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Buell Lightning XB12S 2006 2007 Workshop Service Repair Manual
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Basic Information Identification Make: Buell Model: Lightning XB12S Model Year: 2006, 2007 Codes Engine Code Identifier: Buell Thunderstorm 1200 V-Twin (as derived from XB12S) Introduction Market Position Market Segment: Performance...
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| Basic Information | |
| Identification | |
| Make: | Buell |
| Model: | Lightning XB12S |
| Model Year: | 2006, 2007 |
| Codes | |
| Engine Code Identifier: | Buell Thunderstorm 1200 V-Twin (as derived from XB12S) |
| Introduction | |
| Market Position | |
| Market Segment: | Performance Naked Sportbike |
| Competitive Analysis | |
| Key Competitors: | Ducati Monster series, Triumph Speed Triple, Aprilia Tuono |
| Key Features | |
| Unique Selling Points: | Buell's unique chassis design (fuel-in-frame), perimeter front brake, high torque V-twin engine, aggressive styling. |
| Manual Details | |
| Coverage Areas | |
| Primary Focus: | Repair and maintenance |
| Scope: | Comprehensive service and repair |
| Page Count | |
| Total Pages: | 638 |
| Manual Type | |
| Type: | Workshop Service Repair Manual |
| Language | |
| Language: | English |
| Format | |
| File Format: | |
| Manual Coverage | |
| Systems Covered | |
| Engine: | Yes (Thunderstorm 1200) |
| Transmission: | Yes |
| Chassis And Frame: | Yes |
| Suspension: | Yes (front fork, rear shock absorber) |
| Brakes: | Yes (front and rear systems, including caliper and master cylinder service) |
| Electrical System: | Yes (wiring diagrams, ignition, lighting, charging system) |
| Fuel System: | Yes (carburetor, fuel pump, lines) |
| Exhaust System: | Yes |
| Cooling System: | No (Air-cooled engine) |
| Wheels And Tires: | Yes (wheel bearing service, tire pressure) |
| Bodywork And Trim: | Yes (fairings, seat, fuel tank removal/installation) |
| Procedures Included | |
| Maintenance: | Yes (scheduled maintenance, fluid changes, filter replacements) |
| Troubleshooting: | Yes (diagnostic procedures, common problems) |
| Disassembly And Assembly: | Yes (detailed step-by-step for all major components) |
| Adjustment: | Yes (clutch, throttle, suspension, carburation) |
| Repair: | Yes (comprehensive repair instructions for all systems) |
| Installation: | Yes (component installation and reinstallation) |
| Special Tool Usage: | Yes (references specific tool numbers and shows their application) |
| Technical Depth | |
| Depth: | Extensive, covering from basic maintenance to complete overhaul and diagnostics. |
| Detail Level: | Step-by-step procedures with detailed illustrations and diagrams. |
| Manual Specifications | |
| File Format | |
| Quality: | High resolution, printable |
| Print Quality | |
| Printability: | Yes, all pages are printable |
| Binding Type | |
| Binding: | N/A (Digital Download) |
| Paper Type | |
| Paper Type: | N/A (Digital Download) |
| Compatibility | |
| Operating Systems: | Windows, Mac, Linux |
| Requirements | |
| Software: | Adobe Reader |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | Air-cooled, 45-degree V-twin, four-stroke |
| Displacement: | 1203 cc (73.4 cubic inches) |
| Bore X Stroke: | 3.50 in x 3.81 in (88.9 mm x 96.8 mm) |
| Compression Ratio: | 9.6:1 |
| Performance | |
| Horsepower Est: | ~103 hp @ 6000 rpm |
| Torque Est: | ~84 lb-ft @ 3800 rpm |
| Fuel System | |
| Carburetor: | Mikuni HSR45 |
| Fuel Capacity: | 3.7 US gallons (approx. 14 liters) - integrated into the frame |
| Ignition | |
| Ignition System: | Electronic ignition |
| Transmission | |
| Standard | |
| Transmission Type: | 5-speed manual |
| Optional | |
| Optional Transmissions: | None |
| Features | |
| Clutch Type: | Wet, multi-plate, hydraulic actuation |
| Final Drive: | Belt drive |
| Dimensions | |
| Exterior | |
| Length: | Approx. 77.6 inches (1970 mm) |
| Width: | Approx. 30.5 inches (775 mm) |
| Height: | Approx. 45.1 inches (1145 mm) (seat height varies) |
| Weights | |
| Dry Weight: | Approx. 390 lbs (177 kg) |
| Gross Vehicle Weight Rating: | N/A (Motorcycle specific) |
| Safety Features | |
| Ratings | |
| Crash Test Ratings: | N/A (Motorcycle specific) |
| Active Features | |
| Braking System: | Buell ZTL (Zero Taper Lock) front brake system with 375mm disc and 6-piston caliper; 250mm rear disc with 2-piston caliper. |
| Suspension Adjustment: | Adjustable front fork (compression/rebound) and rear shock absorber (preload/rebound). |
| Passive Features | |
| Frame Design: | Aluminum frame with integrated fuel-in-frame technology. |
| Lighting: | Halogen headlamp, LED taillight. |
| Technology Features | |
| Infotainment | |
| Infotainment System: | N/A (Basic motorcycle instrumentation) |
| Driver Assistance | |
| Driver Assistance Features: | None |
| Connectivity | |
| Connectivity Features: | None |
| Instrumentation | |
| Gauge Cluster: | Analog tachometer, digital speedometer, odometer, trip meters, fuel level warning light, oil pressure warning light, turn signal indicators. |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Refer to manual (typically 3,000-5,000 miles or annually) |
| Spark Plug Replacement: | Refer to manual (typically 7,500-10,000 miles) |
| Belt Tension Check: | Regularly (refer to manual for specific intervals) |
| Fluid Specifications | |
| Engine Oil Type: | Viscosity and specification (e.g., SAE 20W-50, Harley-Davidson SYN3 or equivalent) as per manual |
| Engine Oil Capacity: | Refer to manual (typically around 3.0 US quarts) |
| Brake Fluid Type: | DOT 4 recommended (check manual for specific type) |
| Transmission Fluid Type: | Refer to manual (often a specific gear oil or heavy-duty lubricant) |
| Known Issues | |
| Common Wear Items: | Belt drive wear, clutch actuation issues, potential stator or regulator issues, vibration damping components. |
| Electrical Gremlins: | Buells of this era can sometimes exhibit electrical gremlins; thorough wiring inspection and troubleshooting are key. |
| Suspension Maintenance: | Regular fork seal and rear shock maintenance is crucial for optimal handling. |
| Vehicle History | |
| Brand Heritage | |
| Brand Origin: | Founded by Erik Buell, known for innovative motorcycle design and performance. |
| Model Evolution | |
| Xb Series Introduction: | The XB series was introduced in 2002, representing a significant redesign and departure from Buell's earlier models. The XB12S Lightning was introduced later in this line. |
| Production | |
| Manufacturing Location: | East Troy, Wisconsin, USA |
| Production Period: | Buell ceased operations in 2009, though some models were produced shortly after. This manual covers the 2006 and 2007 model years. |
| Awards & Recognition | |
| Recognitions | |
| Motorcycle Journal Reviews: | Praised for its unique engineering, handling characteristics, and powerful V-twin torque. Often noted for its 'raw' riding experience. |
| Certifications | |
| Emission Standards: | Compliant with prevailing emission standards for its model year. |