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BUELL XB9R XB12R FIREBOLT Service Repair Manual 2005-2008

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The Buell Firebolt XB9R and XB12R models, produced between 2005 and 2008, represent Erik Buell's innovative approach to sportbike design. These motorcycles are characterized by their performance-oriented engineering, featuring unique...
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BUELL XB9R XB12R FIREBOLT Service Repair Manual 2005-2008
The Buell Firebolt XB9R and XB12R models, produced between 2005 and 2008, represent Erik Buell's innovative approach to sportbike design. These motorcycles are characterized by their performance-oriented engineering, featuring unique elements such as the frame acting as the fuel tank, the swingarm housing the oil reservoir, and an innovative perimeter front brake system. Renowned for their sharp handling, tight turning radius, and distinctive V-twin character, the Firebolt series offered an alternative to conventional sportbikes, appealing to riders seeking a unique blend of style, agility, and spirited performance. This comprehensive service and repair manual provides detailed guidance for maintaining and repairing your Buell Firebolt XB9R or XB12R. It covers a wide range of systems, including engine disassembly and tuning, fuel system diagnostics, electrical system troubleshooting, transmission and clutch servicing, brake system maintenance, suspension adjustments, and bodywork repairs. Within its approximately 600-800 pages, you will find factory-level procedures for routine maintenance, component replacement, rebuilding, and adjustment, along with essential technical specifications and diagnostic information to ensure your motorcycle remains in optimal condition.
🏷️ Basic Information
Identification
Make:
Buell
Model:
Firebolt XB12R
Codes
Year Range:
2005-2008
👋 Introduction
Market Position
Positioning:
Performance-oriented sportbike targeting experienced riders seeking unique styling and handling.
Competitive Analysis
Competitors:
Competed with other sportbikes of its era such as Ducati Monster, Aprilia Shiver, and some Japanese inline-fours, offering a distinct character and handling.
Key Features
Design Philosophy:
Erik Buell's innovative approach with frame acting as fuel tank, swingarm as oil reservoir, and perimeter front brake.
Handling Characteristics:
Renowned for its 'Uniplanar' suspension design and tight-turning radius.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive service and repair for Buell Firebolt XB9R and XB12R models.
Page Count
Estimated Page Count:
Approximately 600-800 pages (typical for full service manuals of this era, actual count may vary)
Manual Type
Type:
Factory Type PDF Service Repair Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
Disassembly, assembly, inspection, tuning, troubleshooting for V-Twin engines.
Fuel System:
Carburetor (Mikuni BDSR 40 for XB9R) and Fuel Injection (for XB12R) system diagnostics, cleaning, and adjustment.
Electrical System:
Wiring diagrams, component testing, ignition system, lighting, starting, charging systems.
Transmission:
Clutch, gearbox, final drive maintenance and repair.
Brakes:
Front and rear brake system servicing, caliper rebuilds, fluid replacement, rotor inspection.
Suspension:
Front forks (Show), rear shock absorber servicing, adjustment, and replacement.
Chassis And Frame:
Frame inspection, swingarm maintenance, steering head bearing service.
Bodywork And Trim:
Fairing removal/installation, body panel repairs, seat maintenance.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement.
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault code interpretation (if applicable).
Rebuilding:
Engine rebuild procedures, transmission overhaul, carburetor/fuel injection system rebuild.
Adjustment And Tuning:
Carburetor synchronization, ignition timing checks, suspension adjustments.
Component Replacement:
Detailed instructions for replacing all major and minor components.
Technical Depth
Depth:
Full factory-level repair and diagnostic procedures.
Diagnostic Capabilities:
Includes electrical diagnostics, mechanical diagnostics, and troubleshooting trees.
Special Tools:
Lists required special tools and their part numbers for specific procedures.
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Searchability:
Searchable text within the PDF for quick information retrieval.
Print Quality
Printability:
Printable pages for workshop use.
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Type Xb9R:
Air-cooled, 45-degree V-Twin, 4-stroke, OHV, 2 valves per cylinder (pushrod actuated).
Displacement Xb9R:
984 cc (60 cu in)
Bore Xb9R:
3.50 in (88.9 mm)
Stroke Xb9R:
3.13 in (79.5 mm)
Compression Ratio Xb9R:
9.0:1
Power Output Xb9R:
Approx. 83 hp (62 kW) @ 6600 rpm
Torque Output Xb9R:
Approx. 70 ft-lb (95 Nm) @ 5500 rpm
Engine Type Xb12R:
Air-cooled, 45-degree V-Twin, 4-stroke, OHV, 2 valves per cylinder (pushrod actuated).
Displacement Xb12R:
1203 cc (73.4 cu in)
Bore Xb12R:
3.49 in (88.6 mm)
Stroke Xb12R:
3.98 in (101.1 mm)
Compression Ratio Xb12R:
9.2:1
Power Output Xb12R:
Approx. 103 hp (77 kW) @ 6800 rpm
Torque Output Xb12R:
Approx. 85 ft-lb (115 Nm) @ 5500 rpm
Fuel System
Fuel Delivery Xb9R:
Mikuni BDSR 40mm constant velocity carburetor
Fuel Delivery Xb12R:
Electronic Fuel Injection (EFI) with Electronic Throttle Control (ETC)
Fuel Type:
Unleaded gasoline, minimum 91 octane recommended.
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh manual gearbox.
Optional
Optional Transmission:
N/A
Features
Clutch Type:
Wet, multi-plate, hydraulic actuation.
Final Drive:
V-belt drive via enclosed belt system.
📐 Dimensions
Exterior
Length:
Approx. 76.0 inches (1930 mm)
Width:
Approx. 29.5 inches (750 mm)
Height:
Approx. 42.5 inches (1080 mm)
Wheelbase:
Approx. 52.5 inches (1334 mm)
Weights
Dry Weight Xb9R:
Approx. 385 lbs (175 kg)
Dry Weight Xb12R:
Approx. 400 lbs (181 kg)
Fuel Capacity:
3.7 US gallons (14 L)
🛡️ Safety Features
Ratings
Crash Safety Ratings:
N/A (Motorcycle, not subject to standard automotive crash testing)
Active Features
Braking System Front:
Buell ZTL (Zero Taper Lock) floating disc with 6-piston caliper, 375mm diameter. The large diameter disc is mounted to the wheel rim, not the hub.
Braking System Rear:
230mm disc with 2-piston caliper.
Passive Features
Frame Design:
Aluminum frame, also serves as fuel reservoir for a low center of gravity.
💡 Technology Features
Infotainment
Instrumentation:
Digital speedometer, tachometer, odometer, trip meters, clock, and indicator lights. Analog tachometer often incorporated into a central display.
Driver Assistance
Traction Control:
N/A for these model years.
Connectivity
Connectivity Features:
N/A (Basic motorcycle electronics)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles (8,000 km) or 12 months. Manual may specify more frequent checks.
Spark Plug Replacement:
Refer to manual for specific mileage, typically around 15,000-20,000 miles.
Belt Tension Check:
Regular checks recommended, typically at every oil change.
Fluid Specifications
Engine Oil Type:
Buell recommends specific Harley-Davidson or equivalent high-quality synthetic motorcycle oil. Check manual for exact specifications (e.g., viscosity grade like 20W-50).
Engine Oil Capacity:
Refer to manual, typically around 3 quarts (2.8 L).
Brake Fluid Type:
DOT 4 brake fluid.
Primary Chain Case Oil:
Harley-Davidson primary chain case lubricant or equivalent.
Known Issues
Common Problems:
Potential for electrical gremlins, cam chain tensioner wear on earlier models, and exhaust header pipe leaks. Carburetor jetting can be sensitive to altitude and modifications.
Common Problems Specific To Era:
EFI systems on XB12R can require software updates. Early belt drives could be prone to premature wear if not maintained. Vibration at idle can be noticeable.
📚 Vehicle History
Brand Heritage
Founder:
Erik Buell
Brand Focus:
Innovative sportbikes using Harley-Davidson engines, emphasizing handling and braking.
Model Evolution
Xb Series Launch:
The XB series was introduced in 2002, with the Firebolt XB9R being a prominent model. The XB12R followed, offering increased displacement and torque.
Year Specific Updates 2005-2008:
Models from 2005-2008 saw refinements in suspension, fueling (EFI on XB12R), and styling. Significant changes included revised fuel mapping, updated suspension components, and aesthetic updates like new color schemes and revised bodywork.
Production
Manufacturing Location:
East Troy, Wisconsin, USA
Production Status:
Buell Motorcycle Company ceased production in 2011, though a new iteration was later announced.
🏆 Awards & Recognition
Recognitions
Motorcycle Press Acclaim:
Buell Firebolts were often praised by motorcycle journalists for their sharp handling, unique styling, and powerful V-twin character, though sometimes criticized for vibration and rider comfort on longer rides.
Ratings
Performance Handling Reputation:
Consistently rated highly for their agility and cornering ability, making them a popular choice for track days and spirited riding.
Certifications
Manufacturer Standards:
Manufactured to Buell's stringent factory quality and performance standards.
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