Positioning:
Essential resource for Buell Lightning owners and technicians seeking to perform maintenance, diagnosis, and repairs.
Alternatives:
This manual is positioned as the 'official full COMPLETE factory service repair manual,' aiming to provide comprehensive and accurate information compared to unofficial guides.
Unique Selling Points:
Comprehensive coverage, step-by-step repair solutions for all experience levels, detailed technical data, circuits, and diagrams, strong customer support from the seller.
Covered Systems:
Engine Mechanical, Engine Control System, Fuel System, Ignition System, Transmission, Clutch, Driveline, Suspension, Brakes, Steering, Electrical System, Wiring Diagrams, Chassis, Bodywork, Cooling System, Lubrication System, Exhaust System, Emission System, Restraint System, Air Conditioning
Estimated Page Count:
Hundreds to thousands of pages (as indicated by product description)
Type:
Factory Service Repair Workshop Manual
Language:
English (presumed based on product description)
Format:
PDF (primarily), potential for ISO files
Engine:
Engine mechanical, lubrication, control system, cooling system, exhaust system, fuel injection/fuel system, emission system
Transmission:
Transmission service/repair, clutch, manual transaxle, automatic transaxle (if applicable to the specific model covered by the manual, though Buell typically used manual transmissions)
Driveline:
Differential/Drive, Axle (front and rear)
Suspension:
Front suspension, rear suspension, road wheels & tires
Brakes:
Brake system, parking brake system, brake control system
Steering:
Steering system, power steering system
Electrical:
Electrical system, wiring diagrams, starting & charging system, lighting system, driver information system, wiper/washer/horn, body control system, audio visual, navigation & telephone system, power supply
Body:
Chassis/Body, Body repair, lock & security system, glasses, window system, roof, exterior & interior, instrumental panel, seat, restraint system (seat belts, SRS)
Heating Ac:
Heater/Air Conditioner, Air Conditioning System
General Maintenance:
General maintenance, periodic lubrication, maintenance schedules
Troubleshooting:
Troubleshooting guides for various systems and common issues
Engine Repair:
Engine service/repair, disassembly, reassembly, tune-up procedures
Transmission Repair:
Transmission service/repair, clutch service, gear inspection and replacement
Brake Service:
Brake system service and repair, bleeding procedures, pad and rotor replacement
Electrical Service:
Electrical system diagnosis, wiring harness repair, component testing, charging system service, starter service, lighting service
Chassis Suspension Steering:
Suspension system service, steering system service, wheel and tire service, alignment procedures
Body Interior Exterior:
Body repair, interior and exterior component replacement, lock and security system service
Fuel System Service:
Fuel injection system service, fuel pump replacement, fuel filter replacement
Depth:
Complete repair and maintenance, from basic checks to full rebuilds, detailed technical data, circuits, and diagrams
Type:
V-Twin, Air-Cooled, 45-degree V-Twin (Buell's signature design)
Displacement Xb9:
984 cc (60.0 cubic inches)
Displacement Xb12:
1203 cc (73.4 cubic inches)
Bore Stroke Xb9:
3.50 in x 3.13 in (88.9 mm x 79.5 mm) (Approximate, requires specific manual data)
Bore Stroke Xb12:
3.50 in x 4.13 in (88.9 mm x 104.9 mm) (Approximate, requires specific manual data)
Horsepower Xb9:
Approx. 92 hp @ 7500 rpm (Actual may vary)
Torque Xb9:
Approx. 70 lb-ft @ 5500 rpm (Actual may vary)
Horsepower Xb12:
Approx. 103 hp @ 6800 rpm (Actual may vary)
Torque Xb12:
Approx. 82 lb-ft @ 5500 rpm (Actual may vary)
Injection Type:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Fuel Pump:
In-tank electric fuel pump
Cooling Method:
Air-cooled (with potential for oil cooling)
Dashboard:
Digital/Analog combination instrument cluster displaying speed, RPM, odometer, trip meter, fuel level, and warning lights. Buell's 'DynaVerse' or similar digital display features may be present.
Braking System Design:
The ZTL front brake system, a large single rotor with a caliper mounted on the fork leg, is a key technological feature for improved braking performance and reduced unsprung weight.
Diagnostics:
The manual will cover diagnostic procedures using Buell-specific tools or standard OBD-II interfaces if applicable, for engine control unit (ECU) diagnostics.
Oil Change:
Typically every 5,000 miles or annually, whichever comes first. Refer to manual for specific mileage.
Spark Plugs:
Recommended replacement around 10,000-15,000 miles.
Belt Drive Tension:
Regular checks and adjustment are crucial as per manual recommendations.
Engine Oil:
Refer to manual for specific API service classification and viscosity grade (e.g., SAE 20W-50 or similar, often a motorcycle-specific oil).
Transmission Oil:
Refer to manual for specific type and capacity (often a dedicated transmission fluid or heavy-duty gear oil).
Brake Fluid:
DOT 4 (typically).
Common Problems:
Belt drive tension issues, fuel pump failures (especially in early models), charging system issues (stator/regulator), carburetor tuning (on earlier non-EFI models, but EFI models can still have sensor issues), potential frame cracks from impact (due to its structural role).
Maintenance Tips:
Adherence to the service manual for belt tension, regular inspection of electrical connections, and use of quality fluids are critical for longevity.
Origin:
Buell Motorcycle Company, founded by Erik Buell, known for its sportbike engineering and association with Harley-Davidson.
Xb Series:
The XB series represented a significant shift for Buell, focusing on mass centralization and a unique riding experience. Introduced in 2002, it evolved through various models like the X1, M2, S1, and then the XB family.
Production Period:
Buell ceased production in 2009, though Erik Buell Racing (EBR) continues to produce motorcycles and components. The 2005 model falls within the peak production years of the XB series.
