2003 Buell XB9S: Fuel System 4-115
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1WARNING1WARNING
Do not use any injector that has damaged or deformed O-
rings. Damaged O-rings may leak gasoline. Gasoline is
extremely flammable and highly explosive. Use of dam-
aged O-rings could result in death or serious injury.
4. Inspect all injector O-rings for cuts, tears or general dete-
rioration. Replace injector if O-rings have been damaged
or have taken a definite set.
5. Apply a thin coat of clean engine oil to top and bottom
injector O-rings.
6. See Figure 4-104. Install fuel injectors.
a. Install both injectors (2, 5) into intake manifold.
b. Press the fuel rail assembly (3) onto the top of the
injectors.
c. Apply a drop of LOCTITE 222 (purple) to threads of
fuel rail fasteners (1, 6).
d. Secure the fuel rail to the throttle body and manifold
with fasteners. Tighten to 24-28 in-lbs (2.7-3.2 Nm).
7. Snap the injector clips (4) over the flange on the fuel rail
outlet and into the top grove in the injector.
Testing
1. Remove intake cover assembly. See 2.35 INTAKE
COVER ASSEMBLY.
2. Remove airbox cover. See 4.43 AIRBOX.
3. Conduct test.
a. Turn key ON for two seconds.
b. Turn key OFF for two seconds.
c. Repeat Steps A and B five consecutive times.
d. Open throttle, replace fuel injectors if there is any
evidence of raw fuel in throttle body manifold.
4. Install airbox cover. See 4.43 AIRBOX.
5. Install intake cover assembly. See 2.35 INTAKE COVER
ASSEMBLY.
Figure 4-103. Intake Manifold fasteners (gearcase cover
side)
Figure 4-104. Fuel Injectors
2
5
1
1. Upper fuel rail fastener
2. Rear fuel injector
3. Fuel rail assembly
4. Clip (2)
5. Front fuel injector
6. Lower fuel rail fastener
8758
4
3
6
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