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Buell XB9S 2003 User Manual

Buell XB9S 2003
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2003 Buell XB9S: Maintenance 1-1
HOME
GENERAL 1.1
SERVICING A NEW
MOTORCYCLE
1WARNING1WARNING
Always follow the listed service and maintenance recom-
mendations, because they affect the safe operation of
the motorcycle and the personal welfare of the rider. Fail-
ure to follow recommendations could result in death or
serious injury.
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 sys-
tems operation. See 1.3 MAINTENANCE SCHEDULE for
details.
SAFE OPERATING
MAINTENANCE
CAUTION
Do not attempt to retighten engine head bolts.
Retightening can cause engine damage.
During the initial break-in period, use only Harley-
Davidson 20W50 engine oil. Failure to use the rec-
ommended oil will result in improper break-in of the
engine cylinders and piston rings.
A careful check of certain equipment is necessary after peri-
ods of storage, and frequently between regular service inter-
vals, to determine if additional maintenance is required.
Check:
1. Tires for abrasions, cuts and correct pressure.
2. Secondary drive belt for proper tension and condition.
3. Brakes, steering and throttle for responsiveness.
4. Brake fluid level and condition. Hydraulic lines and fit-
tings for leaks. Also, check brake pads and rotors for
wear.
5. Cables for fraying, crimping and free operation.
6. Engine oil and transmission fluid levels.
7. Headlamp, passing lamp, tail lamp, brake lamp and turn
signal operation.
SHOP PRACTICES
Repair Notes
NOTE
General maintenance practices are given in this section.
Repair = Disassembly/Assembly.
Replace = Removal/Installation.
All special tools and torque values are noted at the point of
use.
All required parts or materials can be found in the appropriate
PARTS CATALOG.
Safety
Safety is always the most important consideration when per-
forming any job. Be sure you have a complete understanding
of the task to be performed. Use common sense. Use the
proper tools. Protect yourself and bystanders with approved
eye protection. Don’t just do the job – do the job safely.
Removing Parts
Always consider the weight of a part when lifting. Use a hoist
whenever necessary. Do not lift heavy parts by hand. A hoist
and adjustable lifting beam or sling are needed to remove
some parts. The lengths of chains or cables from the hoist to
the part should be equal and parallel and should be posi-
tioned directly over the center of the part. Be sure that no
obstructions will interfere with the lifting operation. Never
leave a part suspended in mid-air.
1WARNING1WARNING
Always check the capacity rating and condition of hoists,
slings, chains or cables before use. Failure to do so can
lead to an accident which could result in death or serious
injury.
Always use blocking or proper stands to support the part that
has been hoisted. If a part cannot be removed, verify that all
bolts and attaching hardware have been removed. Check to
see if any parts are in the way of the part being removed.
When removing hoses, wiring or tubes, always tag each part
to ensure proper installation.
Cleaning
If you intend to reuse parts, follow good shop practice and
thoroughly clean the parts before assembly. Keep all dirt out
of parts; the unit will perform better and last longer. Seals, fil-
ters and covers are used in this vehicle to keep out environ-
mental dirt and dust. These items must be kept in good
condition to ensure satisfactory operation.
Clean and inspect all parts as they are removed. Be sure all
holes and passages are clean and open. After cleaning,
cover all parts with clean lint-free cloth, paper or other mate-
rial. Be sure the part is clean when it is installed.
Always clean around lines or covers before they are removed.
Plug, tape or cap holes and openings to keep out dirt, dust
and debris.
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Buell XB9S 2003 Specifications

General IconGeneral
Year2003
ManufacturerBuell
ModelXB9S
CategoryMotorcycle
Displacement984 cc
Bore x Stroke88.9 mm x 79.4 mm
Compression Ratio10.0:1
IgnitionElectronic
Transmission5-speed
Final DriveBelt
Front BrakesSingle 375 mm disc, 6-piston caliper
Front Tire120/70-ZR17
Rear Tire180/55-ZR17
Engine TypeAir-cooled, 4-stroke, 45° V-Twin
Torque85 Nm @ 5500 RPM
FrameAluminum frame
Front SuspensionShowa 41 mm inverted fork
Rear SuspensionShowa shock, adjustable preload, compression and rebound damping
Rear BrakesSingle-piston caliper
Wheelbase1321 mm (52.0 inches)
Dry Weight175 kg

Summary

SERVICING A NEW MOTORCYCLE

SAFE OPERATING MAINTENANCE

Essential checks for safe motorcycle operation and rider welfare.

SHOP PRACTICES OVERVIEW

Workshop Practices and Safety

Covers repair definitions, general safety, part removal, and cleaning for workshop practices.

REPAIR AND REPLACEMENT PROCEDURES

Hardware and Threaded Parts

Procedures for installing thread inserts and replacing common hardware and fittings.

Wiring, Hoses and Lines

Guidelines for replacing hoses, wiring, electrical switches, and fuel lines.

Bearings, Bushings, and Seals

Procedures for handling, cleaning, and replacing bearings, bushings, seals, and O-rings.

Gears and Shafts

Checks for gear damage, shaft removal, and inspection of tapered splines.

CLEANING PROCEDURES

Part Protection and Cleaning Methods

Protecting parts and methods for thorough cleaning, including rust removal.

TOOL SAFETY GUIDELINES

Safe Tool Operation

Safety guidelines for operating various tools like air tools, wrenches, hammers, and screwdrivers.

FUEL AND OIL

Fueling Guidelines

Recommendations for using quality gasoline, avoiding alcohol additives, and understanding blends.

Engine Oil and Winter Lubrication

Proper engine oil grades, viscosity, and considerations for cold weather operation.

MAINTENANCE SCHEDULE

Regular Service Intervals

Table detailing service operations and intervals based on odometer readings.

CARE OF MOLDED-IN-COLOR BODY PANELS

Washing and Cleaning Between Washes

Procedures for washing, cleaning between washes, and maintaining the gloss of body panels.

Polishing and Minor Scratch Removal

Steps for polishing, applying sealant, and removing minor scratches from body panels.

BATTERY MAINTENANCE

Battery Inspection and Testing

Information on battery type, inspection, and voltmeter testing procedures.

BATTERY DISCONNECTION AND REMOVAL

Cleaning and Inspection Procedures

Procedures for cleaning battery tops, terminals, and inspecting for damage.

STORAGE

Battery Storage Guidelines

Recommendations for storing batteries, including charging and temperature considerations.

BATTERY INSTALLATION AND CONNECTION

Installation and Connection Steps

Step-by-step guide for placing the battery, connecting cables, and securing it.

ENGINE LUBRICATION SYSTEM

Checking Engine Oil Level

Procedures for checking engine oil level at operating temperature, including dipstick use.

CHANGING ENGINE OIL AND FILTER

Draining Oil

Instructions for draining engine oil using the drain plug.

Changing Oil Filter

Steps for removing and replacing the engine oil filter, including lubrication.

Replacing Oil

Oil Tank Filling and Checks

Procedures for filling the oil tank, inspecting the dipstick o-ring, and checking the oil cooler.

Recommended Oil Grades

Table showing recommended oil grades based on viscosity and ambient temperature.

BRAKE SYSTEM MAINTENANCE

General Checks and Fluid Replacement

Procedures for checking brake fluid, replacing DOT 4 fluid, and inspecting lines and seals.

Bleeding Brakes

Safety warnings and procedures for bleeding brake systems, emphasizing fluid compatibility.

Bleeding Front Brake

Front Brake Bleeding Procedure

Step-by-step guide for bleeding the front brake caliper and master cylinder.

Bleeding Rear Brake

Rear Brake Bleeding Procedure

Step-by-step guide for bleeding the rear brake caliper and master cylinder.

BRAKE PEDAL ADJUSTMENT

Checking and Adjusting Pedal Height

Procedures for checking brake pedal operation and adjusting its height.

BRAKE PAD THICKNESS

Minimum Thickness Check

How to check brake pad minimum thickness and when to replace them.

BRAKE ROTOR THICKNESS

Minimum Thickness and Surface Check

Procedures for measuring rotor thickness and checking rotor surface for damage.

BRAKE PAD REPLACEMENT

Front Pad Removal

Step-by-step guide for removing front brake pads.

Front Pad Installation

Step-by-step guide for installing new front brake pads.

Rear Pad Removal

Removing Rear Brake Pads

Step-by-step guide for removing rear brake pads.

Rear Pad Installation

Installing Rear Brake Pads

Step-by-step guide for installing new rear brake pads.

TIRES AND WHEELS

Tire Inflation and Checks

Guidelines for checking tire pressure and tread wear indicators.

Tire Replacement Conditions

Criteria indicating when new tires are needed.

Wheel Bearings

Procedures for checking and replacing wheel bearings for wear and corrosion.

CLUTCH

Transmission Fluid Service

Procedures for checking and replacing transmission fluid, including capacity.

ADJUSTMENT

Clutch Adjustment Procedure

Step-by-step guide for adjusting clutch cable and mechanism for proper free play.

DRIVE BELT

Belt and Idler Pulley Inspection

Procedures for inspecting the drive belt for wear patterns and the idler pulley.

Belt Cleaning

Guidelines for cleaning the drive belt with mild soap and water.

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