without incurring obligation patents ~ 5295702, 5495584, 5932248, 4989696, 4951774, 4964484, 5209319, 5303795, 4776423, 6213238, 6105701, 6267193, D440190, 6213240. csTABLE OF CONTENTS Page Ne. SECTION 1 - MAINTENANCE 1.1°General. a ‘Servicing a New Motorcycle 1 Sate Operating Maint = 4 XBOA Too! Sei... 2) inspecting. fo 4 Usk Dye ees "1 1.2 Fluid Requirements 12 ‘General... _ 12 United Siatos System. = 12 Matic Systm 12 Primary Deivo/Transmission Pid ree Front POPE Olen 12 Broko Fluid. “ 12 Fook. : : 12 Engine Ol 12 ‘commended Ol Grasee (able) 12 4.3 Care of Molded-in-Color Body Panels 1-4 Sonor. 4 Recommended Product ms Care and Maltananes wan 14 Washing. nnn ra Cain Batwoon Wess. rs Poishing... 4 Minar Serateh Removal te Major Seralenes - is 1.4 Battery Maintenance. 1-5 Goncral - 1 Satta Testing ee 18 Vosimetor Test. 18 Vaimetar Test (abt) 15 Battery Disconnection 8 on 18 ‘Cleaning snd inspaction 16 Storage st 13 Battery inetalstian and Connection... 7 1.5 Engine Lubrication System 18 ONO oer - ee’) hacking Engine Oi Level os hanging Engine Oil and Fier. a Draining OF 18 hanging Fiter 19 Replacing Ol... ES 3 Recommended Gil Grades (bie). 110 1.6 Brake System Maintenance 1414 General + Bleeding Brakes vs - it Brake Troubleshooting (table) ~~ +42 Bleeding Front BrGko nan 443 Bieeding Rear Brake vnc n Dota Brake Pedal Adjustment 145 Page No. Brake Pad Thickna6S ...oronennon 146 Brake Rotor Thickness. 116 Brake Pad Replacement 117 Front Pad Romoval Front Pad Inctalltion Roar Pad Removal Rear Pad Insiabation 1.7 Tires and Wheels 1-19 “Tice Infation os 119 Tire Preseures (tal) 118 weet woanngs... Coenen HB 1.8 Clutch “Transmission Fluid... Adjusiment 1.9 Drive Belt System General Inspection ear Sprocket Dawe Belt Ieler Pulley Ider Pulley Removal... +28 Ider Puley inatalstion 1-26 Drive Belt Wear Analysis (tatty 1-27 1.40 Primary Chain inspection... F Primary Chain Tension (tabie) pea 29 Austen : z +30 1.11 Suspension Damping Adjustments. 131 OETA nen sete gt Suspension Adjustments 121 Sefing Rear Shock Preto. 131 Soling Front Fork Preload. 421 Recommended Damping Setings (tabi) +32 Adjusting Suspension Damping v.18 Recommended Suspension Damping SSTNgS (EB) enna il ae 4.12 Front Fork Oil Chang: Fatk Oi CHENgE ern nn Disassembly. Drain and Repiace Of. Reassembl 1.19 Steering Head Bearings 1-38 Genera. 1-98 inspection. So 198 1,14 Spark Plugs. 1-39 InspOCHOR. 1-88