Buell XB9R 2003 - Page 2

Buell XB9R 2003

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1-2 Edit Me: Printed June 5, 2002 12:26 pm

Table of Contents

Tools3
Removing Socket/Pin Terminals9
Installing Socket/Pin Terminals9
Amp Multilock Electrical Connectors9
Release Tang and Back out Terminals10
Multilock Connector Cutaway View10
Secondary Locks Open (Socket Housings Shown)11
Stamped Numbers on Secondary Locks Indicate Wire Color Locations11
Crimping Instructions12
Amp Multilock Crimping Procedure12
Deutsch Electrical Connectors13
Removing/Disassembling13
Removing/Installing Sockets13
Depress Terminal Latches/Back out Pins14
Removing/Installing Pins14
12-Pin Deutsch Connector (Exploded View)14
Deutsch Connector Pick Tool15
Attachment Clip Installation15
Deutsch Crimping Procedure16
2-Pin, 3-Pin and 4-Pin Deutsch Connectors17
Packard Electrical Connectors18
Pull-To-Seat Terminals19
Removing External Latch Type19
Installing External Latch Type19
Removing Push-To-Seat Terminals20
Installing Push-To-Seat Terminals20
Inspect Core and Insulation/Seal Crimps21
Packard Terminal Crimp Tools21
Electrical Connector and Location Table22
Electrical Connectors22
Table of Contents24
Index to Wiring Diagrams24
XB9R Wiring Diagrams24
Main Harness25
Engine Management Circuit26
Lighting Circuit27
Horn and Instruments Circuit28
Starting Circuit29
Starting and Charging Circuits30
Component Circuits31
- Metric Conversions32
- English Torque Values33
- Fastener Torque Values33
- Metric Torque Values33
- Front and Rear Brake Systems, Right Side View34
- Hose and Wire Routing34
- Rear Brake Systems, Top View35
- Rear Brake Systems, Left Side View36
- Evaporative Emissions Control, California Models, Top View37
- Evaporative Emissions Control, California and 49 State Models38
- Wiring Harness, Left Side View39
- Wiring Harness, Top View40
- Wiring Harness, Right Side View41
- Oil Lines, Right Side View42
- Oil Lines, Bottom View43
- Clutch and Throttle Cables, Right Side View44
- Clutch, Throttle and Seat Release Cables, Left Side View45
- Clutch, Throttle and Seat Release Cables, Top View46
- Maintenance48
- General50
  - Inspecting50
  - Safe Operating Maintenance50
  - Servicing a New Motorcycle50
  - Xb9R Tool Set50
  - Brake Fluid51
- Fluid Requirements51
  - Front Fork Oil51
  - Primary Drive/Transmission Fluid51
  - Regular Service Intervals52
  - Care and Maintenance53
- Care of Molded-In-Color Body Panels53
  - Cleaning between Washings53
  - Recommended Products53
  - Battery Electrolyte Antidotes54
- Battery Maintenance54
  - Battery Testing54
  - Voltmeter Test54
  - Battery Disconnection and Removal55
  - Battery Self-Discharge Rate55
  - Cleaning and Inspection55
  - Storage55
  - Battery Installation and Connection56
  - Checking Engine Oil Level57
- Engine Lubrication System57
  - Changing Engine Oil and Filter58
  - Changing Filter58
  - Draining Oil58
  - Replacing Oil58
  - Dipstick Location/Engine Oil Level59
  - Oil Filter59
  - Oil Tank Drain Plug59
  - Recommended Oil Grades59
  - Bleeding Brakes60
- Brake System Maintenance60
  - Brake Troubleshooting61
  - Bleeding Front Brake62
  - Front Caliper Bleeder Valve62
  - Front Master Cylinder Reservoir62
  - Bleeding Rear Brake63
  - Rear Caliper Bleeder Valve63
  - Rear Master Cylinder Reservoir63
  - Brake Pedal Adjustment64
  - Pushrod Adjustment64
  - Brake Pad Thickness65
  - Brake Rotor Thickness65
  - Front Brake Rotor65
  - Brake Pad Replacement66
  - Front Pad Installation66
  - Front Pad Removal66
  - Rear Pad Installation67
  - Rear Pad Removal67
  - Tire Inflation68
  - Tire Replacement68
- Tires and Wheels68
- Wheel Bearings68
- Clutch69
  - Clutch Inspection Cover69
  - Primary Drain Plug69
  - Transmission Fluid69
  - Adjustment70
  - Clutch Adjustment70
  - Clutch Cable Adjuster Mechanism70
  - Adjusting Clutch Free Play71
- Drive Belt System72
  - Idler Pulley72
  - Rear Sprocket72
  - Drive Belt Installation73
  - Drive Belt Removal73
  - Rear Wheel Mounting, Right Side73
  - Belt Guard Assembly74
  - Idler Pulley Assembly75
  - Idler Pulley Installation75
  - Idler Pulley Removal75
  - Drive Belt Wear Patterns76
  - Measuring Primary Chain Tension78
- Primary Chain78
  - Primary Chain Inspection Cover78
  - Primary Chain Tension78
  - Chain Tension Adjusting Fastener79
  - Setting Front Fork Preload80
  - Setting Rear Shock Preload80
- Suspension Damping Adjustments80
  - Front Fork Preload and Rebound Adjuster81
  - Rear Shock Preload Adjuster81
  - Recommended Suspension Settings81
  - Adjusting Suspension Damping82
  - Setting Front Fork Compression Damping82
  - Setting Front Fork Rebound Damping82
  - Setting Rear Shock Rebound Damping82
  - Recommended Suspension Damping Settings83
  - Fork Spring Compressing Tool84
  - Fork Tube Holder (HD-41177)84
- Front Fork Oil Change84
  - Drain and Replace Oil85
  - Measuring Fork Oil Level85
  - Front Fork Assembly86
  - Measuring Steering Head Bearing Resistance87
  - Steering Head Bearings87
- Spark Plugs88
  - Typical Spark Plug Deposits88
  - Rear Spark Plug Access89
  - Air Box, Fuel Vent Tube and Fuel Vapor Valve90
  - Air Cleaner Filter Element90
  - Installed Air Cleaner Filter Element90
  - Airbox Baseplate91
  - Idle Adjuster (Behind Left Fork)92
  - Throttle Cable Adjusters92
- Throttle Cable and Idle Speed Adjustment92
  - Checking Static Timing93
  - Correct Timing93
- Ignition Timing93
  - Timing Plug93
  - Adjust Timing94
  - Advanced Timing94
  - Cam Position Sensor94
  - Timer Cover94
  - Checking Headlight Alignment95
  - Headlamp Switch95
- Headlights95
- Headlamp Height Adjustment96
- Throttle Position Sensor (Tps)97
  - Removal from Storage98
  - Engine Turns over but Does Not Start99
  - Starter Motor Does Not Operate or Does Not Turn Engine over99
  - Starts Hard99
- Troubleshooting99
  - Electrical System100
  - Fuel System100
  - Oil Does Not Return to Oil Tank100
  - Pre-Ignition or Detonation100
  - Spark Plug Fouls Repeatedly100
  - Drags or Does Not Release101
  - Handling Irregularities101
  - Jumps out of Gear101
  - Shifts Hard101
  - Front Suspension Problems102
  - General Suspension Problems102
  - Rear Suspension Problems102
  - Suspension102
  - Chassis104
  - Capacities106
  - Dimensions106
- Specifications106
  - Weight Speciﬁcations106
  - Torque Values107
  - Rim Markings110
  - Tire Fitment-Tubeless Cast Wheels110
- Tire Specifications110
- Abbreviated V.I.N. Location111
- Vehicle Identification Number111
  - Vehicle Identiﬁcation Number (V.I.N.)111
  - Checking Tire Inﬂation Pressure112
- Wheels112
- Wheel Service113
- Front Wheel114
  - Front Wheel Mounting114
  - Front Wheel Removal and Installation114
  - Assemble Puller115
  - Bearing Removal115
  - Expand the Collet115
  - Install Collet and Ball Bearing115
  - Front Rotor Removal116
  - Remove the Bearing116
  - Remove the Spacer116
  - Removing Bearing from Puller116
  - Bearing Installation117
  - Install Bearing117
  - Install the Backing Plate (B-43993-11) and Forcing Screw117
  - Front Rotor Installation118
  - Insert Forcing Screw and Backing Plate118
  - Install the Bearing118
  - Install the Spacer118
  - Front Wheel Assembly119
  - Rear Brake Caliper Carrier Fasteners120
- Rear Wheel120
  - Anti-Seize Lubricant Location121
  - Removing Wheel Bearing121
  - Rear Wheel Assembly122
- Checking Cast Rim Runout123
  - Rim Lateral Runout123
  - Rim Radial Runout123
  - Wheel Runout123
  - Loosening Beads from Rim Flange124
  - Starting Bead on Rim124
  - Starting Tire off Rim124
- Tires124
  - Checking Tire Lateral Runout125
  - Checking Tire Radial Runout125
  - Tire Runout125
  - Weights for Cast Wheels126
  - Wheel Balancing126
  - Wheel Weights126
- Brake Pedal127
  - Brake Hand Lever128
  - Front Brake Master Cylinder and Hand Lever 2.10128
  - Front Master Cylinder128
  - Piston Assembly in Master Cylinder128
  - Front Brake Hand Lever Assembly129
- Front Brake Master Cylinder129
  - Brake Fluid Level130
  - Brake Lamp Switch Connectors130
- Front Brake Line131
  - Front Brake Caliper Mounts133
  - Pad Spring (Typical)133
  - Removing Pistons (B-42887)133
  - Front Rotor Runout134
  - Front Caliper Assembly135
  - Brake Line Switch Connector136
- Rear Brake Master Cylinder136
  - Rear Master Cylinder Mounting136
  - Remote Reservoir136
  - Master Cylinder Internal137
  - Rear Master Cylinder Assembly138
- Rear Brake Line139
  - Rear Brake Line Switch/Banjo Bolt139
  - Caliper Mount Clip141
- Rear Brake Caliper141
  - Brake Pads142
  - Rear Rotor Runout142
  - Removing Rear Brake Caliper Piston142
  - Rear Reservoir143
- Front Fork144
  - Stopper Ring144
  - Fork Cap Assembly145
  - Holding Damper Rod Assembly145
  - Damper Rod Assembly146
  - Damper Rod Disassembly146
  - Fork Assembly146
  - Rebound Assembly and Fork Cap Assembly146
  - Fork Seal Driver147
  - Cable Straps on Upper Fork Clamp150
- Fork Clamps, Upper and Lower150
  - Steering Stem Assembly151
  - Steering Head Bearing Lip152
  - Steering Head Bearings Installation Tools152
  - Install Bearings153
  - Lower Bearing153
- Swingarm and Brace154
  - Oil Line Fittings155
  - Swingarm155
  - Final Swingarm Inspection156
  - Swingarm Assembly157
  - Clutch Cable P-Clamp158
  - Front and Rear Isolators158
  - Front Isolator158
  - Rear Isolator158
- Frame159
  - Lift Frame off Motorcycle159
  - Adjuster Screw Alignment160
  - Cable Strap160
- Rear Shock Absorber160
  - Rear Shock Absorber Assembly161
  - Cable Connections162
- Throttle Control162
  - Throttle Control Cables162
  - Clutch Hand Control Assembly163
- Clutch Hand Lever163
- Headlight Connector164
- Headlight Support Bracket164
  - Headlight Support Bracket Assembly165
  - Headlamp Pivot Groove166
- Fairing Support Bracket167
  - Fairing Support Bracket Assembly168
  - Handlebar Clip-On Mounting Fasteners169
- Handlebars169
  - Left Clip-On169
  - Right Clip-On169
  - Handlebar Clip-On Assembly (Left Clip-On Shown)170
  - Exhaust Header171
- Exhaust System171
  - Mufﬂer171
  - Rear Mufﬂer Mounting Block171
  - Front Mufﬂer Mounting Block172
  - Mufﬂer and Straps172
- Footpeg, Heel Guard and Mount173
  - Remove Footpeg173
  - Remove Heel Guard173
  - Rider173
  - Install Footpeg174
  - Install Heel Guard174
  - Passenger174
  - Remove Mount174
  - Chin Fairing Assembly175
- Sprocket Cover175
  - Front Fender176
  - Rear Fender176
- Belt Guards177
- Chin Fairing179
- Intake Cover Assembly180
- Air Scoops181
  - Engine Shroud Air Scoop181
  - Oil Cooler Air Scoop181
  - Ram Air Scoop181
  - Inside Tail Frame Hose and Wire Routing182
  - Left Side Tail Frame Hose and Wire Routing182
- Tail Frame and Body Work182
  - Remote Reservoir Clamp Nut183
  - Tail Frame and Body Work Assembly184
- Front Fairing, Windshield, and Mirrors185
  - Accessing Rider Seat Screws186
  - Pillion Seat186
  - Rider Seat186
- Seat186
- Passenger Seat Lock187
  - Seat Lock and Cable Assembly187
  - Sidestand Removal188
  - Sidestand Switch Removal188
  - Sidestand Switch with Cable Strap188
  - Sidestand Assembly189
  - Sidestand Disassembly189
  - Sidestand Installation189
  - Sidestand Switch Installation189
  - Engine190
  - Engine Ignition Speciﬁcations192
  - General Information192
  - Valve and Valve Seat Speciﬁcations192
  - Valve Spring Speciﬁcations192
  - Cylinder Head Speciﬁcations193
  - Cylinder Speciﬁcations193
  - Piston Ring and Piston Pin Speciﬁcations193
  - Rocker Arm Speciﬁcations193
  - Flywheel Speciﬁcations194
  - Gearcase Speciﬁcations194
  - Hydraulic Lifter Speciﬁcations194
  - Oil Pump Speciﬁcations194
  - Pinion Shaft Bearing Speciﬁcations195
  - Electrical Items for Engine Removal and Replacement196
  - Adjustment/Testing197
  - Fuel197
  - Gasoline/Alcohol Blends197
  - Lubrication197
  - Air Leakage Test198
  - Compression Test Procedure198
  - Compression Test Results198
  - Cylinder Leakage Test198
  - Diagnosing Smoking Engine or High Oil Consumption198
  - Engine Rotation for Service199
  - Fuel Line and DDFI Electrical Connections199
  - Electrical Connections and Throttle Cables200
  - Mufﬂer and Mounting System201
  - Clutch Cable Retaining Clamps202
  - Oil Line Connections at Oil Cooler202
  - Engine Mounting System203
  - Front Isolator and Tie Bar Assemblies204
  - Rear Isolator Bolt and Rear Tie Bar204
  - Lubrication Points on Front Isolator Bolt205
  - Oil Cooler Feed and Return Oil Line Orientation and Clearances206
  - Stripping Motorcycle for Engine Service210
  - Electrical Connections216
  - Rear Isolator Bolt and Swingarm Pivot Shaft217
  - Supporting the Swingarm217
  - Supporting Vehicle for Disassembly217
  - Transmission Vent Line217
  - Center Tie Bar Mount218
  - Front Exhaust Mount Bushings (2 Piece)218
  - Removing Threaded Insert218
  - Rear Isolator and Mounting Hardware219
  - Rolling Chassis219
  - Securing Vehicle for Relocation219
  - Engine Installation220
  - Engine Prep for Re-Installation220
  - Installing Engine in Frame221
  - Installing Rear Isolator Bolt221
  - Supporting Vehicle for Assembly221
  - Mufﬂer Mounting System224
  - Oil Lines and Connections225
  - Oil Line Clearances and Torques226
  - Clamp Orientation and Oil Line Spacing228
  - Oil Cooler Feed and Return Oil Lines Location and Orientation230
  - Oil Cooler Oil Lines230
  - Correct Routing of Wiring Harnesses231
  - Cylinder Head236
  - Rocker Arm and Pushrod Cover Assemblies236
  - Lower Rocker Box Fasteners237
  - Removing Rocker Arm Shafts237
  - Rocker Box Assemblies237
  - Cylinder Head Assemblies238
  - Head Screw Loosening/Tightening Sequence238
  - Valve Spring Compressor238
  - Cylinder Head, Cylinder and Piston Assembly239
  - Checking Gasket Surface240
  - Cylinder Heads240
  - Measuring Rocker Arm Shaft Bore Diameter in Lower Rocker Cover241
  - Measuring Rocker Arm Shaft Diameter241
  - Rocker Arm Assemblies241
  - Valve Guides242
  - Valve Seats242
  - Valve Springs242
  - Replacing Rocker Arm Bushings243
  - Cleaning Valve Guides244
  - Installing Shoulderless Valve Guide244
  - Replacing Valve Guides244
  - Valve Stem Clearances and Service Wear Limits244
  - Neway Valve Seat Cutter245
  - Procedure for Using the Neway Valve Seat Cutter245
  - Intake & Exhaust Valve and Seat246
  - Valve and Seat Dimensions246
  - Valve Guide Seal Protector Sleeve248
  - Valve Seal and Lower Collar Assembly248
  - Push Rod Cover Installation250
  - Push Rod Locations250
  - Push Rod Selection250
  - Push Rods and Push Rod Cover Assembly250
  - Cylinder Head Installation251
  - Tightening Head Screws251
  - Lower Rocker Box Hardware253
  - Cylinder and Piston254
  - Piston Pin and Piston Identiﬁcation255
  - Removing Piston Pin Circlip255
  - Removing Piston Rings255
  - Deglazing Cylinder257
  - Measuring Cylinder Bore257
  - Fitting Piston Rings258
  - Measuring Ring End Gap258
  - Piston Rings258
  - Measuring Ring Clearance in Groove259
  - Ring End Gap Position259
  - Connecting Rod Bushing260
  - Connecting Rod Clamping Tool260
  - Installing New Wrist Pin Bushing260
  - Removing Wrist Pin Bushing260
  - Installing Piston Pin Circlip261
  - Piston Support Plate261
  - Compressing Piston Rings262
  - Changing Oil and Filter264
  - Checking and Adding Oil264
  - Lubrication System264
  - Winter Lubrication264
  - Oil Hose Routing and Oil Reservoir265
  - Oil Pressure Indicator Switch266
  - Oil Pressure Signal Light266
  - Troubleshooting Oil Pressure Signal Light266
  - Crankcase Breathing System267
  - Reed Valve Assembly268
  - Reed Valve Replacement268
  - Reed Valve Stop and Reed Valve268
  - Oiling System269
  - Oil Pump270
  - Oil Pump Hardware271
  - Gerotor Wear Limits272
  - Separator Plate Slots272
  - Oil Filter Mount273
  - Oil Filter Mount Assembly273
  - Hydraulic Lifters274
  - Lifter Assembly (Typical)274
  - Base Circle275
  - Valve Lifter Service275
  - Gearcase Cover & Cam Assembly276
  - Gearcase Cover and Cam Gears276
  - Cam and Pinion Gear Location and Timing Mark Indexing277
  - Bushing Inspection278
  - Cam and Pinion Gear Identiﬁcation278
  - Gear Shaft Speciﬁcations278
  - Aligning Pinion Gear279
  - Crankshaft Locking Tool279
  - Checking Cam Gear End Play280
  - Gearcase Cover Mounting Screw Torque Sequence280
  - Crankcase281
  - Crankcase Halves281
  - Rear Isolator Assembly281
  - Crankcase Fasteners282
  - Piston Jets282
  - Piston Oil Jet Assemblies282
  - Crankcase and Flywheel Assembly283
  - Removing Flywheels from Left Crankcase283
  - Removing Left Main Bearing from Crankcase284
  - Removing Left Main Bearing Retaining Ring284
  - Removing Sprocket Shaft Inner Bearing Race284
  - Factory Inner Race Sizes285
  - Fitting Pinion Bearings285
  - Paint Dot Speciﬁcations285
  - Removing Pinion Bearing Inner Race285
  - Factory Outer Race Sizes286
  - Roller Speciﬁcations286
  - Stamp Speciﬁcations286
  - Bearing Selection287
  - Pinion Shaft Bearing Selection287
  - New Component Speciﬁcations288
  - Outer Pinion Race Service Wear Limits288
  - Pinion Shaft Bearing Tools288
  - Inner Race Location289
  - Pinion Inner Race Fitment Speciﬁcations289
  - Checking Connecting Rod Side Play290
  - Lapping Engine Right Main Bearing Race290
  - Left Main Bearing Assembly291
  - Left Main Bearing Installation292
  - Pinion Shaft Bearing292
  - Sprocket Shaft Seal/Spacer Installer294
  - Cylinder Studs295
  - Fuel System296
  - Fuel System Speciﬁcations298
  - Fuel Tank Speciﬁcations298
  - Idle Speed Speciﬁcations298
  - Dynamic Digital Fuel Injection (Ddfi)300
  - Buell Dynamic Digital Fuel Injection301
  - Check Engine Lamp302
  - Diagnostic Introduction302
  - Resolving Problems302
  - System Problems302
  - Checking for Trouble Codes303
  - Engine Stop Switch303
  - Ignition Key Switch303
  - Check Engine Lamp Blinks304
  - Code Types304
  - Multiple Trouble Codes304
  - Retrieving Trouble Codes304
  - Check Engine Lamp Diagnostics305
  - Diagnostic Test Wire305
  - Installing Diagnostic Test Wire305
  - Clearing Codes306
  - Breakout Box307
  - Installed Breakout Box307
  - Fluke 78 Multimeter (DVOM)308
  - Wiggle Test308
  - Diagnostic Notes309
  - Engine Performance Problems309
  - Engine Starts Hard309
  - General Information309
  - Initial Diagnostic Check309
  - Engine Exhaust Emits Black Smoke or Fouls Plugs310
  - Trouble Codes and Fault Conditions310
  - Check Engine Lamp Not Illuminated at Key on 4.9314
  - Electronic Control Module314
  - Check Engine Lamp Circuit315
  - Check Engine Lamp on Continuously317
  - Engine Cranks but will Not Start320
  - Spark Plug Tester (Part No. HD-26792)320
  - Test Lamp320
  - Ignition Circuit321
  - Clutch Switch325
  - Neutral Switch325
  - No Ecm Power325
  - Sidestand Switch325
  - ECM Power Circuit326
  - Fuel Line328
  - Fuel Pressure Test328
  - Fuel Pump Connector328
  - Fuel Pressure Gauge (Part No. HD-41182)329
  - Fuel Pressure Gauge Adapter329
  - Fuel Pump Circuit330
  - Engine Idle Speeds333
  - Idle Adjustment Cable333
  - Idle Speed Control333
  - Misfire334
  - Misﬁre at Idle or under Load334
  - Spark Plug Cables334
  - Ignition Coil Circuit335
  - Throttle Position Sensor338
  - TP Sensor Assembly338
  - TP Sensor Terminals [88A]338
  - Trouble Code 11338
  - Throttle Position Sensor Circuit339
  - Oxygen (O2) Sensor342
  - Oxygen Sensor342
  - Oxygen Sensor (Shock Absorber Removed)342
  - Trouble Code 13342
  - Oxygen Sensor Circuit343
  - Engine Temperature Sensor347
  - Engine Temperature Sensor Speciﬁcations347
  - Trouble Code 14347
  - Engine Temperature Sensor Circuit348
  - Intake Air Temperature Sensor351
  - Intake Air Temperature Sensor Speciﬁcations351
  - Trouble Code 15351
  - Intake Air Temperature Sensor Circuit352
  - Battery Voltage355
  - Electrical Relays355
  - Fuse Block355
  - Trouble Code 16355
  - Battery Voltage Circuit356
  - And Rear Fuel Injector (Code 32)359
  - Front Fuel Injector (Code 23)359
  - Fuel Injectors359
  - Trouble Codes 23 and 32359
  - Fuel Injector Circuit360
  - And Rear Ignition Coil (Code 25)363
  - Front Ignition Coil (Code 24)363
  - Trouble Codes 24 and 25363
  - Fuel Pump366
  - Fuel Pump Assembly366
  - Trouble Code 33366
  - Instrument Module Connector [39]369
  - Trouble Code 35369
  - Tachometer Circuit370
  - Code 35 Test371
  - Cooling Fan High Voltage372
  - Cooling Fan Low Voltage372
  - Cooling Fan Speciﬁcations372
  - Trouble Code 36372
  - Cooling Fan Circuit373
  - Code 36 Test (Part 1 of 2-Fan Runs Continuously)374
  - Code 36 Test (Part 2 of 2-Fan Does Not Run)375
  - Bank Angle Sensor376
  - Bank Angle Sensor Operation376
  - Trouble Code 44376
  - Bank Angle Sensor Circuit377
  - ECM Failure380
  - Trouble Codes 52, 53, 54 and 55380
  - Cam Sync Failure381
  - Trouble Code 56381
  - Cam Position Sensor Circuit382
  - Electronic Control Module386
  - Cam Position Sensor and Rotor388
  - Marking Ignition Timing388
  - Ignition Components389
  - Ignition System Circuit390
  - Connecting Sensor Wires391
  - Ignition Coil392
  - Ignition Coil Primary Circuit Test392
  - Ignition Coil Secondary Circuit Test392
  - Ignition Coil Substitution392
  - Ignition Coil Location393
  - Installed Oxygen Sensor394
  - Oxygen Sensor Connector394
  - Intake Air Temperature Sensor Installed398
  - Cooling Fan400
  - Draining Fuel Tank401
- Fuel Pump401
  - Fuel Pump Puller402
  - Fuel Pump Removal402
  - Fuel Filter Replacement403
  - Fuel Pressure Regulator Replacement403
  - Low Fuel Level Sensor Replacement403
  - Fuel Pump Clips404
  - Fuel Pump Speciﬁcations404
  - Fuel Screen Replacement404
  - Regulator Housing O-Rings404
  - Fuel Pump Connector Disassembly405
  - Fuel Pump Wire Harness Replacement405
  - Fuel Pump Installation406
  - Wire Harness Removal Direction406
  - Fuel Pump Drain Screw407
- Fuel Tank Vent Valve407
- Fuel Cap Retaining Ring408
  - Throttle Body409
  - Throttle Body/Intake Manifold Assembly410
  - Fuel Injectors411
  - Intake Manifold411
  - Repair411
  - Throttle Cable Bracket (Typical)411
  - Intake Manifold Fasteners412
  - Intake Flanges413
- Intake Leak Test414
  - Leak Tester414
  - Nozzle414
- Airbox416
- Airbox Cover416
- Baseplate416
- Evaporative Emissions Control-Ca Models418
- Carbon Canister Installation418
- Vent Valve419
- Canister419
- Carbon Canister Mounting419
- Hose Routing420
- Emissions Hose Attachment420
- Electric Starter422
- Starter Speciﬁcations424
- Service Wear Speciﬁcations424
- Electric Starter System425
- Wiring Diagrams425
- Starter Relay425
- Starting System Diagnosis427
- Starter Terminals427
- Solenoid Clicks428
- Relay Clicks428
- Nothing Clicks429
- Starter Stalls or Spins too Slowly430
- Starter Spins, but Does Not Engage430
- Starter Activation Circuits431
- Typical Circuity431
- Diagnostics/Troubleshooting432
- Voltage Drops432
- Electric Starting System Circuit433
- Starter System Testing434
- “On-Motorcycle” Tests434
- Starter Relay Test434
- Starter Current Draw Test434
- Starter435
- Starter Mounting435
- Starter Wires (Protective Boot Not Shown)435
- Starter Solenoid436
- Solenoid Pull-In Test436
- Free Running Current Draw Test436
- Testing Assembled Starter436
- Solenoid Hold-In Test437
- Return Test437
- Solenoid Return Test437
- Hold-In Test437
- Disassembly, Inspection and Repair438
- Field Wire438
- Removing the Thru-Bolts438
- Starter Components438
- Undercutting Mica Separators439
- Shorted Armature Test Using Growler440
- Grounded Armature Test440
- Open Armature Test440
- Brush Holder Insulation Test441
- Open Field Test441
- Grounded Field Test441
- Starter Drive Assembly442
- Starter Assembly443
- Drive/Transmission 6446
- Primary Cover, Primary Chain Adjuster and Shifter Assembly450
- Primary Cover451
- Removing Primary Cover451
- Clutch Release Mechanism451
- Primary Chain Adjuster Inspection & Replacement452
- Measuring Chain Adjuster Shoe452
- Clutch Release Mechanism454
- Primary Drive/Clutch456
- Clutch Assembly457
- Clutch Pack458
- Compressing Clutch Diagram Spring458
- Pressure Plate Assembly458
- Primary Chain/Drive459
- Sprocket Locking Link Tool459
- Mainshaft Nut and Washer459
- Adjusting Screw Assembly459
- Aligning Tabs460
- Compensating Spring Set461
- Measuring Friction Plates462
- Checking Clutch Shell462
- New Needle Bearing in Clutch Shell463
- Clutch Hub Bearing Race463
- Removing Clutch Shell Needle Bearing464
- Clutch Shell Bearing Remover/Installer464
- Replacing Clutch Shell Bearing464
- Bearing Installer464
- Clutch Hub and Shell Assembly465
- Clutch Pack Stack-Up (Cut-Away View)465
- Friction Plates465
- Spring Seat Installation466
- Adjusting Screw Assembly Aligning Tabs467
- Sprocket Locking Link467
- Transmission470
- Transmission Power Flow470
- Shifter Drum Neutral Detent471
- Countershaft Retainer471
- Right Crankcase Removal471
- Case Disassembly for Transmission Removal471
- Scribed Line on Shifter Drum at 6 O’clock472
- Removing Shifter Shaft Assembly472
- Shifter Shaft Assembly472
- Separating Crankcase Halves473
- Removing Flywheels from Left Case Half473
- Transmission Disassembly474
- Transmission Removal from Left Crankcase474
- Removing Shifter Fork Shafts474
- Shifter Forks, Drum and Shafts474
- Shifter Mechanism475
- Removing Transmission Assembly from Left Case Half476
- Mainshaft/Countershaft477
- Transmission Parts Identiﬁcation477
- Transmission Assembly-Right Crankcase Half477
- Transmission Assembly-Left Crankcase Half478
- Mainshaft Disassembly479
- Countershaft Disassembly480
- Transmission Assembly481
- Mainshaft Assembly481
- Countershaft Assembly482
- Transmission Countershaft Assembly/Reassembly482
- Main Drive Gear483
- Main Drive Gear Assembly483
- Removing Main Drive Gear483
- Bearing Remover Cross Plate Mounting483
- Needle Bearing Installation Tool484
- Main Drive Gear Installation484
- Transmission Assembly Right Crankcase Half485
- Transmission Right Case Bearings486
- Shifter Drum Bushing486
- Countershaft Needle Bearing486
- Mainshaft 5Th Gear Ball Bearing486
- Transmission Assembly Left Crankcase Half487
- Transmission Left Case Bearings488
- Mainshaft and Countershaft Bearings488
- Shift Drum Bushing Assembly488
- Transmission Installation489
- Transmission Assembly in Fixture489
- Installing Transmission in Left Case Half489
- Shifter Forks and Drum Assembly490
- Installing Shift Fork Shafts490
- Gear Detent Assembly Aid492
- Installing Right Crankcase492
- Shifter Shaft Installation493
- Installing Shifter Shaft Assembly493
- Shifter Shaft Return Spring493
- Transmission Sprocket494
- Transmission Sprocket Tightening495
- Aligning Transmission Sprocket496
- Table of Contents498
- Battery Speciﬁcations500
- Regulator Speciﬁcations500
- Spark Plug Speciﬁcations500
- Ignition Coil Speciﬁcations500
- Ignition System502
- Ignition System Components503
- Indicator Markers504
- Ignition/Headlight Key Switch504
- Ignition Key Switch Positions504
- Upper Fork Clamp505
- Ignition Switch Assembly506
- Ignition Switch Connector (Viewed from Underneath Fairing)506
- Ignition Key Switch Wiring507
- Spark Plug Cable Location508
- Testing Resistance509
- Starter Interlock510
- Starter Interlock Troubleshooting510
- Starter Circuit510
- Diode Polarity511
- Ohmmeter Diode Test511
- Diode Wiring511
- Starter Test512
- Ignition Test512
- Interlock Circuit514
- Testing/Replacement515
- Sidestand Switch515
- Ignition Relay516
- Key Switch Relay516
- Main Fuse516
- Diodes517
- Fuse Block (Contains Diodes)517
- Fuses and Diodes517
- Charging System518
- Alternator518
- Voltage Regulator518
- Battery518
- Symptom: Battery Becomes Discharged519
- Voltage Regulator Bleed Test522
- Total Current Draw Test522
- Milliampere Draw Test522
- Current and Voltage Output Test523
- Voltage Output Test523
- Positive Regulator Cable (Red Wire)523
- Test for Grounded Stator523
- AC Output Check524
- Check for Stator Resistance524
- Check Stator AC Voltage Output524
- Rotor Assembly525
- Removing Rotor from Sprocket525
- Stator525
- Rotor525
- Pressing Rotor Onto Sprocket526
- Voltage Regulator Connector [77]527
- Battery Cables528
- Negative Battery Cable528
- Positive Battery Cable529
- Maintenance-Free Battery (Typical)530
- Battery Warning Label530
- Load Test531
- Battery Load Test531
- Battery Testing531
- Voltmeter Test531
- Disconnection and Removal532
- Safety Precautions533
- Charging Battery533
- Battery Charging533
- Battery Charging Rates/Times534
- Battery Cable Routing534
- Headlight Bulbs536
- Tail Lamp538
- Tail Lamp Assembly538
- Turn Signals539
- Bulbs539
- Front Turn Signal Connections539
- Front Turn Signals539
- Rear Turn Signals540
- Rear Turn Signal Connections541
- Turn Signal Controls542
- Turn Signal Flasher542
- Handlebar Switches543
- Right Side543
- Left Side543
- Right Handlebar Switch Connection543
- Left Handlebar Switch Connection544
- Vehicle Speed Sensor545
- Speedometer Sensor545
- Vehicle Speed Sensor Wiring545
- Instrument Module546
- Speedometer Performance Check547
- Speedometer Operation Test547
- Speedometer Tester547
- Vehicle Speed Sensor Connector547
- Test Harness548
- Speedometer Sensor Test548
- Odometer, Trip Odometer and Reset Switch Testing549
- Inoperative, Inaccurate or Erratic Speedometer550
- Tachometer Performance Check552
- Tachometer Accuracy Tolerances and Conversions552
- Sweep Test553
- Testing Tachometer553
- Horn554
- Horn Assembly554
- Horn Wiring554
- Horn Switch555
- Neutral Indicator Switch556
- Neutral Indicator Switch Location556
- A Main Fuse Location557
- Main Fuse and Fuses557
- Main Wire Harness558
- Tail Harness Connector558
- Battery Tray Wiring558
- Sidestand Switch Connector559
- Wire Harness Clip560
- Corner Mounting Tab560
- Cable Straps561
- Fairing Wiring (Viewed from Underneath Fairing)562
- Sprocket Cover Wiring563
- Cam Position Sensor Wiring563
- Neutral Switch Connector564
- Neutral Switch Wiring564
- Assembled Wiring564

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