EasyManua.ls Logo

Buell 2003XB9S User Manual

Buell 2003XB9S
588 pages
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Page #1 background imageLoading...
Page #1 background image
2003 BUELL XB9S
SERVICE MANUAL
Part Number 99490-03Y
Section 1: Maintenance
Section 2: Chassis
Section 3: Engine
Section 4: Fuel System
Section 5: Starter
Section 6: Drive/Transmission
Section 7: Electrical
Appendices

Table of Contents

Question and Answer IconNeed help?

Do you have a question about the Buell 2003XB9S and is the answer not in the manual?

Buell 2003XB9S Specifications

General IconGeneral
BrandBuell
Model2003XB9S
CategoryMotorcycle
LanguageEnglish

Summary

2003 BUEL XB9S

SERVICE MANUAL

Section 1: Maintenance

1.3 Maintenance Schedule

Table of regular service intervals based on odometer readings.

1.6 Engine Lubrication System

Procedures for checking engine oil level and changing oil and filter.

1.7 Brake System Maintenance

Checks for brake fluid, lines, caliper seals, and bleeding procedures.

1.12 Suspension Damping Adjustments

Recommended suspension settings for rider weight and adjustment procedures.

1.13 Steering Head Bearings

Procedures for removing, installing, and determining proper resistance.

1.17 Ignition Timing

Procedures for checking and adjusting ignition timing.

1.21 Troubleshooting

Checklists for common engine and electrical troubleshooting.

CHASSIS 2

2.9 Brake Pedal

Removal and installation procedures for the brake pedal assembly.

2.10 Front Brake Master Cylinder and Hand Lever

Removal, disassembly, cleaning, inspection, and assembly procedures.

2.11 Front Brake Line

Removal and installation procedures for the front brake line.

2.12 Front Brake Caliper

Removal, disassembly, cleaning, inspection, assembly, and installation procedures.

2.13 Rear Brake Master Cylinder

Removal and disassembly procedures for the rear brake master cylinder.

2.14 Rear Brake Line

Removal and installation procedures for the rear brake line.

2.15 Rear Brake Caliper

Removal, disassembly, cleaning, inspection, assembly, and installation procedures.

2.16 Front Fork

Removal, disassembly, cleaning, inspection, and assembly procedures for the front fork.

2.17 Fork Clamps, Upper and Lower

Removal and installation procedures for fork clamps and steering stem.

2.18 Steering Head Bearings

Procedures for removing, installing, and determining proper resistance.

2.19 Swingarm and Brace

Removal and installation procedures for the brace and swingarm.

2.22 Rear Shock Absorber

Removal and installation procedures for the rear shock absorber.

2.23 Throttle Control

Removal/disassembly and assembly/installation procedures for throttle control.

2.24 Clutch Hand Lever

Removal/disassembly and assembly/installation procedures for the clutch hand lever.

2.25 Headlight Assembly and Support Bracket

Removal and assembly procedures for the headlight assembly and support bracket.

2.27 Handlebars

Removal and installation procedures for handlebars.

2.29 Exhaust System

Removal/disassembly and assembly/installation procedures for the muffler and exhaust header.

2.30 Footpeg, Heel Guard, and Mount

Procedures for removing and installing rider and passenger footpegs, heel guards, and mounts.

2.37 Left Tail Section and Battery Pan

Disassembly and assembly procedures for the left tail section and battery pan.

2.38 Center Tail Section

Disassembly and assembly procedures for the center tail section.

2.39 Right Tail Section

Disassembly and assembly procedures for the right tail section.

2.41 Seat

Removal and installation procedures for the seat and its attachment mechanism.

ENGINE 3

3.3 Engine Rotation for Service

Procedure for rotating the engine down for top-end repairs.

3.4 Stripping Motorcycle For Engine Service

Disassembly procedures for removing the engine from the chassis.

3.5 Engine Installation

Procedures for preparing the engine and installing it into the frame.

3.6 Cylinder Head

Procedures for removing, disassembling, cleaning, inspecting, and assembling cylinder heads.

3.7 Cylinder and Piston

Removal/disassembly and cleaning/inspection procedures for cylinders and pistons.

3.8 Lubrication System

Information on checking and adding engine oil, and winter lubrication.

3.9 Oil Hose Routing And Oil Reservoir

Details on routing oil lines and connections at the oil cooler and crankcase.

3.10 Oil Pressure Indicator Switch

General information, troubleshooting, and oil pressure checks.

3.12 Oiling System

Detailed explanation of engine oil flow and lubrication paths.

3.13 Oil Pump

General information and disassembly/assembly procedures for the oil pump.

3.14 Oil Filter Mount

Removal, installation, cleaning, and inspection procedures for the oil filter mount.

3.15 Hydraulic Lifters

General information, removal, cleaning, inspection, and installation of hydraulic lifters.

3.16 Gearcase Cover And Cam Gears

Procedures for removing, inspecting, and assembling gearcase cover and cam gears.

3.17 Crankcase

Procedures for disassembling and assembling crankcase halves.

FUEL SYSTEM 4

4.2 Dynamic Digital Fuel Injection (DDFI)

Introduction to the DDFI system, its features, sensors, and general operation.

4.4 Checking For Trouble Codes

Procedures for checking the check engine lamp behavior and identifying trouble codes.

4.5 Check Engine Lamp Diagnostics

Detailed procedures for retrieving and interpreting trouble codes using the check engine lamp.

4.6 Breakout Box

General information and installation/removal procedures for the breakout box.

4.7 Wiggle Test

Procedure for testing wiring harnesses for intermittents using a DVOM.

4.8 Initial Diagnostic Check

General approach to identifying electronic system malfunctions, including tables for common issues.

4.9 Check Engine Lamp Not Illuminated at Key ON

Diagnostic steps for when the check engine lamp does not illuminate.

4.10 Check Engine Lamp On Continuously

Diagnostic steps for when the check engine lamp remains illuminated.

4.11 Engine Cranks But Will Not Start

Troubleshooting chart for diagnosing why the engine cranks but won't start.

4.13 Fuel Pressure Test

Procedures for testing fuel pressure using a gauge and adapter.

ELECTRIC STARTER 5

DRIVE/TRANSMISSION 6

ELECTRICAL 7

Related product manuals