Buell XB9R '03 Service Manual

oes e ee eS — ra = ap at OFFICIAL FACTORY MANUAL - Part No. 99493-03YIMPORTANT 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 CorporationMAINTENANCE 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 products 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 subject 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 damage 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 hazardous 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 resulting 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. csTABLE 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. 1-88Page No. 1.15 Air Cleaner Filter. 141 Removal. os Vt ‘Gieaning and Inspection... rms TAT Inataliation.... ee ee 1.16 Throttle Cable and Idle Speed 1.17 Ignition Timjng . 1-48 Inspection... 104 Checking Stalie Timing... 1-48 Adjust Timing... 1.18 Headlights Inspection... Agusiment 1.19 Throttle Position Sensor (TPS). 1-48 IRSPOCHION nearer 148 Adjustment ee ae. 1.20 Storage 1-49 General 4.43 Flemoval From Storage... 49 1.21 Troubleshooting . 1-50 General ' on) Engine so Stare Motor Does Not Operate nares 180 Engine Turns Over But Doss Not Star. +50 StEME HAM — 1-50 ‘Stars Bu Runs ineguialy or Misses 1-80 ‘Spark Plug Fouls Repeatedly... 131 Pralgntion or Datonation (Knocis or Pings). 151 Overheating... an +61 valve Train Noi. - 181 Excestive Vitration Seal 1st Engine Lubrecation System iat Gil Does Nol Retum To Gil Tank 15 Engine Uses Too Much Oll ot Smokes, 181 Engine Leaks Oil From Cases, Push Rod, HOS evr nenmnm 151 Electrical System — - 151 Altemstor Does Not Charge. oS Aerator Charge Rate ls Below Normal 1-51 Ful System —— Cs Fuel System Floods ASL aor Fut Economy con +51 Transmission vo a 152 Shit Hard rdetreo R Jumps Out of Gear. eosin 3 BE Clute a meee ‘Slips . vere 1462 Drage or Does Not Release. car a CaO ene - eee) Chassis. : 432 Iregulaninadegusio Brake Acioa 152 Handing Irequtates +52 Sucpenston +53 General Suspension Problems (able). 183 Rear Suspension Problems table). 153 Front Suspension Problems (table). 153 SECTION 2-CHASSIS 5 2.1 Specifications... 24 Dimensions (table)... satrseeasnesie at Weight Specifications (table) a —_ at Capactice (able)... - - 24 Tire and Postion (abio} 24 Torque Values (tabla). - 22 2.2 Tire Specifications . 25 General... 25 “Tire Fiment-Tubelass Cast Wheels (table) 25 2.3 Vohielo identification Number. 26 General... 26 2.4 Wheels 27 General... eae: Has gy Troubleshooting. vr mnnnn mn ah Sigg Wheel: ‘Sorgce (table) cate 2B 2.5 Front Wheel. 29 Removal. 88 Disassembly. 240 Beating Removal 240 Front Rotor Removal - Bat leaning and nspcton it Assembly. 212 Bearing instalation Front Rotor Installation ‘Checking Tire Lateral Funout.. 22 (Checking Tire Radial Runcul. 221 A|UBIMAME nn ~ BRI ‘Wheel Balanong.... 221 2.9 Brake Pedal Removal mere Installation ern 22.40 Front Brake Master Cylin inder.. FROMOVA nn Ce 7 Brake Hand Lever Front Master Cyande Cleaning and Ingpection .... ASSEMBIY ow Front Master Cylinder. Brake HAP Leta cnn Inatallaion . 2.11 Front Brake Line Removal... nine Installation 2.12 Front Brake Caliper. Fiemoval DisassEMBty ann Greaning ane Inspact ‘Aapembly.... oe Installation... i 2.19 Rear Brake Master Cylinder Removal .. Disassembly .. (Cleaning and inspacton 7 ‘Ascombly Installation 2.14 Rear Brake Line. Flemanal nnn Installation 2.15 Rear Brake Calipe Removal Disascombly - (Cleaning and Inspection. ASOmB ca inealisnes ~~ 2.16 Front Fork. 239 ‘General a a 233 Ramovalnccsecr 229 Disassembly a 239 Damper Rod Disassembly 2tt ‘Cleaning and Inspection... Dat Acsombly 24 Damper Fld Assembly mn 241 Fork Assembly 241 ‘instalation eS a) 2.17 Fork Clamps, Upper and Lower 2-45 RomovalDIssss0mBHy cnn 245 Removal... serene Installation vi instalation 2.10 Swingarm and Brace General... Removal Brace Disassembly... 250 BRO eo 250 Swingarm 250 ‘Geanna on inepacton 251 - 251 251 251 251 251 est Final Swingarm inepection Bt ‘Oil Line Fitings (fabio) 252 2.20 Front and Rear isolator. 253 Front Issiate ceed 259 Removal catwoman 253 Installation eee 253 Rear Isoistor 7 283 2.22 Rear Shock Absorber 255 GBEMEFA nse senes soe 255 Removal. satis 255 Installation... a 255 2.23 Throttle Control 257 Removal Disascembly os 257 (Geaning and inspection " 257 ‘Assembiy/instaliation ec 257 2.24 Clutch Hand Lever 2-58 RemovalDissssembly...... - 258 ‘Assembly/insiallation .. ‘ 258 2.25 Headlight Support Bracket 2-59 Romoval 2.27 Handlebars Removal. Right Clipon Left Cipon Intallaton Right Clipan .. Left Cipon. 2.28 Exhaust System 2-66 RemovalDianeaernbly.... cae 68 MUFIE - a) Front Muffler Mounting BIOGNSHAD wnnon—- 2-88 Rese Muffler Mouniing Blok... 268 Exnaust Header ee a Assembiyfnstallation. ais “287 Exhaust Header .0.0- 287 Far Muffler Mounting Biock.. ce 287 Front Mufler Maunting Block... 267 Mutter and StS08 nu 2erPage No. 2:20 Footpeg, Heel Guard, end Mount: 2-68 sz 2.68 288 258 268 Install Footpeg sa 208 Insta Heol Guard 288 Install Mount, soe 258 PARSEN DEF wn 269 Fomuve Foopdg 2.69 Remove Heel Guard. 208 Flemove Mount nn 269 Insta Footpes 269 Install Hac! Gusrd ° TT 2eo Install MoU nanan peo 2.30 Sprocket Cover 2-70 Femoval/Disassembly aol Installation... svomnaiinaranwanane FO 2.31 Fenders... 271 Front Fendor aan) Removal... se CT Installation. ara Rear Fender... ecw BP Removal. art Removal. an 2.32 Belt Guards 272 Romoval.. - 272 Installation ——— 27 2.33 Chin Fairing 2-74 274 274 2.34 Intake Cover Assembly 275 REMOVE nec nnren 278 Instaation non mn ars Engine Stroud air Scoop. Femoval....... 278 Installation... 278 ‘Oil Cooter Air Scoop 278 Removal 276 Installation, 276 2.36 Tail Frame and Body Work 277 Disassembly —= eat ‘Cleaning . a 278 ‘Assemb) 278 2.37 Front Fairing, Windshield, and Mirrors 2-80 Removal nnn 250 Installation... 2-80 2.38 Seat. 2-81 a 281 Floor Seat 281 Pilon Seat roe BT “ Installation Rlidor Sox... Pilfion Seat 2.39 Passenger Seat Lock .. Removal... Uistalla08 nnn 2.40 Sidestand .. General nn Sidestand Disassembly. Sldgstana Acoombly.. Sidestand Switch Installation. Sidestand insiallation... " 2a SECTION 3-ENGINE 3.1 Specifications ‘General (table)... Engine ignition (abi Valve and Valve Seat (table) WAIVE (TADIE) «oa rssnron Valve Spring (abi) Outer Valve Springs (lable). Rocker Arm (tabi). Rooker arm (8006) Piston Ring an Piston Piston (table)... Gylnder Head able} ‘Cylinder Heed (ible) Cylinder tab) | Orlinder (table) ‘Connecting Rod (table). ‘Connecting Rod (table). Fiygraule Liter apie “Tappets (able) Oi Pump (table ‘Sprocket Shaft Bearing (tabie) Sprocket Shatt Bearing (table) Pinion Shaft Bearing (table), Pinion Sham Bearings (lable). 3.2 Engine .. Fuel... Gasolne/aicone! Blonds ‘Lubrication... ‘Adjustment/Testing.. General. ‘Compression Test Procedure... ‘Comprassion Test Reauits (table) ytindor Loakago Test... ES Ba Compression Test Results (labo) 37 Air Leakage Test (table)... 37 Diagnasing Smoking Engine or High Oa Consumtion Air Leakage Test (table).Disassembly... este 38 Rlesssembly. ere) 3.4 Stripping Motorcycle For Engine Ser- vice. . 3419 Disassembly 21a 3.5 Engine Installation 3-29 Assembly... wea Engina Preplor Re-nstalaion 229 Instaling Engine in Frame 3.6 Cylinder Head. Removal locker Bax Assembis Rocker Box Assembles... Gylinder Head Assembbas Disessembly Cleaning and Inspectien.. (Cylinder Heads... Rocker Aim Assemblies VI 08 nnn Valve S815 vores Valve Guides an alve Springs = ‘Spark Plug Threads... Pushods Rocker Arms and Bushings. opigcing Vane Guides ane Valve Stem Clearances (table). Procedure For Using the Newsy Valve Seat Guller. $-5¢ Neway Valve Seat Cult . 358 AgSEMb!Y vo SF Push Rod Cover installa... st 359 Push iad Selection (table). ese Gyfindor Head Installation... - 360 Lower Rocker Box Hardware (II) x crn-- 382 3.7 Cylinder and Piston .. FRemavalDisascombly Cleaning and Inspection Checking Gesket Suriace Measuring Gyindor Bore 1. (Deglazing Cynder... Cylinder Bore Senvce Wear Limite (able)... 3-88, Fitting Piston Rings. 367 Fig EN GAB enero 367 Connecting RES BUSHING ncn 38D Assombly/netallstion...——. eg. TO 3.8 Lubrication System. . 373 Chacking and Adding Oil... cat OB Changing Olt and Filter. 873 Winter Lubrication... - 378 3.9 Oil Hose Routing And Oll Reservoir 374 General - B74 3.10 Oll Pressure Indicator Switch... 3-75 General - 375 ~ 38 - 35 Trewilashaoting Cl Pressure Signal igh! (able) 3-75 Page No. 3.11 Crankease Breathing System... 3-76 General a scar TB Read Vaive Replacement. 37 3.12 Oiing System 3-78 General 378 3.13 Oil Pump 3-79 General. — 378 RemovalDisassembiy.cn > 80 Cleaning and inspection aa Ascembiylnstalain . 381 3.14 Oil Filter Mount 3-82 Cenerat 32 Disaccarly co 382 Clean nd nspecton 382 Assembly 342 3.18 Hydraulic Lifters . 3-83 General sernsnens 385 Removal. ee 343 Cleaning anal inapaction vn na 303 Installation oe 3-04 3.16 Gearcase Cover And Cam Gears 3-85 : 385 : 3-86 leaning and inepecton 87 Carv/Finion Gear loentitation, Inspection, and Selection a7 Bushing Inspection andl Removal 387 Gear Shatt Spectications (able). ear AssembhylInstalston 2-08 3.17 Crankease General... Disassembly Grankcase Halves, Pion Jet - . Fitng Pinion earings aa Pinion Shaft Bearing Selection (lable). 3-08 Lapping Engine Main Bearing Rose. 399 Cheeking Connecting Rod Si0@ Pray 309 PSSOMBY on 7 C2 a0 Grankoase Halves. coono 3-100 SECTION 4-FUEL SYSTEM 4.1 Specifications .. a ual Syatern (table). Se a Fuel Tank Capacity (table). savenneemans “1 Idle Speed Adjustment. a Torque Values : at 4.2 Dynamic Digital Fuel Lnjection 43 Yee uction 43 General 43 Far Mors Information 43 “Troubleshooting 43 Fuel Injection Components 43 vil4.3 Diagnostic Introduction ‘system Problama, No Stat... 4.4 Checking For Trouble Codes. 46 Check Engine Lamp tes 46 Gode Types... ae 47 Curent nnn ees AT HiBt OF vnnone ea. 47 Functional cores 47 otioving Trouble Codes 47 Multiple Trouble Codes 47 Check Engine Lamp Binks 47 4.9 Check Engine Lamp Diagnostics 48 Retieving Trouble Codes... 48 Clearing Cooes... ae te 49 4.6 Breakout Box Gene Insialation.———— 4.8 Initial Diagnostic Cheek 412 General ialisaiciass AOA Diagnostic Notes, ane Circuit Diagram/Wire Hames Gonnacior Table... 4-32 Jeb Time Code Values oo ang Initial Diagnosties. en ang General Information paca ane Diagnostic Notes. 2 ase Engine Stans Hard (tbls) az Engine Performance Problems (table) Engine Exhaust Emits Black Smoke or Fouls Plogs Trouble Cades and Fault Conditions (table)... Wire Hamess Connectors (table). rs Diagnostic Check (Part 1 of 2) (flow chant). Diagnostic Chack (Part 2 of 2) (Bow chart) +16 4.9 Check Engine Lamp Not Muminated st Key ON. a7 General. A a7 Diagrosics —— 417 Diagnostic Ties EO a7 Diagnostic Notes “7 Wire Hamess Gannectors (able), a8 Test 4.9 (How eran 19 4.10 Check Engine Lamp 0: On Continuously. Genecal Diagnostics... “ Diagnostic Noles... - 420 ‘Wire Harness Connectoss ftable) 42 Test 4.10 flow chan) 422 4.11 Engine Cranks But Will Not Start 4-23 General 423 vill Diagn ast nn Diagnostic Noles Wire Hameas Connectors (tbe) Test 4.11 (Pat tof 3) (ow chert). Test4.11 (Pan 2 of 3) flaw shart). “Tesl 4.11 (Pam 3 of 3) (Row char) 4.12 No ECM Power.. General... Diegnostics Diagnostic Notes... ‘Wire Hamase Connectors (table] No ECM Power (flaw chart). 4.13 Fuel Pressure Test Ingpection .... Diagnostics... Diagnostic Notes ‘Wire Hamess Connectors (table! Test 4.13 (Par 1 of 2) (flow char?) ‘Test 4.13 (Part 2 of 2) iflow chart) 4.14 Idle Speed Control.. Adjustments. 4.15 Misfire. Genera once Mistiee At inie er Under Les Diagnostics... s Diagnostic Notes s Spark Plug Gables (table)... ‘Wire Hamase Connectors (table) Test 4.15 (Pan 1 of 2) low cher} ‘Test 4.15 (Pan 2 of 2) (low chart) 4.16 Trouble Code 11... General... ‘Throttle Position Sensor... Diagnostics. Diagnostic Tips. Diagnoatic Notes ‘Wire Hamess Connectors (lable) Code 11 Test (Pant 1 of 2) (ow chart. ‘Code 11 Test (Part 2 of 2) thew ean. 4.17 Trouble Code 13 .. General... ‘Oxygen (02) Sensor. Diagnostics Diagnostic Tips - Diagnostic Notes . ‘Wire Hamess Connectors (table) ‘Code 13 Test (Part 1 of 3) Mew chart) ‘Gode 13 Test (Part 2 of2) few char). ‘Coda 13 Test (Part 3 of 3) tNow cha)4.18 Trouble Code 14. 4-50 Getta en Engine “Temporalure Sensor, 450 pughosee set) Dagost: Te. mare's Disgreetc Nowe SS ae Engine Temperature Sensor Specifications (table) 4-60 Wie Harness Conmestors (Dt) 51 Goce Tee Paro) flow char) ga Gode 14 Test (Part 2 of 2) (How chart) ..... +53 4.19 Trouble Code 15. 4-54 Generel ase aks Aa Tornpowsire Banor te one " Dagpets Tyee ot Dingbete Noes ae Intake Ar Torpesire Sensor Speciation acl) 4-54 Wire Hamess Connectors (table) ........ 2" 4-55 (Cade 15 Tact (Part 1 of 2) (flaw char) Cove 16 Test (Part 2 of 2) (tlow chart) 4.20 Trouble Code 16. General... fei Batiery Voltage Diagnostics... - Diagnostic Notes Wire Hamecs. Connectors (table) - Code 16 Test (Part # of 8) (flow chart) Code 18 Test (Par 2 of 2) (Now chart) 4.21 Trouble Codes 23 and 32 . Genera... Front Fue! injector (Code 23) and | Injector (Code 32)... Diagnostics. Diagnostic Notes Wire Hamess: Connectors (table) Code 23/32 Test (Part 1 of 2) (low chart) Code 28/32 Test (Part 2 of 2) (low chart) 4.22 Trouble Codes 24 and 25. Gen6ral. Front ignition Coil (Cade 24) and Rear Ignition Coit (Coote 25) Diagnostics. Diagnostic Notes. Wire Hames Connectors (table) Coe 24/25 Test (flow chart) 4.23 Trouble Code 33. General Fuel Pump Diagnostios Disgrostic Nees Wire Hamess Connectors (table). Cade 33 Test low chan) 4,24 Trouble Code 35.. General... “72 Tachometer 472 Diagnostics... 472 Diagnostic Notes. ATE Wire Hamess Connactors (tablo) TS Cade 35 Test (low chat) TH Page No. 4.25 Trouble Code 36 475 Gen ann 475 Cam Syne Faire 475 Gam Syne Failure “75 Diagnostics 475 Diagnostic 275 Wire Hames Connsctors (tabi). 478 Coge 36 Test (fan runs continously) (iow chat) 4-77 Goce 36 Tast (fan does not run) (Now chart) n.n. 7B 4.26 Trouble Code 44 General... Bank Angle Sensor Diagnostics... iagnosue Notee., ore Bank Angle Sensor Voltage (table) TO. Wire Harness Gonnectors (lable}.. 4-60 Cade 44 Test (Pan 1 of 2) (How chan}.. 481 Code 44 Test (Part 2 of 2) (low chart. 482 4.27 Trouble Codes 52,53, 54.and55 4-83 co 2 483 EOM Faaure.... 2 483 4.28 Trouble Code 56 4-84 General 484 Cam Syne Failure 48s Diagnostics... 434 Diagnostic Notos.. Ba Wire Hamess Connectors (table)... 4.85 Cade 56 {Part 1 af 2) (low chart. 486 Code 86 (Part 2.0f 2) (flaw chat... 487 ‘Removal 489 Installation. “a9 Pin Table for ECM Connectar [10] (Bisck) 420 Pin Table for ECM Connector [11] (Gray). 490 4.30 Cam Position Sensorand Rotor 4-91 Removal. Removal. Installation. 4.31 Ignition Coil Troubleshooting Ignition Coil Primary Circult Test 495 Ignition Cod Secondary Cxcult Tee! 9s eas 495 496 498 96 456 4.32 Oxygen Sensor 4-97 General. 497 Removal 497 Removal “97 Installation. 7 conn 887 4.33 Engine Temperature Sensor 4-98 Engine Temperature Senor, Gener a. 498 Removal nen 2 458 Installation... 2 - 40aPage No. 4.34 Bank Angle Senect2 . 4-100 General vo 4-100 Removal 4-100 Installation 4300 4.35 Intake Air Temperature Sensor 4-101 General a e101 Removs eens . det Ingtallaton " . 440 4.36 Throttle Pogition Se Sensor 4-102 Removal... are 4102 Installation : - 4-102 4-103 4.103 e103 Installation 4103 4.38 Fuel Pump. 4104 Removal... aia 4105 Repair... eave 4-108 Fuel Pressure Regulator Replacement... 4108 Low Fuel Leve! Sensor Replacement 4-108 Fuel Finer Replacament seen 4108 Fusl Screen Fleplacement connie AAOP Fuel Pump Specifications (tabl6) vernminnnnmn 107 Installation ven 4108 4.39 Fuel Tank Vent Valve. 4110 General vo cneenene 4110 Removal... oncencnnnimaneaninanee 4110 Inctalation von N10. 4.40 Fuel Cap Retaining Ring « ait Removal me 4111 Installation... : anit 4.41 Throttl Body and Intake Manifold 4112 General... oo ante Removal... asic Repair... aot td “Throttle Postion Sensor... 7: bit Repair vo aad Testing. tortion 4115 Installation .n.~ eisai 118 417 a7 ‘Tester Assembly Intake Leak Test 4.43 Airbox REMOVE — Inepectien LoS Insialaion —— 4.44 Evaporative Emissions Control- California Models: General ~ Troubleshooting Removal. 3 Page No. Vent Vave. pepo anzi Canister - 4421 installation i 2 Vent Valve. vn 4122 Canister 4122 Hose Fouting.. co ies SECTION 5-ELECTRIC STARTER 5.1 Specifications 51 ‘Starter Specifications (table) a Service Wear Limits (table)... H Torque Values 1 5.2 Electric Starter syste 52 GEMEFAl nnn 52 Wiring Diagrams... 52 Starter Relay. 52 Starter Interlock . 52 Opera rn BB 54 54 a : 54 Starter Test 2: Solenoid Otek nan BB Starter Test 3: Relay Clicks... 55 Starter Test 4: Nothing Cieks Ss Starter Test 5: Startor Spins, But Doss Nos Engage 5.7 Starter Test 6: Starter Stalls or Spins Too Slowly. &-? 5.4 Starter Activation Circuits. a8 55 Diagnasties/Troubleshoo 59 Benet ren 58 Voltage Drops. — 59 5.6 Starter System Testing. 5-11 TOR MOtoreyele” Fests a nnnennneniarneee Set Stanor Rolay Tost BA Starter Current Drew Test... ~ ei 5.7 Starter, ONE Testing Assembied Starter... 513 Free Running Curent Draw Test #13 Starter Solenoid - 518 Solenoid Pullin Test. nn mo BAB Solancid Holdin TSE oncom 514 Solenoid Retuen Test. a She) Disassembly, Inspection and Repair. 515 Assembly oe 19 Installaton 519 5.8 Starter Solenoid. 5-21 Genel 521 Olsassamsiy oe 5.21 ASE OMbIY one a oe BAPage No. SECTION 6-DRIVE/TRANSMISSION 6.1 Specifications. 61 Prirhary Drive Specifications (table) i 4 Final Drive Specifications (table). vs 61 “Transmission Speciicalions (blo). OH Wet Giith Specticasons (able). ‘Wet Clutch Specifications: table setnseremorsnan ie 62 Torque Values. aes 6.2 Primary Chain 63 General, 63 Removal -_ ea Piteary Gaver aa oe Primary Chain Adjuster. sais 65 Installation... ce Ed 68 Ptimary Cover - bs 6.3 Clutch Release Mechanism. 67 Dicasserbly oe 67 Cleaning end inopecton rs Assen oa 6.4 Primary Drive/Clutch . 69 Genera. co 2 emovalDsascoraly.. 611 Chath Pack I en Primary ChaivDive wate Assam ccna ete luton a0 ee bestia 520 6.5 Transmission. 6-23 GONECAL enone a 62a 6.6 Case Disassembly For Transmission Removal.. 6-24 Fight Crankease Removal... e24 6.7 Transmission Disassembly. 6-27 ‘Transmission Removal From Left Crankoase 627 Mainshaht Disassembly... age eae Cloatring and Inspection oem 32 ‘Countershaft Disessembiy... 6s3 Cleaning and Inspection smn ea 6-34 Mainghatt Aseambly on on no BBM Countershatt Assembly... 6-05 6.9 Main Drive Gear.. 6 Mainshaf Sth Gaar Ball Bearing... 630 ‘Countarshaft Needle Bearing... 6.30 ‘Shitt Drum Needle Bearing... 638 6.11 Transmission Left Case Bearings Removal ose ae SA Malnshait and Countershan Bearings. th Shi Drum Bushing. oat Inston. ae Mainshafl and Coumorchan Bearings a Shit Brum Bushing eat 6.12 Transmission Installation. 6-42 Intalaon sn ‘ ee Shifter Forka and Drum Assembly a 8 Installing Right Crankoase-.. vs 645 6.15 Shifter Shafl Installation 6-46 instalation —— o-46 6.14 Transmission Sprocket. Removal. nmi oar inetal a eas SECTION 7-ELECTRICAL 7.1 Specifications TA Batley (able) mabe ora Spark Pugs ible) - nm ‘Aker lable) nn a" m4 Roguletor (able) a 1 Igniton Coli Resistance (able) A Electrical Systom (table) Bik ae ee Bulb Chart (table). a satis 7H Torque Values 72 7.2 Ignition System. 73 General. 78 Troubleshooting 7.3 Ignition/Headlight Key Switch... 7-5 General f ——— 75 lgniton Key Switch Positions (lable). 7S Inginater MarR (18012) ceonrnne 75 REMOVAL cnn on 78 Disassembly. fae Sai ay + Assembly. * — Installation, TB 7.4 Spark Plug Cables 7-9 Ghreral 79 Plomoval cnr 79 Inspection. ne 740 Stallion ce FAD ‘Spark Plug Cables (1able) a. 7107.5 Starter Interlock General ‘Starter Circut Ignition Circuit ‘Starter Interlock Troublesheating (table) Diagnostics . ignition Test (ow chart ‘Starter Test (Part 1 of 2) (flow chart) ‘Starter Teat (Part 2 of 2) (flow chart) ‘Testng/Feplacement zs Side Stand Switen...[ Ohah St ignition Relay Kay Swilch Relay Main Fuso Diode nang 7.6 Charging System T-19 General. 719 "Atemator 79 Voltage Regulater 79 nae 78 — 719 79 \oltage Regulator inspection 719 Test (Part 1 of 2} (flow chat)... 7-20 Tost (Part 2 of 2) (flow chert) = Feat Testing 723 Voltage Regulator Bleed Test 723 Miliampere Draw Test na Total Currant Draw Tost 723 Current and Voltage Output Test. Ted Voltage Outnut Test... 724 Removal Disaseombly 7.26 olor. z 726 Stator 726 ‘Cleaning and Inspection yar Assombly/inatalation 7.27 7.8 Voltage Regulator 7-28 General . Removal. Instaliston.. Battery Electrolyte Antidotes (table). Battery Testing, — 732 Voltmeter Test ns 7.32 Load Test.. 232 Votrmatar Test (table)... 782 Ballery Load Test (table) 782 Disconnection and Removal 738 ‘Cleaning and Inspection .. 738 Page No. Battery Charging... ee 734 ‘Salety Precautions 7 m 38 Charging Batlery.. coe TBH Battery Changing Rates!Times (table) 735 Battery Cable Routing . 7-35 Battery Ingtallation and Connacton.. Storage... 7.11 Headlight Goneral.. Headlight Bulb... Fomoval Instaabon wn 7.12 Tail Lamp. FlemovalDisassembiy.. Assemblylnsialiafn. 7.43 Turn Signals. 7.44 Turn Signal Flasher... Removal Installation 7,15 Handlebar Switches .. Removal Fight Sige. Lat Side Instazation Fight Side, Let Sloe 716 Speedometer Sensor Removal Installation 7.17 Instrument Module General... Removal .. Installation 7.18 Speedometer Performance Check.. General..= Testing Speedometer Operation Tost rae Speedometer Test Frequency (table). 7a Speedometer Needle SWEEP TEL cnn FH) Speedomiste’ Sensor Test. oo 749 Speedometer Test: Chart 1 lowchart) 750 Specdomete: Test: Chan 2A (fowchan).—— 7-51 Speedometer Test: Chart 28 (flow chatl)mnnnn- FBZPage No. 7.19 Tachometer Performance Check 7-53 General. o 753 Testing 753 Operation Tet onn ann 88 Tachometer Accuracy Tolerances and Gonversions (table)... a P88 ‘Sweep Teet.. vn 758 7.20 Horn. 7-55 General 7-05 FOMOVAL i flimnennmnnninnennnnnnnnn SS Installation nn coe TES Troubleshooting “ 7-58 7.21 Neutral Indiestor Switch 7.57 FST 787 _ ST 7.22 Main Fuse and Fuses.. 7-58 General Fuses. Installation 7.24 Sprocket Cover wing - Co Page No. APPENDICES . A.1 Tools .. Al B.1 Amp Multilock Electrical Connectors. B-1 Removing SockstPin Tarminals. - Bt Ingtaling Socket/Pin Terminsle, - Bet Crimping Instruction BS B-5 B.2 Deutsch Electrical Connectors... Hemovingiinstaiing Sockets Flemoving/insialing Pins. Assembingltnstalling (Crimging instructors . Genera. Pullto-Seat Termin Feemoving Extemal Latch Type... Instaling External Latch Type. Pust-to-Seat Tein on. Removing Push-to-Seat Tarminals Installing Push-to-Seat Terminals... Crimping instructions... 5.4 Electrical Connector: General. ectrical Connector and Location Tabie (able) B.5 Index to Wiring Diagrams... C.1 Metric Conver Metric Conversiona (tabla) : €.2 Fastener Torque Values English Torque Values, a Meliic Torque Values (HaB16} rn D.1 Hose and Wire Routing valNOTESMAINTENANCE SUBJECT PAGE NO. 1.1. General - . - a 1.2 Fuid Requjrements oe 12 1.8 Care of Moldeckin-Color Body Panels, be 1d 1-4 Battery Maintenance «4... rn - 1s 1.5 Engine Lubrication System .....e.c0.00-- - 18 16 trako System neaintenance - : ce tt 1.7 Tites and Wheels : - - og 1.8-Ciutet - Cos ieee rte tneee ce 120 1.9 Drve Beh System oo. ee secre - 123 1.10 Primary Ghain = ce ce a 188 1.11 Suspension Damping Adjustments 131 4:12 Front Fork Oil Change... ae foe 1S 1.18 Steering Head Bearings - cette ce 188 1.14 Spatk Pgs cos - TEIN a 1.18 Air Cleaner Fiter - cece Hed 1.16 Throttla Cable and Ile Speed Adjustment - a 188 4.17 Ignitlan Timing - feccteecteeereees 148 118 Headlights . cette etter, 15 1.19 Tree Postion Sensor (TPS) se cere 148 1120 Storage... - - - a5, 1.21 Troubleshooting ==. - co 180GENERAL 11 SERVICING A NEW MOTORCYCLE ed Always follow the listed service and maintenance rect mendations, Because they affect the safe operation of ‘the motorcycle and the personal welfare of the rider. Fail- ure to follow recommendations could recult in death or ‘serious injury. Service operations to be performed betore customer delivery ‘sre spectied in the sppicable modal yoar PREDELIVERY "AND SETUP MANUAL. “The performance of new motorcycle initial service is required 10 keep warranty in force and to ensure proper emissions syS- toms operation. After 2 new motorcycle has been driven ils frst 1000 miles, (1800 km), and at every 2500 mile (#000 kr) interval thereat ‘er, have = Buall dealer perform the service operations listed in Table 1-2. ‘SAFE OPERATING MAINTENANCE Ge % Do not attempt tore-lighton engine head belts. Re tightening can cause engine damage, @ During the initiol 1000 mile (1600 km) break-in period, use only Harley-Davidsen 20WSO engine oil. Fallure to use the recommended oil will result in Improper break-in of the engine cylinders: and piston rings. ‘A caratul check of cartain equipment is necessary after peri= ‘ods of storage, and frequently benneen regular aervice intervals, to determing if adcitional maintenanae is required. Check 1. Twas for abrasione, cute and correct prescura Dive belt for proper tension and condition Brakes, steering ans thatte for responsiveness ES Brake fluid level and condition, Hydraulic ines and fittings for leaks. Also, check brake pads and rotors for 5, Cables tor fraying, crimping and tree operation, 6, Engine oil and transmission fui levels, 7. Headlamp, passing lamp, tail lamp, brake lamp and turn signal operation. : XB9R TOOL SET ‘The Busll XB9R comes with a standard too! sot (stored in the ‘runk) that eorsists of the following: @ Shock Spanner Wrench T2T TORK Wrenen 7/8" Asda Wrench (Hex) Too! Kit Pouch Serew Driver INSPECTING Leak Dye When using leak dye with the black light leak dalector, ad 1/4 02, (7-4 tml) of dye for each 1 quart (0.9 Iter) of fluid Inthe system being chacked, 2003 Buell XB9R: Maintenance 1-1FLUID REQUIREMENTS 1.2 GENERAL FUEL United States System Unless otherwise specified, al fluid volume measuremerits in this Service Manual are expressed In United States (U8) untts-of measure, S22 below: © {pint (US) = 16 fuid ounces (US) © t quart (US) =2 pints (US) = 32 8 02. (US) © 1 galon (US) = aqua (Us Metric System Flug volume measurements in this Service Manual include the metic system equivalents. Inthe metric system, { iter (L) = 1,000 milters (mil), Should you need to convert fram U.S. Uunita-of meaaure ta matric units-ol- measure (or viee versa), refer to the flowing: © fluid ounces (US) x 29.574 = milliliters © pints (US) x 0.473 = liters © quarts (U.S) x 0.966 = Iters © gallons (US) x 3.785 - mers © milters x 0.0888 = fluid ounces (U.S.) © fore x 2.114 = pints (US) . . 281. 02 (US) Wers x 1,087 = quarts (US.) liters x 0.264 = gallons (ULS.) PRIMARY DRIVE/ TRANSMISSION FLUID Use only SPORT-TRANS FLUID (Part No. 9885496 quart size or Part No. S8855-06 gallon size). FRONT FORK OIL Use only TYPE E FORK Oil (Part No. 9984-80). BRAKE FLUID fe (D.O.T. 4 brake fluld can cause irritation of eyes and skin, and may be harmful if swallowed. If large amount of fluld is swallowed, Induce vomiting by sdministoring two tablespoons of est in a glass of warm water. Cail a doc- tor. In case of contact with skin or eyes, flush with plenty of water. Get medical attention for ayaa. KEEP BRAKE FLUID OUT OF THE REACH OF CHILDREN. Fallure to comply could result in death or serious injury. Usa only 0.0.7.4 BRAKE FLUID (Part Na. 99953-007), ‘+2 2003 Buell XBR: Maintenance Use @ good quality unleaded gasoline (911 pump octane 0 higher). Pump octane is the octane number usually shawn on. the gas pump. See 3.2 ENGINE for a detailed explanation of allornative tuols ENGINE OIL Use the proper grade of oil for the lowact temperature expected bafora the next oll change: I IUIs necessary 10 add oil and Harley-Davidson ol is not aveliable, use an oil certified for diesol engines. Acceptable diesel engine oll designations include CF, CF4, CG-4 and CH-4. The preferred viscosities for tne aiese! engine ols, in eecending ordor, are 20WV-50, 15W-40 and TOW-4a. At the first opportunity, see = Buell deaier to change back lo 100, percent Harley-Davidson oil Table 1-1. Recommended Oil Grades co ‘ama. | wma Lege amr. saclQSEYo— | wacosry | carson | Amer | “stu Airwa"| Tees | See or aan | ae aa ae, | vom | ee | er Tamme | oe Tae zowsy | MO% | troy | Oe TE Fopis Fama | Bae Teo | pay wo | too | “are |r a re ae o isl ercy sTable 1-2. Regular Service Inter a 5 ODOMETER READING PERATIONS (see chart code below) “fyecosn deem [Recon gecneu, —Tytese— aaron = Foown= Looow [Sworn cen ~ |[Hiapes etaner baver aaa ‘Cisper as paras wee [Rast pereary chain, eae eae Het ag enn pean) HERES TS aR A = a T qa Feoaen aeoone Ef Waly Feeons gocawa| z erie ana oo | Cees engrnsdeepee — TO [Seng be arr Tati te: x [jst ec cable = guerra cea OS * i [cataract pug ROSS BO AST BTS} h very TED i 24,000 | [Cerner a are pros ad ape ISS cheep ete Coane = thet te Te . See Figure 1-20. Set fres play by tuning adjuster (a. ‘G Tighlon jarn mul (3) against adjuster (4). 4. Slide boot (1) over cable adjuster mechanism, 7 Change or add transmission fluid if necessary. 8. See Figure 1-17, Install clutch inspection cover and gas- ‘eat using thros taatanare and wathere: and tighten to 7- ‘9 fedbs (10-12 Nm). 98. Check eluten cable thee play. See Stop 6 above. 1-22 2003 Buell XBOR: Maintenance Figure 1-22. Adjuating Clutch Free PlayDRIVE BELT SYSTEM 1.9 ne GENERAL The drive belt tension on a new belt wil be considerable tight ‘and will oosen after approximately 1000 miles. The drive batt tension is aulomalieally sdjusted by the idlor pulley. Axie ‘alignment is nat acfustablo, (Chock crivo boll and idler pulley condition: Ale 1900 mile (1600 km) carvioa interval, © AL overy 8000 mile (8000 km) service interval Replace drive belt and idler pullay assembly: © Atevery £5000 mile (24000 kan} service interval. INSPECTION Rear Sprocket Nore Itetvome chins or gouges lo rear sprocket are large enaugh 12 bs harmful thay wil leave @ panier an the bet ace 1. Inspect each tooth of rear sprocket fr a. Major oth damage Large chrome chins with sharp 6968. ©. Gouges caused by hard abject : G. Excessive loss of chrome paling (S08 S162) 2, To check i enrome plating nas wom of, crag scribe or chap knife point across the botom of a. groove (2) {Deteon ti tet with melon pressure 4. Hf eerbe orate point ales across groove without {ggg i of leaving a vistie mark. chrome plaling is sl good if sorte of knife point sigs nan lvoe 2 visite thang itis cuming te bare alummum. A kno poi wl net penatrate the chrome psting 8. Replace rear sprocket # malar tooth damage ois of crvome exits Drive Belt ‘Se Figure 1-27. Inspect drive belt for: (© Cuts or unusual wear pateyns on bath aides of bet. © Quisige edge beveling (8). Soma baveling is common, [but it indicatas thal sprockets are misaligned © Outsice surtace for signs of stone puncture (7). feracks! damage axis near odge of bett, replace belt immodi- alely, Damage 10 center of bet will raquire belt replsoe- ment eventually, but when cracks oxtend 10 edge of belt bolt fluro is imminent. (© Inside toothed portion) of bell far exposed tengile cords (normally covered by nylon layer and polyethylene kayer}. This canaitien will result in belt failure and Indicates wom ‘anamission sprockot teeth, Replace belt and transmis: sion sprocket. © Signs of puncture or cracking al the ase af the belt teeth, Replace belt elther condition exists, Idler Pulley Inspect Ider pulley fer signs of uneven woar. Excessive play ‘or roughness indicatas worn bearings. Replace idler pulley 2s ‘an assembly. See following section. CLEANING Keep dirt, grease, oil, and debris off the belt, idler pulley artd sprockols. Ciean the drive belt with a mild soap and water spray solution as required. Dry thoroughly. De not immerse belt in solution, 2003 Buall XBOR: Maintenance 1-23DRIVE BELT REMOVAL 1. Place a. scissor jack under jacking point and raise rear ‘whee! off ground. For localion of jacking paint see Figure ge. 2. Remove right side rider tootpeg support bracket. See 2.29 FOOTREG, HEEL GUARD AND MOUNT. Remove right passenge: looted support bracket, See Figure 1-24. Remove front sprocket cover (5) by removing fasteners. See 2:30 SPROCKET COVER. NOTE The rear chin falring fasteners must be removed to access the front sprocket cover: Front belt gusrd (3) wall dangle bur ‘Gan NOT be removed st this tima, 5. Soe Figure 1-23. Loosen rear axle pinch fastener (2) 6. Loogen rear axis (1) approximately 15 rotations to: allow partial onion to be removed from rear drive system, Remove idler pulley assembly by removing nuts and washers. See IDLER PULLEY REMOVAL in 1.8 DRIVE BELT SYSTEM 8. See Figure 1-24, Remove lower batt guard {3} by remor ing fasteners (6) 9. Remove upper bolt quard (10} by removing fasteners (7). , NOTE The upper bell quand is attached to the swingarm brace and 237 not be removed from vohicte a is ime 10. Remove swingarm brace, See 2-19 SWINGARM AND BRACE 2 Remove tastonar (8) and spaces oollar (2) between upper belt guard (10), inner belt guard (1) ari Sit: arm brace b, Allow inner belt quard (1) 10 drape. NOTE Inner bell guard does not have to be removed to remove belt orreae wheel 411, Remave unper belt guard (10) by removing fasteners (9) from awingarm brace. When removing or Installing belt, do not bend or twist belt, partially slide belt onto sprocket and “roll” wheel or batt damage will aceur. 42, Side belt ram sprocket and remove, DRIVE BELT INSTALLATION ual When removing or installing belt, do not bend or twist bolt. partially slide belt onto sprocket and “roll” wheel or belt damage will occur. 1. Side belt onto eprockst. 2. See Figure 1-24. Install upper belt guard (10)-t0 swing: farm brace fightoning fasleners (9) 10 12-36 Inti. (1- 4Nm} 124 2003 Buell XBSR: Maintenance 10. “ 12, 18 4, 6 bh p2 Loosely install swingarm Dace. See 2.13 SWINGARM AND BRACE ‘Position the inner belt guard (1) and upper belt ‘quard (10) ano swingarm. Install fastener (8) and spacer collar (2) between upper belt guard (10), inner Belt guard (1) and swingerm brace. Install upper bolt guard (10) and tighten tasteners (7) 10 42-96 In-iba (1-4 Nm), Tighten swingarm brace fasteners to 25-27 ft1bs (94 ‘97 Nm} Install lower bell quaec {5} and tighten fasteners (6) to 12-96 In-iba (1-4 Nm), Install icber pulley assembly tightening washers and nuts fo 99-35 fib (45-47Nm). See IDLER PULLEY INSTALLATION in 1.9 DRIVE BELT SYSTEM. See Figure 1-25, Tighten rear axis (1) a 48-52 tbs (65- 70 Nm} Tighten rear axle pinch fastener (2) to 40a45 flbs (54: 61 Ne. Rotate rear wheal to ensure the bell. doos not make visi bie oF audible contact. |t may be necessary ta loosen belt guardis) to adjust for proper clearance. See Figure 1-24 Install front spracket cover (5) by tightening fasteners to 12G8inIbs (1-4Nm). See 230 SPROCKET COVER, Install chin fairing fasteners and tighten to 96-48 in-tbs (-SNm), See 2.93 CHIN FAIRING. Install ight side rider foataeg mount and tighten fasten- ars to 108-122 in-lbs (12-15 Nm), See 229 FOOTPEG, HEEL GUARD AND MOUNT. Install ght passenger footpeg maunt, use LOCTITE 272 and tighten fasteners to 25-28 N-lbs (34-28 Nm) Remave scissar jack trom motorcycle. ‘axle Pinch bolt fastener Thur 128 Rear Wheel loaning, Right ide1 2 3 4 5 é 2 a 2 10. Innor bett guard Spacer collar Lower belt guard Front belt guard Sprocket cover Sprocket cover fasteners. Lower bet guard fasteners: Upper belt guard fasteners, short Upper belt guard feateners, long Upper bolt guard Figure 1-24, Bolt Guard Assembly 2003 Buell XBSA: Maintenance 125IDLER PULLEY REMOVAL IDLER PULLEY INSTALLATION 4. See Figure 1-25. Loosen rear axle pinen fastener (2) 2. Unthread axle approximately 15 rotations to release ten- fom drive belt 8. Remove front sprocke! cover See 230 SFROCKET COVER. 4. See Figuee 7-26. Remove idler pulley bracket nuts and washers (5) from studs (3). Slide ialer pulley brackst (4) off siuds (3) Ingpect pulley by spinning whee! (1) and chacking for whael bearing wear, 7. If pullay whee! needs replacement, remove fastener (6). ‘washer and nut (2) from idler pulley bracket (4) and discard wheel. Replace wan new pulley wnee! (1) ee NOTE The pulley wheel basrings ean no! bo replaced separately Figure 1-25. Rear Wheel Mounting, Right Side 1-26 2008 Busll XBSR: Maintenance 4. See Figure 1-26. inctall new or existing pulley whoo! (1), if removed, and tighten washer and nut (2) wheal fastener (6) to 96-120 in-s (11-14 Nr). 2. Slide ier pulley bracket (4), washer and nuts (5) on to studs (3) and tighten to 83-95 fells (45-47 Ne). 8. Install front sprockel gover. See 2.90 SPROCKET COVER. Never tighten rear axie with swingarm braee removed. 4. See Figure 1-25, Tighten rear sede to 48-82 ibe (6S. 7ONm. 5. Tighten reer axle pinch fastener (2) to 40-45 fins (54 61 Nm). Wheel Wheel nut stud Idler pulley bracket Idler pulley bracket nut and washer Wheel fastener Figure 1-26. Idler Pulley Assemblya) ‘Sprocket Side of Belt (a) @) Figure 1-27. Drive Belt Wear Patterns Table 1-8. Drive Belt Wear Analysis in Figure 1-27. PATTERN ‘CONDITION REQUIRED ACTION 1 Internal tooth cracks (haiing) [OK to run, but monitor eondion 2 | Extemal tooth cracks Replaco bet 3 [Missing weet Replace bel 4, | Ghinping (net seriovs) ‘OK run, bat monitor condition | 3 Fuzzy edge cord ‘OK to run, but monitor eondition | & Hook wear Replace belt | 7 [Stone damage Fepiace bet if damage is onthe edge 3 Bevel wear (outboard edge only) [OK te run, but monitor condition 2003 Buell XBSR: Maintenance 1-27PRIMARY CHAIN 1.10 INSPECTION ‘Check primary chain tension: 12 Atthe 1000 mile (1600 fo) service interval ‘$ Atevery 5000 mie (2000 km) earview interval thereafter. ‘See Figure 1-28, Measure primary chain tension through the inepacion cover opening. Adusi primary chains not meoting ‘vertical fee play specifications 1. See Figure 1-28, Remove two fasteners with captive \waners sna primary chan inspection cover with g88Ket {rom primary cover. 2 See Figure 1-28. Check pimary chain torsion By mas- suring vertical ree poy. a. Mesure verical free play through chain Inspection ‘cover opening b, Rotate engina to move primary chain to a ottterent position on sprockets. ©. Mesure vertical tras play soveral limes, each ma wih primary chain moved so that the moasurament ig taken with sprockets rolaled to the tightest chain position. 3. Thotightest measurament takan in Stop 2 must be within the specications sted in Table 1-9. necessary, adjust fs described under 1.10 PRIMARY CHAIN in ADJUST- MENT. NOTE The ina! primary chain vertical tee play specication used al the assembly lenis 14-172 in. (6.4-12.7 rum) witha cold engine. The 14 in (6.4 mam} minimum is only allowed! atthe absolute ighiest pont in the drive. as measuréd wit spacial- ized factory equipment. If 4 chain has fess than 14 (6-4 mm vertical fo play (wily @ cold engine). adjust tree blay 10 the “eld” specication of 8-1/2 in. (9.5-12.7 mm). ‘The looser specification wil avoid overfighening. which might oinerwise occur during adjustment using “nan-laciory” equipment and mattods. 4. See Figure 1-28. install primary chan inspection cover and gasket to primary cover using two fastonors wih captive washers. Tighlen fasteners to 40-60 inebs (5- 7 Nm. Figure 1-28. Primary Chain inspection Cover Figure 1-23, Measuring Primary Chain Tension Table 1-9. Primary Chain Tension ] ENGINE [eats rrecruy | [tar mS ae Hot (parmal running | temperature) in | 8485mm | 2003 Buell XBSR: Meintenance 1-29ADJUSTMENT NOTE (1 verigal free play cannot be set within me limits specified, then pimary chein andor chain acfucter are. worn beyond agjusiment limts. Replace parts as necessary. See 6.2 PAI- MARY CHAIN. ‘See Figure 1-80. Loosen looknut (1). 2 Tumashusting fastener (2): 2 Clockwise (inward) to reduce free play. b, Counterclockwise (outward) to increase tree play. 3, Tighten locknut (1) 0 20-25 ftlbs (27-84 Nm) 4. Locknut 2. Adjusting screw Figure 1-30. Chain Tension Adjusting Fastener 130 2003 Buell XB9R: MaintenanceSUSPENSION DAMPING ADJUSTMENTS 1.11 a , GENERAL Before evaluating and adjusting suspension settings, check the motorcycle's tires. Tires must be in geod ¢an- dition and properly inflated. Failure to check the tires could result in death or serious injury. Make all suspension adjustments In one or two efick incre- ments, Agjusing more than one or two clicks at & time may cause you to skip the best anjustment Taat ride afier each adjustment. When an adjustment makes no difference, return to the previous adjustment and try a different approach. IF both preload adjustments are correct, and you have the rebound and compression damping set at the factory recommended points, the motorcyola should handle and ride prop~ erly. I you wish fo fine tune these settings they can be changed according to the following procedures. NOTE Evaluating and changing the rebound and compression damping is a vary subjective process. Many variables affect ‘motorayola handling under different circumstance. Approach all changes carefully and consul Table 1-11 SUSPENSION ADJUSTMENTS Setting Rear Shock Preload The factory setting ls #2 ramp pasition (#7 position being the tallest ramp and maximum preload). See Table 1-10. for recammended spring preload. 1, Remove s0al, See 2.98 SEAT. 2. See Figure 1-31. Change the spring preload by turning the preload adjuster at the upper part af the shock wih ‘SHOCK SPANNER WRENCH (HO-34700-520) or Wrench included in the-toot ict. a. Tum adjuster to seting specified In Table 1-10. Folale adlluster clockwiae to inerease preload. 1b. Rotate adjuster counterclockwise to decrease preload. 3. Install two fasteners and seat Setting Front Fork Preload 1. Sa Table 1-10, Check number af ins (3) 1 be showing {or yaur load condition. 2. See Figure 1-22, aglust preload by tuming the adjuster rut (2) with @ wrench, tg Always adjust-each fork leg to the same settings. Uneven adjustment between left and right forks may lead to a lose of control which could result in death or serious injury. 2003 Buell XBOR: Maintenance 1-31Table 1-10. Recommended Suspension Settings PRELOAD SETTINGS: \ RIDING CONDITION | Rear Setting | Front Setting (Ramp | (Number of | position) nes showing) | Fide, 180 bs (68 Kg) oF ; 7 leas ldo, 150-780 bs (68-88 ko) | (Note; this is the factory * oe: | sing) Fier, 180-210 bs (22-95 ka} ree = geod [Rider 270-260 bs | | 5-143 ka) JassPacrat soot ~ Fier passengerseargo, oe | 250-325 is (113-147 kag 6 | 3 S ‘otal | Rliderepassengerscargo, Maximum Proload Adjustment (Ramp Number 7) 325-00 Ibs (147-177 kg) ‘otal aww Up to 410 ibe (186 kg) of riderepassengerecargo Minimum Prelosd Adjustment (Ramp Number 1) Figure 1-31. Rear Shock Proload Agjustar |. Rebound Adjuster Screw 2. Prajoad Adjuster Nut 3. Four Lines Visible (factory setting) Figure 1-82. Front Fork Prelosd And Rebound Adjuster 1532 2003 Buell XBSR: MaintenanceAdjusting Suspension Damping See Table 1-11. The recommended rebound and comorsson damping satings for vasious toad and ricing eonditons are given inthe table, NOTE All wm settings in Fabio 1-10 are “ums out from maximsurn” That i first gonty tum adjusiment screws tly oloctonise (unti they slop), then tum adjustment serews ‘counterlockwise the amaunt specified in Table 1-F0, Setting Front Fork Rebound Damping 1. See Flqure 1-92. Using 2 screwdriver, tun the slotted dial (1) dlockwise unit stops. This i the maxémum rebound ‘samping setting 2 Then tum the chal eovntorolosteoe the racommondad amount specified in Table 1-11. Setting Front Fork Compression Damping 1. Seo Figure 1-33. Using 2 screwdriver. tun the slatted dial ‘lockwiae until it stops. This Is the maxirmurn comorsssion damping setting. 2, Tren wm tha dial countorclackwise the recommended amount specttied in Table 1-11. Setting Rear Shock Rebound Damping 4. Seo Figure 1-34, Using a screwdriver turn the somted otal @oetnwise until stops. This is the maximum rebound damping sting. 2. Then tum the dial counterclockwise Ihe recommended amount specified in Table 1-11 Setting Rear Shock Compression Damping, 1. Sep Figure 1-95. Using 2 screwdriver tum the sioted dial Clockwise unlit stops. This is the maximum compression damping setting 2. Then him the dlal caunterslackwie the recommended amount specified in Tale 1-11 Figure 1-34, Rear Shock Rebound Adjustment Figure 1-95. Rear Shock Compression Adjustment Figure 1-38. Accessing Rear Shock Compression. ‘Adjuster 2003 Buell XB9R: Maintenance 133Table 1-11. Recommended Suspension Damping Settings is Riding/Road Conditions ‘Counterclockwise Turns, Rear Shock Front Forks Rebound | Compression Rebound. | Compression ‘Smoath surface, aggressive riding, Max feedback (race rack) “Average roads, but high preload (2-up or heavy rider) ‘Average Roacs, sport riding (Noto: this the factory eotting) ‘Moderately rough roads, mare comfort, less sport ough roads, long rides, ‘max comfort setting” 4-84 2008 Buell XBSR-Maintensnce 7 1 a 1A wa 1 14 Ted or 18 12 - 134 2 va 238 Bie |FRONT FORK OIL CHANGE 1.12 \FORK OIL CHANGE Replace fork oil © Atavery 10000 mile (22,000 km) service intarval @ Fork is submergedin water. NOTE {Fork otis emulsified, aerated or fight Brown in calor, then it ‘has bean contaminated by water I this happens, replace Une fork oll seas, Disassembly Nore Record rider suspension stings before cisass6mo 4. Remove front fork.Se0 REMOVAL in 2.16 FRONT FORK. 2. See Figure 1-27, Clamp the FORK TUBE HOLDER: TOOL (Part No. HD-#1177) in a vise and install the Upper front fork in the haiding tool Figure 1-97. Fork Tube Holder (HO-81177) 3. See Figure 1-28. Remove snap ring (2). est 4. Rebound adjuster screw 2. Snap ring 3. Preload adjuster 4. Remove preload adjuster (8) by turing countercioek After fully unthreading preload adjuster (3), gently pull on adjuster 8, Remove fork cap (4) from culter lube. 6. Sea Figure 1-38. Move the fork assembly from the hold ing tool and oamprass fork in thé FORK SPRING COM PRESSION TOOL. | | LL heii Figure 1-38. Fork Spring Compressing Tool 7. See Figure 140. Hold damper rod assembly (8) and remove fark cap (1) NOTE ‘See Figure 1-40. Be careful not ko damage preload pins (2) while helsing damper rod assembly (3), ‘8 Rlamove proload washer (@) and slider i | Fork cap | Damper rad assembly Proload washer Slider piston Figure 1-38. Fork Cap Assembly Figure 1-49, Holding Damper Rod Assembly 2008 Buell KBOR: Maintenance 1-353. See Figue 1-39, Uncompress fork and remove trom FORK SPRING COMPRESSION TOOL Drain and Replace Ol \ 1. See Figure 2-42. Over drain pan, remove spring (15), spring collar (16). and dain fork al Drsin remaining fork oil ty pumping the damping red spprosuimately 8 10 10 times OF until damping rod moves: ‘realy 3. Install the front fork right side up in the FORK TUBE HOLDER TOOL (Part No. HD-41177). 4. Pour7 ox. (204 cc) Inno the Tork pipe. NOTE Use only TYPE & FORK Oil. (Part No. HD-9088480) S. Completely compress front fork and slowly pump the damper rod approximately 12-15 limes or until resistanee is fal 6 Pour? az. (204 cc) more fork ail into the slide pipe. 7. See: Figure 1-41. Acjust fork oil evel with FRONT FORK OIL LEVEL GAUGE (Part No. &-590008) sa that @ is 4.8in. (118 mm) trom the top ofthe fork Lube. Fork Olt Level | SNS 1 2 Adjuster 3. Damper assembly 4, Fork oil lavel | Figure 1-41, Measuring Fork Oil Levat See Figure 2-42. Install spring (16), and spring collar (15), 9. Move fork sesembly from holding tool to the FORK ‘SPRING COMPRESSION TOOL. 1-36 2003 Buell XBR: Maintenance: Reassembly ‘1. See Figure 2-42. ingtall preload washer (5) and sider pation (6). 2. See Figure 1-40. Hold damper rod and install fork op conte damper rod aasembly tightening to 22-30 ffs (30- 40 Nm). Nove ‘Be caret! not to damage preload pins wile holding damper rod assembly (3). 3. See Figure 1-36. Install preioad adjuster (9) back to rider suspension stings. 4. Apply fork oil oF ght grease to o-nngs on prolosd adjuster and install preload adjuster (3). 5. natal nao cng 2). ©. Inetal tnt fore. See FORK INSTALLATION in 2.16 FRONT|. Praload adjuster . Preload adjuster o-rings Fork cap Fork cap o-ring Proload washer Slider piston Inner slider piston o-ring |. Snap ring 1. Rebound adjuster assembly 10. Damper locknut 11. Damper rod assembly 12. Centering plate 13. Ceiling washer 14. Center bolt 18. Collar 18. Spring 47. Spring joint 18. Outer tube Figure 2-42. Front Fork Assembly 2003 Busll XBSR: Maintenance 137STEERING HEAD BEARINGS GENERAL ‘The stecring head bearings on the XBOR are sealed, angular ‘contact bearings and do not require addtional lubrication. ‘Check steering head bearing resistence: ‘© At evary 5000 mile (2000 km) service interval ‘© When storing or removing ine motorcyeie for ihe season. INSPECTION NOTES © Check thal throlle cables de not bind when measuring peanmng resistance. © Slooring head bearings ara sealed and do nat require ‘addtional lubrication. © Steoring heed Bearing resistance ig net actistable Replace bearings hal do nol moet resistance specitica tions. 1. Detach etuten cable al handlebar, 2. Place a scissor jack undor jacking point and raise front ‘whee! off ground. For location of jacking point see Figure 2-98. @warnine Steering must be smooth and free with no binding or interference. Anything Interfering with steering system ‘operation may cause lo83 of vehicle centrol, which could rasult in daath or serious Injury. 3. (Check steering stem bearings for notches by turing front whee! ull ight and then lol, Flapeat if necessary. 4. Next place wheel lacing straight ahead and grabbing both fork cides at the bottom mova front-end forward and back to check for steering head piay. 5. Tp inspect for correct steering head resistance turn front wheel all the way tothe right 6 See Figure 1-49. Hook a spring scale into the hole in the front axe. With scale 90 degrees from fork leg, pull front whee! to center position. a, I should take a maximum of 7 bs. (32 kg) to pull ‘front wheel to center. b. I slooiing head resislanes measurement is not ‘within specification, seé ADJUSTMENT. 7. When adjustment is complete, attach cluich cable and Adjust. $20 1.8 CLUTCH, 438 2003 Buell XB9R: Maintenance Figura 1-43, Measuring Steering Head Bearing Resistance ADJUSTMENT (Dotach clutch cable at handlebar and ensure that throttle ‘eablag do not bind betore measuring steering head Doar- ing resistance, 2. Remove slegring siem pinch fastener at upper fork clamp. 3. Loosen steering stam capnut and back off several turns 4. Remove lower fork clamp pinch fasteners, two per side. 5. Tighten steering stem capnut to 38-42 f-lba (52-57 Nm), 6. Turn front whee! all the way to the right 7. Soe Figure 1-43. Hook s spring scala into the hole in the front axie. With scale 80 Gegroos from ork log, pull front wheel to canter positon The correct resistance is between 4.5-6.5ibs (2.0-2.9 kg) with a maximum resistance of 7 Be. (2.2 Rg). NOTE If the comect specifestion eannet be achieved, the steering esd besrings mus! be roplaced, Sve 2.18 STEERING HEAD BEARINGS. 9. Once correct sieoring head resistance has been verified apply LOCTITE 272 to steering stem pinch bolt, install and lighten to 17-19 filbs (23-28 Nm) 10. Apply LOCTITE 272 ta lower fork clamp fasteners, Install and lighten to 1315 Nlbs (18-20 Nm). 11. When adjustment is complete, attach cluich cable and agjusl See 1.8 CLUTCH. 12, Remove sclseor jack,SPARK PLUGS 1.14 INSPECTION Check spark plugs: @ Inspect at every 5000 mila (8000 km} service interval @ Replace every 10,000 mile (16,000 km) service interval. © Use only Harley-Davidson 10R12A spark plugs (Part No. 27671-01K). 1. Remove lefl side air 8600p to access front cylinder spark: plug. See 2.35 AIR SCOOPS. 2, Disconnect cable from front spark plug. 3, Using & 5/8 in. box end wrench and 5/8 in. spark plug ‘socket, romowe front spark plug. 4. Remove seat, See 2.38 SEAT. 5. Remove air box assembly, See 4.43 AIRBOX, 6. Disconnect cable trom rear spark plug (uss automotive ‘park plug boot ramaver/install il requitédh. 7. Using a 5/8 in, wobble socket and 12 in. extension, temeve tear spark plug 8. Soo Figure 1-44. Campare your observations of the plug ‘daposite with the descriptions provided nelow. Awol, black and shiny deposit on plug base, lec: odes and ceramic insulator tip indicales an oil fouled plug. The condition may be caused by one or ‘more of the following: worn pistons. worn piston rings, worn valves, worn valve guides, worn valve sale, a weak batlory oF @ faulty Ignition system 1b. Ady, Mully or sooty black deposit indicates an airs fuel mixture that is too rich andlor engine idling for exoacsiva periods, eae | aay T Rear srs | Load Capac 405 194 = 1 Rail wait SoniopSpenmexradait — | «24S, | NOTE : Gros Vehicle Weight Rating (GVWR) (maxim allowable loaded vehicio weight) and coespandiing Gross Axle Weight Ratings (GAWR) are given on an infarmation discal cated on the steering head. 180/85 ZR 17 DZO7U Table 2-5. Rotor Runout peor, | we | eT ra a | Lateral _ | 0.0248 0.63 REAR ~ rail vs [tar I a fava Bo not inflate any tie beyond Its maximum inflation Pressure a5 specified on tire sidevrall, Overinflation may ‘eauge tire te sucdenly deflate which could result in death ‘or serious injury. 2003 Buell XMBOR: Chassis 2-1TORQUE VALUES \ TreMs: NOTES: ‘Aon cove asienare TaNe | page 275 Aor fasener aonm | page 262 7 ‘ale pinch lastener, rear SeeiNm | page2t6 2 Axle pinch fasteners, ront 2750Nn | pageeta "| Axle front 5256Nm | ANTISIEZE, Lat handod thread, page2-@ Bank angle sensor T4Nm | page 2-60 7 | Belt guard, upper aanm | pagezsi Brake handiever housing fasteners | 60-00indbs | S10Nm | page225 rake lamp snitch fastener, front TiGinlbs | _O84.0Nm | page225 Brake ne pela tastanor ont | 36-60miba | 47Nm | page22e | Brake line p-ctamp fastener, rear 36-60 inelbs 47m | page?-35 | ‘Brake pedal fastener 22:24 feos s03aNm | LOGTITE 272, page 2.22 Brake pin hanger set, front TA ibs ss49Nm | page229 ‘rake pin hanger eat, ear | Het tebe 45:20Nm | page 2-37 Brake pin plug. rear 22-26 Inibe 2aNm | page2ar - “Brake resewoirlastener, rear O6-120indbs | -4Nm | page278 = CGaiper banjo bol, front 716-20 tbs 2227 Nm | matric, pags 227 | Caliper bano bolt, rear yeonbs | e2a7Nm | page das = eee] Caliper banjo bot, rear 16-20 tubs 2227Nm | page 238 | Calvertieeder vals 36-60iniba | 47 Nm | matin page 222 | Caliper carter, rear 24.26 tbs S295Nm | page 2-16 | Calpgr fasteners, front Tetembe | 2b25Nm | papez2e Caliper mounting fasteners font ssa7hte | a750Nm | page2ze | Caliper mounting large fastener, ear | 1821 tebe 2428Nm | page 238 Caper moaning amallastoner wear | 418m-bs | 12eNn | page208 a | Chin fairing fasteners 36-48 inibs | 25Nm | page2-74 | Giutoh cable p-clamp Teenie | tanm | page2sa | Chachieverclemp pinch taserer | S6-60lmibe | #7Nm | pagu2sa _| (Chteh lever pot fatonar “ao-4gimibs | @SNm | page2Sa | Electronic control module fasteners | 72-06imibs | @-11Nm | page2t | [ Engine shroud air scoop 12.36 Inds 1-4Nm | page276 | | Esnmuat heer mounting nt “Teggimibe [811m | page27 = | Faring support bracket fastener Wits | 2226Nn | poge eee ; | Fisher fastener 30-a9imibe | S5Nm | pago2-00 | Footpeg mount iasteners, der 108-192imbbs | 1215Nm | page2-68 - | Fooiseg maurt paseenget | 25-20 Tbs S0-98Nm | LOCTITE 272, page 2-69 | Fockcap za0tbs | s0-40NM | page242 | | Fock canter bot zaaotiee | aoaNm | page 242 "| 22 2003 Busll XBR: ChassisITEMS TORQUE NOTES Fork damp, lower 13-15 tbs 18-20Nm | LOCTITE 272. page 2-43 Fork lamp, upper 17-19 Ds 2326Nm | LOCTITE 272, page 2-45 Fork damper lockrat | eesonee | 3040Nm | pape 2-4i Frontiender fasteners | ieasimibs | im | page ar "Front iolatr bot sesinns | eesonm | paeoss Frnt ieliorbacktmcutha | ogre | weaoNm | page 253 | [ Font atnarsnutber upper 7236imibe | 14Nm | page ass Frontisolatorthresdad trams insert | 49-51 fits | 66.489.1 Nm | LOGTITE 222.009 2-63 (Fuse tock and relay fasteners 72GSinibs | _GaiNm | page 262 Hand ever pivot fastener soig0intbe | o14Nm | page 224 Handlebar cllpon fastener, left 24-26 frlbs 88.85Nm | LOGTITE 272, page 2-54 - Handisbarcipon fastener, night zee nine | 33350 | LOCTITE272, pago 2-64 Headight fasteners 2025inibe | 2326Nm | page 260 Headlghtsuppor bracket pot fae- | cosogimtbe | e1tNm | page2st Hoel guard fasteners, passenger 48-72 intbs sanm | page 2-69 = Heel guard fastener, rider 7aGimibs | Gti Nm | page 268 Instrument custr tastener 364ainibe | 45Nm | pago 262 | License pate fasteners | se-4ainibe’ | 45Nm | page 278 | Se ae eee Ser a eS Master cylinder banjo bal, rear eid fobs | 2227Nm | page 2-65 Master eytinder cover fasteners, front | 9-13imibe | 1.0-15Nm | page 2.25 | Master evnder mounting tastenes | se72 imine Britim — | page 233 [tarrtaienars 60-70 fib 7anm | page 250 | Muiter mounting block tastaner. front | 22-25 Neds 30-34Nm | page 2-67 (Matec mounting Hocktastener rear | S236 tubs | <249Nm | page 267 | [ Mutter strap fastener, frm 1oei20inibe | 124m _| page 267 Mir strap fastener, rear a860intbs | _57Nm | pave 267 Oiteo0ier air scoop rzo-te4imips | s416nm | page276 Oil plug zeae | s042Nm | cage 2-51 Oiline tings Pedi tebe | S842Nm | page 251 _ i Passenger seat laton cose iniss | 7-11Nm | pape27e Fivot shaft pinch bolt 17-19 filbs. 23.26Nm__| page 251 amar se00p | tesemibe | tanm | page2Te Fear lender fastener 12:06 ths 4oiNm | page 274 Foror mouning fasteners ont Bear ires | 687m | moino, Roplace with new, page 2-13 | Rotor mounting fasteners, rear 25-27 ibs | 3437Nm | motrc. Replace with new, page 2-18 | Salety ntrionk fastener Toit | 087.1Nm | page2 58 | 2003 Buell XB9R: Chassis 2-3mens ToRQUE NOTES Seat fasteners 1238 [ vanm | page 288 ‘noc abso, ower Tone | 29-2eNm | page 2st Shock mounting lastener, upper wssifes | 66-69Nm | page 2-55 Shack remate reserve fastener ser2oiniee | 1etenm | pape2-33 ‘Shack reservoir clamp, rear 120-144 ints | -14-16Nm | pege2-78 ‘Sidestand bracket fastonars 2earnm | 3637Nm | page 284 ‘Sidestand vet bait we20 ne | 2e27nm | page 2a | Sidesland swich fastener SS0inibs | 47Nm | page oes Spreckat caver festanar ye26inies | Anim | LOCTITE 222, page 2-70 ‘Sprockat fasteners 35-07 tes | _48-50Nm | Rplace with new, page 2-18 | Steering stam eap Beaanios | 52-57Nm | page 245 Seeing senpactasenet >| irene | ze2enm | Locwte are pages | Swingarm brace mounting fasteners | 25-27 fHibs 3497Nm | page 2-51 | Swingarm givet shat [24-26 rms e2asnm | page 251 ae | Switch housing fasteners, right | 25-38 in-ibs s4Nm | pape2s7 | tal body work lower [36-48 inabs a5Nm | page 278 | [toa vor usp Treseimee [nn | page 79 [a trameto tame | er2smbs | _291Nm | LOOTITE272, page 278 | Tecacame—S”S™~*~*~S~S*SS S| SRT | pO | “Tum signals and rafectore | 2520miee | 29Nm | pape27@ | Valve stern ut | sossinins | 45Nm | page2-20 = | 2-4 2003 Buoll KBOR: ChassisTIRE SPECIFICATIONS 2.2 \ GENERAL ‘Tires must be correctly matched to wheel rims. Only the ‘tres listed In the fitment tables below can be used for replacement. Mismatehing tlres and rims can cause damage to the tire bead during mounting. Using tires other than those specified can adversely affect motorcycle handling and could result in death or serious Injury. See Figure 2-1. Tite sizee are molded on tne sigomau. Hm 12@ and comour ara marked on the mfn’s exterior suriace Example: MT 8.5.x 17.0 DOT © MT Gesignates the rim-contour, © 35isthe width of the bead seal measured in inches. © 17.0 ig tha normal diameter of the rim in inches, measured at the bead seat diameter Table 2-6. Tire Fitment-Tubeless Cast Wheels © DOT means that the rim meets Department af Transpor- tation Federal Matar Vehicle Safety Standards, ‘See Table 2-6 Figure 2-1, Fim Marnga RIMVALVE | DUNLOP SPORTMAX RADIAL | WHEEL SIZE CONTOUR & ‘& POSITION RIM SIZE, HOLE DIAMETER | TIRE SIZE Tin, — Froat MT35x 17.0 DOT O85in sp0i70 247 DeO7FY MTSSxIZODOT | + 038in. nals ZRn7 D207 ‘Tin, - Rear 2003 Buell XBSR: Chassis 2-5VEHICLE IDENTIFICATION NUMBER. 2.3 GENERAL ‘The [ull 17 digit sorial or Vehicle Iaenttication Number (V.LN.) is stamped on the steering head and on an information decal al the same location, ‘See Figure 2:2. An abbreviated V.LN. is stamped on the front Jef sige of the crankcase, NOTE See Figure 2.9. Always give the VIN. or abbreviated VIN. whan ordering parts or making inquiries about your Buoll motorcycle, Manufacturer: Busll Motoscycie Company vee —Type Designation Firebott XBR ee 12 = Word maine 57 = Caltomia | f Horsepower Code | ode Yeer-2008 | 2 Mitnaensrestn Buc Yh | . ‘Sequential __ | 40007-20000 = Word a ey a ) *Vavias - can be 0-9.0r X ‘Sampis V.IN. as it appears on the steering head - 4MZAX12J132400001 Sample abbrevisted VIN. 2s t appears on the lef side crankease - AX123400001 Figure 2-3. Vehicle Identification Number (VIN) 28 2003 Buell XBR: ChassiaWHEELS. — ee \GENERAL Good handling and maximum tire mileage are dltectiy ralated to the care of wheals and tires. Regularly inspect wheels and tires for damage and waer. I handling problems occur, see 4.21 TROUBLESHOOTING or Table 2-7 See 1.7 TIRES AND WHEELS for tre pressures. Keep tires: inflated fo the recommended air pressure. Always dalance Ine whee! after replacing a tire, Do net Infiste any tire beyond Its maximum inflation Pressure as specified on tire sidewall. Overinfiation may ‘cauae tire to-sucidenly deflate which could result in death ‘or serious injury. ~ TROUBLESHOOTING ‘See Figure 2-4, Cheek tte Inttation preasure at loast once ‘each eek. At the same time, inspocttire tread for punctures, ‘cuts, breaks and other damage. Repeat the inspection before Jong trs. Figure 2-4. Checking Tire Inflation Pressure 2003 Buell XBGR: Chassis 2-7Table 2-7. Wheel Service CHECK FOR | Loop axes REMEDY Tighten front axle with LOGTITE ANTI-SEIZE to si-a1 ftbs (53-56 Nm) Tighten ear axde with LOCTITE ANTISSEIZE to 48-52 fils (65-70 Nm). Excessive side-play or radial (up-and-awn) play In whee! nus, Replace wheel besrngs, Fims and tires out-of-rue sideways: should not be more than 0.080 in. (2.03. mm). place ris, See 2.8 TIRES. ime and ties outot-round or eccentric | with nub; should not be mare than 0,090 in | Replace rime. See 2.8 TIRES. gba eee ee Floplace as described under 2.5 FRONT WHEEL, 2.6 REAR WHEEL and 2.8 TIRES. (Correct tre and whee! balance, ‘Steering head bearings, | Iniste tres to corect pressure See 1.7 TIRES AND WHEELS | static balance may be satisactory if dynamic balancing lacities are not | available, However, cynamic balancing is strongly recommended. | Check for proper torque nd replace worn or damaged besrings. See 1.13, ‘STEERING HEAD BEARINGS, Damper tubes. (Check for leaks. See 2.18 FRONT FORK. ‘Shock absorbers. (Check damping action and mounts. See 1.11 SUSPENSION DAMPING ADJUSTMENTS. ‘Swingarm bearings. a To prevent death or serious injury, use RNING ‘guidelinas when Installing & new tire or repairing a flat: 1. Always locate and eliminate the cause ture failure. | (check for proper torque and replace wom er damaged bearings. See 2.19 SWINGARM AND BRACE. A Buell recommends replacement of sny tire punctured or damaged. In some cases small punctures In the tread ‘area may be repaired from within the demounted tira by your Busll desler. Speed should nat exceed 50 mph (60 km/h) tor the first 24 haurs after repair and the repaired ed the following of the original 2. Donot patch or vuleanize a tire casing. These procedures weaken the casing and increase the risk of blowout. 3. The use of tires other than those specified can adversely affect handling which cauld result In death ‘or serious injury. 4. Tires and wheels are critical Items. Since the servicing of these components requires special tools and ‘skills, Buell recommends thet you see your desler ‘or these services. 28 2002 Buell XBOR: Chosale tira should NEVER be used over 80 mph (129 km/h). In ‘emergency situations, It a temporary repair Is made, ride slowly with as light of a load es possible until the tire is Permanently repaired or replaced. Failure to follow this, warning could result in death or serious injury. Replace excessively worn tires. Excessively worn tires adversely affect motorcycle traction, steering and han dling and could result In desth or serious Injury. At requiar intervals of 2500 miles (4000 km) or whonover handling imegularties are noted, perform the recammendad serviga checks. See Table 2-7. It bres must be replaced, same as original equipment tires must bs used. Other tires may not fit comecty and may be hazardous tose.FRONT WHEEL 2.5 _—$ —____ —_ \ REMOVAL 4. Place a scissor jack under Jacking paint and raise tron wneet cil ground, Forloeaton of jacking pom see Pegure 2-8. NOTE De mot operate fron! brake lover with front wineel removed oF Caliper pistons may be forced out, Resesting pistons requires caliper disassembly. 2 Flerove the right side fender fasteners See 2.51 FEND- ERS. 3. ce Figure 26. Looeon front axdo pinch factonors (2) {metric} on front fork. ~~ “Ale (left handed thread) NOTE 2. Front axle pinch fasteners (2) (metric) The front axl is left anced thread. 5. See Figure 2-8. Raise tne whee! up until the rotor clears the caliper and rotate the fork log countercociowies slowing whoo! clearance for removal 6. Remove wheel 4. Remove axle (1) Figure 25. Frent Whee! Mounting Figure 26. Front Wheel Removal and Installation 2003 Buell ABSA: Chassis 2-9DISASSEMBLY Bearing Removal ‘ NOTE On single alse whowis, atways remove the Drake disc sido frat if the wheel has two brake discs, remove the left bearing fist, 1. See Figue 2-7. Remove wheel bearings. using BUSH- ING AND BEARING PULLER (Part No. B42383-7) and WHEEL BEARING REMOVER AND INSTALLER (Part No. HD-44060). 2. Sparingty anply Extrome Pressure Lubricant (J-26444-A) 40 the threads of the short forcing screw (1) to prolong ‘Service life and eneure emacth oporation. Figure 2-7. Assemble Pullor 3. Assemble he shor forcing serew (1), put (2), Nloe bearing (3). washer (4) and bridge (5) from the Wheel Bear- ing instale/Fiemover (HO-48060). 4, See Figure 2-8, Insert the Front Wheel Bearing Remover Collet (8-43893-7) into the whee! bearing until it fully seats apsinst the bearing. 210 2003 Buoll XBOR: Chassis Figure 2-8, Install Collet and Ball Bearing 5, Ingert tne pall bearing into he collet 6. Ses Figure 2-0 Thread the puller assembly (1) into the collet (2) 7. Hold the collet (2), and tum the foreing screw (3) 10 ‘oxpane the collet Figure 2-8. Expand the Collet 8, Sea Figure 2-10. Place the bridge (1) agsinat the whacl hu, 8. Hold the forcing screw (2), and turn the nut (3) clockwise: Until the bearing is free of the hub.Figure 210, Remove the Bearing 10. Soo Figure 2-11. Loosen the: nut (1), and back off the bridge (2). Hold the forcing screw (3) while holding the ‘collal (4) lo romave the forcing ecraw from the colle! 11. Remove the ball bearing (5) and whee! bearing (6) from the colet (4h. 5. Ball bearing 6. Whee! pearing Figure 2-11. Ramoving Bearing frem Pul 12, See Figue 2-12. Remove the spacer. Figure 2-12. Remove the Spacer 18. Repeat Stops 4.12 or ine bearing on the other side of the wheel Front Rotor Removal 1. Ses Figure 2:18, Remove and discard ratar maunting fasteners (7). Remove and inspect brake rotor (6) for wear and warp- Ing. See 1-7 TIRES AND WHEELS. iemave drive bushings (8) and discard Fiemove washers (9) and discard, Fiemove rotor spring (4) and discard. CLEANING AND INSPECTION AwarNinG Never use compressed alr to “spin-dry" bearings. Very high bearing speeds can damage unlubricated bearings. ‘Spinning bearings with compressed air can also cause a bearing to fly apart, which could result In death or eer ous injury. 1, Ingpact all parts for camago or exceseive west. NOTE XB whee! beannge are designed as sealed bearings which fre not intended to be disassembled, serviced or cleaned with sofvents. Cae) Always replace brake pads In complete seta for correct brake operation. Never replace just one brake pad. Fall Ure to Install brake peds as a set could result In death or serious injury. 2. Inspect brake rotor and pads. Sat 1.6 BRAKE SYSTEM MAINTENANCE, 2003 Buell XBOR: Chassis 2-11ASSEMBLY 1. See Figure 2-18, Install spacer (5) 2, Ingtall new wheel bearings (2} Into hub using suitable crlver. Press on outer race only NOTE Frese the rotor sige bearings in first ensuring itis seated om the shoulder of the wheel. Followed by pressing the siternare side unlit contacts the spacer. Do not allow brake fluid, bearing grease, lubricants, atc to contact brake rotor or reduced braking ability will ‘occur, whieh eould result in death or serious injury. Bearing Installation NOTE On single wise wheels, always instal the brake alse side fst. | the wheel has two brake discs, instal tho laff bearing first. “The following procedure describes the bearing installation for ‘he tront whoek;the procedure for the rear wheel is the same, 1. See Figure 2-13. instal he Backing Plata (B-43903-11) ‘onto the long forcing screw from the Whee! Bearing InstallenRemover (HD-4060), with the smaller diameter toward the wheel hub. Insert the forcing serew ana back: ing plate into the wine! nub. eaesas | Figure 2-13, Install the Backing Plate (B15983-11) Forcing Screw 2. See Figure 2-14 Sparingly apply Extreme Pressure Lubreant (1.29444) to the theeads of the ong forcing screw (1) to prolong service life and ensure smooth operatn 242 2003 Buall XBR: Chassia 3. Ingest a new wheal bearing (2) squarely into the hub, vith the letered aide pointing aut (away trom the whes)). 4. Slide the Front ¥heo! Bearing Installer Tool (B-43003- 10) (8) onto the forcing screw (1), with the smaler dlam- ter toward the beering bore 5. Install a washer (4), Nice bearing (5) and nut (8) onto the foreing sorew (1). 6. While holeing the forcing aerew (1), tighten the: nut (6) until the bearing tush with the hub. 7. Remove the nul, bearing. washer, Front Wheel Bearing Installer (8-43093. 10) and forcing scrout 1. Long forcing serew 2 Wheel 3. Front Wheel Bearing Installer (B-43983-5) 4. Washer eens Sane | Figure 2-14. Install Bearing 5. See Figure 2-15, Remove the Backing Plate (Ba98s- 1) from the long forcing screw. Reinstall the Backing Plate onto tne forcing screw, wih the smaller dameter toward the hex-head. 9. Insert the forcing screw through the wheel nub on the opposite side at the whee!Figure 2-15. Insert Forcing Screw and Backing Plate 10. See Figure 2-16. Install the spacer. Figure 2-16. Install the Spacer 11, See Figure 2-17, Ingenta new wheel bearing (1) ‘squarely info the hub, with the Iettared side pointing out (may from the whee!) 12. Slide the Front Wheel Bearing Installer Teo! (B-43992- 10) (2) onto the forcing sorew (3), with the smalier diam- ‘ater foward tho bearing bore, 13. Install 8 washer (4), Nice bearing (5) and nut (6) onto the ‘forcing screw (2). NOTE ‘See Figure 2-10. Center the spacer while installing the wheal bearing, Failure to center the spacer could cause the bearing pt ta pullin straight 114. While holding the forcing screw (3), tighten the nut (6) until the bearings flush with the hub. 15. emove tha nut, bearing. washer, Front Whee! Bearing Installer (B-18883-10) and forcing screw. 416. Install the wheel Ses INSTALLATION in this esetian ‘according to the procedure in the Service Manual 1. Wheel bearing | 2. Front Wheel Bearing installer (8-43993-10) } Forcing screw | a Washer | | Figure 2-17. Install the Bearing Front Rotor Installation 4. See Figure 2-18. Install new spring (4). 2. Install new washers (9) 3. Install drive bushings (8) Into rotor. NOTE Note the identifying mark of rotor is up and raaius end at drive bushing (6) toward center of whesi. See Figure 2-18, 4. See Figure 2-18, Align reference dot an front rotor with the valve stem. 5 Install new rotor mounting fasteners in a criss-cross pat- tem around the wheal to insure proper fting between rolor, fastener and bushing. Tighten to 25-27 flbs (84- 37'Nm. Rotor mounting fasteners must be seated into drive bushings and drive bushings must be fitted into: rotor properly. Failure to comply may affect braking ability and lead to brake failure which could result in death or ser ‘ous injury. UT! 2003 Buell XBSR: Chassis 2-13INSTALLATION 1, Flalge front wheel to allow clearance for the caliper to ‘sang under the front rotor. 2, Install caliper, 1&. Align wheel so that rotor mounting fasteners strad- de caliper, 1b. Rotate right tront fork counterclockwise lo align call par with rotor. c. Lowerfrant whee! into-caliper assembly. 3. Install front axis. @. Apply LOCTITE ANTH-SEIZE LUBRICANT to axe, See Figure 2-5. With pinch fasteners (matric) loose, insert threaded end of axle (1) through lef sic fork, ‘wheel hub and thread into right fork, Compress the front suspension to make sure it is trae and not binding. d. Tighten axe (1) (motric) to 99-41 fla (62-56 Nm). NOTE The front axle is eft handed thread. 4. See Figure 2-6. Tighten the front axle pinch fasteners (2) to 20422 fdbs (27-30 Nm). 5. Install ight side tender fasteners. See 2:21 FENDERS. weeps Front wheel spacer Front brake rotor Rotor mount fastener (6) Drive bushings (6) Weshers (6) wane Figure 2-18, Front Wheel Assembly 214 2009 Buell XBOR: ChassisREAR WHEEL 2.6 \REMOVAL CLEANING AND INSPECTION aneennecineiann arate ee Never use compressed alr to “spin-dry” bearings. Very rc ny, ee Do not operate resr brake pecs! with sar whes! removed or Spinning beerings with comprassed air can also cause a caliper pision may be iorced out. Reseating piston requires bearing to fly apart, which could result In death or seri- caliper disassembly. ous injury. 1. Inspect all parts for damage ar excessive wea. 2. inspect Draxe rotor. See 1.6 BRAKE SYSTEM Mamnere- NANCE DISASSEMBLY 1. Remove sprocket 4. Remove sprocket fasteners and washers, Discard fastonors. b. Remove eprockat from wheal 2. Remove rear rotor 8, See Figure 2-25. Remove and discard rotor mounting fasteners (1). 2. Remove dive belt See 1.9 DRIVE BELT SYSTEM. Remove and inspect brake rotor for wear and warp ing. Seo BRAKE ROTOR THICKNESS In 16 BRAKE SYSTEM MAINTENANCE. 3. Remove rear whee! bearings using BUSHING AND BEARING PULLER (Part No. 643960-8) and WHEEL BEARING REMOVER AND INSTALLER (Part No. HO: 44060). Figure 2-19. Rear Brake Caliper Carrler Fasteners NOTE The procedure for the rear whee! bearing remousl 19 the ‘same as front wiisel bearing removal. See Bearing Removal In2.5 FRONT WHEEL 4. Remove rear whee! spacer (4), 1. Axle 2. Pinch bolt fastener Figure 2.20. Rest Wheel Mounting, Right Side 3, See Figure 2-29, Remove rear axis (1)- 4, Remova rear wheel 2003 Buell XBOR:Chassic 2-15= Figure 2-21. Removing Wheel Bearing ASSEMBLY tr Da not allow brake fluid, bearing gresee, lubricants, etc. te eontaet brake rotor or reduced braking ability will ‘occur, which could result in death or serious injury. 1. See Figure 2-28. Install whee! besring (2) on rotor side ot motorcycle, 2. Install rear wheel spacer (4) 3. Install whoo! bearing (3) on sprocket side of motorcycle. Remove rear wheel bearing. ‘The procedure for the rear wheat bearing installation |S {he same aa front whee! boaring installation. See Bear- ing Installabon in 2.6 FRONT WHEEL. 4, Install sprocket a. Position sprocket (8) on whee! (5) keeping lip of _sprockel facing the inside b. Install new sprocket fasteners (7) and washers light ‘ening to 95-27 ftps (48-50 Nm). 5, See Figuie 2-28. Install rear rotor (2) a. Position rear brake rator (2}on whe! (5) Install brake: rotor (2) with mew rater mounting t23- anaes (4) ant tightan ts 95.97 ft (4.37 Nm) 216 2008 Buell XBOR: Chassis INSTALLATION 1. See Figure 2-25, Install the rear axle by threading partially info swingarm. a. Cento wheel In swingarm and lower bike to align swingarm and hub. 1b. Soe Figure 2:22, Coat the axle with ANTI-SIEZE LUBRICANT. c. Slide axl theough right side of swing arm and whest nub. 2. Inotall drive belt. Soa ORIVE BELT INSTALLATION in 1.8 DRIVE BELT SYSTEM. 3. Install ier pulley. See IDLER PULLEY INSTALLATION. in 1.9 DRIVE BELT SYSTEM. 4, Inotall pprackst cower. See 2.30 SPROCKET COVER, Never tighten rear axle with swingsrm brace removed. 5, See Figure 2.20. Tighien rear axle (1) to 48-82 ft-lbs (85- 7ONM). & Tighton pinch fastener (2) on right side of swingarm 10 agea5 felbs (54-81 Nm) 7. See Figure 2-19. Install caliper camer and tighten fas- fener to 24-26 "lbs (G2-95Nm). See 2.15 REAR BRAKE CALIPER, NOTE The brake pads may becarte cocked and wail nat allow the rotor to skge Into the caliper. Press on the brake pad from the ‘uiside of the caliper to straighian out dhe pad. oe Always test motorcycle brakes at low speed after servic ing or bleeding system. To prevent death or serlous injury, Buoll recommends that all brakes repairs be per formed by # Buell desler or other qualified mechanic. . Figure 2-22, antiSelze Lubricant LocationFigure 2-23. Rear Wheel Assembly 2003 Buell XBOR: Chassis 2-17CHECKING CAST RIM RUNOUT 2.7 GENERAL CChack wheels for lateral and radial runout betore installing & new tira Rim Lateral Runout 1. See Figure 2-24. Install tnving artor in wheol hub and piges wheel b WHEEL TRUING AND BALANCING ‘STAND (Part No. HD-99800-80). 2. Tighten arbor nuts so hud will tum on its bearings. 2. Cheek rim Istoral runout by placing a gauine dl or cal indicator near the rim bead. Replace wheel it lateral runout exceeds specification snown in Table 2-2, Rim Radial Runout 1, See Figure 2.25. instas ruing arbor in wheet hub: and place whee! In WHEEL TRUING ANO BALANCING STAND (Part No. HO-$3500-80), 2, Tighten artor nuts 60 hub wil (urn on its bearings. 2. Check radial runout as shown. Replace whee! it runout exceeds specification shown i Table 28 Table 2-8. Wheel Runout | CAST WHEEL Nn i) a Maximum Lateral Sunset | 0.080 4.02 Maximum Facial | banal | a.030, ore 248 2003 Buell XBSA: Chassis Wheel Truing and Balancing Stand (Part Na, HD-99500-80) Wheel Trulng and Balancing | Stand (Part No. HD-89500-80) |TIRES 2.8 \GENERAL Inspect tires Yor puncturas, cuts, broaks and woar al least weeny. Cais) © Always check both tire sidewalls for arrows Indicat- Ing forward rotation. Some tires require different tire rotation depending on whether tire is used on front or roar wheel. Inatalling & tlre with the wrong rotation could result in death oF serious injury. © Dunlop front and rear tires for Buell motorcycles are not the same. They are not interchangeable. Use front tite ONLY for a front tire. DO NOT put s rear tire ‘on the front of a vehicle. Failure to follow this warn= ing could result in death or serious injury. py Some tires have arrows molded Into the tre sidewall ‘These tires should be mountad on the rim with the arrow pointing in the direction of forward rotation. The yellow sircle on the sidewall is a balance mark and should be aligned 180 degrees tram the balsnes mark (blus dot) on ineide ot rim. : Pry bead over rim edge and remove tire from rim REMOVAL rors 1, Remove wheel from motorcycle. See 2.5 FRONT WHEEL or 2.6 REAR WHEEL, titer ‘en Lubricate rim flange and both 3, Soo Figure 2-26, Loosen both tre beads from rim flange. ee: Do not use excessive fores when starting bead over rim. Excessive force may damage tire or rim and adversely affect handling which could result in death or serious injury. 4. a bead breaker machine is not available, attach RINE PROTECTORS (Part No: HD-01289) to the rim. Using lire tools (oot sharp instruments), star upper bead over ‘2x92 of rim at valve. Repeat all around rim until first bead 5, See Figure 2-27, Push lower bead into rim wall. an one ‘ide and insert tre tool underneath bead from opposite ‘ide, Pry bead owes rin edge. Remove tre from rim. 6, Remove valve stem if tia damaged or leaks. 7. Mount tire an TIRE SPREADER (Part No. HD-21000) or inspection and repair procedures, boads before installation Figure 2-28. Starting Bead on Rim 2003 Buell XBOR: Chassis 249a CLEANING AND INSPECTION 1. Clean inside of tre with ory 29 2. himis dry ar corroded, csan witha si wire brush 8. Inspect tie for wear and damage. Replace wor or dat aged tires, Seo 1.7 TIRES AND WHEELS. INSTALLATION Pe a Only install original equipment (stock) tire valves and valve caps. A vaive or valve and Gag combination that ie too long may Interfere with (strike) adjacent components, damage the valve and cause rapid tire deflation. Rapid tire deftation could cause loss of control. These events could recult in death or serious injury. Eau) Aftermarkot valve caps that are heavier than the stock cap may have clearance st slow speeds; but, at high speed the vaive/cap will be moved outward by centrifugal force. This outward mavemsnt could cause the valvelcap te strike the adjacent eomponenta, damage the valve and cause rapid tire deflation. Rapid tre deflation could cause losa of control, Thess events cauld result in death 9r serious injury, 1. Damaged or leaking valve stems must be replaced, 2. Install and tighten fastener lo 40-44 in-tbs (4-5 Nm). 3. Thoroughly lubricalo-rim flanges and both beads of tie with tire lubricant. 4. See Figure 2-28, Starting al the valve stem, start first Dead Into the Fim wall using a bead breaker machino. I no machine is available, work bead on as far as possible by hand. Use # tire tool to pry the remaining bead over rim flange. 5. Sari 180" from valve stem hole and place second bead fon im. Wark bead onto rim with tire tools, working toward valve in both sirections. a De not Inflste over 40 psl (275 kPs) to seat the beads. Inflating the tire beyand 40 psi (275 kPa) to seat the beads can cause the tire rim assembly to burst with force sufficient to cause death or serious injury. if the beads fail to seat to 40 psi (275 KP8), defiste and retubricste the bead and rim and reinfiate to seat the boads, but do not ‘exceed 40 psi (275 kPa). 6. Apply alrio stem 10 seat beads on rim. it may be neces say 10 use 9 TIRE BEAD EXPANDER (Part No. HD+ £28700) on tha tre unl beads Seal on rim 2-20 2003 Buell XB9R: Chassis Figure 2-30. Checking Tire Redial Runout Table 2-9. Tire Runout RUNOUT Ww. Fadil | 0.060 Lateral ‘0.080 wi 152 2.08Checking Tire Lateral Runout 1. See Figure 228. Tum wheel on axle and measure ‘amount af displacement from a fixed point 10 lie slo wall (Chock tre eed for appropriate runaut specification. See Table 2-9. f runout is more then specication, remove {ice from rim. 3, Check rim bead side runout. See 2.7 CHECKING CAST FIM RUNOUT. Replace ima not meeting specifications. 44. Install tire nd check again for tire tread lateral runout Checking Tire Radial Runout 1. See Figure 2-30. Tum wheel on axle and measure tread redial uncut 2. Check tire tread for apprapriste uncut speciicaion. S68 Table 2-8. If runout is rhore then specication, remave {ie from ti, 3. Cheoicrim bead runout. Sea 27 CHECKING CAST RIM FUNOUT. Repiade ris not meeting specifications. 4. Install lire and check ire tread radial runout again ADJUSTMENT Wheel Balancing Wheel balancing is mcammended to improve handling and reduce vibration, especially al high road speess. In most cases, static balancing using WHEEL TRUING AND BALANCING STAND (Part No. HD-99500-80) will produce ssatistaclory results. However, dynamic balancing, ulizing a wheel spinner, can be used to produos finer tolerances: for better high-speed handling characteristics. Follow the insiruc- tions supplied with the balanee machine you are using, NOTE 1 the rear whee! on the XBSA will not fit.on @ stack dynamic soln balance shafi, use the Carlson whee! balance shaft (Part No, AFIS). WEIGHTS FOR CAST WHEELS ‘The maximum weight permissible to accomplish balance ls: © 1.002. 289) total weight applied to the tront wheel. © 2.00z (669) total weight applied to the rear wheel. Wheels should be balanced to within 1/402. (7 g) at 60 MPH (97 KWH, See Figue 2.31. Use only WHEEL WEIGHTS (Part No. 49692947) which have special set-achesive backings, Apply WHEEL WEIGHTS te the fial surtace of ite wheel rim, 4. Make sure that area of application is completely clean, dry and free of olland grease. 2. Remove paner backing Irom welght. For additional ache- ‘she swengih, apply three drops of LOCTITE SUPER+ BONDER 420 to adhesive side of weight 9. Locate a flat eurface on the right side of the wheel rim sand press weight liemiy in place, holding for ten seconds. 4. Aloe eight hours for adhesive lo curd completely before: using wheel NOTE whee! assembly fa out af speciation (1-az front, Z os rear) rotate tire and rebatance uni! whee! is within specification. Figure 2-31. Wheel Weights 2003 Bucll XBOR: Chassis 221BRAKE PEDAL REMOVAL ‘See Figure 2-22, Remove cater pin (7) and discard, Fiemove devie pin (2), Flomove pedal fastener (5). Flemove shift brake pedal sioeve (é). Remove pedal bushings (3). Fiemove brake pedal (8). INSTALLATION ‘Seo Figure 2:92. Install pedal bushings (3). Install shit brake pedal sleeve (4). Install brake pedal (6) using LOCTITE 272 and tighten fastener (5) 10-22-24 tebe (20-33 Ne). 4. Install eleva pin (2). 5. Install new colter pin (7) Rear master cylinder body Clovis pin Pedal bushings (2) Shift brake pedal sleeve | Brake pedal fastener Brake pedal Cotter pin, 1 2 a 4 5 6. 7. Figure 2-32, Brake Pedal Assembly 2:22 2003 Buell XB9R: Chassis.FRONT BRAKE MASTER CYLINDER AND HAND LEVER 2.10 \REMOVAL NOTE Steps 1 i not required or removing whe master cyiinder assembly from the handlebars. Do not alsassemble masicr cylinder unless problems are experienced. 1. Drain brake fluid into a suitable container. Discard used fluid aceanding to local las ‘2. Inslall a length of plastic tubing ovee caliper bleeder valve, Place free oft in a suitable eomainer b. Open bleeder valve (metric) about 1/2-tur, Pump brake hand lever to drain brake fluid. Tighten bleader valve 10:36-60 Inlba (4-7 Nm). UTION Damaged banjo bolt sesting surfaces will leek when reassembled. Prevent damage to seating surfaces by carefully removing brake lina components. 2, Sep Figure 2.35. Ramove the banjo bolt (12) (metic) land two copper washers (14) 19 disconnect brake fine 143) from master cyinder (4). Dlseard capper washers. ‘3, ‘Unpiug terminal (11) to detach brake lamp ewitch (19). NOTE The indviaval parts of the brake lamp switch are not service able. Replace switch upon failure. 4. Remove mounting clamp fasteners (5) (metric) to detach master cylinder reservoir (4) from handlebar. DISASSEMBLY Brake Hand Lever 1. Seo Figure 2-85. Remove pivot bolt nut (8) (metrioy and pivot sit (15) from hand lever pivot 2. Detach front brake hand lever assembly (7) trom hand lever pivot 3. Detach tront brake lamp switch (10) by removing the ‘switch fastener (2). Front Master Cylinder ‘See Figure 2-35. Remove master cylinder cover (2) by Femaving cylinder cover fasteners (1) 2. Discard excess brake fluid 3. See Figure 2-94. Remove rubber boot (1) and wiscard. 4. See Figure 2:33, Depress pision assembly (1) and remove internal snap ring (2) and discard, &. See Figure 2-95. Remove piston assembly (6) from front master eviinder reservoir (4) and discard. ‘CLEANING AND INSPECTION ‘Clean brake system components using denatured alce- hhol. Bo not use mineral-base cleaning solvents, such ss ‘gazoling or paint thinner. Use of mingralsbase solvents ‘eauses deterioration of rubber parts that continues after assombly. This. may result In improper brake operation ‘which could resuit in death or serious injury. 1 Clean ait parte with denatured slenhol or DOT & BRAKE FLUID. Do not contaminate with mingral oil or other solvents, Wipe dry with a clean, int tree cloth. Blow ‘out driled passages and bore with a clean air supply. De ot use 2 wice or similar instrument to-clean driled pas- ‘sagas in bottom of reservoir. 2. Inspect pisten bore in master cylinder housing for scor- ing, pitting or corrosion. Repisce housing if any of these ‘conditions are found, 9. Inspect oullel port inet mates with Draka ling fiting. As a criteal sealing surface, rapiace housing if any scratches, decis or other damage Is noted. |. Piston assembly 2. Snap ring Figure 2-33, Piston Assembly in Master Gylinder 2003 Buell XBOR: Chassis 2-23ASSEMBLY Brake Hand Lever 1. See-Figure 2-85. Lusrieste plvot bolt (15) with LOCTITE ANTL-SBIZE, Front Mi: asier Cylinder 2, Align bole in hand lever (7) ith hole in hand lever pivot 1. Obisin PISTON ASSEMBLY KIT. and ingtall pivot Dott (15) trough lop of hand lever pivot 2. Soe Figure 2-24. Assemble new piston components ‘and tighten to 80-120 in-tbs (3-14 Nm). Placing small end of spring (5) behind primary seal of piston (4). ves 8. Lubrioste master cyincier body and piston seals with special lubricant found in the service parts kit When installing snap ring to secure master cylinder, be ‘sure the snap ring snaps Inte place. Fallure te do se-¢an result in Improper brake operation which could result in death or serious injury. 4. Soe Figure 2-25. Insert piston assembly (6), spring first, into master cylniser resorvoir (4) S. See Figure 2-33, Secure piston assembly (1) wih a new sap ring (2) 1 6 See Figure 2-94, Install age on boot {1} inte groove on piston (3) 1. Ridge on rubber boot 2) Snap ring 3. Groove on piston Primary seal of piston 5. Spring Figure 2-34. Front Master Cylinder Piston Assembly 1. Reservalr cover tasteners 2. Rosorvair cover 3. Reservoir cover gasket 4. Master cylinder reservoir 5S. Master cylinder housing fasteners (metric) 6. Piston assembly 7. Brake hand lever 8. Pivot bolt nut (metric) 9. Brake switch fastener 10, Brake switch 11, Brake switch terminal 412, Banjo bolt (metric) 13. Brake line 14, Copper washers 15. Pivot boit Figure 2.95, Front Brake Hand Lever Assembly 2-24 2003 Buell XBSR: ChassisINSTALLATION 4. Sas Figure 2.35. instal front brake lamp suitch (10). Install brake lamp: awitch (10) with switch fastener (9) andl tighton to 7-10 Ines (0.81.0 Nm), b. Gonnect brake ewiteh terminal (11) ta brake lamp ‘switch (10) & Test gatich action. Tang on switch must release when hand lever is moved. 2. Install master cylinder to handlebar by fastening lamp with fasteners and tighten to 80-90 In-lba (9-10 Nm. a) Use only copper crush banjo wrashors (See Parts Catalog for Part No.) with D.0.T. 4 brake fluld. Earlier sitver banjo washers are not compatible with 0.0.T. 4 fluld and will not seal properly over time, Fallure to comply mey adversely affect braking ability and lead te brake failure ‘whieh could result in death or serious injury. To avoid leakage, verity that banjo washers, banjo bolt, hydraulic brake line and master cylinder bare are com pletely clonn. 3. See Figure 2-35. Connect brake line to master cyinder using two new copper washers (14) and banjo batt (4) (metric) ana tighten to 16-20 Fibs (22-27 Nem. See Figure 2-26, Very brake lamp switch wiros are tight 5. Soe Figure 2-25, Remove two master cylinder cover screws (1), cover (2) and cover gasket (3) 6. See Figure 2-7. With the master oylindor in a level posi tion, add D.O.T. 4 BRAKE FLUID. Bring fluid level to within 1/8 In. (3.2 mm) of mokied bass inside front master cylinder reservoir CG \Vorify proper operation of the master cylinder relief port. 1A plugged or covered relief port can cause brake drag or lockup, which could result in loss of vehicle control ‘which could result In death or serious injury. 7. Verify proper operation of the master cylindar relief port. ‘Actuate the brake lover with the reservoir cover remaved. ‘Assign spurt of faid will break the surfoce i al intemal ‘components are working properly. 8. Bleed brake system. See 1.6 BRAKE SYSTEM MAINTE- NANCE 9. Ses Figure 2-36. Altach master cylinder cover (2) and ‘corer gasket (3). Tighten to cover fasteners (1) 10 9 18 Imdb (1.0-1.5 Nm). Cas) Always test motoreyele brakes at low speed atter servic- Ing or bleading system. To prevent death or serious Injury, Buell recommends that all brake repairs be performed by 2 Buell desler or other qualified technician. Check for proper brake lamp operation before riding motorcycle. Visibility is a major concern for motorcy- lists. Failure to nave proper brake lamp operation could ‘egult In death or carious injury. 10. Tarn ignition key switch to ON. Apply brake hand lever to test brake lamp operation. Turn ignition key switch 10 OFF one Figure 2.36. Brake Lamp Switch Connactors Figure 2.37. Brake Fluid Level (Standard Brake Reservoir Shown} 2003 Buoll XBSA: Chassis 2-25FRONT BRAKE LINE 2.11 REMOVAL 1. Drain brake fluid into @ suitable container. Discard of Used fluid according to local laws. ‘4. Install a length of plastic tubing over caliper blesder ‘valve, Place free end in a suitable container, b. Open bieeder valve (metric) about 1/2turn. Pump brake hand lever to drain bake fluid. 4. Tiahion bloedor valve to 96-80 in-lbe (4-7 Nm 2. Sea Figure 2-38. Remove p-clamp (1) detaching brake line from right side of lower fork clamp. Damaged banjo bolt seating surfaces will leak when reassembled. Provont damago to seating surfaccs. by ‘carefully removing brake line components. 3. See Figure 2-25. Remove master oylindar banjo bolt (12) (metric) and two copper washers (14) to disconnect brake line from master cylinder (4). Discard copper washers 4. See Figure 2-38. Romove caliper banjo bolt (5) (metric), two copper washers and wire form (3) to disconnect brake line (2) trom caliper Discara-copper washers, 5. Carefully inspect the brake line for dente, cuts, ehatfing or other dolocts. Replace the brake line Hany damage is noted. INSTALLATION Caen ‘To avold leakage, verity that gaskets, banjo bolt, hydrau- nd master cylinder bore ere completely 1. See Figure 2-25. Connect brake line (13) ta master cylin ‘dor (4) using two mew copper washers (14) and a banjo bolt (12) (matric), Loasely install bolt inte master cylin ‘er. 2, Route the brake line from the master cylinder to-the cal ber, See D.1 HOSE AND WIRE ROUTING for front brake ling routing. Use only copper crush banjo washers (See Parts Catalog for Part No.) with D..T. 4 brake fluid. Esrller silver banjo washers are not compatible with D.O.T. 4 fluid and will Rot seal properly ver tims. Failure to comply may adversely affect braking ability and laad to brake failura which could result In death or serious injury. 2:28 2003-Buell KBR: Chassis ed To avoid leskage, verify that gaskets, banjo bolt, hycraue lic brake line and caliper bore ars completely clean. Install brake line to caliper. & See Figure 2:38, Install new copper washer, brake line (2), new copper waster and wire form (3) onto banjo Bat (5) by Finger tighten nanjo bolt (6) onto front ealipor boing ‘careful not to pinch wire form (3) while tightening, ire form should rotate around banlo bol resty. and clock © Twist brake tine (2) into-wire foern (3) spi wire form agains! bleeder valve (4). Tighten p-ciamp with fastener (1) on lower tripe clamp to 36-60 ines (4-7 Nem) P-clamp Brake line Wire form Bleeder valve Banjo bolt Figure 2-38. Front Brake Lina5. See Figure 2-38. Tighten master cylinder banjo bolt (12) (metric) to 16-20 feibs (22-27 Nm. 6. Seo Figure 238. Tighten brake caliper banjo bol (5) (enetric) to 18-20 f-lbs (22-27 Nm). Always teat motorcycle brakes at low speed after servie- ing or bleeding system. To prevent desth or sorious Injury, Busll recommends that ll brako repairs be performed by a Busll dealar or other quslitled mechanic. 7. Install blaedar valve: if removed. Refill master cylinder ‘and blood brakes, See 1.6 BRAKE SYSTEM MAINTE- NANCE. Check for proper brake lamp operation befors rising motarcyele. Visibility Ia a major concer tor motorey- liste. Failure to have proper brake lamp operation could result in death or serjous Injury. 8, Tum ignition key swlten t0-ON. Apply beaks hand lever to test brake lamp operation, Turn ignition key switch to Loox. 2008 Buell XBOR: Chassis 22FRONT BRAKE CALIPER 2.12 REMOVAL 1. Drain rake fluld Inio a suitable container. Discard used {uid eccerding to local laws, 8. installa length of plastic tubing over caliper bleeder valve, Plaoe free end in a suitable container. b. Open bleeder valve (metric) about #/2-turn. Pump brake hand lever to-drain brake fui. Tights Lots wel ba 30-00 intl (4-7 Nn). Damaged banjo bolt seating aurfaces will leak when reassembled. Pravent damaye to seating surfaces by carefully removing brake line companents. | | 5 Mounting astaners (2 2, See Figure 2-40. Disconnect brake line st caliper. Sae 2.11 FRONT BRAKE LINE Figure 2-40, Front Brake Celiper Mounts 8. Remove caliper mounting fasteners (5) 4. Slide caliper down the tnior to clear fork lower and then remove off rotor, DISASSEMBLY 1. See Figure 2-81, Remove pin hanger set (1), caliper pad spring (2) and brake pads 2 Spit caliper by removing caliper asteners (3) 3. Ses Figure 2-42. Remove and discard o-ring (6). 4. See Figure 2-89. Remove pistons using s BRAKE PIS- Pin hanger set TON REMOVER (Part No. 8-42887). Caliper pad spring | 3. Caliper fasteners Figure 2-41. Ped Spring (Typical) — Figure 299, Removing Pistons (B-42887) 5. Remove and discard top and botiom seal. 228 2003 Buell XBSR: ChassisCLEANING AND INSPECTION INSTALLATION Clean brake eystem components using denatured alco- hel. De net use mineral-base cleaning solvents, such as gasoline or paint thinner. Use of mineral-base solvents Causes deterioration of rubber parts that continues after assembly. This may result in improper brake operation which could result In death or serious injury. 1, Clean all paris with denatured sloohol or D.OT. # BRAKE FLUID. De not contaminate with mineral oll or ther solvents. Wipe dry with a. clean, lint fees cloth. Blow out dled passages and bore with a clean alr Supply. Do ot use a wire or similar Instrument to cian drilled passages. 2, Carefully napect all components, Replace sny parts that ‘=ppear damaged or wom. Do not hone caliper piston bore. ‘Always replace brake pads in complete sets for correct twrake operation. Never replace just one brake pd. F ure ta inatall brake pads as a $¢t could result in death or sarious injury. 3, Inspect brake rotor and pads. See 1.6 BRAKE SYSTEM MAINTENANCE, 4.” Check rotor eurface. Replace if warped or badly scored. ‘Sop Table 2-10. Table 2-10. Front Rotor Runout wm i Rag ous | Lard oe _—| ASSEMBLY 1, See Figuie 2-42. Inatall pistons and o-ings. a. Lubricate new o-rings (6), pistons (5), and caliper pision bores with 0.0.1.4 BRAKE FLUID: Install two new o-rings (6) in groaves of each piston bore, ‘¢.Ingtallpistona (6) in each piston bore. 2. Install new o-ings (8) between caliper halves, 3. Clamp caliper together with callper fasteners (11) and sighten to 15-19 fllbs (20-26 Nm). ‘See Figure 2-42. instal brake pads (10) Install pin hanger set (1) and tanten to 11-14 felba (15- 19Nm). 3. Rotate front fork counterclockwise and Install caliper on caliper mount. Using LOGTITE 272. tighten fasteners (9) to 35-97 fibs (47-50 Nm} 4. Rotale tront forkicaliper clockwise and slide caliper onto rotor. Fd Use only copper crush banjo washers (See Paris Catslog for Part No.) with 0.0.7. 4 brake fluid. Earlier silver Banjo ‘washers are net eempatiple with D.O.T. 4 Tula ang wilt ‘not seal proparly over time. Failure to comply may adversely attect braking ability and lead to brake failure ‘which could result in death or serious Injury. 5, Install brake line to caliper. See 2.11 FRONT BRAKE UNE 6. Bleed front brokes. See BLEEDING BRAKES in 1.6 BRAKE SYSTEM MAINTENANCE OG Check for proper brake lamp operation before riding motorcycle. Visibility is a major concern for motorcy- ‘clists. Failure to have proper brake lamp operation could reeult in death or serious injury. 7. Tum ignition key swatch to ON. Apply brake hand lever 10 ‘teat brake lamp operation, 2003 Buell XBSR: Chassis 2-29Figure 2-42. Front Caliper Assembly 2-30 2003 Buell XBOR: ChassisREAR BRAKE MASTER CYLINDER 2.13 \REMOVAL 1. Drain brake tig Into a sutable container, Discard used ‘fuid according to local laws. a. Install a length of plastic tubing over caliper bleeder valve. Piace tres endin a suitable container. b. Open bleeder valve (matric) about 1/2-tuen, ‘6. Pump brake foat pedal to drain brake fluid. d._Tighton bleodar valve to 36-60 inlbs (4:7 Nm). 2 Remove brake psdal. See 2.9 BRAKE PEDAL. 3. Remove heel guard Sse 220 FOOTPEG, HEEL ‘GUARD AND MOUNT. 4, Soe Figure 2-47, Remove brake reservoir hase at master ‘eylncsr. Damaged banjo bolt aurfaces will leak when reassembled. Prevent damage to seating surtsces by carsfully removing beaks line components 5 Romova seat. Sea 2.38 SEAT. 8 See Figue 243. Disconnect brake light connector located undior the seat Figure 2-43. Brake Line Switch Connector 7. Remove right side rider focipeg mount. See 229 FOOT PEG, HEEL GUARD AND MOUNT. 8, Soa Figure 2-47. Remove banjo bom (2) (metric) and two ‘copper crush washers (3) to detach brake switch (1) from master cylinder (4). Discard copper crush washers, 9, See Figure 244. Remove fasteners (2) (metric) 19 ‘detach master cylinder (4) from rider fooipeg mount. Brake line Banjo bolt (metric) Fasteners (2) (metric) (Master cylinder body ‘Clamp Remote reservoir hose a | Figure 2-44. Rear Master Cylinder Mounting 10. See Figure 2-45. Detach remote reservoir 8. Remove top clamp (4) on hose connected to master eyvtingar. b. Remove fastener (2) to detach reservoir (1) from frame if necessary. Reservoir Fastener and washer Remote reservoir hose Clamp Figure 2-48. Romote Reservoir 2003 Buell KBSA: Chassis 2-31DISASSEMBLY ASSEMBLY 1. See Figure 2-46. Slide rubber boot on rod assembly (3) ‘away from master cylinder body (1). 2. Dépress rod assembly (8) and remove inteenl snap rink (2). Discard snap ning. 3. Remove piston sesembly (4) from master cylinder body () 1. Loosen adjuster locknut on the rod assembly (2) 5. Remove tha clavis from the rod assembly (3) NOTE Do not disassemble master oylinder unless problems art experienced, Discard ail seals during tne disassembly proce- ‘dure, Install a complete rebuild kit upon ascomty. CLEANING AND INSPECTION Clean brake system components using denatured alcohol. Do not use mineral-base cleaning solvents, such as gasoline or paint thinner. Uso of mineral-base solvents ‘causes deterioration of rubber parts that continues after ‘seaembly. This may result in improper brake operation which could result In death or serious injury. 1. Thorougniy clean master cylinder and all brake system componenis. Stand master cylinder on wooden biocle ar towel to protect seating auriaces. & Examine walls of master cylinder reservoir for seratches and groaves, Replace if damaged. 1b. Verity that vent holes on master cylinder are com pletely open and free of dict or debris. 2. Inapect boot on front of master éytinder tor cuts, teara or (general deteriaration. Replace if necessary. 2-32 2003 Buell XBSR: Chassis 4. Obtain PISTON ASSEMBLY KIT. 2, 1. Master cylinder body 2. $nop ring 3. Rodassembly 4 Platon sesembly 5 Seals Figure 2-48. Master Gylinder Internal 2. See: Figure 2-48. Assemble new piston components placing small end of spring behind primary seal of piston . 3. Lubricate master cylinder body (1) and piston saats (5) with D.O.T. 4 BRAKE FLUID, Place round side of rod assembly (2) over piston, Depress piston (a) Into master cylinder body (1) and ‘secure with anew snap ring (2). Snap ring must be snapped into the groove of tne master cylinder body. Hf the snap ring ia nat properly installed, improper brake operation could result In death or seri- ‘oua injury. 5. Tuck rubber boot-on rod assembly (3) into master cylin ‘dar body (1).INSTALLATION 1, See Figure 2-47. Install master cySinder (4) anta foolpeg mount with fasteners (11). Tighten to 72-86 in-lbs (&- 11Ne. 2. Install rear brake switch (1) and banjo bolt (2) and new copper crush washers (3). Tighten to 16-20 fabs (22- 27 Nm). 3. Install iooipeg mount lo frame. Soe 2.29 FOOTPEG, HEEL GUARD AND MOUNT. CS Use only copper crusis banjo wershers (See Parts: Cally for Part No.) with 0.0.7. 4 brake fluid. Earlior silver banjo washers are not compatible with D.O.T. 4 fluld and will not geal properly over time. Failura to comply may agversely affect braking ability snd lead 10 brake failure ‘which could result in death or serious injury. ‘To avoid leakage aftor assembly, verity that banjo wash- ‘ers, banjo bolt, hydraulic brake line and bore of master ceylinder are completely clean. 4, See Figure 2-45, Gonnect remote reservoir @. If removed, allach remote reservolr (1) to frame using clamp fastener (2). Tighten to 48-72 indbs (648.1 Nm), Attach hose (3) lo rear brake reservoir using clamp 5. Soe Figure 2.43. Connect brake line ewiich connector under seat . Install heel guard. See 2.28 FOOTPEG, HEEL GUARD AND MOUNT. ~ Install rear brake pedal. See 2.9 BRAKE PEDAL ° ‘Adjust rear braka podal, See BRAKE PEDAL ADJUST- MENT in 1.6 BRAKE SYSTEM MAINTENANCE. 9. Inslall master cylinder to brake pedal. See 2.9 BRAKE PEDAL, aT ‘Always test motorcycle brakes: at low speed after servic~ ing or bleeding systom. To prevent death or serlous Injury, Suell recommends that all brake repairs be performed by Buell dealer or other qualified mechanic, 10. Add brake fluid and bleed brake system, See 1.6 BRAKE SYSTEM MAINTENANCE, Cad ‘Check for proper brake lamp operation before riding motorcycle. Visibility Is a major concem for motorcy- cllsts. Fallure to have proper brake lamp operation could result in death or serious injury. Brake line Copper washer Rear master cylinder body Clovis pin Pedal bearing Sloovo Brake pedal fastener Brake pedal Cotter pin Fear master eylinder mount serow Figure 2-47, Rear Master Cylinder Assembly 2003 Buell XBSR: Chassis 233REAR BRAKE LINE 2.14 REMOVAL 1, Remove seat See 2.88 SEAT. wa To protect against accidental startup of vehicle and possible personal Injury, disconnect the nogative battery cable before proceeding. Inadequate safety precautions FOUIS eause 8 battery explosion, which could result In ddoath oF serious injury 2. Weoanneet Dattery Dy untneacing rastener removing negative cable (black) from battery firs. See 7.4 BAT- TERY MAINTENANCE 8 See Figure 2-48. Disconnect brake ne connector from ‘under seat in the front of the Batory 4. Rlemow right side heel‘ quard. Seo 229 FOOTPEG, HEEL GUARD AND MOUNT, 5. Drain brake ful into a suitable container. Discard used fiuid sccording to local laws. 2, Install a leng@h of plastic tubing over caliper bieader valve, Plaoe frae end in a suitable conlaines Open blooder valve (meta) about 12-tum, Pump brake foot pedal to drain brake Mui. dd, Tighlon blesder valve 199-60 Inaba (4-7 Nm). 6. See Figure 2418, Remows p-clamp (3) and wire form (2) ‘securing brake line (1) tothe left side of swingarm. Damaged banjo bolt sesting surfaces will leak when reassembled. Prevent damage to seating surfaces by Carefully removing brake line components. 7. Remove banjo bolt (4) from rear caliper, Discard copper washers. 3. See Figure 2-50. Remove brake line switehvbanjo Balt from rear master cylinder. Discard copper washer. 9. Remove brake tine trom matorcycie. NG 2-94 2003 Buell XBSR; Chassis sep Brake fine Wire form P-clamp Banjo bert Figure 249, Rear Brake Line Figure 2-50, Rear Brake Line Switch/Banjo BoltINSTALLATION 4. See Figure 2-50. Install brake line switch’banjo bolt with Rew copper washers to the master cylinder. Tighten to \ 16:20 Nps (22-27 Mm), NOTE Tighten the right side banjo bait with FLARE NUT SOCKET tool (SNAP-ON Part No. FFX?) ora crowsfoat ean Use only copper crush banjo washers (See Parts Catalog ‘for Part No.) with D.O.T. 4 brake fluid. Earlier silver banjo washers are not compatible with 0.0.7. 4 fluid and will not seal properly over time. Failure to comply msy adversely affect braking ability and lead to brake failure which could result in death or serlous injury. 2. Install brake line switchibanjo bolt and mew copper washers to rear caliper Tighten to 16-20 filbs (22- 27 Nm), . 3. See Figure 2-40, Secure brake line (1) to lah side of ssuingarm with p-clamp (3), wire form (2), and tighten to 96-00 in-lbe (+-7Nm). See D.1 HOSE AND WIRE OUTING tor brake line routing. 4. See Figure 2-51. Connect brake line awitch connector undemeath sez. See D.1 HOSE AND WIRE ROUTING ‘or brake line routing. 5. install rignt nee! guard. See 229 FOOTPEG, HEEL ‘GUARD AND MOUNT. 6 Bload brakes. See BLEEDING BRAKES in 1.6 BRAKE ‘SYSTEM MAINTENANCE. Oia Always connect the positive battery cable first. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery ‘explosion which could reeult in daath or serious injury. 7. Install battery by threading postive cable {red} into threaded hols fret tightening to 72-06 in-lbe (8-11 Ne. ‘See 1.4 BATTERY MAINTENANCE 8. Install seat. See 2.38 SEAT. Check for proper brake lamp operation before riding motoreycia, Visibility is & major cancer for matorcy- lists: Fallure to have proper brake lamp operation could result in death or serious injury. 9. Tur ignition kay ON, depress rear brake pedal and ‘check for proper brake light operation, ‘After completing repairs or bleeding the system, always. tast motorcycle brakes at low speed. If brakes ere not ‘operating properly or braking etficleney Is poor, testing at high speeds could result in death or serious injury. 10. Test ride motorcycle and check for proper brake opers- ‘ton, 2003 Buell XBQR: Chassis 2-95REAR BRAKE CALIPER REMOVAL NOTE Stops { and 2 are not required tor detaching caliper from rator. Drain tid only when disassembling caliper. Damaged banjo bolt seating surfaces will leak when reassembled. Prevent damage to seating surfaces by ‘caretully removing brake line components. 1. Drain brake fluid into & suitable container. Discard used Nui according to local laws, 5. Install length of plastic tubing over caliper bleeder ‘valve, Plaoe fres end in a suitable container. ©. Open bleeder valve tmetle) about 1/2-1ur, c. Pump brake foot pedal to drain brake fluid GL Tighten bieeder valve to 96-60 In-tbs (4-7 Nm). 2. Flemove banjo bolt connecting brake line to rear caliper. See 2.14 REAR BRAKE LINE, 3. See Figure 2-51. Remove caliper mounting fasteners (6 and 7) DISASSEMBLY 1. Sea Figure 2-51. Remove pin plug (6) and pad hanger (metric) to free brake pads. 2, See Figure 2-83, Remove spring clip (1) 3. See Figure 2-54. Remove piston (3) using BRAKE CALI PER PISTON REMOVER (1) (Part No. B-42887) wilh ‘adaptor (2) 4. Rlemove two o-rings irom groove in caliper bore and ois card. 2-96 2003 Buoll XBOR: Chassis | 1. Brake line 2 Banjo bolt (metric) 3. ‘Copper washers (2) 4 Blacder valve (meizic) & Pin plug &. Small caliper fastoner 7. Larger ealiper fastener 8. Caliper mounting fasteners Figure 2-51. Rear Brake Caliper 1. Clip 2. Rear caliper mount Figure 2-52. Caliper Mount GlipCLEANING AND INSPECTION Giean brake system components using denatured alcohol. Do not use mineral-base cleaning solvents, auch as gasoline or paint thinner. Usa ot mineral-base solvents Causes deterioration of rubber parts thst continues after ‘assembly. This may result in improper brake operation whlch could reault In death or serious injury. 4. Olean all parts with denatured alcohol or D.O.T. 4 BRAKE FLUID. Do nol contaminate with mineral ail oF ‘other solvents. Wipe dry with a claan.fint free cloth. Blow ‘oul dled passages and bore wit @ clean air supply. Do rot use a wire of similar instrumont to clean drled pas- ‘sages. 2. Carefully inspect all components, Replace any parts that ‘appear damagad or worn. Do not ane caliper piston bora : 3. Inepact brake rotor. &. Measure rotor thickness. leplace If minimum thiek- Ness ls lese than 0.18 in. (d.§ mm) Check rotor surtace. Replace if warped or baci scored. See Table 2-11 Always replace brake pads In complete sets far correct brake operation. Never replace just one brake pad. Fall- ure to Install beake pads as a set could result in death oF serious injury. 4. Inspect brake pads for damage or excessive wear. Replace both pads as a set if the friction material of ‘elNor pad ig wor 19:0.04 In. (1.0 mm) oF less. ASSEMBLY 1. See Figure 2-53. Place clip (1) inside caliper body as shawn, NOTE To ensure proper brake pad-fo-brake rotor clearance when the caliper is installed, piston must be pressed all the way into the bore whenever new brake pads are used. 2. Install pistons and o-tings. 8. Apply 2 light eoat of 0.0.7. 4 BRAKE FLUID to o- rings, piston and caliper piston bore. b, Place two new o-rings inside aroaves of piston bore. Install piston inside caliper body. 3. See Figure 2-58. install brake pads (3) using pad hanger and pin plug (2). 6. Install pad hanger pin (metric). Tighten to 11-14 fe lbs (15-19 Nm). b. Install pin plug. Tighten to 22-26 Invibs (2-3 Nm). 4, Install a new bieeder valve (metric) if necessary and tighten to 36-60 in-lbs (4-7 Nm). @) 1. Clip 2. Pin plug and pad hanger (metric) 3. Brake pads (2) Figure 2-53, Brake Pads Brake caliper piston remaver Figure 2-54, Removing Rear Brake Caliper Piston Table 2-11. Rear Rotor Runout | RUNOUT nN mn Radial 00177 0.45 Lateral 0.39 | corsa 2003 Buell XBR: Chassis 237°INSTALLATION 1. See Figure 2-52. Install caliper mount clip (1) if removed. 2 Ses Figure 2:51. Install caliper assembly on caliper ‘mount. Brake pad surlaces must face rear brake rolor 4. Install large caliper screw (7) (metric) tighlening to 18-21 felbs (24-28 Nm. Install small caliper sozeve (6) (metric) tightening to 14-46 felbs (19-24 Nm). ¢. Install ealiper carrier onta swingarm tightening call por carrer fastoners (8) 10-24-26 fslbe (35-85 Nm). ead Use only copper crush banjo washers (See Parts Catslog {or Part No.) with D.O.T. 4 brake fluld. Earlier silver banjo washers are net compatible with D.O.T, 4 fluid and will not seal properly over time. Failure to comply may adversely affect braking ability and lead 10 brake failure which could result in death or serious injury. Cure To avoid leskege, verify that gaskets, banjo bolt, hydraulic brake line and caliper bore are completely clean. 3. See Figure 2-51. Connect brake line (1) fo caliper using {wo new capper washérs (3) and banjo bolt (2) (metric). Tighten to 16-20 tips (22-27) 4. Dopross rear brake pedal several times. 10 set brake pads to proper position wilhin caliper. Bleed brake system. 5. Verify proper fluid level in reservoir. Aarne Always test motorcycie brakes at low speed after sorvic~ Ing or bleeding system. To prevent death or serious injury, Buell recommends that all brake repairs be pet formed by 2 Buell dealer or other qualified mechanic. 6. Turn ignition key switch to ON. Apply brake pedal te test brake iamp operation. Turn ignition key swileh to LOCK. Awannine Check for proper brake lamp operation before riding motorcycle, Visibility Is a major concern for motorcy- cllats. Fallure ta have proper brake lamp operation could result in death or serious injury NOTE Avoid making hard stops for the first 100 mites (160 km) 10 fallow Rew brake pads fo "wear in” properly with the Lake rotor. 2-98 2003 Buell XBR: Chassis Figure 2-55. Rear ReservoirFRONT FORK 2.16 , GENERAL ‘The front fork consiate of two telescoping outer tube/inner slider assemblies. Each assembly has an intemal compression spring which supports the forward weight of the venicle ‘and rider. The compression apring extends and retracts to Cushion tho ride over rough or irequiar road surfaces. An cil filled damping mechanism controls the telescoping action of each lubeislider assembly, See 1.11 SUSPENSION DAMPING ADJUSTMENTS for ~ mere information. REMOVAL ~~ 1. Remove tront fonder. See.2.31 FENDERS. 2, emove front wheel. See 2.5 FRONT WHEEL. 3. Remove caliper mounting fasteners. See 2.12 FRONT BRAKE CALIPER. 4. Seo Figure 2-56. Loosen upper and lower fork. clamp pinch fasteners Figure 2-56. Upper and Lower Fork Clamp Pinch Fasteners 5S. See Figure 2-87. Remove fork trom upper fork clamp and. slide the stopper ring up and over the top of the fork. 6. See Figure 2-69. Remove fork from lower fork camp (6), 7. Ropoal 4 through 6 on opposite side Figure 2-57. Stopper Ring DISASSEMBLY NOTE Record rider suspension satiings before disassembly. 1. Flamove front fork. See REMOVAL in 2.16 FRONT FORK. 2 See Figure 258. Clamp the FORK TUBE HOLDER TOOL (PartNo. HD-41177) in a visa and instal he upper font fork in the holding toot. Figure 2-58. Fark Tube Holder (HD-41177) 3. See Figure 2-59. Remove snap ring (2). 12003 Buell XB9R; Chassis 2-39Rebound adjuster screw ‘Snap ring Preload adjuster Fork cap Prejoae pins ‘ Proload washer Slider piston Naoko o Figure 2-65. Fork Gap Assembly 4, Remove preload adjuster (3) by wing counterciock. wise, NOTE Alter fully uattweading preload aduster (3). gently pull on duster 5. Remove fork cap (4) from outer lubé, 6. See Figure 2-60. Move the fork assembly trom the hold. Ing too! and compress fork in the FORK SPRING COM PRESSION TOOL, = 7. See, Figue 2:61. Hold damper rod assembly (3) and remove Tork cap (1). Figure 2-60. Fork Spring Compressing Tool NOTE See Figure 261. Careful not to damage preload pins (2) while holding damper rod assembly (3). 8. Remove proload washer (¢) and slider piston (5) 2-40 2003 Buell XBOR: Chassis 1. Forkeap 2. Preload pins 3. Damper red assembty 4. reload washer 5. Slider piston Figure 2-61. Holding Damper Rod Assembly ©. Soe Figure 2:60, Uncompress fork and remove trem FORK SPRING COMPRESSION TOOL. 10. See Figure 2-67. Over dain pan, remove spring (16) ‘pring colar (15), and drain fork ci 11. Drain remaining fork ol by pumping the damping rod (11) spproximataly 8 to 10 times o° unll damping rod moves tree. 12, Clamp fore upside dawn in the FORK TUBE HOLDER ‘TOOL over drain pan allowing fork oi to drain. 12, Fomove center bot (14) 1 relegse damping rad assem. by (11). NOTE Be careful not ta dros damping rod assembly into ail pan when remeving canter tt 14, Remove centering plate (12) tram dampaning rod (11), and Be careful not to scratch the slide pipe ar the auter tube. Improperly operating forks may lead to a loss of control whieh could result in death or serious: injury. 18. Ramova duct seal (26) to access oll seal stopper ring (25) 16, Feelease tne olf seal stopper ring (25) out from the outer tube with a amall pry teal 17. Using a slide hammer action, remave the alice pipe (27) trom the outer tube (18). 18, Remove the side bushing (21) from slide pipe by prying the slide bushing at the spit NOTE Careful not to over expand siide bushing. 19. Remove guide bushing (22). seal spacer (23), oll seal (24), slonper rina (19) and dust sea! (28).Damper Rod Disassembly IMPORTANT NOTES See Figure 2-67. Disassembly of damper rod is nol required Uuniess damper lackrut (10) nas been moved. if damper roc ‘needs servicing refer to the Fireboit Parts Catalog (Part No .99574-03¥) for kit information If damper Iocknut has been moved, proosed with tho Follow lng disassembly and assembly procedures for seting the cor rect range of motion. 1. See Figure 2-59, Lightly tu the rebound adjustar screw (1) counterclockwise til it stops. 2. See Figure 2-67. Holding the damper locknut (10), unsoraw the rebound adluster assembly (9) and remove ‘rom damper rod assembly (11) 3. Remove damper lockrut (10) Irom damper rad assembly mm. CLEANING AND INSPECTION 1. Thoroughly cloan and Inspect all parts. Replace any parts that are bent, broken or damages. 2. See Figure 2-67, Check the slide pipe (27) and outer lube (18) for score marks, scratches and excessive or abnormal wear, Replace if worn or damaged. 3. Chack the slide bushing (21) and the quide bushing (22) for excessive wear or scratches. Replace Il damaged or 4, Replace the stopper ring (19) it dictortod, 5. Measure spring (16) fres lenath. Replace springs sharter than service weer limi of 9.13 in. (282 mm). 6. See Figuro 2:62, Measure lide pipe runout. Replace pipe ituncut exceeds the service wear limit of 0.008 in. (02 mm. Figure 2-62. Pipe Runout ASSEMBLY Damper Rod Assembly Noto Skip to ork assembly damper rod assembly was not disassembled 1. See Figure 2-67. Fully thread the damper rod locknut (10} 0010 damper rod (11) clockwise til it lightiy bottoms. NOTE Set bon forks 10 the exact same suspension sotings 2. Aust rebound assembly for proper range of mation 2. Lightly turn the rebound adjuster screw (9) counter loctewioe ti it stope. 1. Tum the rebound adjuster screw three full tums lockewise, 3. Fully thread rebound adjuster essambiy (3) onto the damper rod assembly (11) until tightly bottoms. Do not tighten. 4. Thread the damper locknut (10) until Eettome lightty on the rabound adjuster assembly. Do not tighten 5. Turning the rebound adjuster screw (8) caunter clockwise three full tueng or until stops. & Tighten tne damper locknut (10) to 22:30 tbs (30- «49.Nm. 7. Rlepeat for other fork assembly. | foes 1. Fork cap assembly 2. Rebound assembly Figure 2.63. Rebound Assembly and Fork Cap Assembly Fork Assembly 1. See Figure 2-67. Wrap the end of the slo pipe (27) and the side bushing channe! with tape to avoid damaging the ol seal ip when instaling 2. Insiall a mew dust seal (28) and stopper ring (19) oto the sha pipe (27). 3. Coat the coating ips of tho new oil seal (28) with fork cll + sealing grease and install onto the slide pibe with ts marked side lacing the dust seal (26) emove the tape from the side pipe enc. Install the seal spacer (23), the quide bushing (22) and the slide bushing (21) onto the slide pine (27). Goat the slide pushing (21) end the guide bushing (22) ‘with foro um! N ‘Ths outer tubs can move freely up and down an the side pipe. Always held both the slide pipe and outer tube to prevent damage to bushings and seals. 7. See Figure 2-67. Drive the guide bushing (22) with the ‘seal spacer (28) and oll seal (24) into postion in the ‘outer lube using a FORK SEAL DRIVER (Part No. B- 43721), See Figure 264 ‘8, Install the cil seal stopper ring (25) and a new dust seal 28). 2003 Buell XB9R: Chassis 2-418, Pigee the fork in the FORK TUBE HOLDER TOOL (Part No. HO-41 177) and clamp into vise horizontally. 10, Soo Figure 2-67. Install the centering plete (12) onto the ‘amper assembly (11) and insert the damper sesembly Inta tne shoe pipe (27) ‘1. Replace the sealing washer (13) and canter Batt (14) (metric). Tighten the conter bolt to 22-90 tts (20- 40.Nm). 42, Flemove the tront fark from the FORK TUBE HOLDER TOOL and install back in the FORK TUBE HOLDER TOOL vertioaly NOTES ‘The recommended fork oil Fytaullc fork oll Type "=" Use only TYPE E FORK Oil. (Part No. HD-89803-80) 18, Pour 7 oz, (204 cx) into te fork pipe. 14. Pump the damper red appronimately 12 to 15 times or uni resistance is fen. 15, Piace the damper rad in the ily botiomed postion and compress fork completely. 16, Pour 7 02, (204 ce) mare fork ol into the slide pipe. 17. Soe Figure 2-65. Adjust fork ol level with FRONT FORK GIL LEVEL GAUGE (Part No. B-S2Q00A) so that it is 4.6m. (118mm) trom the top ofthe fork tube 242 2003 Buell XBSR: Chassis 4. Outer tube 2 Adjuster 3. Damper assembly 4. Fork oil level Figure 2-65. Measuring Fork Ol Level 18, See Figure 2-67. Install spring (16) and cosa (15). 13. Move fork assembly from holding tool to the FORK SPRING COMPRESSION TOOL, 20, See Figure 2-61. Install proioad washer (4) and sider piston (5). 21. Hold damper rod ascombly (3) and instal fork cap (1) from dampar rod assembty (3) tightening to 22-80 felba (30-40 Nm. NOTE See Figure 2:61. Careful not to damaga preload pins (2) while holding damper rod assembly (3), 22. Koply fork cil or light grease to ovings on preload adjuster and install preload aguster (2). 23, Insta'snap ring (2).INSTALLATION 4. See Figure 2-57. Install ene front fork assembly into. rower fork clamp. \2._ Slide the stopper ring over top of fork assembly and into ‘preove, ‘Carefully install the fork Into the upper fork clamp. Forc- ing the fork into: the upper fork clamp eould move the ‘stopper ring out of the groove which will not allow the correct upper fork clamp load resulting in possible loss. ‘of control of the motorcycle and could result In death or ‘serious injury. 3. Install fork assembly into upper fork clamp, Awarninc Both forks should display the same number of alignment lines. Forks that aresnet property aligned may lead to 8 joes of control which eould result in death or serious injury. 4, See Figure 2-66, Position fork with alignment lines (4) visi and reflector facing to the side and tighten the lower fork clamp. Do not tighten. 5, Repeat step 1 through 4 an second front fark, 6. Temporarily install front ale to the fork assemblies to verify correct alignment. 7. Use LOCTITE 272 on upper fore clamp fasteners and tighten to 17-19 fulbs (23-28 Nm). Use LOCTITE 272 07 lower fork stamp fasteners: and tighten t0 13-15 fulbs (18-20 Nm). 8. Repeat toque sequence in sieps 7-and B. 10. instal front brake caliper onto caliper mount. Sae 2.12 FRONT BRAKE CALIPER. 41. Inatall front wheal. See 2.5 FRONT WHEEL, 412. Install front fender. See 2.31 FENDERS. 19, Check headlamp alignment. See 1.18 HEADLIGHTS. 414. Adjust front forke suspension ta rider preferences, See 1.11 SUSPENSION DAMPING ADJUSTMENTS, 1. Rlevoune aajuster screw 2 Preload adjuster nut | 3. Four preload alignment tines visible (tactory setting) 4. Alignment tines Figure 2-66. Front Fork Preload And Rebound Adjuster 2003 Buell XBGR: Chassis 2-03Proload adjuster Proload adjuster o-rings Fork cap Fork cap o-ring Proload washer Silder piston Inner sider piston o-ring ‘Snap ring Rebound adjuster assembly SPN ETB eD = 2-44 2003 Buall XBSR: Chassis Figure 2-67, Front! Fork AssemblyFORK CLAMPS, UPPER AND LOWER 2.17 REMOVAL INSTALLATION 1. Remove front fork assembiies. See 2.16 FRONT FORK. 2, Remove handlebars, See 2.27 HANDLEBARS. 3. See Figure 2-68. Remove cable stape attached to the uppar fork clamp. _ ae Ee Figure 2-68. Cable Strape On Upper Fork Giamp 4. Flemove intake cover, assembly, See 2.94 INTAKE COVER ASSEMBLY, 5, See Figure 2.69, Remove steering sterh pinch fastener 2). 6, Under right cide of front fairing. cul cable strap holding ‘ignition switch, fuse block and right handlebar switch ‘wires. See 7.3 IGNITIONHEADLIGHT KEY SWITCH. 7. Unplug the ignition awiteh. See 7.3 IGNITION/MEAD- LIGHT KEY SWITCH. 8. Soo Figure 2-69. Hald or brace the lower fork clamp and remove steering stem cap (1) 98. Remove the upper fork claro (4), 10, Remove the lower fork clamp (8). 11, Remove ignition switch. See 7.8 IGNITION/HEADLIGHT KEY SWITCH 12. If steering nead bearings need replacing, see 2.18 ‘STEERING HEAD BEARINGS. 4. See Figure 2-69. Install the lower fork clamp (8) Into the steering stem bore and install the upper fork clamp (4. 2. Install steering stern cap (1). Tighten but do not torque. Carefully install the fork Into the upper fork clamp. Forc- ing the fork into the upper fork clamp could move the stopper ring out af the grave which will not allow the correct clamp load causing a possible loss of control ot the motereycle which could result In death or serious Injury. ‘3. Install one front fork assembly into lower fork clamp (8). 4. See Figure 2-67. Slide the stopper ring (19) over top of ‘orl asgembly and into groove. 5, Intell upper clamp on fork assembly. Tighien but do not torque lower fork clamp pinch fasteners. 6. Feepest previous two steps on second fork assembly. 7. Tighten steering stom cap to-98-42 feibs (62-57 Nm). 8. Install steering stem pinch bolt applying LOCTITE 272 and tightening to 17-19 Meibe (23-26 Ne, Both forks should display the same number of allanmant lines. Forks that are not properly aligned may lead to s loss of contre! which could result in desth or serious Injury. 8. See Figuee 2-68, Position beth forks with same number alignment lines (4) visible and reflectors facing lo the sides. Do not tighten. 10. Use LOCTITE 272 on upper fork clamp fasteners and tighten to 17-19 filbs (29-28 Nm). 11. Use LOCTITE 272 on lower fork clamp fasteners and fighten to 13-15 tos (18-20 Nm). 12. Repaat torque sequence In steps 10.and 11 13. Inotall intake cover assembly. See 2.34 INTAKE COVER ASSEMBLY 44, Install handlabars. See 2.27 HANDLEBARS. 15, See Floure 2-68. Install cable straps. a. instal cable strap to the right of ignition switch securing right hand switch and Drake line wires: to ‘upper fork clamp. b. Install cable strap to the Jet of ignition switch secur- ling let hand switch and clutch cable wires to upper {ork clamp. 2003 Buell XB9R: Chassie 2-45‘Stem capnut ‘Stem pineh tastenor Upper fork clamp pineh fastener Upper fori ciamp Head bearing Stem aN Ee pe Lower fork clamp pinch fastener Lower fork clamp Figure 2-89, Steering Stem Assembly ‘248 2008 Buell XB9R: ChassisSTEERING HEAD BEARINGS. 2.18 ee REMOVAL a. See Figurs 2:72, Place the upper bearing squartty in the steering stem bore with the Inner race lip pointing away from the steering head. 1. Place @ acissar jack under jacking point and raise front wheel ot ground. For loestion of jacking point soe Figuro 1b. Sea Figure 2-71. insert the stearing head bearing = eg * installation too! inlo the upper bearing, with the 2 Re brake | mn See 2.10 FRONT BRAKE unouiser i ti pealna. nets emove brake laver housing rae oon ti Insert the forcing screw trom the steering head MASTER CYLINDER AND HAND LEVER. eaitigi eanratebinct wioapi:tha:-maatnethood 3. Remove frant forks, lowar fork clamp, brake and whe! bearing nstaalon tool 8 front-end assembly. aT a, See Figure 2-68. Loosen steering stem pinch fas- | tt fener (2) and upper and tower fork camp pinch mse | snare (2, 7). b. Brace wneel while removing steering stern cap fase | | sener (1). ©. Remove upper fork clamp (4) and front-end assem bly which includes front wheel, steering stemniowor ‘ork cit. 44. Remave upper and loner siecring hesd bearings (5) 2a ia | a. See Figure 2-70. Locate notches inside steering Nee head stem bore (upper bearing removed for clarity}. Steering Head Bearing Race Installer b. Pisce a suitable tool in the notehes of tho steering | (Part No. HD-38302) slem Gore and remove upper and lower steering head bearings. wease ‘Steering Head Bearing Installer (Part No. B-85521) Figure 2-71, Steering Head Bearings Installation Tools, Figure 2-70, Lower Steering Head Bearing Notchea (upper bearing removed for clarity) NOTE Discard steering head bearings and replace with new. Steer lng head bearings are mot reusable, INSTALLATION NOTE Ll For easior instalistion af beaving, lubricate the outer bearing Figure 2-72, Steering Head Bearing Lip with engine aif prior fo instaling into sieering stem bore. 1. See Figure 2-71. Install new upper and lower steering hoad bearings inte the steering stem using STEERING HEAD BEARING RACE INSTALLER (Part No. HD 39902). and the STEERING HEAD BEARING INSTALLER (Part No. B-45521), 2003 Buell XBSR: Chassis 2.472. See Figue 2-79. Sparngy apply Extreme Pressure Lubricant (+2364) 0 the threads of the forcing screw (j) from the Steering Head Bearing Face Installer (HD- 99902), to protong service life and ensure smooth opera: 1. Ingert the forcing screw (1) through the Steering acs Bearing Installation Tool (2-45521) (2). NOTE For ease of steering head bearing Installation, lubricate the outside of the steering head bearings. 3. See Figure 73. Pisce the lower bearing (3) anta the foreing screw (1), with the inner race lip painting away from the steering head. 4. Place the Steering Head Bearing Installation Tool (& 45521) (2) onto the forcing scren, with the shoulder into the besring bore, 5. Install the bearing (4), washer (5) and nut (6) from the ‘Steating Head Bearing Race Installer (HO-29302) onlo the forcing screw (1). 6. Tighten the nut (6) by hand, untl both bearings are stgted into the bores in the steering head 1. ° Foreing serew 2. Steering Head Bearing Installation Tool (B-45521) 3. Lowor bearing Bearing Washer Nut Figure 2-73, Lewer Bearing 7. Sap Figure 2-74, Hold the forcing screw while tightening the nut to draw tha bearings into the steering head. Cone tinue tightening until both bearings are tully seated. Visually check to make sure the bearings are completely seated against the shoulders in the steering head 248 2003 Buell XB9R: Chassis Figure 2-74, install Bearings 8, Install forks, front wheel. and lower fork clamplateering stem a8 an assembly. 10, Insta uppar fork clamp. 11, Tighten steering stem cap to 96-42 f-1bs (62-57 Nm}. 12, Use LOCTITE 272 on steering tem pinch fastener anc © fightan te 17-19 ftlbs (25-26 Nm).SWINGARM AND BRACE 2.19 a \GENERAL a “The upper bett quard is attached to the swingarm brace and ‘The svingarm algo serves as the oll tank on the Buell XBR, #7 70t be removed fram vehicle at this time For information on the swingarm function 2c the oll tank, see §. See Figura 2-78. Remow swingarm brace mounting fas- 8.8 LUBRICATION SYSTEM. leners (12) and swingarm brace (13). “The swingarm features = remavable brace on the right sida to 7. See Figure 2-75. Remove belt guard epacar (3). allow drive belt replacoment, Sealed bearings eliminale tM 8, Flemove swingarm brace. peed for preload adjustment REMOVAL Brace wy Botore removing swingarm brace, always relieve belt tension first. Flamoving swingarm brace without releasing, {enslon will cause swingarm brace damage. 1. Rlemove righ sige rider footpeg mount. See 2.29 FOOT- PEG, HEEL GUARD AND MOUNT. 2. Remove right side passenger loolpeg mount. See 229 FOOTPEG, HEEL GUARD AND MOUNT. ‘See Figure 2-76. Loosen rear axle pinch fastener (2) Loosen rear axle (1) approximately 15 rotatians to allow partial tension ta be removed from raar drive system, 5. See Figure 2-75. Remove upper bolt guard (1) by remow- ing estoners (2). \\) Ws a 1. Upper belt guard 2. Uppor belt guard fasteners, 3, Belt quard spacer Figure 2-75, Belt Guard Assembly 2003 Buell XBOR: Chassis 2-49Swingarm Eat To prptect against accidental start-up of vehicle and pos- stble personal Injury, disconnect the negative battery cable before proceading. Inadequate safety precautions could cause a battery explosion, which could rosult in death or seriaus injury. 1. Disconnect battery by unthreading fasteners removing egatve cable (black) ‘rom battery first. See 14 BAT ‘TERY MAINTENANCE 2. See Figure 2-78, Remove of drain plug (9) and drain of ‘rom swingarm. See Draining Oil in 1. ENGINE LUBRI- CATION SYSTEM, 3. Remove rear wheel. See 2.6 REAR WHEEL, 4. Remove three oll lines trom swingarm filings. See 3.9 ‘OIL HOSE ROUTING AND GIL RESERVOIR, &. Remove p-clamp and washer that secures rear brake line to swingarm, 6. See Figure 2-85, Remow lowor shock absorber mounting fastener (9) and spacer tram shack absorber and ‘wingat, 7. See Figure 2-78. Loosen pivat shatt pinch fastener (7) 8, Flemove pivot shaft (10) with & special 7/8 in. hex toot Jocatted in too! kit. DISASSEMBLY ‘Caretully mark all bearing components as. they a removed so that they may be returned to thelr origin locations. De not intermix bearing components. Brace Fomove upper belt guard assembly, See 2.92 BELT GUARDS. ‘Swingarm +. See Figure 2.77. Removs oi jne fitings from swingarm See Table 2-12 2. See Figue 2-72. Remove ewingarm bearings (5, 9) using ide hammer (SNAP-ON Fart No. CJ1278 or equivalent) snd 3/4 in. bearing remover and spacer. 9. Remove shock mounl bushings (3) and sleave, 4, Remove rear fendar. Sea 2.31 FENDERS. NOTE See Figure 278, Ramave swingarm bearings (5, 9) only it roplacement i required. The complete bearing assembly ‘must bo roptaced as a umit when reptacement is necessary. ‘Do not intermix bearing components. 2-50 2003 Buell XBOR: Chassis 1. axle 2 Pinch bolt fastener Figure 2-76, Rear Wheel Mounting, Right Side Figure 2-77. Oil Line FittingsCLEANING AND INSPECTION ARNING ‘compressed air can pierce the skin and cause Injury. Newer use your hand to check fet leaks or to determine air flow rates. Wear safety glaseos to shield your eyes from fying dirt and debris. Fallure to comply could result Indeath or setious injury. 1. Traroughly clean all components in soNent. Blow dry wit compressed ai 2. Careuly inspec ll bearing components for wear andor feonmson. Replace compte. hearing assembly It ary ‘component is damaged 3. Chock thal swingarm Is nat bent ar twist. eplaco i amazed ASSEMBLY Brace See Figure 2-75, Install upper belt guard (1) onto swingarm brace, See 2.32 BELT GUARDS, Swingarm 1. See Figure 2-78. Install new shock mount bushings (3) ‘and sieeve (4) Install new bearings (5, 9) and spacer (4) with BEARING. INSTALLER (Part No. HO4a060) by lightly seating spacer NOTE ‘Swingarm bearings should be repteced as = unit. Do nol Intermix componsnts. Mark all components $0 they may be covreety installed. 3. See Figure 277. Install oll line fittings on swingartt, Tighten to 20-31 fiibs (39-42 Nm), Seo 3.9 OIL HOSE ROUTING AND OIL RESERVOIR. 4. See Figure 2-78, Install drain plug (9). Tighten to 29- 31 flbs (89-42 Nm) INSTALLATION Swingarm 1. See Figur 2-78, Align swingarm (1) n pict of engine crnkoase (6) nal pivot shaft (10) with @ special 7 In. nex t00 located ool kt, ANTESIEZE and ight to 24:26 bs (82:35 Nm Taian pivot ahah pinch fastener (7) 40 17-19 bs (23- 26Nmi 4. See Figure.285, Install lower shock absorber mounting ‘fatene” 8) and apace: om shock abeorbar an aang far an igen fo 17-19 Mes (20-28 Nm. 5. instal p-clamp and waster tnt secures rear brake fe 10 swingarm and tighten to 36-60 inelts (4-7 Ne). 6 Install hee oil ines from swingarm fiings. S88 3.9 Ol HOSE ROUTING AND OIL RESERVOFR 7. Install ear wheel. See 2.6 REAR WHEEL. NOTE Installing the rear whsel will include installation of the bell drive system. See 1.9 DRIVE BELT SYSTEM. 8, Fill motorcycle with recommended oil. See 1.5 ENGINE LUBRICATION SYSTEM. ed Always connect the positive battery cable first_If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explo- ‘sion which could result In death or serious injury. Install batiery by Uweading postive cable (red) into threaded hole first tghtsning to 72-98 in-lb (8-11 Nii). See 1.4 BATTERY MAINTENANCE. OGL ‘Aiter completing repairs or bleeding the system, always test motorcycle brakes at low sposd. If brakes are not ‘operating properly or braking efficlency Is pacr, testing at high speeds could result in daath or sorious injury. Brace 1, Se0 Figura 2-75. Poattion upper bet guard (1) and ‘spacer (3) 2, See Figure 2-78, Insiall swingarm brace (13) with ewing- ‘arm brace mounting fasteners (12) loosely. Do not tighten, 3. See Figure 2-75, Tighten upper beit guard (2) fasteners 10 12:96 Indba (1-4 Nem). 4. See Figure 2-78. Tighlon swingarm brace fasteners (12) to 25-27 fips (34-7 Nm). 5, See Figure 2-76. Tighten rear axle (1) 10 48-52 ‘tbs (65- 7ONm) 6. Tighten rear axle pinch fastener (2) to 40-45 feibs (54- 81 Nm} 7. Install right side passenger footpeg mount lightening tas- tenets to 18-18 M-te (20-24 Nm). Sae 2:29 FOOTPEG, HEEL GUARD AND MOUNT. 18, install right side rider foctpeg mount tightening fasteners, fo 108-182 Indbs (12-15 Nm). See 2.29 FOOTPEG. HEEL GUARD AND MOUNT. 9 Install heal guard, See 229 FOOTPEG, HEEL GUARD AND MOUNT. 10. Remove rear wheel support stand. Final Swingarm Inspection 41. Check oil favel aftr starting motorcyele- and allowingjt to reach operating temperature 2. Check ear brake operation. 2003 Buell KBQA: Chassis 2-51ll drain plug Swingarm bearing Pivot shaft Belt guard spacer ‘Swingarm brace fastonors ‘Swingarm brace Rear axle pinch fastener Figure 2-78. Swingerm Assembly [1 Swingarm 2 Dipatick 3. Swingarm bushings 4. Swingarm spacers 5. Swingarm bearing 8. Engine crankeaso 7. Pivot shaft pinch fastener Table 2-12. Oil line Fittings FITTINGS HEXSZE | HEXSIZE (FUNETION) | (SWINGARM) | (HOSE) Right’Smatl (Vent) ove ahe CantarLarge (Supply) | 1/16" Se | Lettitedium (Retumn) a 2 252 2003 Buell XBSR: Chassis,FRONT AND REAR ISOLATORS 2.20 \FRONT ISOLATOR Removal tn ‘Avoid cross-threading front isolator bolt or insert. Keep weight of motorcycle off front isolator by alternately loosening frent isolator belt and ralaing scissor jack to support engine. 1. Place a scissor jack under jacking point for supporting, ‘engine only, For location af jacking point see Figure 2-96. 2, Soe Figure 2-79, Remove clutch cable p-clamp. Figure 2-79. Cluteh Cable P-clamp ‘See Figure 2-80. Remove trot isolator bot (6). 4, Remove front isolator mount fastonere (5) 5. Remove front isolator bracket (4). 6, Remove upper srubber fastener (2} and remove upper rubber (1). Installation 4. See Figure 2-80. Install upper snubber (1) tightening snubber fastener (2) to 12-96 Ina (1-4 Nm) 2, See Figure 2-81. Lubricate front isolator bolt with ANTI- SEIZE and loosely install, 3. See Figue 2-80. Use LOGTITE 272 on front Isolatar racket (4) and install. Tightening fastenar(S) 10 49-51 M- [bs (66-69 Nm. ee ‘Avoid cross-threading front Isolator bolt or insert. Keep welght of motorcycle off front isolator by alternately fightening front isolator bolt and raising scissor jack to ‘support engine. 44, Tighten front isolator Balt (6) 10-49-51 fhbs (66-69 Nm), 5, See Figure 2-79. Install clutch cable p-clamp. Tighten fastener to 12-36 ln-ba. (1-4 Nm. NOTE ‘Ses Figure 2-80. if the thrasied insert (3) ie damaged and needs to be ropiaced, install new insert with LOCTITE 272 ‘and tighten to 48.51 FisLbs (66.469. 1 Na) 1. Upper snubber 2. Upper snubber fastener 3. Insert 4, Front isolator bracket 5, Front Igoister bracket faataner to engina 6. Front isolator bolt Figure 2:80. Front lsolator inta on Front laolator Bolt Figure 2-61. Lubrication REAR ISOLATOR NOTE tis necessary lo remove engind lo access rear Isolatar, ‘Soo 3.4 STRIPPING MOTORCYCLE FOR ENGINE SER- VICE to access the rear isolsior 2003.Buell XBQA: Chassis 2-69FRAME 2.21 REMOVAL 1 2 romove fuel from frama, See DRAINING: FUEL TANK in 438 FUEL PUMP. Folale engine, See 3.9 ENGINE ROTATION FOR SER- Vice. Remove exhaust header, See 228 EXHAUST SYSTEM, Romove tail frame, See 2:36 TAIL FRAME AND BODY WORK. Famove rear shock, See 222 REAR SHOOK ABSORBER, Remove upper and lower fork clamps. See 2.17 FORK CLAMPS, UPPER AND LOWER. Flemove main wire haress. See 7.23 MAIN WIRE HAR NESS. Remove rear isolator fastener. See 2.20 FRONT AND REAR ISOLATORS. Lit and remowe frame trom the motorcycle. INSTALLATION 2 Place frame over the motorcycie. Install rear isolator fastener. Ses 2.20 FRONT AND REAR ISOLATORS, Install main wire hamess, See 7.23 MAIN WIRE HAR NESS. Install upper and Jawer fork clamps. Se 2.17 FORK CLAMPS, UPPER AND LOWER. Install year shock, See 2.22 REAR SHOCK ABSORBER, Install tall frame. See 2.56 TAIL FRAME AND BODY WORK, Install exhaust header. See 2 28 EXHAUST SYSTEM. Rolle engine. Sse 3.3 ENGINE ROTATION FOR SER- VICE. 2-54 2003 Buell XBSR: Chassis Figure 2-62, Lit Frame On MotorcycleREAR SHOCK ABSORBER 2.22 (GENERAL ‘The rear euspension is controlled by the shock absorber. The BSR shock allows adjustment of rear compression and rebound damping and spring preload ‘The most important rear shock adjustment isthe preload s2t- ling, Betore making any damping adjustments, set the proper praioad See 1.11 SUSPENSION DAMPING ADJUST: MENTS, NOTE The roar shock absemer canting na near aarvinesthia pars REMOVAL 1. Remove seal. See 2.98 SEAT, oe Always disconnect the negative battery cable fist. if the positive cable should contect ground with the negative cable Installed, the resulting sparks may cause a battery ‘explosion which could result in death or serious injury. 2 Disconnect and remoue battery. See 1.4 BATTERY MAINTENANCE. 3. Rlemove tail body work. See 2.96 TAIL FRAME AND BODY WORK. 4, Place & scissor jack under jacking point and raise roar whee! off ground. For location of jacking point see Figure 286. 5. See Figure 2-85. Remove upper shock (5) and lower ‘shock mount fasteners (8 and 9) and lower shock mount sleove (8) Remove rear shook reservoir cart (2). See Figure 2-64, Cut cable stan, Feed rear shook reservoir through tail section. Flomove rear shock. a. Raise molowyeie Up approximately 2 more inehes (1mm). B. Remove shock through the top of the tail section (opening undemeath rider seat). INSTALLATION ‘Ses Figure 2-85, Install upper shock mount and ightan fastoner (5) 10 49-51 ftbs (68-69 Nm). 2 Install lower shock mount with fasteners (6,9) and lower shock mount sleeve (8) and tighten to 15-17 fitbs (20.3- 2a Nm) 3. Feed rear shock reservoir through tail saction. D.1 HOSE AND WIRE ROUTING tor correct routing, Loosely install reservoir in clamp. See Figure 2-83, Temporarily place upper body works conto tail section and aojust reservoir placement £0 dal aligns with bextywor, Tighten clamp on reservoir to 96-120 in-Ibs (11-14 Nm. 4. See Figure 2-84, Add cable strap. NOTE Verify compression dial is facing up. Ses Figure 2-85. 5. Install upper body work. See 2.36 TAIL FRAME AND BODY WORK os Always connect the positive battery cable first. f the positive cable should contact ground with the negative cable installed, the resulting sparks may couse a battery explosion which could resutt in death or serious injury. 6 Ingtall batery by threading positive cable (red) into threaded hole first ightoning to 72-96 Ineibs (8-11 Nan). ‘See 1.4 BATTERY MAINTENANCE. Install seat. Seo 2.98 SEAT. ‘Adjuster screw Adjuster screw alignment hole Figure 2-83. Adjuster Screw Alignment Figure 2-64. Coble Strap 2003 Buell XBSR: Chassis 2-55a @ |. Shock remote reservoir clamp fastener 7. Lower shock mount 1 1 2. Shock remote reservoir elomp 8. Lower shock mount sloave | 3 Shock mmote reservoir 3. Lower shock mount fastener and washer | 4. Shockreservoir body 40. Shock spring retainer kit | Upper shock mount fastener 11, Rear sheek spring 6 Lower shock mount nut and washer Figure 2-85. Rear Shock Absorber Assombly 258 2003 Buell XB9A: ChassisTHROTTLE CONTROL \REMOVAL/DISASSEMBLY 1. See Figure 2-86, Loasen eable adjuster lock {thick disc) (B)on gach cable. 2. Tum adjusters. (thin cise) (2) in direction which will ‘shorten cable housings to minimum length. 3, Remove fasteners (1) on right switch housing and spe: rate housing from handlebar. 4. See Figure 2-87. Remove cables (2, 3) from notches in ‘ont nousing (4) 5. Remove ferulas (6) rom trots (7) 8. Remove sirsox covar and baseplate. See 4 43 AIRBOX 7. Disconnect eablastrom throttle body maniold to rerhove 8. Cul cable straps and remove cables. CLEANING AND INSPECTION a Compressed air can pleree the skin and cause injury Never use your hand to check for leaks or to determine air flow rates, Wear safety glasses to shield your eyes trom flying dirt and debris, Fallure to comply could result In death or serious Injury. Giean all parts except oablas in a nontlammable cisaning soWent. Blow ory with compreacad air. Replace cables if Irayed, linked or bent ASSEMBLY/INSTALLATION 4. Rute cable a8 shown in D.1 HOSE AND WIRE ROUT na. 2, Add cable straps as shown in the throttle cable routing in D1 HOSE AND WIRE ROUTING. 3. Install tome grip and position termes (6) into cable wheel (7). 4. Insert idle contra! into rent witch housing. 5, Silkie eviaeh housing over throttle 6. Insert throttle cable into front switch hausing. 7. See Figure 2-86. Attach rear switch housing and position housings on right handlebar by engaging lacating pin on front housing with hole in handlebar, Atlach housings with two fasteners, insialing longer fastener on Bottom. Tighten to 25-33 ints (3-4 Nm}. 8. Adjust cables, See 1.18 THROTTLE CABLE AND IDLE ‘SPEED ADJUSTMENT. 9. Install sirbox accombly. See 4.43 AIRBOX. Right switch housing fasteners Adjusters ‘Cable adjuster lock ‘Throttle control cable Idle contral cable Figure 2-86. Throttle Control Gables Sorew (short, top) Idle control cable Throttle control cable with molded end Front housing Sorew (long, bottom) Ferrules Cable whee! | Rear housing Locating pin Figura 2-87. Gable Connections 2003 Buell XBSR: Chassis 257CLUTCH HAND LEVER 2.24 REMOVAL/DISASSEMBLY NOTE For Clute adjustment, soo 1.8 CLUTCH. 4. See Figure 2-29, Remove p-clamp trom trent isolator. 2, See Figure 2-88. Slide clutch cable adjuster boot (6) up {o access clulch adjuster (7) Loosen clutch adjuster (7) fo release tension from hand lover (4). 4. RRomowe clutch cable torrie (8) trom trae leust (a) Remove hand lewer pinch bait (3). Flemove hand lever (4) from hand lever elamp (2). 7. emmove safely interlock switch (5) 8. Remove hand lever clamp fastener (1) snd spin ‘champ (2) lo access safety inlertock switeh (5) 1. Hand lever clamp pinch fastener b. Disconnect safety intertock-ewiteh connector (5)and | 2 Hand lever clamp remove switch fastener (6) and switch (5) 3. Hand lever pinch fastener and nut 4. Clutch hand lever NOTE 5. Safely interlack connector and switch The individual parts of the clutch switch are nol serviceabie. | @, Safety interlock switch fastener | Replace switch upon isllure 7. Clutch adjuster | 8. Clutch cable adjuster boot | 8. See Figure 2-00. Gur cable strep trom left upper fork | aa as we 8. Clutch cable ferrule 9. Rlemave lef elip-on. Ses 2.27 HANDLEBARS. Figure 2.88, Cluteh Hand Control Assembly 10. Remove clutch assembly fram clip-on, ASSEMBLY/INSTALLATION 1, See Figure 2-88, Slide hand lever slutch clamp (2) over Jet clip-on, Loosely tighten hand lever pineh fastener and rut (3) 2. Install let clip-on. See 227 HANDLEBARS. 3. Connect safety interlock connector and awitch (5) 4 Install safety interlock switch (5) with fastener (6) tightening to 7-10 ines (0.8-4.0 Nei. NOTE Apply small amount of LOCTITE ANTI.SEIZE LUBRICANT 10 ot (9). Figure 2-89, Clutch Cable P-clamp 5. Install clutch hand lever (4) in hand lever clamp (2) and tighten hand lever pinch fastener (3) to 99-48 in-be (4 5 NM 8. Position hand lever (4) to nder preference and tighten hand laver clamp pivot fastener (1) to 36-60 inelbs (4 7 Nm) 7. Connect clutch cabs ferrule (9) to hand lever clamp (2). ‘8, See Figure 2-90. Inctall cable atrap holding safety intar- lock switch and left switch housing on left upper fork. Do: not aver tighten cable strap ‘2. It Not yet pertonmed, roule clutch cable to primary cover D.1 HOSE AND WIRE ROUTING for clutch cable rout ing. Figure 2-80. Cable Straps On Upper Fark Clamp 10. With clutch cable lower section connected to primary cover, adjust clutch. See 1.8 CLUTCH. 2-58 2003 Buell XBOR: CheasloHEADLIGHT SUPPORT BRACKET \REMOVAL 1. Remove seat. See 2.88 SEAT. ey ‘To protect against accidental start-up of vehicle and pes- sible personal injury, disconnect the negative battery cable before proceeding. Inadequate safety precautions ould cause a battery explosion, which could result in death or serious injury. 2. Ulsconnect Denery Dy untnrowny fastener ren moving negative cable (black) from battery first. See 1.4 BAT- TERY MAINTENANCE. 3. Remove fron! fairing. See 2.37 FRONT FAIRING, WIND- ‘SHIELD, AND MIRRORS. 4, See Figure 2-01. Diseonneet flasher (1) and bank angle ‘gengor (2). Remove electronic control module fasteners: @. 5, See Figure 2-98. Rotate headlamp support bracket 8 Loosen headlamp pivot fasteners (1). b. Rotate headlight bracket (2) down. See Figure 2-92. Disconnect headlight connection. Disconnect and remove elzetronic control module. See 4.29 ELECTRONIC CONTROL MODULE: 8. See Figure 2-50. Removs headlight support bracket (2). iG ae Flasher 2 Bankcangle sensor Electronic control module Figure 2-91. Headlight Support Bracket Figure 2-92. Headlight Connector 2003 Buell XBR: Chassis 2-59DISASSEMBLY 1. See Figure 2.91. Remove bank angle sensor (2). 2, Rimove tasner (1), 3. See Figure 2-03. Remove black rubber cover (4) from rear of headlights. 4. Bieconnect black connector from headlights. 5. Disconnect headlight bulb (8) connector (white) trom ‘wire hamess. 6. Remove headlights (5, 7) rarn headlight support bracket (0) by removing headlight fantanare (6). 7. Remove headlights (5,7) 1. Headlight pivot fasteners 2. Headlight support bracket 3. Electronic control module fasteners 4. Black rubber cover 5. Lew bearh headlight 6. High besm headlight 7, Headlight fastener 8. Headlight bulb: 8. Bank angle sensor 10, Bank angle sensor fastener ASSEMBLY 1 ‘See Figure 2-80. Align headlights (5, 7) into headlight ‘support bracket (2). Tighten headight fasteners (6) to 20- 251m Ibs (2-2.8 Nm) Connect headlight bulb (8) connector (white) into wire ramess. Gonnact black headlight connector. Install black eubber cover (4). See Figure 2-91. Install bank angle sensor connector 258 (2) Tighten to 12-36 ind (1-4 Nev Install aster (4) and tighten to 8-#0-inelle (3-5 Nan. Figure 2-93. Headlight Support Bracket Assembly 2-60 2003 Busll XBOR: ChessisINSTALLATION 1. See Figure 2-94. Pasition headlight pivol fasteners into {groove of the headlight support bracket flat side of nut \ fined up with groave, Figure 2-94, Headiamp Pivot Groove 2. Sao Figure 2-83, Install headlight pivot fasteners (1) but dda nat fighten 9. Connact electronic control module. See 4.28 ELEC- ‘TRONIC CONTROL MODULE. 4. See Figure 2-92. Attach neadlight connecter to headlight support bracket 5. Connact headlight connections. See 7.11 HEADLIGHT. ‘Soe Figure 2-09. Rotate headsight support brackst up (2) land tighten pivot fasteners (1) 10 7296 inelbs (6-11 Nr. 7. See Figure 2-81. Install electric control module. 8. Figure 2.93. Align electronic control module and headlight support bracket with fairing support bracket 1 Tighten electronic control module fasteners (9) to 72-96 ineibs (8-11 Nm}. & See Figure 2-91. Connect flasher (1) and bank angle ‘sensor (2) 8 Install front fairing. See 2:37 FRONT FAIRING, WIND- ‘SHIELD, AND MIRRORS. ‘Always connect the positive battery cable first If the positive cable should contact ground with the negative cable Installed, the resulting sparks may cause a battery expio- ‘sion which could result In death or serious injury. 10, Install battery by throading postive cable (red) into threaced hole first tightening to 72-36 In-ibs (8-11 Nm). See 1.4 BATTERY MAINTENANCE 11, Install seat, See 2.98 SEAT. 2009 Buell XBOR: Chassis 2-61FAIRING SUPPORT BRACKET 2.26 REMOVAL 1. Remove seat. See 2.38 SEAT. FINI To protect against accidental start-up of vehicie and pos~ sible personal injury, disconnect the nogative battery cable before procesding. inadequate safety precautions could cause @ battery explosion, which could result in death or serious injury. 2. Dikconnect battory by unthresding fastener removing negative cable (black) Irom battery ‘first. See 1.4 BAT TERY MAINTENANCE 3. Remove front fairing. Soe 2.37 FRONT FAIRING, WIND- SHIELD, AND MIRRORS. 4. Remove headlight support bracket, See 2.25 HEAD- LIGHT SUPPORT BRACKET, 5. Remove tuse block (1) and relay block (d) and p-clarmp. ‘See 7.22MAIN FUSE AND FUSES. 6. Disconnect and remove horn (§). S80 7.20 HORN. 7. Disconnect and remove. instrument cluster (2, 9). See 7.17 INSTRUMENT MODULE, 8. See Figure 2-55, Flomove fairing support bracket fasten- @r8 and washers (4), p-clamp (7) ta remove fairing support bracket (5). 2-62 2003 Buell XBOR: Chassis INSTALLATION 1. Route the wire hamess. See 0.1 HOSE AND WIRE ROUTING for wire harness routing 2. See Figure 2.06. Install faring support bracket with fasteners and washers (4). Tightoning to 16-18 tbe (22. 26 Non). 3. Inatall p-clamp (7) with p-clamp fasteners and washers @) 4. Connect instrument cluster connector and instal Inst ant cluster. Tightening 10 26-48 in-Ibé (4-5 Nm). See 1-14 INS THUMEN MODULE. 5. Install horn and tighten fasteners to 72-56 Inebs (@-10.Nm), See 7.20 HORN, 6. Install fuse block, relay and peciamp tightoning fasteners to 72.968 indbs (@-11 Nm). See 7.22 MAIN FUSE AND FUSES, 7. Install lower haaclight support bracket. See 2.25 HEAD LIGHT SUPPORT BRACKET. ‘8 Install ront fairing. See 2.37 FRONT FAIRING, WIND: ‘SHIELD, AND MIRRORS. Can Always connect the postive battery cable first. if the pos- hive cable should contact ground with the negative eable Installed, the resutling sparks mey cause a battery explosion which could result in death of serious injury, 9, Install battery by threading positive cable (red) into thresded hole frst ightening 10 72-96 ine (€-11 Ne). ‘See 1.4 BATTERY MAINTENANCE, 10, Install eat. Se 2.98 SEAT.Figure 2-85. Fairing Support Bracket Assembly 2003 Buell XBGR: Chassis 2-63HANDLEBARS 2.27 GENERAL INSTALLATION BSR handlebars use a cip-on assembly and are not achust hie Right Clip-on REMOVAL Right Clip-on 1. lemore sight switengear housing. See 7.15 HANOLE- BAR SWITCHES 2. Flemowe font brake master cylinder and grip. See 2.10 FRONT BRAKE MASTER CYLINDER AND HAND Lever 3. See Figure 2.87. Remove right clip-on assembly. ‘& Partilly leosen clip-in mounting tastenar (8). Using a rubber mallet, tap the partially loosened ias- tenor (5) to push th clip-on (3) from the upper right fork clamp (4). Repeat this procedure until fastener ‘and efp-on has been removed trom fork clamp (4)- 4. Remove cip-on endoap (1). Left Clip-on 1. Plemows left ewitzhgear housing, Sea 7.15 HANDLEBAR SWITCHES, 2, See Figuie 2-96, Remove clip-on assembly. &. See Figure 2-07. Panially loosen clip-on mounting fastener (5). b Using a rubber mallet, tap the partially wasened tas ‘tener (5} to push the clip-on (3) fromm the upper loft fork camp (4). Repeat this procedure until fastener (8) and clip-on (9) has been remaved from fork clamp (4), 3. Remove clutch lever assembly. See 2.24 CLUTCH HAND LEVER. 1. Remove olp-an endeap (1). 2-64 2003 Buell XBR: Chassis Inctal right ewitch gear housing. Install tront brake master cylinder. Tighten but do not torque. | tall sight 8p on Inte right tore slamp: using LOOTITE 272 and tightan fastener (6) to 24-26 fins (33-35 Nm) 4. Install throttle and grip onto right clip-on. See 2.23, ‘THROTTLE CONTAOL. 5. Install endcap onte right clip-on. See Figure 2-35, Position brake hand lever to rider pret ‘erences and tightsa fastener (5) to 80-00 in-bs (9- 10.Nm). See 2,10 FRONT BRAKE MASTER CYLINDER, ‘AND HAND LEVER, Left Clip-on 4, Install clutch hand lever assembly onta p-on. Tighten but de nat torque. 2, Install let ewitchgear housing. See 7.15 HANDLEBAR, ‘SWITCHES. 3. See Figure 2-87- instal grip (2) and endcap (1). 4. Install left clip-on into upper forts clamp (4) and using LOCTITE 272, tighten fastener (5) to 24-28 Fulbs (33- 35.Nm), 5, See Figure 2-88, Position clutch hand lever to rider praf- ferences and tighten fastener (1) to 36-60 Indbs (- 7 Nm). See 2.24 CLUTCH HAND LEVER. Figure 2-96. Handlebar Clip-on Mounting Fasteners {tight ello-on shown)Clip-on fastener Figure 2-97, Hencllabar Clip-on Assembly (left ellp-on shawn) 2003 Buell XBR: Chossis 2-85EXHAUST SYSTEM 2.28 REMOVAL/DISASSEMBLY Muttler 4. Remove chin fairing. See 2.35 CHIN FAIRING. 2 Remove front sprocket cover. See 2.80 SPROCKET COVER, 3. Remove ioler pulley. See DRIVE BELT REMOVAL in 1.9 DRIVE BELT SYSTEM. 4. See Figue 2-8. Loogen front mutler strap mount fastener (7) but do not reenowe, 5, Remove rontand rear mute sans. Front: Remave front mutfer strap tastener (5). Front strap will not be removed. Rear; Aternataly Jocseg roar strap fasteners (1) and remove siraps (2) 6. See Figue 2-89. Loosen Tarea clamp (1) and remove mutter. NOTE Tha muffler may be removed tor replacement without removing the exhaust header. Front Muffler Mounting Block/Strap 4. Remove mufler. See Muti inthis secon, a& Sa, | uacking point symbol shown | onboth sides of mutter. Rear mutfler strap fastener Rear muttier strap Muffler Front muffler strap Front muffler strap fastener peeps 2. See Figure 2-88. Remeve front mufflar mounting black fastener (7). 3. Remove strap (4) from front mutter mounting block (6). 4. Remove front mounting black bushings (8) by punching ‘out with suitable tool Rear Muffler Mounting Block 1, Remove muffler. See Mutfer in thia section 2. Drain oil See Draining Oil in 1.5 ENGINE LUBRICA- TION SYSTEM. 3. Remove ail linge trom awingarm. See 3.9 Oil HOSE ROUTING AND OIL RESERVOIR, 4, Ses Figure 2-08. Remove reer mutfier mounting block fasteners (10) 5. Slide ol ines from rear muftler block. and remove rear ‘mutter strap mount block (3), Exhaust Header 1. Rotate engine down. See 3:3 ENGINE ROTATION FOR SERVICE, 2. Remove oxygen sensor. See 4,92 OXYGEN SENSOR, 3. See Figure 2-89. Remove exhaust header (2) by remav- Ing mounting fasteners (3). 4. Remove exhaust ring (4), rataining ring (5) and port gasket (8). 6. Front mutter strap mount 7. Front muffier strap mount fastener 8. Front muffler strap mount bushings 8. Rear muffler strap mount block 10. Rear muffler strep mount fasteners Figure 2-58. Muffler Assembly 2-68 2009 Buell XBOR: Chassis:ASSEMBLY/INSTALLATION Exhaust Header \. soo Figure 2.88, fstall exhaust ring (4), retaining ring (5) and new port gasket (6). 2 Install exhaust header (2, Tanten mounting fasteners (G)t0 72-08ine (2-11 Nem) NOTE Tighten header nuts gradually. atemating between studs #0 insure that exhaust ngs are fush with engine 3. Install oxygen sensor. See 4.92 OXYGEN SENSOR 4. Rotate engine up, See 8.9 ENGINE ROTATION FOR SERVICE. Rear Muffler Mounting Block See Figure 2-08. Sika rear muffler mounting block (8) over ail ines 2. Install rear mutier mounting block fasteners (10) and tighten to 22-96 f-bs (49-49 Ne) 3. neta clings to awingarm. Soe 2.9 OIL, HOSE ROUT: ING AND OIL RESERVOIR 4. Fillswingarmiol tank wit 25 quarts (3.3 Bers) ol. See Draining Oil in 1.5 ENGINE LUBRICATION SYSTEM. 15 Install mutter. Sse Muti inthis section. 1 Front Muffler Mounting Block 1. See Figure 2.98. Install front mounting block bushings @. 2, Install strap on front muffier mounting block (4). 3. Inalall front muffler mounting block fastener (7) loosely. Do not tighten 44. Install muthier. See Muti in this section. Muffler and Straps Nore Toroa mufior lamps navo olminated the need fr scare or graphite tape during assembly. To ensure sealing iniegrity of mule clamos and provent ihe passibity of leaksoe, Buell recommends that mufisr clamp assem be deosrced snd repiacod each time Mey are removes 1. nal muti ang new Tores clamp onto header. NOTE necessary, use-a fiber hammer to fit mutfier on header. 2, See Figure 2-08. Loosely install tront and rear muffler straps (2, 4) Muffler straps must be tightened in steps te keep from ‘over tightening or mutfler will be crushed. 8. Tighten front strap fastener and altemately tighten rear mufor strap tasteners evenly til fasteners are tightened to: Front: 108-120 Inne (12-14 Nm). oor: 48-60 in-tbe (5-7 Nm) 4, Ses Figure 2:98. Tighten tront muffler mounting block fastener (7) to 22-25 f-lbs (90-34 Nm). 'S. See Figure 2-99. Tighten the Torea clamp (1) 10 40-45 ft Ibs (5464 Nev. 6. Install idler pulley. See ORIVE BELT REMOVAL in 1.9 DRIVE BELT SYSTEM, 7. Install tront sprocket caver. See 2.80 SPROCKET COVER, 8, Inetallchin fairing. See 2.83 CHIN FAIRING, Torca clamp: Header Header mount fastener Exhaust ring Exhaust retaining ring Exhaust port gasket pea ep Figure 2-99. Exhaust Header 2003 Busll XBSR: Chassis 2-57FOOTPEG, HEEL GUARD AND MOUNT RIDER Remove Footpeg 1. See Figure 2-100. Remove e-ring (5). 2, Remove tootpea pin (6) 3. Remove fooipeg (7). Remove Heel Guard 1. See Figue 2-100. Remove heel guard tastenrs (4), 2 Remove nee! guard (3). Remove Mount 1. See Figure 2-100. Remiove faotveg mount fasteners (2). 2, Remove feotpeg mount (1, install Footpeg 1. See Figure 2-100. install e-ing (5) 2, Postion eotpeg (7) on te footpeg mount (3) 8. Install foopeg pin (8) Install Heel Guard 1. See Figure 2-100. Position hes! guard (2) onto footpeg ‘mount (1). 2, Install heel quae (8) with tasteners (4). Tighten to 72- 6 In-be (8-11 Nm). Install Mount 1. See Figure 2-100. Position footpeg mount (1). 2, Install footpeg mount wih fasteners (2). Tighten to 108- “182Inetos (12-15 Nm), 268 2003 Buell XBSA: Chassis Figure 2-100. Rider Footpeg, Mount and Heel Guard ‘AssemblyPASSENGER Remove Footpeg Mi. See Figure 2-101. Remove o-ring (7). 2. Renee fotped pin 9). 3 Remove tootpey (8), detent plete (6), ball (5) and spring (4). Remove Heel Guard 1. See Figure 2-101. Remove heel guard fasteners (1). 2 Remove heel guard (2). Remove Mount 1, Seo Figure 2-101. Rentove fooloeg mount fasteners a9. 2, Remove footpeg mount (2). Install Footpeg , 1. See Figute 2-101, Position footpeg (8), detent plate (6), ball (5), and spring (4) on to footpeg mount (3}. 2 Install footpeg pin (5). 3. Install e-ring (7). 4. Check thal foolpeg clicks in the up and down position. Install Heel Guard 4. See Figure 2-101. Position heel guard (2) onto footpeg “mounts (3). 2. Install heel guard (2). Tightening heel guard fasteners tb 48-72 In-lbs (5-8 Not). Install Mount 1. See Figure 2101, Poston footpey maunt (3) onto ti frame 2. Install footeeg mount (3). Using LOCTITE 272 tighten, fasteners (10) 10 25-28 frlbs (34-38 Nm). Figure 2-101, Passenger Footpeg, Mour ‘Assombly 2003 Buell XBGR: Chassis: 2-69.

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