2003 Buell XB9S: Chassis 2-79
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BELT GUARDS 2.33
REMOVAL
1. Place a scissor jack under jacking point and raise rear
wheel off ground. For location of jacking point see Figure
2-99.
2. Remove right side rider footrest support bracket.
3. Remove right passenger footrest support bracket.
4. See Figure 2-106. Remove front sprocket cover (5) by
remove fasteners (6).
NOTE
Must remove two chin fairing fasteners for access. Front belt
guard will dangle but can not be removed at this time.
5. Loosen rear axle pinch fastener.
6. Loosen rear axle approximately 15 rotations to allow par-
tial tension to be removed from rear drive system.
7. Remove idler pulley assembly by removing nuts and
washers. See IDLER PULLEY REMOVAL in 6.5 DRIVE
BELT SYSTEM.
8. Remove lower belt guard (3) by removing fasteners (7).
9. Remove upper belt guard (10) by removing fasteners
(8, 9).
NOTE
The upper belt guard is attached to the swingarm brace and
can not be removed from vehicle at this time.
10. Remove swingarm brace by removing fasteners. See
2.19 SWINGARM AND BRACE.
a. Remove spacer collar (2) between upper belt guard
(10), inner belt guard (1) and swingarm brace.
b. Allow inner belt guard (1) to drape.
NOTE
Inner belt guard does not have to be removed to remove belt
or rear wheel.
11. Remove upper belt guard (10) by removing fasteners
from swingarm brace.
12. Remove belt from sprocket.
NOTE
Inner belt guard does not have to be removed to remove belt
or rear wheel.
13. Removing inner belt guard (1).
a. Remove rear axle.
b. Remove inner belt guard (1) from swingarm.
NOTE
The rear wheel does not have to be removed to remove inner
belt guard.
INSTALLATION
1. See Figure 2-106. Installing inner belt guard (1).
a. Slide inner guard between rear wheel and swing-
arm.
b. Partially install rear axle.
2. Install front belt guard (4). Do not tighten.
3. Install belt.
4. Install upper belt guard (10) to swingarm brace tighten-
ing fasteners to 12-36 in-lbs (1-4 Nm).
5. Loosely install swingarm brace. See 2.19 SWINGARM
AND BRACE.
a. Position the inner belt guard (1) and upper belt
guard (10) onto swingarm.
b. Install spacer collar (2) between upper belt guard
(10), inner belt guard (1) and swingarm brace.
6. Install upper belt guard (10) and tighten fasteners (8, 9)
to 12-36 in-lbs (1-4 Nm).
7. Tighten swingarm brace fasteners to 25-27 ft-lbs (34-
37 Nm).
8. Install lower belt guard (3) and tighten fasteners (7) to
12-36 in-lbs (1-4 Nm).
9. Install idler pulley assembly tightening washers, nuts and
fasteners to 33-35 ft-lbs (45-47 Nm). See IDLER PUL-
LEY INSTALLATION in 6.5 DRIVE BELT SYSTEM.
10. Tighten rear axle to 48-52 ft-lbs (65-70 Nm).
11. Tighten rear axle pinch fastener to 40-45 ft-lbs (54-
61 Nm).
12. Rotate rear wheel to ensure the belt does not make visi-
ble or audible contact. It may be necessary to loosen belt
guard(s) to adjust for proper clearance.
13. Install front sprocket cover (5) by tightening fasteners (6)
to 12-36 in-lbs (1-4 Nm).
14. Install chin fairing fasteners and tighten to 36-60 in-lbs
(4-7 Nm).
15. Install right side rider footrest mount and tighten fasten-
ers to 108-132 in-lbs (12-15 Nm).
16. Install right passenger footrest mount. use LOCTITE 272
(Red) and tighten fasteners to 25-28 ft-lbs (34-38 Nm).
17. Remove scissor jack from motorcycle.
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