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Buell Lightning XB9S XB9SL 2004 Workshop Service Repair Manual
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Basic Information Identification Make: Buell Model: Lightning XB9S / XB9SL Year: 2004 Codes Engine Code: XB9 (air-cooled V-twin) Vin Prefix General: 1FB (Buell - U.S. built) Introduction Market Position Market...
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| Basic Information | |
| Identification | |
| Make: | Buell |
| Model: | Lightning XB9S / XB9SL |
| Year: | 2004 |
| Codes | |
| Engine Code: | XB9 (air-cooled V-twin) |
| Vin Prefix General: | 1FB (Buell - U.S. built) |
| Introduction | |
| Market Position | |
| Market Niche: | Performance naked sportbike, known for its unique styling and Harley-Davidson derived V-twin engine. |
| Competitive Analysis | |
| Key Competitors Era: | Ducati Monster, Aprilia Tuono, Triumph Speed Triple, Yamaha FZ1. |
| Key Features | |
| Unique Selling Points: | Under-seat exhaust, perimeter frame, zero-rise handlebars (XB9S), powerful V-twin engine, distinctive Buell styling. |
| Manual Details | |
| Coverage Areas | |
| Coverage Scope: | Comprehensive repair and service for Buell Lightning XB9S and XB9SL models. |
| Page Count | |
| Page Count: | 596 |
| Manual Type | |
| Manual Type: | Workshop Service Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | PDF (Digital Download) |
| Manual Coverage | |
| Systems Covered | |
| Engine Mechanical: | Engine disassembly, assembly, inspection, overhaul, cylinder heads, pistons, rings, crankshaft, connecting rods, valve train. |
| Engine Fuel System: | Carburetor (Mikuni BST40), fuel pump, fuel lines, fuel tank, fuel filter. |
| Ignition System: | Ignition timing, spark plugs, ignition coils, electronic control unit (ECU), wiring diagrams. |
| Exhaust System: | Exhaust pipes, muffler, catalytic converter (if applicable), mounting hardware. |
| Transmission Drivetrain: | Clutch operation, transmission disassembly and assembly, gear selection, final drive (belt drive system). |
| Electrical System: | Battery, charging system (stator, regulator/rectifier), starter motor, lighting (headlight, taillight, turn signals), instrumentation, wiring harness. |
| Chassis Frame: | Frame inspection, steering head bearing maintenance, swingarm, pivot bearings. |
| Suspension Front: | Front forks (telescopic), oil seals, springs, damper rods, adjustments. |
| Brakes Front: | Brake caliper, brake disc, master cylinder, brake lines, brake fluid, bleeding procedures. |
| Wheels Tires: | Wheel bearing maintenance, tire inspection and replacement, tire pressures. |
| Bodywork Cosmetics: | Fairings, fuel tank cover, seat removal and installation, fenders, minor body panel repair. |
| Controls Instruments: | Handlebars, grips, levers, throttle control, brake levers, dashboard indicators, switches. |
| Suspension Rear | |
| Suspension Rear: | Rear shock absorber, spring preload adjustment, damping adjustments, linkage system (if applicable). |
| Brakes Rear | |
| Brakes Rear: | Brake caliper, brake disc, master cylinder, brake lines, brake fluid, bleeding procedures. |
| Procedures Included | |
| Maintenance Procedures: | Routine inspections, oil changes, filter replacements, chain/belt adjustment, brake fluid flush, spark plug replacement. |
| Troubleshooting Diagnostics: | Systematic diagnosis of common and uncommon problems, fault finding charts, symptom-based troubleshooting. |
| Repair Procedures: | Step-by-step instructions for component removal, disassembly, repair, assembly, and installation. |
| Adjustment Procedures: | Carburetor adjustments, clutch free play, throttle cable free play, suspension adjustments. |
| Special Tool Usage: | Identification and usage instructions for required special service tools. |
| Technical Depth | |
| Depth Of Coverage: | Comprehensive, from basic maintenance to complete engine and transmission overhauls, including detailed electrical diagnostics and chassis component repairs. |
| Manual Specifications | |
| File Format | |
| File Format: | |
| Print Quality | |
| Printability: | Yes, all pages are printable. |
| Binding Type | |
| Binding Type: | N/A (Digital PDF) |
| Paper Type | |
| Paper Type: | N/A (Digital PDF) |
| Software Requirement | |
| Software Requirement: | Adobe Reader (or compatible PDF viewer) |
| Compatibility | |
| Operating Systems: | Windows, Mac OS, Linux |
| Engine Specifications | |
| Primary Engine | |
| Engine Type: | Air-cooled, 45-degree V-twin, 4-stroke |
| Displacement: | 984 cc |
| Bore X Stroke: | 3.50 in x 3.13 in (88.9 mm x 79.5 mm) |
| Compression Ratio: | 9.6:1 |
| Valve Train: | OHV (Pushrod), 2 valves per cylinder |
| Performance | |
| Horsepower Estimated: | Approximately 75-80 HP @ 6000 RPM (manufacturer claims may vary) |
| Torque Estimated: | Approximately 70-75 ft-lbs @ 4500 RPM (manufacturer claims may vary) |
| Fuel System | |
| Fuel Delivery: | Mikuni BST40 flat-slide carburetor |
| Fuel Tank Capacity: | 3.7 U.S. gallons (14 liters) |
| Lubrication | |
| Oil Type Specification: | Refer to manual for specific viscosity (e.g., SAE 20W-50, or Harley-Davidson recommended oils). |
| Oil Capacity: | Approximately 2.5-3.0 U.S. quarts (2.4-2.8 liters) with filter change. |
| Transmission | |
| Standard | |
| Transmission Type: | 5-speed manual |
| Optional | |
| Optional Transmissions: | N/A |
| Features | |
| Clutch Type: | Wet multi-plate, cable-actuated |
| Final Drive: | Belt drive, 140 tooth rear belt, 34 tooth front pulley. |
| Dimensions | |
| Exterior | |
| Wheelbase: | 57.5 inches (1460 mm) |
| Overall Length: | 82.5 inches (2095 mm) |
| Overall Width: | 31.5 inches (800 mm) |
| Seat Height: | 30.5 inches (775 mm) |
| Weights | |
| Dry Weight: | Approximately 420 lbs (190.5 kg) |
| Wet Weight: | Approximately 455 lbs (206.4 kg) (with fluids) |
| Safety Features | |
| Ratings | |
| Safety Ratings: | N/A (Motorcycles typically do not receive NHTSA crash ratings). |
| Active Features | |
| Active Safety Features: | Powerful dual front disc brakes, responsive rear disc brake, good chassis dynamics. |
| Passive Features | |
| Passive Safety Features: | Sturdy frame construction, rider ergonomics designed for control. |
| Technology Features | |
| Infotainment | |
| Infotainment System: | Basic analog instrumentation (speedometer, tachometer), indicator lights. |
| Driver Assistance | |
| Driver Assistance Features: | N/A (None) |
| Connectivity | |
| Connectivity Features: | N/A (None) |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Typically every 3,000-5,000 miles or annually, refer to manual for precise recommendations. |
| Belt Tension Check: | Regularly check and adjust belt tension per manual specifications. |
| Spark Plug Replacement: | Refer to manual for mileage or time-based replacement intervals. |
| Fluid Specifications | |
| Brake Fluid Type: | DOT 4 recommended (refer to manual for exact specification). |
| Primary Chain Case Oil: | Specific Buell or Harley-Davidson primary case lubricant (refer to manual). |
| Known Issues | |
| Common Wear Items: | Belt drive wear, fork seal leaks, voltage regulator failures, carburetor adjustments can be sensitive. |
| Potential Electrical Gremlins: | Can occur with age and mileage, especially wiring harness connections and grounds. |
| Technical Tips | |
| Special Tools Importance: | Crucial for accurate adjustments and repairs, particularly for belt tension and wheel bearings. |
| Vehicle History | |
| Brand Heritage | |
| Brand Origin: | Founded by Erik Buell, an American engineer, with a focus on performance and innovation. |
| Model Evolution | |
| Xb Series Introduction: | The XB series, including the Lightning, marked a significant shift for Buell, utilizing a unified frame and engine design philosophy. |
| Xb9Sl Distinction: | The XB9SL was a slightly different configuration, often featuring different handlebars or minor styling cues compared to the standard XB9S. |
| Production | |
| Production Period: | Buell motorcycles were produced from 1987 to 2009. |
| Awards & Recognition | |
| Recognitions | |
| Motorcycle Press Reviews: | Generally well-received for its performance and unique character, though ergonomics and comfort could be divisive for some riders. |
| Ratings | |
| Reliability Perception: | Buells of this era are known for their robust engines but can require diligent maintenance and attention to electrical components. |
| Certifications | |
| Emissions Certification: | Meets applicable emissions standards for its model year. |