Complete digital official shop manual contains service, maintenance, and troubleshooting information for the Buell S1 Lightning, X1 Lightning, XB9R Firebolt Motorcycle. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your bike like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.
This manual for Buell S1 Lightning, X1 Lightning, XB9R Firebolt Motorcycle is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.
The rear compartment of the left and right crankcase halves form the transmission case. An access cover (door) allows removal of transmission components without removing the engine or disassembling (splitting) the crankcase.
1. Raise rear wheel off floor using REAR WHEEL SUPPORT STAND (Part No. B-41174).
2. Remove rear fender. See FENDERS in Section 2.
3. See Figure 6-12. Loosen rear axle nut (metric). Reduce tension on secondary drive belt by turning axle adjuster nuts on each side of swing-arm an equal number of turns counterclockwise. Move rear wheel as far forward as possible.
4. Remove muffler. See EXHAUST SYSTEM in Section 2. Place a drain pan under the engine. Remove drain plug and drain lubricant from primary drive/transmission.
5. Remove swing-arm/drive support screws and retaining nut. Remove sprocket cover, washer and spacer.
6. See Figure 6-13. Place transmission in first gear. Remove two socket head screws (5) and lockplate (4).
Figure 6-12. Secondary Drive Belt Adjustment b0249x6x
Transmission sprocket nut has left-hand threads. To prevent damage, turn nut clockwise to loosen and remove from main drive gear shaft.
7. Remove transmission sprocket nut (3) from main drive gear shaft (1).
8. Remove secondary drive belt from transmission sprocket (2). Remove transmission sprocket from main drive gear shaft (1).
9. Remove primary cover. See PRIMARY CHAIN on page 6-3.
10. Remove clutch assembly, primary chain and engine sprocket. See PRIMARY DRIVE/CLUTCH on page 6-10.
11. See Figure 6-14. Lock transmission in gear. Remove countershaft TORX screw and retainer.
12. See Figure 6-15. Detach spring (1) from groove in post (2).
13. Remove retaining ring (10) and detent plate (9). You will need to use a new retaining ring for installation.
14. Remove two locknuts (3) and washers (11) which attach shifter shaft assembly (6) to studs at transmission case. Remove shifter shaft assembly.
15. Remove five access door bolts (7) and washers (8). Remove transmission assembly by pulling it straight outward, away from transmission case.
CLEANING, INSPECTION AND REPAIR
Thoroughly clean transmission compartment with cleaning solvent. Blow parts dry with compressed air. Inspect parts to determine if any must be replaced. Replace all parts that are badly worn or damaged.
Neutral Indicator Switch
See Figure 6-16. The neutral indicator switch is threaded into the transmission portion of the right crankcase half. See NEUTRAL INDICATOR SWITCH in Section 7 for testing, removal and installation procedures.
1. Position motorcycle on a suitable lift and position REAR WHEEL SUPPORT
STAND (Part No. B41174) under swing arm. Secure motorcycle to lift.
2. Disconnect negative battery cable.
3. Remove seat and fuel tank. See appropriate service manual, Section 4 for procedure
4. Remove air box cover (and left fairing lower on S3Ts) and filter box.
5. Remove two nuts and 2 socket head screws from air cleaner backplate and front isolator mount.
6. Position floor jack under engine under front shock mount to support engine.
7. Remove and discard isolator locknut and remove bolt, two washers and D washer.
8. Remove and discard two bolts and washers from left and right side of front
9. Remove front isolator mount from left side of motorcycle.
10. Clean residual lactate from threads in engine with a suitable nonflammable solvent and dry with compressed air.
11. Apply LACTATE THREAD LOCKER 271 (red) to threads of new front isolator mount bolts.
12. Apply a thin film of clean HD 20W50 engine oil to both sides of new thick washers and to bottom of bolt heads. Exercise caution to avoid mixing oil on washers with lactate on bolts.
13. Position new front isolator mount and secure with two new front bolts with new thick washers. Tighten bolts 60 ft-Ibs (81 Nm) initially and then loosen each bolt full turn. Tighten bolts again to 60 ft-Ibs (81 Nm). Make sure flat on D washer remains oriented to front of motorcycle while tightening bolt.
14. Position washer between front isolator mount and isolator. Install bolt, washer, D washer and new locknut.
15. Making sure flat on D washer stays oriented to front of bike, tighten bolt to 100 ft-Ibs (135.6 Nm)
16. Apply LACTATE THREAD-LOCKER 243 (blue) to threads of air-box screws.
Install air box screws to air box and isolator mount. Install locknuts to screws.
17. Install air cleaner filter box and cover.
18. Connect negative battery cable.
19. Install fuel tank and seat.
The 2000 Model Year ECM software and overheat indication are explained in the 1999/2000 Buell Service Manuals for the
X1 and S3/S3T.
On 2000 Model Year DDFI equipped models (X1 and S3/S3T), as part of the standard software in the ECM, the check engine lamp will blink during operation to warn of potentially damaging engine temperatures. If the key is in the ON position and the check engine lamp is blinking, this indicates that the engine is approaching a potentially damaging temperature.
While this condition is in effect, the ECM will automatically reduce engine power to assist in cooling the engine down to normal operating temperature. The check engine lamp will blink until the engine has cooled to normal operating temperature.
The rider may experience this condition during extended high speed operation with high ambient temperatures or during extended periods at idle. Inform customers of this feature and explain that it protects the engine from overheating damage and that if the check engine lamp blinks during high speed operation, normal operation may be continued without fear of engine overheating damage, but slowing down slightly will assist engine cooling and make full power available again sooner. If the check engine lamp blinks during extended periods at idle, and if there is no way of increasing the flow of air across the engine, the motorcycle should be shut down and allowed to cool.
If engine is removed from chassis, do not lay engine on primary side. Placing engine on primary side will damage clutch cable and fitting. If fitting is damaged, clutch cable must be replaced.
Always connect positive battery cable first. If the positive cable should contact ground with the negative cable installed, the resulting sparks may cause a battery explosion which could result in death or serious injury.
Pull up on seat to verify that it is properly secured, front and rear. A loose seat may shift during vehicle operation and startle the rider, possibly causing loss of vehicle control resulting in death or serious injury.
At this point it will be necessary to install the oil lines. It is important to follow this procedure to ensure correct orientation of oil lines in order to establish the proper clearances needed between the oil lines and varied components on the vehicle.