Buell 2004 XB9S Bedienungsanleitung

2004 BUELL XB9S

SERVICE MANUAL

Part Number 99490-04Y

Section 1: Maintenance

Section 2: Chassis

Section 3: Engine

Section 4: Fuel System

Section 5: Starter

Section 6: Drive/Transmission

Section 7: Electrical

Appendices

1-2 Edit Me: Printed September 26, 2003 2:32 pm

Appendix A A-1

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APPENDIX A–TOOLS

Part No. B-41174 Rear Wheel Support Stand and

Part No. B-41174-2 Replacement Pad

Part No. B-42887 Brake Caliper Piston Remover

Part No. B-43721 Front Fork Seal Driver

Part No. B-46279 7/8" Axle Wrench (Hex)

Part No. B-43993-7/-8 Wheel Bearing Collets

Part No. B-45521 Steering Head Bearing Remover/

Installer

Part No. HD-39302 Steering Head Bearing Race Installer

(Used with B-45521)

Part No. B-59000B Pro Level Oil Gauge

A-2 Appendix A

HOME

Part No. HD-01289 Rim Protectors

Part No. HD-45966 Fork Spring Compressing Tool

Part No. HD-28700 Tire Bead Expander

Part No. HD-33416 Universal Driver Handle

Part No. HD-33418 Universal Puller Forcing Screw

Part No. HD-94700-52C Shock Spanner Preload

Adjustment Tool

Part No. HD-44060 Wheel Bearing Remover/Installer

Part No. HD-99500-80 Wheel Truing

and Balancing Stand

Appendix A A-3

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Part No. HD-95637-46A Wedge Attachment for

Claw Puller. Use with HD-95635-46.

Part No. HD-96921-52A Oil Pressure Gauge

Part No. HD-35457 Black Light Leak Detector

Part No. HD-33223-1 Cylinder Compression Gauge

Part No. HD-35667A Cylinder Leakdown Tester

Part No. HD-34902-B Bearing Race Remover/Installer

Part No. HD-43984 Crankshaft Locking Tool

Part No. HD-38362 Sprocket Locking Link (XB9S)

Part No. HD-46283 Sprocket Locking Link (XB12S)

CYLINDER LEAKDOWN TESTER

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CYLINDER LEAKDOWN TESTER

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A-4 Appendix A

HOME

Part No. HD-39964 Reamer Lubricant (Cool Tool)

Part No. HD-39782 Cylinder Head Support

Part No. HD-39786 Cylinder Head Holding Fixture

Part No. HD-34736B Valve Spring Compressor

Part No. B-45524 Valve Guide Installer

Part No. B-45523 Valve Guide Reamer (7mm)

Part No. B-45525 Valve Guide Hone

Part No. HD-34751 Nylon Valve Guide Brush

Appendix A A-5

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Part No. HD-94804-57 Rocker Arm Bushing Reamer

Part No. HD-33446A Cylinder Torque Plates

and Torque Plate Bolts Part No. HD-33446-86

Part No. HD-34623C Piston Pin

Retaining Ring Installer/Remover

Part No. HD-42322 Piston Support Plate

Part No. HD-96333-51C Piston Ring Compressor

Part No. HD-95952-33B Connecting Rod

Clamping Tool

Part No. HD-95970-32D Piston Pin Bushing Tool

Part No. HD-94800-26A Connecting Rod Bushing

Reamers and Pilots

A-6 Appendix A

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Part No. HD-35102 Wrist Pin Bushing Hone (20 mm)

Part No. HD-38515-A Clutch Spring Compressing Tool

and Part No. HD-38515-91 Forcing Screw

Part No. J-5586 Transmission Shaft

Retaining Ring Pliers

Part No. HD-97292-61 Two Claw Puller

Part No. HD-95760-69A Bushing/Bearing Puller Tool Set.

Set includes items 1-7. Items 8 (HD-95769-69), 9 (HD-

95770-69) and 10 (HD-95771-69) are optional.

Part No. HD-39965 Deutsch Terminal Crimp Tool

Part No. HD-41354 Speedometer Tester

Part No. HD-41609 Amp Terminal Crimp Tool

2004 Buell Lightning: Appendix B B-1

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AMP MULTILOCK ELECTRICAL CONNECTORS B.1

REMOVING SOCKET/PIN

TERMINALS

1. Remove connector from the retaining device, either

attachment or rosebud clip.

2. Depress the button on the socket terminal side of the

connector (plug) and pull apart the pin and socket

halves.

3. Bend back the latch slightly and free one side of second-

ary lock, then repeat the step to release the other side.

Rotate the secondary lock outward on hinge to access

terminals in chambers of connector housing.

4. Looking in the terminal side of the connector (opposite

the secondary lock), take note of the cavity next to each

terminal.

5. See Figure B-1. With the ﬂat edge against the terminal,

insert the pick tool (Snap-On TT600-3) into the cavity

until it stops. Pivot the end of the pick away from the ter-

minal (locktab is inside housing) and gently tug on wire to

pull terminal from chamber. Do not tug on the wire until

the tang is released or the terminal will be difﬁcult to

remove. A “click” is heard if the tang is engaged but then

inadvertently released. Repeat the step without releasing

the tang.

NOTE

●

If pick tool is not available, a push pin/safety pin may be

used instead.

●

An ELECTRICAL TERMINAL CRIMP TOOL (Part No.

HD-41609) is used to install Amp Multi lock pin and

socket terminals on wires. If new terminals must be

installed, see Crimping Instructions on the next page.

INSTALLING SOCKET/PIN

TERMINALS

NOTE

For wire location purposes, numbers are stamped into the

secondary locks of both the socket and pin housings. See

Figure B-2.

1. From the secondary lock side of the connector, insert the

terminal into its respective numbered chamber until it

snaps in place. For proper ﬁt, the slot in the terminal

must face the tang in the chamber.

Figure B-1. 10-Place Amp Multilock Connector

d0242x3x

Secondary lock open

Pin housing

Latch

Pin terminal

Socket housing

Secondary lock open

Socket terminal

Button

Latch

B-2 2004 Buell Lightning: Appendix B

HOME

NOTES

●

See Figure B-3. The tang in the chamber engages the

slot to lock the terminal in position.

●

On the pin side of the connector, tangs are positioned at

the bottom of each chamber, so the slot in the pin termi-

nal (on the side opposite the crimp tails) must face down-

ward.

●

On the socket side, tangs are at the top of each chamber,

so the socket terminal slot (on the same side as the

crimp tails) must face upward.

●

Up and down can be determined by the position of the

release button (used to separate the pin and socket

halves). Consider the button to always be on top of the

connector.

2. Gently tug on wire end to verify that the terminal is

locked in place and will not back out of chamber.

3. Rotate the hinged secondary lock inward until tabs fully

engage latches on both sides of connector.

4. Insert the socket housing (plug) into the pin housing

(receptacle) until it snaps in place.

5. Install connector on retaining device, either attachment

or rosebud clip.

Figure B-2. Release Tang and Back Out Terminals

Pin terminal

Socket terminal

Secondary lock open

Pick tool

Pin housing

Socket housing

1. Open secondary lock.

2. Insert pick into cavity on inboard side

of connector.

3. Pivot end of pick to release tang.

4. Gently tug on wire to remove terminal

from housing.

d0243x8x

Figure B-3. Multilock Connector Cutaway View

Pin housing

Tang

Socket housing

Tang

d0244x8x

Button

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