Te RATA BS freee gran wanuat~ anasicnsyIMPORTANT NOTICE Buoll motorcycles conform to all applicable U.S.A. Federal Motor Vehicle Safety Standards and U.S.A. Environmental Protection Agency regulations effective on the date of manufacture. ‘To maintain the safety, dependability, and emission and noise control performance, itis essential that the procedures, specifications and service instructions in this manual are followed. ‘Any substitution, alteration or adjustment of emission system and noise control components outside of factory specifications may be prohibited by law. Buell Motorcycle CompanyAMERICAN MOTORCYCLES 2009 Buell 1125 Models Service Manual ©2008 Buell Motorcycle Company ALL RIGHTS RESERVED 9491-09 Printed in the U.S.A. VISIT THE BUELL WEB SITE /werwpuell.com CMI- 2m - 08/08NOTEScutters cut Here ' I ' n ' ' ' ' ' I ' I I Il 1 Hl 1 1 H 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ' ' 1 1 I 1 1 ' ' ' ' ' ' ' ' READER COMMENTS The Buell Motorcycle Company maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we need user feedback - your critical evaluation of this manual. Please comment on the completeness, accuracy, organization, usabili y and readability of this manual. Pi the page, item, and part number(s) of any errors you find in this manual. Please tell us how we can improve this manual. Occupation: Street: _ ‘Department: City: State: Zip: 2009 Buell 1125 Models Service Manual (99491-09Y) Please clip out and mail to: ‘Service Communications Department Buell Motorcycle Company P.O. Box 653 Milwaukee, WI USA 53201ABOUT THIS MANUAL GENERAL “This Service Manual has been prepared with two purposes in ‘mind. Fit, it will acquaint the user with the construction of the Buell product and assist in the performance of basie mainten- ance and repair. Secondly it wil introduce to the professional Buell Technician the latest field-tested and factory-approved major repair methods. We sincerely believe that this Service Manual will make your association with Buell products more pleasant and profitable. HOW TO USE YOUR SERVICE MANUAL Rte othe lable below forthe content layout ofthis manual 1 [Maintenance Chassis Engine Fuel System Cooling System Drive/Transmission Electrical Appendix A Connector Repair ‘Appendix B Wiring Appendix G Valve Lash Appendix D Conversions: ‘Appendix E Glossary mlololal> lala sew Use the TABLE OF CONTENTS (which follows this FORE- WORD) and the INDEX (at the back of this manual) to quickly locate subjects. Sections and topics in this manual are ‘sequentially numbered for easy navigation, For example, a cross-reference shown as 2.1 SPECIFICA- TIONS refers to chapter 2 CHASSIS, heading 2.1 SPECIFIC, ATIONS For quick and easy reference, all pages contain a section ‘number followed by a page number. For example, page 3-5 relers to page 5 in section 3. ‘A number of acronyms and abbreviations are used in this document. See the E.1 GLOSSARY for a list of acronyms, abbreviations and definitions, PREPARATION FOR SERVICE Stop the engine when refueling or servicing the fuel ‘system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result In death or serious injury. (00002a) Good preparation is very important for efficient service work, ‘A clean work area at the start of each jeb will allow you to perform the repair as easily and quickly as possible, and will reduce the incidence of misplaced tools and pars. A motorcycte that is excessively dirty should be cleaned betore work starts, Cleaning will occasionally uncover sources of trouble. Tools, instruments and any parts needed for the job should be gathered before work is started. Interrupting @ job to locate tools or parts is @ distraction and causes needless delay. NoTES + To.avoid umecessary disassembly, carefully read all re ative service information before repair work is started. * In figure legends, the number which follows the name of {a part indicates the quantity necessary for one complete assembly, SERVICE BULLETINS In addition to the information presented in this manual, Buell Motor Compary will periodically issue Service Bulletins to Buell dealers. Service Bulletins cover interim engineering changes ‘and supplementary information. Consult the Service Bulletins to keep your product knowledge current and complete USE GENUINE REPLACEMENT PARTS Awaaning Do not use aftermarket parts and custom made front forks which can adversely affect performance and handling. Removing or altering factory installed parts can adversely affect performance and could result in death or serious injury. (00018) To varity salistactory and lasting repairs, carefully follow the ‘manual instructions and use only genuine Buell replacement parts. This is your assurance that the parts you are using will fitright, operate properly and last longer. WARNINGS AND CAUTIONS — | Statements in this manual preceded by the following words ‘are of special significance, Gn Ned WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious Injury. (00119a) rein CAUTION indicates 2 potentially hazardous situation ‘which, if not avoided, may result in minor or moderate Injury. (00138a) Nee CAUTION used without the safety alert symbol indicates 2 potentially hazardous situation which, if not avoided, ‘may result in property damage. (00140a) NoTE Felers to important information, and is placed in italic type. It Is recommended that you take special notice of these tems. Proper service and repair is important for the safe, reliable ‘operation of all mechanical products. The service procedures, recommended and described in this manual are effective methods for performing service operations. FOREWORDCI SGes ‘Always wear proper eye protection when using hammers, arbor or hydraulic presses, gear pullers, spring com- Pressors, slide hammers and similar tools. Flying parts ‘could result in death or serious injury. (00496) Some of these service operations require the use of tools specially designed for the purpose. These special tools should be used when and as recommended. It is important to note that some warnings against the use of specific service mothods, which could damage the motorcycle or render it unsate, are stated in this manual. However, please remember that these warnings are not al-inclusive. Inadequate safety precautions ‘could result in death or serious injury Since Buell Motorcycle Company could not possibly know, ‘evaluate or advise the service trade of all possiblo ways in hich service might be periormed, or of the possible hazardous. ‘consequences of each method, we have not undertaken any ‘such broad evaluation. Accordingly, anyone who uses.a service Procedure or tool which is not recommended by Buell Motor- ‘oycle Company must first thoroughly satisfy himself that neither his nor the operator's safety will be jeopardized as a result, Failure to do 0 could result in death or serious injury. PRODUCT REFERENCES Wn) Read and follow warnings and directions on all products. Failure to follow warnings and directions can result in ‘death or serious injury. (00470b) When reference is made in this manual to a specifi brand name product, tool or instrument, an equivalent product, too! or instrument may be substituted. Kent-Moore Products All tools mentioned in this manual with an "HD", "J" or "Bt preface must be ordered through SPX Kent-Moore. For ordering FOREWORD information or product returns, warranty or otherwise, visit wwru.spx.com, Loctite Sealing and Threadlocking Products ‘Some procedures in this manual call for the use of Loctite products. If you have any questions regarding Loctite product, usage or retaileriwholessler locations, please contact Loctite Corp. at wwrwiloctite com. PRODUCT REGISTERED MARKS Alcantara S.p.A., Allen, Amp Multilock, Bluetooth, Brembo, Delphi, Deutsch, Dunlop, Dynojet, Fluke, G.E. Versilube, Gunk, Hydroseal, Hyiomar, Kevlar, Lexan, Loctite, Lubriplate, Keps, K&N, Magnafiux, Marson Thread-Setter Too! Kit, MAXI fuse, Molex, MPZ, Mulilock, Novus, Packard, Piroli, Permatex, Philips, Put, Pozidriv, Robina, $100, Sems, Snap-on, Teflon, Threadlocker, Torea, Torco, TORX, Tutcil, Tyco, Ultratorch, Velcro, X-Acto, and XM Satellite Radio are among the trade~ ‘marks oftheir respective owners. H-D MICHIGAN, INC. TRADEMARK INFORMATION 11250R, 1125R, Blast, Buoll, Firobolt, Glaze, Gloss, Harley, Harley-Davidson, HD, H-D, Lightning, Sunwasn, Tender, Triple Tail, Thunderstorm, Ulysses, Uniplanar, ZTL and ZTL-2 are ‘among the trademarks of H-D Michigan, Ine. CONTENTS ‘All photographs, illustrations and procedures in this manual may not necessarily depict the most current model or com- ponent, but are based on the latest proctction information available atthe time of publication. ‘Since product improvement is our continual goal, Buell Motar- ceycle Company reserves the right to change specifications, ‘equipment or designs at any time without notice and without incurring obligation,MAINTENANCE 1.1 FASTENER TORQUE VALUES Fastener Torque Values in this Chapter. 1.2 GENERAL, Servicing @ New Motorcycle. ‘Safe Operating Maintenance. Disassembly and Assembly Checking Torques on Fasteners with Lock Patches... 1-4 Magnetic Parts Trays... 4 Repair and Replacement Procedures... Hardware and Threaded Parts... ‘Throadlocking Agents, Wiring, Hoses and Lines. Instruments and Gauges, Bearings. Bushings. Gaskets. Lip Type sro (Preterm Petree) Be ANS Shafts. Part Replacement. En Seem ela Cleaning... Part Protection Cleaning ProceSs...1. ust or Corrosion Removal. boo o Wrenches... ‘ PlersiCuttrs/Pry bars. Hammers Punches/Chisels, ‘Screwdrivers. Ratchots and Handles. SOCKS... Storage Units. 1.3 MAINTENANCE SCHEDULE General 1.4 FUEL AND OIL FURL rn Gasoline Blends: Buel Engine Lubrication 1.5 ENGINE OIL AND FILTER ‘Checking Oil Level ‘ii Level Cold Check il Level Hot Check. a Engine Ol Change: Buell 1125 Models. fi ro 1.6 AIR FILTER ELEMENT Intake Cover... Removal. Installation. Removal... iar an npn, Installation, 41.7 THROTTLE CABLES Throttle Cable Adjustment. 4.8 TIRES AND WHEELS ‘Tire Replacement: Buell Pirelli Tres... Inspection. When To Replace Tires. Wheel Bearings. 1.9 BLEEDING CLUTCH FLUID LINE Hydraulic Clutch: Buell 1125 Models. Gonoral : Checking Fluid Lavel Bleeding... Reservoir Banjo Bol Bleeder Valve. 1.10 DRIVE BELT MAINTENANCE Inspection.. Rear Sprocket... Drive Bot. Idler Pulley. 1.11 BRAKE SYSTEM MAINTENANCE General... 7 Checking Fluid Level Front Brake Fluid Reservoir. Rear Brako Fluid Reservoir... Bleeding Brakes. Bleeding Front Brake.. Bleeding Rear Brake.. Brake Pedal Adjustment, Brake Pad Thicknes Brake Rotor Thickness... 1 Brake Pad Repiacement. Front Pad Removal. Front Pad Installation... as Rear Pad Removal 4 Rear Pad Installation, 1.12 SPARK PLUGS + BEISSVSRSSISRRKR 131 431 1-31 131 1-82 1-33 Installation... Cleaning, 1.13 HEADLAMP Headlamp Alignment. Headlamp Adjustment: 1125 Models... Horizontal Adjustment. Vertical Adjustment (1125R)... Vertical Adjustment (1 125CR), 1.14 BATTERY MAINTENANCE General. 1-36 Cleaning and inspection. 1-37 Voltmeter Test 1-37 Voltmeter Test. 1-37 Charging Battery.TABLE OF CONTENTS Safety Precautions. Using a Battery Charger. Disconnection and Removal Storage.. Installation and Connection 1.15 ENGINE COOLANT Coolant Lovel: Buell 1125 Models, iA Coolant Type. at Checking Level in Coolant Sight Gauge (Quick Check). 141 heckng nd Adsng Cotat in Expansion Tenk..1-4 Bleeding Coolant. 7 1a 1.16 VALVE CLEARANCE Valve Lash... Lash Measurement. Lash Adjustment 1.17 STEERING HEAD BEARINGS Inspection. 147 Resistance Test. 147 1.18 STORAGE General nn 1-48, Removal From Storage. 1.48, 1.19 TROUBLESHOOTING General 1-49 Engine. 1-49 ‘Starter Motor Does Not Operate or Does Not Turn Engine QVOr nen zi Engine Turns Over But Does Not Stat Starts Hard Starts But Runs Iregularly or Misses, ‘Spark Plug Fouls Repeatedly. Pre-lgntion or Detonation (Knocks or Pings) Overeating. nnn Valve Train Noise. Excessive Vibration. (Check Engine Light iluminates During Operation. Lubrication System. Engine Uses Too Much Oil Or Smokes Excessively. Engine Leaks Od From Cases, Hoses, Ete, Low Oil Pressure.. High Oil Pressure, Electrical System.. ‘Alternator Does Not Charge. ‘Alternator Charge Rate Is Below Normal. Speedometor Operates Eraicaly Transmission. Shits Hard Jumps Out Of Gear. Clutch Sips. ‘Clutch Drags Or Does Not Release Clutch Chatters. Clutch. Slips. Drags or Does Not Release. Chatters, ae Chassis. 1-51 Inregular/inadequate Brake Action. 151 SSERRRERSREEEES IV TABLE OF CONTENTS Handling Kregulartes 151 cooing System “rst Overeats 151 Suspension ag seat CHASSIS 2.1 FASTENER TORQUE VALUES Fastener Torque Values inthis Chapter. 24 2.2 SPECIFICATIONS 1125 Models 26 Suspension Setings. 26 2.3 VEHICLE IDENTIFICATION NUMBER (VIN) Vehicle Identification Number: Buell 1125 Models.....28 2.4 BODY WORK, COVERS, GUARDS AND GUIDES Body Work. 240 Covers, Guards and Guides. 242. 2.5 TIRES General 2414 New Tires 214 Repair 244 ‘Troubleshooting, 214 Specifications. BAS Tire Size 215 Rim Size, 215 Dismounting. 216 Cleaning and Inspection... 216 ‘Mounting: Diablo Corsa Il 2416 Wheel and Valve Stems. 216 Using the Tire Machine. 216 Inflate Tire. 218 unout. 218 Lateral 218 Radial BAD Tite Balancing, 219 2.6 WHEELS ‘Troubleshooting 220 Front Whee! 2-20 Removal ‘i 2-20 Installation. 221 Ingpection and Repatr. 2-22 Inspection. 2-22 Wheel Bearings 2-22 Brake Rotor. 222 Roar Wheol 2-22 Removal 2-22 Installation 224 Ropair. 2:25 Inspection. 225 Drive Sprocket 225 Brake Rotor. 2-28 Wheel Bearings 2-28 Wheel Rim Runout 227TABLE OF CONTENTS Lateral Runout.... 227 Radial Runout 207 Wheel Bearings 2:28 Removal none 2-28 Instalation: Rotor Side Bearing 2-29 Installation: Opposite Side Bearing, 2-30 2.7 FRONT BRAKE Front Brake Hand Lever. Master Cylinder/Reservoir: Removal. Master Gylinder/Reservoir: Repair Disassembly. Cleaning and Inspect Assembly. Master Cylinder/Reservoir Installation. Front Brake Fluid Line... Removal. . Installation. Caliper: Removal and Installationinn.uemn Removal. Installation, Caliper: Repair... Disassembly. Clean and Inspect. Assembly. a 2.8 REAR BRAKE Rear Brake Pedal. Removal. Installations Master Cylinder/Reservoir Removal. Master Cylinder.. Reservotr Master Cyiinder/Reservor Installation. 2-43 Reservoir. 243 Master Cylincer 2-43 Brake Fluid Line. ss Removal. Installation, 245 Caliper. 2-46 Removal... Installation, 2-46 2.9 FRONT FORK Removal, 2-47 Disassembly. 247 Drain the Fork Oil. : 2-47 Fork Disassembly. 2-48 ‘ering ae nape ans 251 Assombly. ° 251 reassembly 251 Fill with Fork Oi, 251 Final Assembly. Fork Clamps: 1 125R, 253 Removal 2-53 Installation... 253 Fork Clamps: 1125CR. 254 Removal. 254 Installation. 254 Installation. 3 255 2.10 STEERING HEAD BEARINGS Removal 256 installation, 2.56 2.11 SHOCK ABSORBER Replacement 2.59 Removal 259 Installation. 2:58 2.12 SWINGARM AND BRACE Axle Sliders. 261 Brace. a 21 Swingarm: Removal = 261 Swingarm: Repait. 262 ‘Swingarm: Insalaon, 2.63 2.13 FRAME Service. 2-64 K-Brackots a 2-65 Moter Mounts 265 2.14 SUBFRAME Tal Section. 2-66 Subrame Pan. 2-65 Removal 2-66 installation. 267 Subframe.. 2-68 Removal... 268 Installation, 2-68 2.15 FAIRING AND HEADLAMP ASSEMBLY: 1125R Windstiol : 270 Cleaning 270 270 : — 270 installation. 2-70 Headlamp Assembly. ari Removal recat 271 instalation. 2m Support Brackot 272 Removal = manne) installation, 273 Nadal Suppo Braet 278 Removal : 2-74 installation. 274 2.16 WINDSCREEN AND HEADLAMP ASSEMBLY: 1125CR Windscreen... se 2-75 Hoadlamp Assembly 275 Removal 278 Installation, 2-78 2.17 HANDLEBARS: 1125R Lett CiP-Oh an ee Removal. 247 Installation ssuaeifd? Left Hand Grip: All Models 277 RIQh ClipO esas TABLE OF CONTENTS VTABLE OF CONTENTS Removal... 278 Installation 278 2.18 HANDLEBARS: 1125CR Lot Side. 2-80 Removal 2-80 Installation 2-80 Right Side, 2-80 Removal 2-80 Installation, 2-80 Handlebar. 2-81 2.19 FOOTPEGS, HEEL GUARDS AND MOUNTS Rider. Wear Pog. Footpeg. Hea! Guards. Right Side Rider Footpeg Mount. Left Side Rider Footpeg Mount. Passenger... Footpeg, Heel Guard Mount... 2.20 SEAT Removal. 2-85 Rider Seat, 2-88 Pilon. 2-85 Installation. 2-85 Rider Seat. 2:85 Pillion. 2-86 Pillion Lock. 2-86 Removal. 2-86 Installation. 287 2.21 SIDESTAND Sidestand. me son BS Removal and Di iy. 2-89 Assembly and Installation... 2-90 Sidestand Stop Bracket. 2-90 ENGINE 3.1 FASTENER TORQUE VALUES Fastener Torque Values in this Chapter...mmnne ot 3.2 SPECIFICATIONS General el 3.3 TROUBLESHOOTING Compression Test. a7 Diagnosing Smoking Engine or High Oil Consumption....3-7 Oil Pressure Test a7 Troubleshooting Tables... 7 38 3.4 ENGINE ROTATION Down Rotation — 349 Propare tho Motorcycle. 313 Front of Motorcycle... 13 VI TABLE OF CONTENTS Rotate Engine. Up Rotation...nnn Rotate Engine.. Mutter. Lett Side. Front of Motoreyele. Upper Engine. Return to Service, 3.5 ENGINE REPLACEMENT Engine Removal. Preparation. Upper Engine. Lett Side... Right Side... Drain the Fiuids/Oi Cooler. KeBrackets. Motor Mounts. Engine Disassembly. Engine Assembiy. Engine Installation. Motor Mounts and K-Brackets Right Side. 3-29 Front of Engine... 3-29 Lett Side 3-30 Final Tightan Exhaust System, 3-30 Upper Engine. . Return to Service, 3-32 3.6 REBUILD TIMING INSTRUCTIONS Timing 3-33 Front Gylinder TOG. 3-33 270 Degree Rotation, 3-93 Rear Cylinder TOC. 3.33 ‘Top Dead Genter (TDC), 3.35, General 3-95 Locking Crankshaft 3.35 3.7 CAMSHAFT ASSEMBLY Valve Covers. 3:96 Removal 3-36 Installation 3-36 Removal. 3-37 Disassembly. 3-38 Cleaning and Inspection. : nO Installation (If camshafts or cam sprocket wore not removed). 341 Assemblyfinstallation. 3-42 3.8 CYLINDER HEADS Cylinder Head: Removal 3-45 Disassembly. 345 Cleaning and inspection. 3-47 (Cylinder Heads. 347 Spark Plug Threads. 3-47 Valves.. 3.47 Valve Seats. 347 Valve Guides... B48TABLE OF CONTENTS Valve Springs. 3-48 ‘Cutting Valve Seats, 3-48 ‘Assembly. 3-50 Cylinder Head: Installation. 350 3.9 CYLINDERS AND PISTONS Removal and Disassembly 352 Cleaning and Inspection... 353 Clean and Inspect Pist 353 Checking PIstOn Pi. 353 ‘Checking Lower Connecting Rod Bearing. 354 ‘Checking Cylinder Gasket Surtace. 354 Measuring Cynder Bore and Cyindero Piston Clearance: 354 Deglazing Cylinder 355 ‘Assembly and Installation, 356 Installing Piston Rings... 3-58 Installing Piston, 357 Installing Cylinder 358 3.10 CLUTCH SIDE Clutch Case Vent Tube 3-60 Removal 3-60 Installation a 3-60 Cluteh Cover: 3.61 Removal. 3-61 Installation 361 P-Clamp. 3-63 Balancer: Water Pumnp Shatt... 3-83 Balancer: Bottorn 3-83 Removal 3-63 Installation 364 il Pump... 3-65 Removal 3-65 Inspection. 3-67 Instalation.. 3.67 i Strainer. 2-68 3.11 ALTERNATOR SIDE i Fite. 270 Pressure Retaining Valve... art Sealing Sleeve, 271 Ignition Cover. 372 Removal 3-72 Installation... 3-73 Balancer: Top, Removal Bearing and : Installation. 376 Starter Friction Gluten 377 Removal. 3-77 Installation... 3-78 Grankcase Breather. 373 General 379 Replacement... 3-79 3.12 VALVE TRAIN DRIVE Front Cylinder. se 381 Removal. 3-81 Installation nn 81 Rear Cylinder. 381 Removal. 3-81 Installation. 3.13 CRANKCASE Split Crankease nn Clutch Side Components Removal... Alternator Side Components Removal Disassembly. il Sump. Removal Installation, ll Nozzles. il Passage Plugs. (Clutch Shatt Bearing: Let Case. Pressure Cavity: Left Case. Oil Nozzle: Lett Case. Oil Nozzle: Right Case, Water Pump Shait Bearing... Removal Installation. Main Bearings... Removal Installation, P-ClamP rn = Join Grankcase Halves. ‘Assembly. Crankcase Gasket... Glutch Side Components instalation. Alternator Side Components installation, 3.14 CRANKSHAFT Removal 393 Disassembly. 3-93 Cleaning and Inspection, 3.94 Assembly. 3-94 Installaton..... 3-94 FUEL SYSTEM 4.1 FASTENER TORQUE VALUES Fastener Torque Values in this Chapter. “ 4.2 AIR CLEANER ASSEMBLY Ram Ar Intake Snorkel 43 Basepiate.. : a 43 Removal an 43 Installation at ‘Throttle Mount Gasket . 45 Romoval : 45 Installation 45 4.3 SENSORS Bank Angle Sensor (BAS). i 46 Replacement 46 Barometric Pressure Sensor (ARO). 48 Fuel Pressure Sensor. i AT 47 Installation, : aT Intake Air Temperature Sensor (IAT), 47 Removal 47 Installation. 48 Manifold Absolute Pressure Sensor (NAP). 48 ‘TABLE OF CONTENTS VilTABLE OF CONTENTS Removal Installation, Oxygen Sensors (02), General. Front Rear. Throttle Position Sensor (TPS). Replacement. Manual TPS Reset. 4.4 THROTTLE CONTROL Throttle Control. : Removal and Disassembly. Cleaning and inspection ‘Assembly and instalation... ‘They Cette Fopacnen Removal Installation, Idle Air Control (IAC), Removal Installation, 4.5 THROTTLE BODY Intake Leak Test Leak Tester... Test. Injector Leak Test Fuel Rail Removal Installation. Fuel Injectors. Removal Installation Throttle Body Removal Removal. Inspection and Disassembly. Intake Flanges. Throttle Body Installation. Intake Flanges. Assembly Throttle Boy. 4.6 ACTIVE INTAKE Cable Adjustment, Removal. Installation. 4.7 EXHAUST SYSTEM Mutfler: Removal. Right Side. Left Side. Headers, Removal. Installation. a Muller: Installation, Right Side. Loft Side, Final Tighten 4.8 FUEL TANK Draining the Fuel Tank. Fuel Cap Retaining Ring... Vill TABLE OF CONTENTS: 414 ANd 414 4-15 415 AAG 415 416 AAG 417 417 AAT 418 418 18 418 4-19 AAS At 4-22 4-22 4-23 4-23 423 424 428 424 424 24 4-25 4-25 426 428 Removal... = 4-26 Instalation 4-26 Vent Valve. 427 Genera : 4-27 Removal cm 427 Installation 4-27 Vent Hose Routing, a 4-28 ‘Tank Set Screws. = 4-29 Battery Ground, 4-29 Wire Guide/Fuel Purp Cover. 4-29 4.9 FUEL PUMP. Fuel Pressure Test. 4-30 Wire Guide/Fuel Pump Cover. 431 Removal 431 Installation 4-92 Fuel Pump: Removal fi hat 433 Fuel Pump: Installation, 4-34 4.10 EVAPORATIVE EMISSIONS CONTROL, (EVAP): CA MODELS General. 4-36 Repair. 4-36 Vent Hose Routing, : 4-36 Canister Removal. 436 Canister installation 436 COOLING SYSTEM 5.1 FASTENER TORQUE VALUES Fastener Torque Values in this Chapter. A 5.2 SPECIFICATIONS General 62 5.3 COOLANT FLOW Description. 5 ay 53 Water Pump. 53 Warm Up and the Thermostat. 53 Operating Temperature and the Radiators.ann-5-3 Cooling Fans. 53 Pressure Cap. 53 Overtiow Tank. eB Engine Coolant Temperature (ECT) Sensor. 4 ‘Skip Spark. 4 Replacement. : 4 ‘Troubleshooting 54 Low Engine Temperature ay High Engine Temperature. 54 Coolant Leaks. a 54 Pressure Cap. 54 Pressure Cap Test. 55 System ProssUte TOSt. nnn eB Leak Detection Dye Test ees 56 Tests for Blown Gasket 57 5.4 ENGINE COOLANT Freeze Point Test. 58 Replacing Coolant. 58 Drain the Coolant: Right Side Radiator. 58 Drain the Coolant: Left Side Radiator.c.unimnnin 5DTABLE OF CONTENTS. Fill with Coolant. 510 5.5 THERMOSTAT Removal Installation, 5.6 WATER PUMP Removal. Installation, 5.7 COOLANT PIPES AND HOSES Removal Installation, 5.8 RADIATORS 5-21 521 Right Side. 521 Installation... nn 22 Lett Side, 5-22 Right Side, 5-22 Overtiow Tank. 523 5.9 OIL COOLER Removal 5-25 Installation. 5:25 Oi Line Fittings, 5-26 DRIVE/TRANSMISSION 6.1 FASTENER TORQUE VALUES Fastener Torque Values in this Chapter. St 6.2 SPECIFICATIONS General. 63 6.3 TROUBLESHOOTING General. 65 6.4 CLUTCH ACTUATOR (Clutch Lever Removal and Installation, Removal. Installation. Clutch Master Cyinder/Reservoir: Removal Clutch Master Cylinder/Reservoir: Repair Disassembly. Cleaning and Inspection. ‘Assembly. (Clutch Master Gyiinder Reservoir Installation... (Clutch Fluid Line... : Romoval Installation Secondary Clutch Actuator. Removal Installation Secondary Actuator Repair. .ssembl. leaning and inspection, ASSeMbIY ann 6.5 CLUTCH Vacuum Assist Hose, e186 ‘Vacuum Assist Diaphragm. 619 Removal. 6-19 Installation 6-19 Inner Diaphragm Cover Oil Seal... 6-21 Gil Jet i Clutch Pack... 6-22 Removal 6-22 Clutch Springs, 6-22 Friction Plates, 6-23 Stee! Plates. 6-23 Installation, G23 Pressure Plate Bearing 6-25 Clutch Basket 6-28 Removal. 6-26 Installation 627 6.6 PRIMARY DRIVE Primary Drive Assembly. 6-28 Disassembly, 6-28 Assembly. 6-28 Primary Drive Engine Spr 631 6.7 SHIFT LINKAGE ‘Shift Lever, 632 Shift Shaft 6-32 Removal and Disassembly 6-32 Assembly and Instaliation.. 6-32 Detent Wheel 6-33 Index Shim. 33 6.8 TRANSMISSION VSS Tigger Wheel 6-35 Removal. 6-35 Installation, 6-35 “Transmission: Removal 6-36 Mainshatt.. 6-36 Disassembly... 6-36 Assembly. 6-37 Clutch Shafter 637 Disassembly... 6-37 Assembly. 6-38 Shift Drum and Forks. 6-38 Transmission: Installation. 6-39 Assembly... 6-39 Verity Operation. 6-40 6.9 TRANSMISSION CASE BEARINGS AND. SEALS Location. 6-41 Shift Shalt Seals, Ott Right Case Seal inner 641 Left Case Seal (Outen. eat Fork Drum, G42 Right Case Bearing. 6-42 Left Bearing, Mainshatt..... Right Caso Bearing Mainshatt Seal Left Case Bearing TABLE OF CONTENTS IXTABLE OF CONTENTS (Clutch Shaft... 6-45 ight Case Bearing 6-45 Left Case Bearing 6-46 6.10 FINAL DRIVE SPROCKET Pulley Assembly, 647 Removal... 6-47 Instalation. 6-47 Rubber Compensator Dampers. 6-49 6.11 DRIVE BELT AND IDLER PULLEY General Drive Belt Tension, Belt Handling Drive Belt Removal ELECTRICAL 7.1 FASTENER TORQUE VALUES. Fastener Torque Values in this Chapter. 7 7.2 SPECIFICATIONS General 73 7.3 IGNITION SWITCH/FORK LOCK: 1125R Replacement 7-4 Removal 78 Installation Pod Repair. von 75 Disassembly. met 75 Assombly. 75 7.4 IGNITION SWITCH/FORK LOCK: 1125CR Roplacement... 78 Removal 78 Installation 78 7.5 ELECTRONIC CONTROL MODULE (ECM) Replacement. rt 7.6 IGNITION COILS 78 78 7.7 BATTERY Y CABLES Negative Battery Cable. 79 Removal... 79 Installation, 79 Positive Battery Cable. 7-10 Removal 7-10 Installation 710 7.8 STARTER Solenoid 712 Removal 712 Installation... 713 X TABLE OF CONTENTS Starter: Removal. 714 Starter: Installation... 745 7.9 VOLTAGE REGULATOR Removal 718 Installation TAB 7.10 ALTERNATOR Removal and Disassembly 747 Rotor. TAT Stator. 747 ‘Assembly and Installation 7418 Rotor. 7-18 Stator. 7-20 7.11 HORN Removal. 7-21 Installation. z 7.12 TURN SIGNALS Front Turn Signals/Mirrors: 1125. Removal Installation... Front Turn Signals/Mirrors: 1125CR. Removal Installation Rear Turn Signals. Removal. Installation 7.13 HEADLAMP: 1125R BUIDS onan Marker Lamp. Headlamp Bulb, Wire Harness. Removal. Installation. . 7.14 HEADLAMP: 1125CR Bulbs, Horan Alignment... Wire Harness... 7.15 TAIL AND LICENSE PLATE LAMP: Tail Lamp. Removal. Installation, License Plate Lamp... Bulb Replacement Wire Harness and Lens. License Plate Bracket. Removal Instalatior 7.16 FUSES AND RELAYS Fuse Block. 7-35 Fuses... 7-35 Battory (Main) Fuse. 7-35TABLE OF CONTENTS Relays, 7-38 7.17 SWITCHES AND CONNECTORS Auxiliary Connector {160} 787 Brake Light Switch: Front, 7-37 Brake Light Switch: Rear. 737 CAN Bus Connector. 7-38 Clutch interlock Switch 7-38 ‘Neutral Indicator Switch, 7-93 Test. 7-39 Removal 7-29 Installation, 7-99 i Pressure Switch 7-40 Sidestand Sensor (HD), 7-40 7.18 CRANKSHAFT POSITION SENSOR (CKP) Removal instalation 7.19 VEHICLE SPEED SENSOR (vss) Romoval instalation 7.20 HANDLEBAR SWITCH HOUSINGS Loft Switch Housing, Removal... Installation, . Right Switch Housing. Removal... Installation. 7.21 INSTRUMENT CLUSTER Replacernent: 1125R... 7-48 Replacement: 1125CR., 7-48 7.22 ENGINE HARNESS: Removal 7-50 Flemove the Engine from the Chassis. 7-50 Wire Harness Support. 7-50 Repaii. Disassembly. 7-50 Assembly. 7-51 Installation, 7-52 Mount the Wire Harness. 762 Install Engine.. 7-52 7.23 MAIN WIRE HARNESS. Removal 7-54 ‘Access the Tail Section 7-54 Separate Connectors and Connections. 7-54 ‘Access Front Harness. 7-55 Remove from Engine... Wire Harness Front Brackot 757 11258 757 M125CR 7.87 Installation, 7-57 Fit to Engine. 757 Front Harness... 7-58 Install Rear Harness. 7-58 7.24 COOLING FANS Removal 7-60 Left Side. 7-60 Right Side. 7-60 Fuel Pump: Installation 761 Instaltation, 762 Lett Side 7-62 Right Side. 7-62 APPENDIX A CONNECTOR REPAIR A.1 AMP MULTILOCK CONNECTORS AMP Muttilock Connector Repair. General Separating Pin and Socket Housings. Mating Pin and Socket Housings. Romoving Terminals from Housing, Inserting Terminals into Housing. Preparing Wire Leads for Crimping... Crimping Terminals to Leads... Inspecting Crimped Terminal. A.2 AUTOFUSE ELECTRICAL CONNECTORS Autotuse Connector Repair. 8 General, AS Disassembiy... AS Assembl AS A.3 DELPHI CONNECTORS Delphi Connector Repair. General ‘Separating Pin and Socket Housings, Mating Fin and Socket Housings. Removing Socket Terminals. Installing Socket Terminals. A.4 DELPHI MAIN FUSE HOUSING Delphi Main Fuse Housing Repair. General. Removing Main Fuse. Instaling Main Fuso. Removing Socket Terminals. Instaling Socket Terminals, A.5 DEUTSCH ELECTRICAL CONNECTORS: Deutsch Connector Repair. Ato General ‘ato Separating Pin and Socket Housings. 10 Maing Pin and Socket Housings 10 Removing Socket Terminals ‘10 Instaling Socket Tecminals A10 Removing Pin Terminals. “nnn ACHR Instaling Pin Terminals ne Crimping Terminals Ata A.6 DEUTSCH STANDARD TERMINAL REPAIR Deutsch Standard Terminal Crimps. Aa Preparing Wie Leads fr Coming. aid ‘TABLE OF CONTENTS XITABLE OF CONTENTS Crimping Terminal to Lead. er Inspecting Crimps. A.7 DEUTSCH SOLID BARREL MINI TERMINAL REPAIR ot Deutsch Solid Barre! Terminal Crimps. M5 Preparing Wire Leads For Crimping. AAS ‘Adjusting Crimpor Tool... AAS Crimping a Barre! Contact To Wire Lead A15 Inspecting Crimps... AAS A.8 DEUTSCH MINI TERMINAL REPAIR Deutsch Mini Terminal Crimps, At? Preparing Wire Leads for Crimping. AAT Crimping a Mini Terminal to Wire Lead AA? Inspecting Crimps. MA? A.9 MOLEX CONNECTORS: Molex Connector Repair Soparating Pin and Socket HOUSINGS... Mating Pin and Socket Housings Removing Terminals. Instaling Terminals, (Crimp Terminal to Lead. Prepare Lead. Prepare ToOl nnn Position Terminal in the PunchiDie.. Insert Stripped Lead. Crimp Terminal to Lead... Inspect Crimp. A.10 PACKARD 150 METRI-PACK CONNECTORS 150 Metti-Pack Connector Repair A22 General A22 Separating Pin and Socket Housings. A22 Mating Pin and Socket Housings. Removing Sockot Terminal Inserting Socket Terminal A.11 PACKARD 280 METRI- AND FUSE BLOCK CONNECTORS Fuse Block Repair Removing Socket Terminals... ‘A26 Installing Socket Terminals. A28 Crimping Terminals... A24 A.12 PACKARD 480 METRI-PACK CONNECTORS ‘480 Metri-Pack Connector Repair. A28 Goneral nn Separating Pin and Socket Housings.. Mating Pin and Socket Housings. ‘A25 Romoving Sockst Terminals. A25 Instaling Socket Terminais. 25 A.13 PACKARD 630 METRI-PACK CONNECTORS 620 Moi Pack Connector Rea B28 General A26 Xil TABLE OF CONTENTS: Separating Pin and Socket Housings... Mating Pin and Socket Housings. Removing Socket Terminal Installing Sockot Terminal A.14 PACKARD METRI-PACK TERMINALS ‘Motr-Pack Torminal Crimps.. Matching Terminal To Crimper. Preparing Wire Lead. Crimping Wire Core... Crimping Insulation/Seal Inspecting Crimps.... A.15 PACKARD ECM CONNECTOR Packard 100W Connector Repair. General Separating Socket Housing From EGM. ‘29 Mating Socket Housing To ECM. ‘29 Removing Socket Terminal. A28 Instaling Socket Terminal... A283 Crimping Terminats.. A283 A.16 PACKARD MICRO-64 CONNECTORS Packard Micro-64 Connector Repair. General Separating Pin and Socket Housings. ASt Mating Pin and Socket Housings. aot Removing Terminal. At Instalting Terminal... ASt Preparing Wire Leads for Crimping A32 Crimping Terminal. Ag2 Inspecting Crimps, N32 A.17 SEALED SPLICE CONNECTORS Sealed Splice Connector Repait Ast General ABt Preparing Wire Leads. At Splicing Wite Leads, At Inspecting Seals. As APPENDIX B WIRING B.1 CONNECTORS Connector Locations, : B+ Function/Location, B+ Place and Color. é a4 Connector Number - B+ Repair Instructions, 4 B.2 WIRING DIAGRAMS Wiring Diagram Information, 83 Wire Color Codes, 83 Wiring Diagram SymbOI5 nn 83 2009 1125 Wiring Diagrams, Ba APPENDIX C VALVE LASH C.1 VALVE TAPPET SHIMS Tables... cATABLE OF CONTENTS C.2 VALVE LASH CALCULATION WORKSHEET 1 Worksheet 1 C.3 VALVE LASH CALCULATION WORKSHEET 2 Workshoot 2. APPENDIX D CONVERSIONS D.1 LENGTH CONVERSION Conversion Table. D.2 FLUID CONVERSION United States System, Metric System. British Imperial System. ce ca Da D.3 TORQUE CONVERSION United States System : Ds Metric System, DB APPENDIX E GLOSSARY E.1 GLOSSARY ‘Acronyms and Abbreviations, BA REFERENCE MATERIAL, ‘TABLE OF CONTENTS XillNOTES XIV TABLE OF CONTENTS‘SUBJECT 1.1 FASTENER TORQUE VALUES. 1.8 TIRES AND WHEELS. 1.9 BLEEDING CLUTCH FLUID LINE, 1.10 DRIVE BELT MAINTENANCE. . 4.11 BRAKE SYSTEM MAINTENANCE, 1.16 VALVE CLEARANCE... 1.17 STEERING HEAD BEARINGS..NOTESFASTENER TORQUE VALUES 1d FASTENER TORQUE VALUES IN THIS CHAPTER ‘The table bolow lists torque values forall fastoners presented in this chapter. ‘Axle, front 53-56Nm | 39-41 ftibs 1.11 BRAKE SYSTEMMAINTENANCE, Brako Pad. Replacement ‘Axle pinch bolts, front 27-30Nm | 20-22 ftlbs 1.11 BRAKE SYSTEM MAINTENANCE, Brake Pad Replacement Battery terminal fasteners 68-7.9Nm | 60-70inibs 1.3 MAINTENANCE SCHEDULE, General Battery terminal fasteners, 88-7.9Nm | 60-70 inlbs 1,14 BATTERY MAINTENANCE, Installation and Connection Battery terminal fasteners 6.8-7.9Nm | 60-70 indbs 1.14 BATTERY MAINTENANCE, Installation and Connection Brake caliper faster 48:50Nm | 35-97 ftlbs 1.11 BRAKE SYSTEM MAINTENANCE, Brake Pad Replacemenv/LOCTITE 271 (red) Brake caliper mounting fasteners, rear | 24.27Nm | 18-20 (tibs 1.11 BRAKE SYSTEM MAINTENANCE, Brake Pad Reptacoment Brake fluid line P-clamp fastener, rear | 9.7-11.0Nm | 84-96 in-Ibs 1.11 BRAKE SYSTEM MAINTENANCE, Brake Pad Replacement Brake pedal adjuster looknut 147-196Nm 11-16 ftibs 1.11 BRAKE SYSTEM MAINTENANCE, Brake Pedal Adjustment Brake pin hanger set, front 147-496 Nm | 11-15 ftibs 1.11 BRAKE SYSTEM MAINTENANCE, Brake Pad Replacoment Brake reservoir cover screws, front 4.0-.5Nm | 9-19indbs 1.3 MAINTENANCE SCHEDULE, General | Brake reservoir cover screws, front 1.0-.5Nm | 9-4@indbs 1.11 BRAKE SYSTEM MAINTENANCE, Bleeding | nares | Brake reservoir cover screws, front 1.0-1.5Nm 9-13 ines |1.11 BRAKE SYSTEM MAINTENANCE, Brake Pad Replacement Caliper bleeder vaive, front 38-6.9Nm | S&-63inlbs [1.11 BRAKE SYSTEM MAINTENANCE, Bleeding Brakes: Caliper bieeder vaive, rear 7.89.6Nm | 6586 in-lbs 1.11 BRAKE SYSTEM MAINTENANCE, Bleeding Brakes (Clutch fluid bleeder valve 5Nm 44 indbs 1.9 BLEEDING CLUTCH FLUID LINE, Bleeding Clutch reservoir banjo bolt 16-20 1.9 BLEEDING CLUTCH FLUID LINE, Bleeding Clutch reservoir cover screws | 1.3 MAINTENANCE SCHEDULE, General Clutch reservoir cover screws 1.9 BLEEDING CLUTGH FLUID LINE, Hydraulic Clutch: Buell 1125 Models (Clutch reservoir cover screws [1045Nm | 84Sindbs [1.9 BLEEDING CLUTCH FLUID LINE, Bleading Clutch reservoir cover screws | 1.04.5Nm | 949indbs |1.11 BRAKE SYSTEM MAINTENANCE, Checking Fluid Love! Engine oil drain plug, left 25.Nm 1Bitlbs —_|1.8 MAINTENANCE SCHEDULE, General Engine oil drain plug, left 25Nm 18 ftlbs | 1.5 ENGINE OIL AND FILTER, Engine Oil Chango: Buell 1125 Models Engine oil drain plug, right 15Nm 11 ftibs __|1.3 MAINTENANCE SCHEDULE, General Engine oil drain plug, right 15Nm 11 ftibs _/1.5 ENGINE OIL AND FILTER, Engine Oil Change: Buell 1125 Models Fender fasteners, front 84-9.2Nm | 74-82 inibs/1.11 BRAKE SYSTEM MAINTENANCE, Brake Pad Replacement 2009 1125 Service: Maintenance 1-1Handlebar leer bracket clamp screw | 90-102Nm | 80-90inlbe 1.3 MAINTENANCE SCHEDULE, Genera Igniton col fastener T2Nim | 106 ilps 1.12 SPARK PLUGS, Replacement Intake cover fasteners 13.0-14.5Nm | 115-128 in-lbs 1.3 MAINTENANCE SCHEDULE, General Intake cover fasteners 13.0-14.5.Nm | 115-128 in-lbs 1.6 AIR FILTER ELEMENT, Intake Cover | (i iter cover fasteners T1Nm | 67indbs 1.3 MAINTENANCE SCHEDULE, General [ci iter cover faseners {thin | 87imibs 1.5ENGINE OIL AND FILTER, Engine Oi Changer] Buel 1728 ModelsTORX. Radiator shroud fasteners "| 90998im | 80:68imiBs 1.15 ENGINE COOLANT, Coolant Lew: uel | 1125 Models | Spark pug iThim | 87 imibs 1.8 MAINTENANCE SCHEDULE, General Spark pug ithim | S?imlbs 1.12 SPARK PLUGS, Repiacement. Steering sem capnut 315569Nm | 66-42 fos 1.17 STEERING HEAD BEARINGS, Resistance Test Steering stom pinch bon BraaNin | BOAT be 17 STEERINGHEAD BEARINGS, Restance | est Switch Rousing sews ——~=~S*S*S* AN —«| SB be 1 A MAINTENANCE SCHEDULE, Goneral Tipe clamp fastones, lower 27s0Nm | 2022 tabs 1.17 STEERING HEAD BEARINGS, Resistance Test 1-2 2009 1125 Service: MaintenanceGENERAL 1.2 SERVICING A NEW MOTORCYCLE eG Perform the service and maintenance operations ai indicated in the regular service interval table. Lack of regular maintenance at the recommended intervals can affect the sate operation of your motorcycle, which could result in death or serious injury. (00010a) Service operations to be performed before customer delivery 2are specified in the applicable model year predelivery and set- Up instructions. The performance of new motorcycle intial service is required 10 keep warranty in force and to verity proper emissions sys ‘tems operation. See 1.3 MAINTENANCE SCHEDULE. SAFE OPERATING MAINTENANCE ‘Acaretul check of certain equipment is necessary after periods. ‘of storage, and frequently between regular service intervals {0 determine if additional maintenance is required. Check: 1. Tires for abrasions, cuts and correct pressure. Drive belt condition, Brakes, steering and throttle for responsiveness. Brake and clutch fluid level and condition. Hydraulic lines and fittings for leaks. Also, check brake pads and rotors. for wear. 5. Cables for traying, crimping and free operation Engine ol evel Headiamp, auxiliary lamp, tail lamp, brake lamp, horn and turn signal operation SHOP PRACTICES Repair Notes General maintenance practices are given inthis section, NOTES + Repair= Disassembly/Assembly. + Replacement = Substitute a new part for existing com- ponent. Al special tools and torque values are noted at the point of use. ‘All required parts or materials can be found in the appropriate parts catalog, Safety ‘Satety is always the most important consideration when per- forming any job, Be sure you have @ complete understanding of the task to be performed. Use common sense. Use the proper tools. Protect yourself and bystanders with approved ‘ee protection. Dont just do the job - do the job safely. Removing Parts ‘Always consider the weight of a part when iting. Use a hoist whenever necessary. Do not it heavy parts by hand. A hoist and adjustable iting beam or sing are needed to remove some parts. The lengths of chains or cables from the holst to the part ‘should be equal and parallel and should be positioned directly ‘over the center of the part. Be sure that no obstructions vill interfere withthe liting operation. Never leave a part suspended in miei, SGI} Be sure to check capacity rating and condition of hoists, slings, chains and cables before use. Exceeding capacity ratings or using lifting devices that are in poor condition can lead to an accident, which could result in death or serious injury. (00466c) ‘Always use blocking or proper stands to support the part that has been hoisted. If a part cannot be removed, vorty that all bolts and attaching hardware have been remaved. Gheck to 80@ if any parts are in the way of the part being removed, When removing hoses, wiring or tubes, always tag each part to verity propor installation Cleaning If you intend to reuse parts, follow good shop practice and thoroughly clean the parts belore assembly. Keep all dirt out of parts;the unit will perform better and last longer. Seals, ters and covers are used in this vehicle to keep out environmental dirt and dust. These items must be kept in good condition to verity satistactory operation When you are instructed in a step to clean fastener threads or threaded holes, procged as follows: Cloan all LOCTITE material ‘rom fastener threads and threaded holes. Use a wire brush to clean fastener threads. Use a thread chaser or other suitable tool to clean threaded holes. Use PJ-1 cleaner or equivalent to remove all traces of oil and contaminants from threads. Blow ‘out all threaded holes with low pressure compressed air. Clean and inspect all parts as they are removed. Be sure all holes and passages are clean and open. Atter cleaning, cover all parts with clean lint-free cloth, paper or other material. Be ‘sure the partis clean when itis installed. ‘Always clean around lines or covers botore they are removed, Plug, tape or cap holes and openings to keep out dir, dust and debris. ‘Always vority cleanliness of blind holes before assembly. Tightening a screw with dirt, water or oll in the hole can cause castings to crack or break Disassembly and Assembly ‘Aways assemble orcisassemble one pat at atime. Do not work on two assembles simultaneously Be sure to make all necessary adjustments, Recheck your work when fnishod. Bo sure that everything is dane Operate the vehicle to pertorm any final check or adjustments ial corec, the vehicle is ready to go backto the customer 2009 1125 Service: Maintenance 1-3Checking Torques on Fasteners with Lock Patches ‘To chock the torque on a fastener that has a lock patch: 1, Sotthe torque wrench forthe lowest salting in the spectiod torque range. 2. Attempt to tighten fastener to set torque. If fastener does ot move and lowest setting is satisfied (torque wrench clioks), then the proper torque has been maintained. Magnetic Parts Trays Magnetic parts trays are becoming commen in the service facility because they are convenient and can keep parts from becoming lost during a repair procedure. However, hardened steel parts can become magnetized when held in magnetic parts trays. Metal fragments that would ordinarily be washed away inthe oil and trapped in the oil fter ‘or magnetic drain plug during vehicle operation could be cap- tured by magnetized parts in the engine, potentially causing accelerated engine wear and damage. Parts that will be returned to service inside the vehicle's powertrain such as gears, thrust washers and especially bearings should never be kept in magnetic parts trays. REPAIR AND REPLACEMENT PROCEDURES Hardware and Threaded Parts Install helical thread inserts when inside threads in castings are stripped, damaged or not capable of withstanding specified torque Replace bolts, nuts, studs, washers, spacers and small ‘common hardware if missing or in any way damaged. Clean Lup of repair minor thread damage with a suitable tap or die. Replace all damaged or missing lubrication fitings. Use Tetlon pipe sealant or LOCTITE 565 THREAD SEALANT Cn pipe fiting threads, Threadlocking Agents Always follow specific service manual procedures when working vith fasteners containing preapplied threaclocking agents when fastener replacement is recommended. When re-using fasteners containing threadlocking agents, be sure to com- pletely remove all existing threadiocking agent from fastener threads with a wire brush or wire wheel. Also, be sure 10 remove residual threadlocking agent from fastener hale using an appropriate thread chasing device and compressed air when Using now or existing fasteners. Always uso the recommended threadlocking agent for your specific procedure. Wiring, Hoses and Lines Hoses, clamps, electrical wiring, electrical switches or fuel lines if they do not meet specifications. Instruments and Gauges Replace broken or defective instruments and gauges. Replace dials and glass that are so scratched or discolored that reading is aifioun, 144 2009 1125 Servi Maintenance Bearings ‘Antiiction bearings must be handled in a special way. To keep out dirt and abrasives, cover the bearings as soon as they are removed from the package. Wash bearings in a nor-‘lammable cleaning solution. Knock ‘out packed lubricant inside by tapping the bearing against wooden block. Wash bearings again. Cover bearings with clean ‘matorial aftor sang them down to dry. Never use compressed air to dry bearings. Coat bearings with clean oll. Wrap bearings in clean paper. When bearings are installed against shoulders, be sure that, the chamfered side of the bearing always taces the shoulder. Lubricate bearings and all metal contact surfaces betore pressing into place. Only apply pressure on the part of the ‘bearing that makes direct contact with the mating part, Install bearings with numbered side facing out ‘Aways use tho proper tools and fixtures for removing and installing bearings. Bearings do not usually need to be removed. Only remove bearings if necessary. Bushings Do not remove a bushing unless damaged, excessively worn (F loose inits bore. Press out bushings that must be replaced, ‘When pressing or driving bushings, be sure to apply pressure in line with the bushing bore. Use a bearing/bushing diver or ‘a bar with a smooth, flat end, Never use a hammer to drive ‘bushings. Inspect the bushing and the mated part for ell holes, Be sure all ollholes are properly aligned Gaskets ‘Atways discard gaskets after removal. Replace with new gas: kets. Never use the same gasket twice. Be sure that gasket holes match up with holes in the mating part. But be aware that sections of a gasket may be used to seal passages. Wa gasket must be made, be sure to cut oles that match up with the mating part. Serious damage can occur it any flange: holas are blocked by the gasket. Use material that isthe right type and thickness. Lip Type Seals Lip seals are used to s2al ol or grease and are usually installed with the sealing lip facing the contained lubricant. Seal orient alion, however, may vary under diferent applications. ‘Seals should not be removed unless necessary. Only remove seals if required to gain access to other parts orif seal damage ‘or wear dictates replacement Leaking oil or grease usually means that a seal is damaged Replace leaking seals to prevent overheated bearings. Always discard seals atter removal, Do not use the same seal twice. O-Rings (Preformed Packings) Always discard O-rings after removal. Replace with new O- ring. To prevent leaks, lubricate the O-rings before installation, Apply the same type of lubricant as that being sealed. Be sure that all gasket, O-ring and seal mating surfaces are thoroughly clean beiore installation.Gears ‘Always check gears for damaged or worn teeth, Remove burrs and rough spots with a honing stone or crocus cloth before installation, Lubricate mating surtaces before pressing gears on shats Shafts ita shaft does not come aut easily, check that al ruts, bolts or retaining rings have been removed. Check to see i other parts are in the way belore using force. Shats fied to tapered spines should be very tight, shafts are nottigh,oisassemble anc inspect tapered splines. Discard parts that are worn, Be sure tapered splines are clean, cry and {nee of burs before puting them in piace. Pros mating parts together tight. (Clean all ust from the machined surfaces of new parts. Part Replacement [Always replace worn or damaged parts with new parts Exhaust System Leakage In the event of an exhaust system leak at a muflr or header pipe connection location, disassemble and clean all mating ‘surfaces. Replace ary damaged components. fleak sil exist, disassemble and repair the leak by applying a bead of Harley” Davidson High-Performance Sealant (Part No, 9650-02) (or an equivalent 02 SensocCatalyst sale aternatve) Reassemble components, wipe off any excess sealant and allow adequate curing imo folowing sealant product instructions before oper~ ating venice. CLEANING Part Protection Before cleaning, protect rubber parts (such as hoses, boots and electrical insulation) from cleaning solutions. Use a greaso- proof barrier material. Remove the rubber part if cannot be property protected. Cleaning Process Any leaning methed may be used as long as it does not result in parts damage. Thorough cleaning is necessary for proper parts inspection. Strip rusted paint areas to bare metal before priming and repainting Rust or Corrosion Removal Remove rust and corrosion with a wire brush, abrasive cloth, sand blasting, vapor blasting or rust remover. Use butting crocus cloth ch highly polished parts that are rustea Bearings Remove shields and seals from bearings belore cleaning. Clean bearings with permanant shields and seals in solution. ESN Using compressed air to "spin dry" bearings can cause bearing to fly apart, which could result in death or serious Injury. (00505b) (Clean open bearings by soaking them in a petroleum cleaning solution. Never use a solution that contains chlorine, Let bearings stand and dry. Do not dry with compressed aie, Do not spin bearings while they are drying. TOOL SAFETY _ Air Tools + Always use approved eye protection equipment when performing any task using air-operated tools, + On all power tools, use only recommended accessories with proper capacity ratings. + Do not exceed air pressure ratings of any power tools. + Bits should be placed against work surtace before air hammers are operated. + Disconnect the air supply line to an air hammer before attaching a bit + Never point an air too! at yourself or another person. + Protect bystanders with approved eye protection. Wrenches + Never use an extension on a wrench handle + Ifpossibie, always pull on a wrench handle and adjust your stance to prevent a fallif something lets go. + Never cock a wrench, + Never use a hammer on any wrench other than a STRIKING FACE wrench, + Discard any wrench with broken or battered points. + Never use a pipe wrench to bend, raise or lita pipe. Pliers/Cutters/Pry bars + Plastic- or vinyl-covered pliers handles are not intended toact as insulation, Do not use on live electrical cirouts. + Do not use pliers or cutters for cutting hardened wire lunless they were designed for that purpose. + Always cut at right angles. + Donot use any pry bar as a chisel, punch or hammer. Hammers + Never strike a hammer against a hardened object, such as another hammer, + Always grasp a hammer handle firmly, close to the end. + Strike the object with the fll face of the hammer. + Never work with a hammer which has a loose head: + Discard hammer if face is chipped or mushroomed. + Wear approved eye protection when using striking tools. + Protect bystanders with approved eye protection. 2009 1125 Service: Maintenance 1-5Punches/Chisels Never use a punch or chisel with a chipped or mush- roomed end; dress mushroomed chisels and punches with a file. + Hold a chisel or a punch with a tool holder if possible, + When using a chisel on a emall piece, clamp the piece firmly in a vise and chip toward the stationary jaw. ‘+ Wear approved eye protection when using these tools, + Protect bystanders with approved eye protection. Screwdrivers + Do not use a screwdriver for prying, punching, chiseling, scoring or seraping, ‘+ Use the right type of screwdriver forthe job; match the tip to the fastener. + Do not interchange POZIDRIV, PHILLIPS or REED AND PRINCE screwdrivers, + Screwdriver handles are notintended to act as insulation, Do not use on live electrical circuits, + Donot use a screwdriver with rounded edges because it will slip. Redress witha fle. 1-6 2009 1125 Service: Maintenance Ratchets and Handles + Periodically clean and lubricate ratchet mechanisms with alight grade oil. Do not replace parts individually;ratchets should be rebuilt withthe entire contents of service kit + Never hammer or put a pipe extension on a ratchet or handle for added leverage, + Always support the ratchet head when using socket ‘extensions, but do not put your hand on the head or you may interfere with the action of its reversing mechanism + When breaking loose a fastener, apply a small amount of pressure as a test to be sure the ratchet's gear wheel is ‘engaged with the paw. Sockets + Never use hand sockets on power or impact wrenches. + Select the right size socket forthe job. + Never cook any wrench or socket. + Select only impact sockets for use with air or elaciric impact wronchos, + Replace sockets showing cracks or wear. + Koop sockets clean, + Always use approved eye protection when using power cr impact sockets. Storage Units + Donotopen more than one loaded drawer at atime. Close leach drawer before opening up another. + Close lids and lock drawers and doors betore moving storage units. + Donot pull on a too! cabinet; push itin front ot you. + Setthe brakes on the locking casters after the cabinet has been rolled to your workspaceMAINTENANCE SCHEDULE 1.3 GENERAL ‘Table 1-1. Regular Service intervals: 2009 Buell 1125 Models [5 Petom every two years Fa specie ara whichover comes is. Engre of piace a x [tt Engine or ar ear piace x i x s "ne ovarer Replace erent a eine 3 x x (Garkcate Beater Gian or rence r x x Tiree Gheskeondien. cask measure | xX) | x | x |X x fees [Check eat |e ve | x ]s spect = |e |. | | x [2 “Tv, beak, cach canis, |Inpect, serve a required |<). |< | « x [fe sidestanc | Brake id | Check eal nd onion ae x] [Brake pa and dns [Inspector wear 2 [|e | ee x ‘Span pg pace x] x x [2 util swiches and equipment Check peration a x Fontoreot Replace x x [2 ‘Exhacst system [inspectorate cade andicose) x | x | * | x | x [s [Dien ctonor or hea ens Bares) ‘hock batory and clean cones 5 tore osira sien Inepectiovl deckclrpsior | =X = = | X | xX | x =| "ohtness a - Conia | Replace every 55,606 kn 105 3) 26 Facisors and allcooier ns | Cleen eyelrtftey x x Bene system endottioes ——_|lepec oriaks Xe x [2 Ciel steers | check ines T x 1% xp? Vat cewance Inspect iz x] x [ae Foadtest [Mery conponentandaysem «X= ~~ x) ROX x Limncone NoTEs: “1. Povtorm annually ofa specified intwal, whicsover comes frst. 2. Shoulsbe porotred Uy an auhoreed Bo dee, les Yeu Pave Re pope 008, ered and re mechanical gated |S\Ghange 00:74 md ard sh brake andchich systems every ta 2) yea, “4: Cau ary wn requooyoepeaton and reig ve, | ecrm anuaty Engine oil and fiter, ‘Table 1-2. Quick Reference Maintenance Chart: 1125 Models Let engine ollren pg torque Fight engine ot drain plug capacity with filer change Tires il capacity without filter change '25 Nm (18 ftibs) Use new aluminum washer. 118 Nm (11 felbs) Use new aluminum washer. 23L@4a) 26L@rad Filter cover fasteners: 11. Nm (97 in-tbs) Solo rider - Front: 234 kPa (34 psi) Rear: 248 kPa (36 psi) [Rider and passenger ‘Same as solo Wear | Replace tire if 0.8 mm (1/32 in) or less tread remains, (Tread wear indicator bars appear) 2008 1125 Service: Maintenance 1