Buell Xb9r Xb12r Firebolt 2006 Factory Service Repair Manual
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PAGES:450+
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Buell Xb9r Xb12r Firebolt 2006 Factory Service Repair Manual
GENERAL:
Service operations to be performed before customer delivery are specified in the applicable model year PREDELIVERY AND SETUP MANUAL. The performance of new motorcycle initial service is required to keep warranty in force and to ensure proper emissions system operation.
ENGINE OIL:
Use the proper grade of oil for the lowest temperature expected before the next oil change. If it is necessary to add oil and Harley-Davidson oil is not available, use an oil certified for diesel engines. Acceptable diesel engine oil designations include CF-4, CG-4, CH-4 and CI4. The preferred viscosities for the diesel engine oils, in descending order, are 20W-50, 15W-40 and 10W-40. At the first opportunity, see a Harley-Davidson dealer to change back to 100 percent Harley-Davidson oil. ENGINE LUBRICATION SYSTEM for all service information.
WINTER LUBRICATION :
Combustion in an engine produces water vapor. During starting and warm-up in cold weather, especially in freezing temperatures, the vapor condenses to water before the crankcase is hot enough to exhaust it through the breather system. If the engine is run long enough for the crankcase to become thoroughly heated, the water returns to vapor and is then exhausted. An engine used for only short trips, and seldom allowed to thoroughly warm up, accumulates increasing amounts of water in the oil reservoir. Water mixed with oil forms a sludge that causes accelerated engine wear. In freezing temperatures, the water becomes slush or ice, which may clog oil lines and result in engine failure. Disassembly and Assembly Always assemble or disassemble one part at a time. Do not work on two assemblies simultaneously. Be sure to make all necessary adjustments. Recheck your work when finished. Be sure that everything is done. Operate the vehicle to perform any final check or adjustments. If all is correct, the vehicle is ready to go back to the customer.
REPAIR AND REPLACEMENT PROCEDURES:
Hardware and Threaded Parts Install helical thread inserts when inside threads in castings are stripped, damaged or not capable of withstanding specified torque. Replace bolts, nuts, studs, washers, spacers and small common hardware if missing or in any way damaged. Clean up or repair minor thread damage with a suitable thread chaser. Replace all damaged or missing lubrication fittings. Use Teflon pipe sealant on pipe fitting threads. Wiring, Hoses and Lines Replace hoses, clamps, electrical wiring, electrical switches or fuel lines if they do not meet specifications. Instruments and Gauges Replace broken or defective instruments and gauges.
- Bearings Anti-friction bearings must be handled in a special way. To keep out dirt and abrasives, cover the bearings as soon as they are removed from the package. Wash bearings in a non-flammable cleaning solution. Knock out packed lubricant inside by tapping the bearing against a wooden block. Wash bearings again.
- Cover bearings with clean material after setting them down to dry. Never use compressed air to dry bearings. Coat bearings with clean oil. Wrap bearings in clean paper. Be sure that the chamfered side of the bearing always faces the shoulder (when bearings installed against shoulders).
- Lubricate bearings and all metal contact surfaces before pressing into place. Only apply pressure on the part of the bearing that makes direct contact with the mating part. Install bearings with numbered side facing out. Always use the proper tools and fixtures for removing and installing bearings. Bearings do not usually need to be removed. Only remove bearings if necessary.
TABLE OF CONTENTS:
Buell Xb9r Xb12r Firebolt 2006 Factory Service Repair Manual
11 General 1-1
12 Fuel and Oil 1-5
13 Maintenance Schedule 1-6
14 Windshield Maintenance1-9
15 Battery Maintenance1-10
16 Engine Lubrication System 1-13
17 Brake System Maintenance 1-16
18 Tires and Wheels1-24
19 Clutch 1-25
110 Drive Belt System 1-28
111 Primary Chain 1-31
112 Suspension Damping Adjustments1-33
113 Steering Head Bearings 1-38
114 Spark Plugs1-39
115 Air Cleaner Filter 1-41
116 Throttle Cable and Idle Speed Adjustment1-43
117 Interactive Exhaust Cable (XB12 Models only)1-44
118 Ignition Timing 1-46
119 Headlights 1-48
120 Throttle Position Sensor (TPS)1-50
121 Storage1-51
122 Troubleshooting1-52
21 Specifications2-1
22 Tire Specifications 2-5
23 Buell Vehicle Identification Number (VIN) 2-6
24 Wheels 2-8
25 Front Wheel 2-10
26 Rear Wheel 2-17
27 Checking Cast Rim Runout 2-21
28 Tires 2-22
29 Brake Pedal 2-26
210 Front Brake Master Cylinder2-27
211 Front Brake Line2-31
212 Front Brake Caliper 2-33
213 Rear Brake Master Cylinder2-36
214 Rear Brake Line2-40
215 Rear Brake Caliper 2-42
216 Front Fork 2-45
217 Fork Clamps, Upper and Lower2-53
218 Steering Head Bearings2-55
219 Swingarm and Brace 2-58
220 Front and Rear Isolator 2-62
221 Frame 2-63
222 Rear Shock Absorber 2-64
223 Throttle Control 2-66
224 Clutch Control 2-67
225 Headlight Assembly and Support Bracket 2-71
226 Fairing Support Bracket2-74
227 Handlebars 2-76
228 Exhaust System2-78
229 Footpeg, Heel Guard, and Mount 2-81
230 Sprocket Cover 2-83
231 Fenders 2-84
232 Belt Guards 2-85
233 Chin Fairing2-86
234 Intake Cover Assembly 2-87
235 Air Scoops 2-88
236 Subframe Tail Assembly and Body Work 2-89
237 Front Fairing, Windshield and Mirrors 2-93
238 Seat2-94
239 Passenger Seat Lock 2-95
240 Sidestand 2-96
CHASSIS 2
31 Specifications 3-1
32 Engine 3-6
33 Engine Rotation for Service 3-8
34 Stripping Motorcycle for Engine Service3-19
35 Engine Installation 3-30
36 Cylinder Head 3-44
37 Cylinder and Piston 3-62
38 Lubrication System 3-71
39 Oil Hose Routing and Oil Reservoir 3-72
310 Oil Line Fittings3-73
311 Oil Cooler 3-75
312 Oil Pressure Indicator Switch 3-77
313 Crankcase Breathing System 3-78
314 Oiling System 3-80
315 Oil Pump 3-81
316 Oil Filter Mount3-84
317 Hydraulic Lifters3-85
318 Gearcase Cover And Cam Gears 3-87
319 Crankcase 3-92
41 Specifications 4-1
42 Dynamic Digital Fuel Injection 4-3
43 Diagnostic Introduction 4-5
44 Checking For Trouble Codes4-6
45 Check Engine Lamp Diagnostics4-8
46 Breakout Box4-10
47 Wiggle Test 4-11
48 Initial Diagnostic Check 4-12
49 Check Engine Lamp Not Illuminated at Key ON4-17
410 Check Engine Lamp On Continuously 4-20
411 Engine Cranks But Will Not Start 4-23
412 No ECM Power4-29
413 Fuel Pressure Test4-32
414 Idle Speed Control 4-37
415 Misfire 4-38
416 Trouble Code 11 4-43
417 Trouble Code 13 4-47
418 Trouble Code 14 4-52
419 Trouble Code 15 4-56
420 Trouble Code 16 4-60
421 Trouble Code 21 4-64
422 Trouble Codes 23 and 32 4-67
423 Trouble Codes 24 and 25 4-71
424 Trouble Code 33 4-74
425 Trouble Code 35 4-77
426 Trouble Code 36 4-80
427 Trouble Code 44 4-84
428 Trouble Codes 52, 53, 54 and 55 4-88
429 Trouble Code 56 4-89
430 Electronic Control Module 4-93
431 Cam Position Sensor and Rotor 4-95
432 Ignition Coil4-99
433 Oxygen Sensor4-101
434 Engine Temperature Sensor 4-102
435 Bank Angle Sensor4-103
436 Intake Air Temperature Sensor4-104
437 Throttle Position Sensor 4-105
Table Of Contents
Continued on Next Page
FUEL SYSTEM 4
438 Cooling Fan4-106
439 Fuel Pump 4-107
440 Fuel Tank Vent Valve 4-115
441 Fuel Cap Retaining Ring 4-116
442 Throttle Body 4-117
443 Intake Leak Test 4-122
444 Air Cleaner Assembly 4-124
445 Evaporative Emissions Control-California Models 4-127
51 Specifications 5-1
52 Electric Starter System 5-2
53 Starting System Diagnosis 5-4
54 Starter Activation Circuits 5-8
55 Diagnostics/Troubleshooting5-9
56 Starter System Testing 5-11
57 Starter 5-12
58 Starter Solenoid 5-21
61 Specifications 6-1
62 Primary Cover 6-3
63 Clutch Release Mechanism 6-7
64 Clutch 6-9
65 Primary Chain 6-16
66 Drive Belt System 6-21
67 Transmission6-25
68 Case Disassembly for Transmission Removal 6-26
69 Transmission Disassembly 6-29
610 Transmission Assembly6-34
611 Main Drive Gear and Bearing 6-36
612 Transmission Right Case Bearings6-44
613 Transmission Left Case Bearings 6-45
614 Transmission Installation 6-46
615 Shifter Shaft6-50
616 Transmission Sprocket6-52
71 Specifications 7-1
72 Ignition System 7-3
73 Ignition/Headlight Key Switch 7-5
74 Spark Plug Cables 7-9
75 Starter Interlock 7-11
76 Interactive Exhaust System (XB12 Model) 7-18
77 Charging System7-23
78 Alternator7-30
79 Voltage Regulator 7-32
710 Battery Cables 7-33
711 Battery 7-35
712 Headlight 7-42
713 Tail Lamp 7-44
714 Turn Signals 7-45
715 Turn Signal Flasher7-48
716 Handlebar Switches7-49
717 Speedometer Sensor 7-51
718 Instrument Module 7-52
719 Speedometer Performance Check7-54
720 Horn7-59
721 Neutral Indicator Switch7-61
722 Main Fuse and Fuses 7-62
723 Main Wire Harness7-63
724 Interactive Exhaust Harness (XB12 Models) 7-68
725 Sprocket Cover Wiring 7-70
A1 ToolsA-1
B1 Amp Multilock Electrical ConnectorsB-1
B2 Deutsch Electrical Connectors B-5
B3 Packard Electrical Connectors B-10
B4 Electrical Connectors B-14
B5 Index to Wiring Diagrams B-16
C1 Metric Conversions C-1
D1 Hose and Wire Routing D-1
E1 Active Intake System (Japanese models only)E-1
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
- This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
- Require some other service manual or have any queries: please WRITE to us at [email protected]