ATV Manuals. Car Manuals. Engine Manuals. Excavator Manuals. Jet-Ski Manuals. Motorcycle, Scooter Manuals. Mower Manuals. Power Tool Manuals. Fault detected. See the Electrical Diagnostic Manual for Valve guides or seals badly worn or damaged. Clutch Slips Open in oiling circuit. Clutch controls improperly adjusted. High Oil Pressure Insufficient clutch spring tension.
Oil tank overfilled. Worn friction discs. Bypass valve stuck in closed position. Heavy front end loading. Non-standard equipment on the runout should not be more than 0. Irregular or peaked front tire tread wear. A good suspension is a balance between damping and track condition. Finding this balance requires exploring all possible compression settings. Lack of tire feedback. Increase compression damping. Tire slides. Over inflated tires can blow out, which could Fuel tank total 4.
Page Suspension Settings Be sure tires are properly inflated, balanced and have Exceeding these weight ratings can affect stability and adequate tread. Inspect your tires regularly and see a Buell handling, which could result in death or serious injury. Riding with excessively worn, Buell V. Regularly inspect wheels and tires for damage and wear. If handling problems occur, see 1. Page Tires and wheels are critical items. Since the servicing of Buell tires are equipped with wear bars that run horizont- these components requires special tools and skills, Buell ally across the tread.
When wear bars become visible and recommends that you see your dealer for these services. For location of jacking point see 4. NOTE Do not operate front brake lever with front wheel removed or caliper pistons may be forced out. Reseating pistons requires caliper disassembly. JA to the threads of the short forcing screw 1 to prolong service life and verify smooth operation. Assemble the short forcing screw 1 , nut 2 , Nice bearing 3 , washer 4 and bridge 5.
Page HOME sm sm 1. Bridge 2. Nut 3. Forcing screw Figure Remove the Spacer Figure Remove and discard rotor mounting fasteners 7. Forcing screw 2. Backing plate Figure Remove the backing plate 2 from the long forcing screw 1. Reinstall the Backing Plate onto 1. Long forcing screw the forcing screw, with the smaller diameter toward the 2. Center the spacer 2 while installing the wheel bearing. Failure to center the spacer could cause the bearing not to pull in straight. See Figure Insert a new wheel bearing 1 squarely into the hub, with the lettered side facing out away from the wheel.
Install new springs 4. Rotor mounting fasteners must be seated into drive Install new washers 9. Install caliper. Rotate right front fork counterclockwise to align caliper with rotor. Lower front wheel into caliper assembly. NOTE The front axle is left handed thread. Install front axle. Using compressed air to "spin dry" bearings can cause NOTE bearing to fly apart, which could result in death or serious injury.
Page HOME Slide axle through right side of swingarm and wheel hub sm and thread partially into swingarm on left side. Install idler pulley. See 5. NOTE Never tighten rear axle with swingarm brace removed. When wear bars become visible and New tires should be stored in a horizontal tire rack. Page Figure Loosening Beads from Rim Flange Buell front and rear tires are not the same.
Interchanging front and rear tires can cause tire failure, which could result in death or serious injury. Work bead onto rim with tire tools, working toward valve in both directions. Do not inflate tire beyond maximum pressure as specified on sidewall. Over inflated tires can blow out, which could result in death or serious injury. Rim Lateral Runout Figure Remove pivot bolt nut 1 and pivot bolt D. Depress piston assembly 1 and remove sm internal circlip 2 and discard.
Remove piston and spring from master cylinder and dis- card. Piston assembly 2. Circlip sm Figure Replace the housing if any scratches, dents or other damage is present.
Clean the reservoir diaphragm, stiffener and cover. Clean the pressure relief channels 2 in the cover. Page HOME Remove caliper banjo bolt 2 and two copper washers to sm disconnect brake line from caliper.
Discard copper washers. Page HOME sm Be sure that all lights and switches operate properly before operating motorcycle.
Low visibility of rider can result in death or serious injury. Test the brake lamp. Carefully inspect all components. Replace any parts that appear damaged or worn. Do not hone caliper piston bore. Always replace brake pads in complete sets for correct and safe brake operation.
Direct contact of D. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Remove two master cylinder cover sm screws, cover and cover gasket.
Always use caution and protect surfaces from spills whenever brake work is per- formed. NOTE Damaged banjo bolt seating surfaces will leak when reas- sembled.
Prevent damage to seating surfaces by carefully removing brake line components. Remove master cylinder banjo bolt metric 14 and two copper washers 16 to disconnect brake line from master cylinder. Install new copper washer 3 , brake line, new copper washer 3 and wire form 4 onto banjo bolt 2. Finger tighten banjo bolt 2 onto front caliper, being careful not to pinch wire form 4 while tightening.
Damage to seating surfaces can cause leakage. Disconnect brake line 1 at caliper 2. Install pad spring 7 and brake pads Always replace brake pads in complete sets for correct Improper brake operation could Install pin hanger set 1 and tighten to ft-lbs result in death or serious injury.
Remove cotter pin 3 and discard. Remove clevis pin 2. Remove pedal fastener 4. Remove shift brake pedal sleeve 5. Remove pedal bushings 6. Remove brake pedal 7. Install pedal bushings 6. Install shift brake pedal sleeve 5. Drain brake fluid into a suitable container. Discard used fluid according to local laws. Install a length of plastic tubing over caliper bleeder valve.
Place free end in a suitable container. Page HOME See Figure Figure Detach remote reservoir. Disconnect hose. Remove fastener 2 to detach reservoir 1 from frame if necessary. Reservoir 2. Fastener and washer 3. Remove seat.
On Ulysses models, remove air flow guide. Disconnect brake light connector located under the seat. Loosen adjuster locknut on the rod assembly 3. Remove the clevis from the rod assembly 3. NOTE Do not disassemble master cylinder unless problems are experienced.
Discard all seals during the disassembly pro- cedure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. Page HOME Be sure that all lights and switches operate properly before After installing seat, pull upward on seat to be sure it is operating motorcycle.
Low visibility of rider can result in locked in position. While riding, a loose seat can shift death or serious injury. See 1. To prevent accidental vehicle start-up, which could cause Install brake line, banjo bolt and new copper washers to death or serious injury, disconnect negative - battery rear caliper. Tighten to death or serious injury, disconnect negative - battery ft-lbs Nm. See D. Page HOME After servicing brakes and before moving motorcycle, After repairing the brake system, test brakes at low speed.
Insufficient If brakes are not operating properly, testing at high speeds pressure can adversely affect brake performance, which can cause loss of control, which could result in death or could result in death or serious injury.
Remove pin plug 5 and pad hanger metric to free brake pads. Place clip 1 inside caliper body as shown. NOTE To verify proper brake pad-to-brake rotor clearance when the caliper is installed, piston must be pressed all the way into the bore whenever new brake pads are used. Install caliper assembly on caliper mount. Turn ignition key switch to ON. Apply brake pedal to test Brake pad surfaces must face rear brake rotor. Turn ignition key switch to LOCK. Install large caliper fastener 7 metric tightening to ft-lbs Nm.
The rear fender captures the rear brake line to help maintain the proper alignment and location. Remove fasteners and washers 2 securing the front fender 1 to front forks. Page HOME right side of the upper front fender before installing and tight- Install the right lower front fender 9 with fasteners 6, 7. Tighten all fender fasteners to in-lbs 4. Align front fender 2 to fender mounts on lower triple clamp, apply LOCTITE red and Install sm front fender fasteners and washers 1 and tighten to Remove caliper mounting fasteners.
Loosen upper and lower fork clamp pinch fasteners 1, 5. HD assembly. The bottom of the preload adjuster is round with two flat sides so a wrench 2 can be used to Page HOME Loosen the damper rod assembly jamnut 3 and back it sm off all the way to the bottom.
Hold damper rod assembly jamnut 3 and remove fork cap 1. Inside the damper rod assembly 6 is a fork push rod 4 that is tapered on one end to control the movement of fluid in the front fork increasing and decreasing the damping properties. For Buell model motorcycles, there are three MODEL different tools that can be used to install the fork seal and dust boot depending on the size of your slider fork. Thread damper rod retrieval tool found sm in the Race Tech Inc.
TBFT 02S onto end of damper rod assembly 6. NOTE While pumping the outer tube up and down be sure not to exceed the travel of the fork assembly. Forks that are not properly adjusted can lead to loss of control, which could XB12R 4. XB9SX 4. Remove handlebars. Remove cable straps securing wiring harnesses to the upper fork clamp.
Carefully install the fork into the upper fork clamp. Forcing the Remove the lower fork clamp with stem 6. Tighten but do not torque. NOTE For additional information, see 2. Position both forks with same number Figure Steering Head Bearing Installation Tool 3. Lower bearing 4. Bearing 5. Washer 6. Nut Figure Lower Bearing Figure JA to the threads of the forcing screw 1 from the steering head bearing race 1. On Lightning and Ulysses models, install front modules.
For information on the swingarm function as the oil tank, see 3. The swingarm features a removable brace on the right side to allow drive belt replacement. Pivot shaft pinch fastener with nut Figure Blow dry with sm compressed air. Replace complete bearing assembly if any component is damaged. Check that swingarm is not bent or twisted.
Replace if damaged. Connect battery cables to battery: positive cable red first. Tighten to in-lbs Nm. Connect three oil lines to swingarm fittings and install and tighten p-clamps to in-lbs 5.
Keep weight of motorcycle off front isolator by alternately loosening front isolator bolt and raising scissor jack to support engine. Place a scissor jack under jacking point for supporting engine only. The aluminum frame of this motorcycle is the fuel tank. See 6. Remove fuel from frame. See 4. Rotate engine.
See 3. The shock allows adjustment of rear compression and rebound damping and spring preload. Page HOME sm Screw and washer, preload adjuster knob Lower shock mount nut Preload adjuster knob Lower shock mount washer, thick Preload adjust assembly Lower shock mount washer, thin Preload adjuster fasteners 2 Lower shock mount sleeve Rear shock body Lower shock mount fastener Remote reservoir clamp fastener Upper shock mount fastener Remote reservoir clamp Remove tail body work.
Page HOME Install the two fasteners holding the preload adjuster in place and tighten to in-lbs 5. Position the throttle control cable in the same manner so NOTE both elbows are inserted into the bracket. Throttle Cable Retention Clip Figure Throttle cable elbow alignment XB Service: Chassis Remove the outer ramp and hook 1 Unscrew the cable fitting from the from the cable end 3 and coupling 2.
Remove cable primary cover. Remove clutch cable and fitting. Install 7 bearings and 8 sleeve into sm the shift lever. Connect negative battery cable to battery terminal.
Tighten Always connect front tie bar to engine mount first. Install front tie bar, p-clamp and clutch cable to front engine mount and tighten fastener to ft-lbs It is the manual used in the local service repair shop. They are specifically written for the do it work as well as the experienced mechanic. With step by step instruction and highly detailed exploded pictures, diagrams to show you how to complete the required job correctly, efficiently using.
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